Raymond 4150 4250 Counterbalanced Schematics Manual 1193671B - PDF DOWNLOAD

©2016 The Raymond Corporation

Serial Numbers 42,000 and Up 42,067 and Up

Issued: 13 Jun 2016

Models

4150 4250

Publication: 1193671B

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

This publication applies to the all subsequent releases of this product until otherwise indicated in new editions or bulletins. Changes occur periodically to the information in this publication.

Schematics

Models 4150/4250 Stand-Up Counterbalanced Lift Truck Schematics

Publication: 1193671B, Issued: 13 Jun 2016

Section 1 .

Figure 1-1. Power Distribution Diagram - Model 4150

2

Publication: 1193671B, Issued: 13 Jun 2016

Models 4150/4250 Stand-Up Counterbalanced Lift Truck Schematics Figure 1-2. Power Distribution Diagram - Model 4250

3

JP B-

TP4

AUX(-)

AUX(+)

SM

-2

-2

-1

-4

JPF4-3

JPF1-1

-2

JPF3-1

JPS1

2

1

-5

STR

2

1

2

2

JPF3-3

1

T°

FU5 (15A)

PCB MOUNTING STUD

FU7 (15A/5A)

1

FU8 (15A/5A)

1

FU6 (15A)

2

2

1

-5

Publication: 1193671B, Issued: 13 Jun 2016

7

6

5

4

-4

-3

FU3 500A 80 VDC

-12

LPC

-6

-2

-4

TP3

STR

-7

TPC

FUSE/ RELAY CARD

-6

Y

X

2

1

FU2 750A 80 VDC TP5

-10

FU1 100A 80 VDC

-11

TP2

-9

3

JPS1-1

-8

JP B+

4

K2

Y

X

JPF1-3

TP1

LPC

X

-9

TPC

K3

Y

-10

JPF2-1

CONTACTOR PANEL

-5

-7

2

-4

BLACK

TLT

WHT

RED

-8

-11

JPS1

K4

K3

K4

TRT

TRE

WHT

RED

WHT

RED

K2

-2

K1

K1

SPL9

AC LIFT

2 S21 EPO

2

1

LM

TS1 -1

-6

-5 KEY

BATTERY

B-

POWER

W

V

U

4

+

1

S1

ZONE G5 SHEET 1

+

RIGHT BRAKE

-2

JPB1 -1

TRAVEL ALARM OPTION

HRN0

HRN+

HRNH

SOUNDER

SWITCH

DEADMAN

S2

H-2(-)

H-1(+)

POS B POS C

-20

-8 -9

-2 -1

-7

JPC14

JPC22-11

JPF2-8

JPF4-7

JPC24-24

BATTERY_SENSE_IN

B+K2

B+K2

B+K4

DGND

ON DEADMAN

JPC22-8 -2

-3

+12VP

B+KEY

EPO_SENSE

RELAY_ENABLE

BRAKES

TRAV/LIFT ALARM

HORN

PA_FAN

DGND

DATA_OUT

SHIFT_CLOCK

ALARM_PWM

DISP_MISO

DATA_LATCH

ADDR_LATCH

+12V

DGND B-F B-F B-F

DGND

STR_SENSE

STR_CONTACTOR

LPC_SENSE

JPC10-1

JPC14-12

JPC22-21

JPC14-6

JPC20-14

JPC18-18

JPC18-16

JPC18-17

JPC6-4

JPC6-2

JPC6-5

JPC24-2

JPC22-10

JPC24-12

JPC24-14

JPC6-6

JPC14-10

JPC22-19

JPC18-11

LPC_CTRL

DD+ DGND

-4

VBUS -3

JPC22-20

JPC18-9

RXD DGND

-2

JPC3-1

-5

TXD

BUS-3

-3

JPC9-2

DGND

-4

-11

BUS+

POS A

-17

JPC22-9

JPC14

+12VP

-1

JPC24

F

JPDS -1

-8

-7

-6

-5 -4

-4 -3

-3

-2

JPD1 -1

-5

-2

-6

OPERATOR DISPLAY

BLU

BLK

WHT

MODEL 4250 - AC LIFT

HRN

ENTER

DN

UP

JPD2 -1

-4

-3

-2

BRN

-14

JPB4-2

LEFT BRAKE

JPB4-1

-

-1

-12

-11

-35

-23

JPL1

-1

STEER POSITION SENSOR

SPL1

-13

POWER AMP FAN OPTION (MODEL 4200 ONLY)

B+K3

ID1

ID0

BUS-

BUS+

B+K3

-12

-11

-35

-23

JPTR1

-1

-12

-11

CAN BUS TERMINATION

SPL2

-7

TO SOLENOID 1

KEYSWITCH OR ROTARY SWITCH

-

4

AMPLIFIER

LIFT POWER

4

ID1

ID0

BUS-

BUS+

B+K3

ID1

ID0

BUS-

-35

-23

-34

-21

JPTL1

-1

JPS2

SPL3

-6

JPF2-4

-10

-5

JPF4-13

-8

-12

JPB3-1

-4

-3

-2

LPC

B+K3

T TEMP+

T VEL PHASE B

T VEL PHASE A

L VEL SENSOR-

ACCESORY

W

V

W

V

U

4

L VEL SENSOR+

TPC

B+K3

T TEMP+

-2

ONLY

U

-6

-13

-8

+

-

AMPLIFIER

T VEL PHASE B

TRACTION RIGHT POWER

4

T VEL PHASE A

-5

-1

-2

V W

+

-

BUS+

CAN TERM L

CAN TERM H

AMPLIFIER

LEFT POWER

TRACTION

T VEL SENSOR-

W

V

U

D

T VEL SENSOR+

T TEMP+

T VEL PHASE B

T VEL PHASE A

T VEL SENSOR-

T VEL SENSOR+

JPF4-11

-3

JPF2-9

JPF4-15

JPF1-4

JL4-DC (DC LIFT) -1 -2

JPL3

-32

-2

-7

-26

JPL1

BLUE

-4 -31

-1

JPL2

-3

JL4-AC (AC LIFT) -1 -2

SPL5

TMR

U

-6

-13

-8

WHITE

RED

-1

-2

BLACK

MOTOR TEMPERATURE

LMT

LME

JPTR3

-32

-7

-26

-31

-2

V W

JPTR1

BLUE

-4 -3

-1

JPTR2

RED

MOTOR VELOCITY

PL4 -1

SPL6

TML

U

WHITE

BLACK

MOTOR VELOCITY

-1

-8

-32

-7 -31

-2 -2

-3

WHITE

MOTOR TEMPERATURE

2

SPL4

-26

JPTL1

BLUE JPTL3

-1

TLE

JPTL2

RED

C MOTOR VELOCITY

MOTOR TEMPERATURE

2

JPF2-2

B

SPL7

A

JPF1-6

FOR NOTES SEE SHEET 4

SPL8 SPL12

E

FLASHWARE USB COMMUNICATIONS

Models 4150/4250 Stand-Up Counterbalanced Lift Truck Schematics

-12

HSA2

TILT

SIDESHIFT

HSA1

DUMP

LOAD HOLD

PROP RELIEF

ISENSE4(K2)

PRIORITY BYPASS

ISENSE3(K2)

AUX SELECT

ISENSE5(K2)

LIFT/LOWER

ISENSE2(K2)

JPC20-15

-8

-15

-14

2

2

2

2

2

2

2

1

1

1

1

SOL9L

SOL7C

SOL10

SOL9R

SOL7R

SOL3

SOL1

SOL5

SOL4

SOL6

SOL2

1

1

1

1

1

1

1

2

2

2

2

-4

-3

-2

-1

JPH2

JPF2-8

MAST CONNECTOR

FUSE RELAY CARD

ZONE C7 SHEET 1

1

SOL11 2

2

SOL12

1

MAST MOUNTED SOLENOIDS

H

Model 4250 - AC LIFT

JPC18-12

JPC20-12

JPC18 -10

-20

-19

-18

JPC20-17

JPC18-1

-13

-16

SEE SHEET 4

G

2

SOL13

1

Figure 1-3. Electrical Schematic - Model 4250 (AC Lift) - Sheet 1 of 5

VEHICLE MANAGER

CONTROL HANDLE

4

JP B-

4

TP4

AUX(-)

AUX(+)

SM

-2

-1

-4

-2

-2

JPF4-3

JPF1-1

JPF3-1

JPS1

2

1

-5

2

MP

1

1

2

JPF3-3

1

T°

FU5 (15A)

PCB MOUNTING STUD

2

FU8 (15A/5A)

1

FU6 (15A)

MP-A

MP-S

FU7 (15A/5A)

DC LIFT MOTOR

STR

2

2

1

-5

Publication: 1193671B, Issued: 13 Jun 2016

7

6

5

4

-4

-3

-2

JPS1-1

-4

3

JP B+

-12

LPC

-6

STR

-7

TPC

FUSE/ RELAY CARD

-6

Y

X

2

1

TP5

FU2 750A 80 VDC

-10

TP3

-8

TP2

-9

FU3 500A 80 VDC

-11

FU1 100A 80 VDC

4

K2

Y

X

JPF1-3

CONTACTOR PANEL

LPC

X

-9

TPC

K3

Y

-10

JPF2-1

TP1

-5

-7

TLT

TLE

SEE NOTE 2

WHT

RED

-8

-11

JPS1

K4

TRT

K2

2 S21 EPO

2

1

SPL6

TML

K1

K1

TMR

SPL9

TPC

B+K3

T TEMP+

+

S1

ZONE G5 SHEET 2

-1

OPTION

ALARM

TRAVEL

HRN-

HRN0

HRN+

ENTER

DN

UP

H

SWITCH

DEADMAN

S2

H-2(-)

H-1(+)

POS B POS C

-5

-2 -1 -8 -9

-7

JPC14

JPC22-11

JPF2-8

JPF4-7

JPC24-24

BATTERY_SENSE_IN

B+K2

B+K2

B+K4

DGND

ON DEADMAN

JPC22-8 -2

-3

+12VP

JPC10-1

B+KEY

EPO_SENSE

RELAY_ENABLE

BRAKES

TRAV/LIFT ALARM

HORN

DGND

DATA_OUT

SHIFT_CLOCK

ALARM_PWM

DISP_MISO

DATA_LATCH

ADDR_LATCH

+12V

DGND B-F B-F B-F

DGND

STR_SENSE

STR_CONTACTOR

LPC_SENSE

JPDS -1

JPC14-12

JPC22-21

JPC14-6

JPC20-14

JPC18-18

JPC18-16

JPC6-4

JPC6-2

-7

JPC24-2

JPC22-10

JPC24-12

JPC24-14

JPC6-6

JPC14-10

JPC22-19

JPC18-11

LPC_CTRL

DD+ DGND

-4

VBUS

DGND

RXD

TXD

-3

JPC22-20

JPC18-9

BUSDGND

-2

JPC3-1

JPC6-5

-8

-3

-3

JPC9-2

-4

-11

BUS+

POS A

JPC14

+12VP

-1

-20

F -17

JPC24

JPC22-9

-6

-5 -4

-4

-3

-2

JPD1 -1

BLU

-3 SOUNDER

WHT

BRN

BLK

-5

-2

-6

JPD2 -1

OPERATOR DISPLAY

-4

-3

-2

-1

MODEL 4150 - DC LIFT

HRN

SPL8

-14

BRAKE

RIGHT

B+K3

STEER POSITION SENSOR

SPL1

-13

JPB4-2

LEFT BRAKE

JPB4-1

4

-12

-11

-35

-23

JPTR1

-1

CAN BUS TERMINATION

JPS2

SPL2

-7

TO SOLENOID 1

KEYSWITCH OR ROTARY SWITCH

1

-

-

ID1

ID0

BUS-

BUS+

B+K2

-12

-11

-35

-23

-34

-21

JPTL1

E

SPL3

-6

JPF2-4

-10

-5

JPF4-13

-8

-12

JPB3-1

KEY

W

V

U

4

-2

-6

-5

BATTERY

B-

POWER

ACCESORY

W

V

AMPLIFIER

T VEL PHASE A T VEL PHASE B

RIGHT POWER

T VEL SENSOR-

-5

-4

-3

-2

U

-6

-13

+

4

ID1

ID0

BUS-

BUS+

CAN TERM L

CAN TERM H

TRACTION

W

V

U

-

TRACTION AMPLIFIER

LEFT POWER

T VEL SENSOR+

T TEMP+

T VEL PHASE B

T VEL PHASE A

T VEL SENSOR-

T VEL SENSOR+

D

JPF4-11

-3

JPF2-9

JPF4-15

JPF1-4

SEE NOTE 2

TS1 -1

-32

-1

-8

-31

-2 -2

-3

WHT

RED

WHITE

-7

-26

V W

JPTR1

U

-8

BLUE

MOTOR TEMPERATURE

K3

K4

-4

BLACK

JPTR3

-1

RED

TRE

JPTR2

MOTOR VELOCITY

-1

-2

-32

-7

-26

-31

JPTL3

SPL4

-2

-1

-3

WHITE

-4

JPTL1

BLUE

RED

JPTL2

BLACK

C

SPL7

MOTOR VELOCITY

MOTOR TEMPERATURE

JPF2-2

B

JPF1-6

2

A

FLASHWARE USB COMMUNICATIONS

Models 4150/4250 Stand-Up Counterbalanced Lift Truck Schematics

-12

+5VP

HORN

LIFT

TRAVEL

HSA2

TILT

SIDESHIFT

HSA1

DUMP

LOAD HOLD

PROP RELIEF

ISENSE4(K2)

PRIORITY BYPASS

ISENSE3(K2)

AUX SELECT

ISENSE5(K2)

LIFT/LOWER

ISENSE2(K2)

DGND

SSHIFT_RIGHT

SSHIFT_LEFT

TILT_DOWN

TILT_UP

FUNCTION 4B

FUNCTION 4A

HORN

LIFT

TRAVEL

+5VP

H_HTR

DGND

SSHIFT_RIGHT

SSHIFT_LEFT

TILT_DOWN

TILT_UP

FUNCTION 4B

FUNCTION 4A

VEHICLE MANAGER

CONTROL HANDLE

JPC12-1

1

SOL2 2

-8

-15

-14

JPC18-12

JPC20-12

JPC18 -10

-20

-19

-18

JPC20-17

JPC18-1

-13

-16

JPC20-15

-12

-9

-8

-6

-5

-11

-4

-10

-2

-3

SOL9L

SOL7C

SOL10

SOL9R

SOL7R

SOL3

SOL1

SOL5

SOL4

1

1

1

1

1

1

1

2

2

-4

-3

-2

-1

JPH2

JPF2-8

-

0

+

0

+

+ 0

-

-

FUSE RELAY CARD

DGND

ZONE C7 SHEET 2

DGND

DGND

DGND

1

SOL11 2

2

SOL12

1

MAST MOUNTED SOLENOIDS

S5

S4

S3

SW2

SW3

SW1

SWITCH INPUT CONTROL HANDLE

DGND

DGND

+5VP

DGND

+5VP

DGND

+5VP

FLEX CIRCUIT BASED HANDLE

MAST CONNECTOR

S9

S8

S7

S6

DGND

VR2

+5VP

DGND

VR1

+5VP

+5VP

HTR6

S9

S8

S7

S6

DGND

VR2

+5VP

DGND

VR1

+5VP

+5VP

H

1

2

SOL13

Model 4150 - DC LIFT

2

2

2

2

2

2

2

1

1

2

-7 -7

SOL6

-2

-12

1

-9

JPC12-1

-6 -8

-15

-5

-9

-1

-8

-14

-6

-10

-4 -11

-12

-13

JPH1-11

-10

-2

-3

G

Figure 1-4. Electrical Schematic - Model 4150 - Sheet 2 of 5

5

VM

+12VP

-10

-18

JPC24 -13

-1

TS1 -3

MANAGER

VEHICLE

-7

JPFA-2

JPFA-1

2

1

S15

S10

RED +

1

2

-2

-3

-2

SF

-2

JPA -1

-2

+

T

FAN

-

SENSOR OPTION

PRESSURE (WEIGHT)

JPWL5 -2

JPWL4 -2

JPWL4 -1

JPWL5 -1

WARNING LIGHT OPTION

PRESS

SPL11

-1

FB

-1

- BLK

JPY1 -1

WL

OPERATOR'S COOLING FAN OPTION

-1

JPW5 -2

JPC24 -23

TS1 -2

TS1 -5

BLK

WHT

AMBIENT TEMPERATURE SENSOR OPTION

DGND

AMBIENT

B-

ACCESSORY POWER

KEY

ACCESSORY POWER

DGND

PRESSURE_AIN

B-

ACCESSORY POWER

(BATTERY)

ACCESSORY POWER

FU12

2A

Publication: 1193671B, Issued: 13 Jun 2016

7

6

5

4

3

-2

TS1 -5

JPWL1 -2

JPWL2 -2

JPWL2 -1

JPWL1 -1

2

1

-1

TS1 -3 FU20 2 S35

1 SL(-)

RD +

2

1

JPWL3 -2

LEFT

JPWL3 -1

WORK LIGHTS RIGHT 2

1

REV

WORKING LIGHTS OPTION

CLIPBOARD SPOTLIGHT OPTION

2A 125V

C

SL - BK +12VP

-2

JPS5 -4

JPC24 -4

JPC20 -8

GATE_R

DGND

+12VP

-1

-3

JPC22 -6 JPC24 -6

+12VP LIFT_LIM

-3 -4

MANAGER

VEHICLE

TP4 (B-)

MODEL 4250 ONLY

GATE

OPTION

GATE

BATTERY

RIGHT

S22B

OPTION

UPPER

UPPER

TILT_DIN

+12VP

DGND

TILT_AIN

+12V

-3

-1 JPT1 -2

JPC20 -5 JPC22 -5

VR6 DGND JPT1 -1

+5VP

JPT5 -2

JPT1 -3

LEFT SIDE

RIGHT SIDE

FOR SERIAL NUMBERS LESS THAN 50500.

JPT1 -4

+5V

REDUCTION (QUAD MAST ONLY)

JPC24 -5

JPT5 -4

LOWER

TILT OPTION

MAST TILT SPEED

S12

REDUCTION TT AND QM ONLY FOR SERIAL NUMBERS 50500 AND HIGHER

BOTTLER'S

OR

S11 MAST TILT SPEED

JPC24 -22

DGND

OR

LOWER

OPTION

SWITCH

LIMIT

LIFT

S12

MODEL 4250 ONLY

OPTION

SWITCH

TILT

MAST

S18

MODEL 4250 ONLY

OPTION

SWITCH

LIMIT

HI-SPEED

S11

MODEL 4250 ONLY

S18 MAST TILT CENTERING OPTION

HTR8-

HTR8+

HTR7-

HTR7+

TP1 (B+)

LEFT

S22A BATTERY

**MUTUALLY EXCLUSIVE WITH BOTTLERS TILT OPTION

FU17

OPTIONAL HEATED PLATES FOR OCSS OPTION

DGND

TILT_AIN JPS6 -4

JPC24 -5 -22

-2

-1

JPT1

-2

JPC22 -5

JPC20 -5

JPC24 -8

JPC20 -6

DGND

TILT_DIN

+12VP

DGND

-1

-1

JPC22 -4

+12VP

JPC22 -22

JPS13 -3

DGND

JPC20 -4

-1

JPC22 -3

-2

JPS14 -3

JPC20 -3

JPC24 -3

GATE_L

HIGH_SPD

T-OCSS

MANAGER

VEHICLE

D

MANAGER

VEHICLE +12VP

DGND

BEAM_R

+12VP

+12VP

DGND

BEAM_L

+12VP

ENABLE

-2

-1

THERMOSTAT

BATT+

BRN

-2

JPC20 -10

BLK

-2

-4

JPC22 -14 JPC18 -6

BLU

BRN

JPW2 -1

BLU

BLU JPW3 -1

BLK

BRN

BLU

BRN

JPC20 -9

-3

JPW4 -1

-2

-4

SPL10

JPW1 -1

DETECTOR

RIGHT

UPPER

EMITTER

RIGHT

LOWER

DETECTOR

LEFT

LOWER

LEFT EMITTER

UPPER

OPERATOR'S COMPARTMENT SENSOR SYSTEM (OCSS) OPTION

INTERNAL HEATER

SWITCH BASED HANDLE

CONTROL HANDLE

HTR6

-5

-3

BATT-

JPC18 -5

JPC22 -13

JPC20 -2

JPC10 -3

JPC20 -1

TP4 (B-)

FU35 2 AMP 125VDC

SHLD

RXD

CONNECTOR TO RAYMOND TM TXD PC9-2

iPORT SUPPLIER WIRELESS MODULE

BATT+

BATT-

DGND

TXD

RXD

JPHT1

TP1 (B+)

-6

-5

-3

-2

CONNECTOR TO THIRD PARTY DEVICE JRDP1-1

TP1

B

F

TP4

2

A

E

B-

B+

G

TP4

TP1

iWAREHOUSE-RED SYSTEM

JPC9

-5

-2

-3

iPORT TRUCK VM

H

Figure 1-5. Electrical Schematic - Options - Sheet 3 of 5

RS-232

Models 4150/4250 Stand-Up Counterbalanced Lift Truck Schematics

SEE INSTALLATION MANUAL FOR DETAILS

6

Publication: 1193671B, Issued: 13 Jun 2016

7

6

5

4

3

2

A

B

Models 4150/4250 Stand-Up Counterbalanced Lift Truck Schematics

C

D

E

HORN

LIFT

TRAVEL

+5VP

H_HTR

DGND

SSHIFT_RIGHT

SSHIFT_LEFT

TILT_DOWN

TILT_UP

FUNCTION 4B

FUNCTION 4A

HORN

LIFT

TRAVEL

+5VP

DGND

SSHIFT_RIGHT

SSHIFT_LEFT

TILT_DOWN

TILT_UP

FUNCTION 4B

FUNCTION 4A

HORN

LIFT

TRAVEL

+5VP

H_HTR

DGND

TILT

SSHIFT

FUNCTION 4B

FUNCTION 4A

VEHICLE MANAGER SEE SHEET 1

CONTROL HANDLE

-10

-11

-5

-8

-4

-12

-10 -4

-11

-5

-8

-12

+5VP

-6

-9 -2

-7

-9 -12

-7

-15

-5

-8

-1

-8

-14

-6

-10 -4 -11

-12 -2

-10

-13 -3

HTR6

DGND

S9

S8

S7

S6

VR2

+5VP

DGND

VR1

+5VP

S9

JPC12-1

S8

S7

S6

-9 -12

JPH1-11

DGND

VR2

+5VP

DGND

VR1

JOYSTICK

DGND

+5VP

+5VP

DGND

+5VP

DGND

+5VP

DGND

DGND

+5VP

DGND

+5VP

DGND

+5VP

-

0

+

-

+ 0

-

0

+

FLEX CIRCUIT BASED HANDLE

DGND

DGND

DGND

DGND

S5

S4

S3

SW1

SW2

SW3

SW1

SWITCH INPUT CONTROL HANDLE

SW2

SW3

-

+ 0

ANALOG INPUT CONTROL HANDLE OPTION

G

H

Figure 1-6. Electrical Schematic - Options - Sheet 4 of 5

DGND

VR2

VR1

+5VP

+5VP

HTR6

SW4

DGND

+5VP

DGND

+5VP

+5VP

-8

-6

-5

-11

-4

-10

-2

-3

JPC12-1

-7

-13

-2

-2

-7

-3

JPH1-1

-3

JPC12-1

F

7

Publication: 1193671B, Issued: 13 Jun 2016

MOTOR ENCODER COLOR CODES SHOWN ARE FOR 4K TRACTION MOTORS (STD & EE).

FOR 5K TRACTION MOTORS (STD & EE), PIN 2 IS WHITE AND PIN 3 IS BLUE.

-5

JPF2-1

JPF1-3

B+ POWER FOR AMPLIFIERS MAY COME FROM K2 (JPF1-6) OR K3 (JPF1-3).

3. THIS PART SHALL COMPLY WITH RESTRICTED SUBSTANCES QAP D20014464.

JPF2-2

2.

4

1. MAST IN FULLY LOWERED POSITION. KEY SWITCH OFF, EPO NOT DEPRESSED, NOT ON DEADMAN.

NOTES:

Models 4150/4250 Stand-Up Counterbalanced Lift Truck Schematics

JPF1-6

CONTROL FUSE FOR VEHICLE MANAGER B+ CONTROL FUSE FOR VEHICLE MANAGER BCONTROL FUSE FOR AUX. POWER B+ CONTROL FUSE FOR AUX. POWER BCONTROL FUSE FOR WARNING LIGHT & STROBE CONTROL FUSE FOR HEATER FOR OCSS PHOTO EYE OPTION FUSE FOR CLIPBOARD SPOTLIGHT OPTION iPORT SUPPLIER WIRELESS MODULE

B7/1&2 B6/1&2 B6/1&2 B6/1&2 A2/3 D5/3 C2/2 F3/3

FU5 FU6 FU7 FU8 FU12 FU17 FU20 FU35

DIGITAL INPUTS CONNECTOR ON VM ANALOG INPUTS CONNECTOR ON VM DISPLAY CONNECTOR DISPLAY CONNECTOR FOR OVERLAY

CONNECTOR FOR OPERATOR FAN B- AUX POWER, B+ POWER AMPS CONNECTOR ON FUSE/RELAY CARD B+ KEY SWITCH RELAYS CONNECTOR ON FUSE/RELAY CARD B- CONNECTOR ON FUSE/RELAY CARD KEY SWITCH, EPO, BATTERY SENSE CONNECTOR ON FUSE/RELAY CARD CONTROL HANDLE CONNECTOR CONNECTOR FOR MAST MODEL 4100 HANDLE HEATER

LIFT POWER AMP CONNECTOR LIFT ENCODER CONNECTOR LIFT MOTOR TEMPERATURE SENSOR CONNECTOR LIFT POWER CONTACTOR CONFIGURATION CONNECTOR

B6/3 A3/1&2 A4/1&2 E6/1&2 D6/1&2 D6/1&2 F5/1&2 D5/3 F5/1&2 F4/1&2 F4/1&2 G3, G4/1&2 D6/3 E6/3 F4/1&2 F5/1&2 G6/1&2 F2/1&2 F2/1&2 F5/1&2 E5/1&2 E7/1&2 B5/3 B6/1&2 C5/1&2 B5/1&2 B6/1&2 G2, G4/1 G6/1&2 F2/3

D4/1 C4/1 C4/1 C4/1

JPA JPB+ JPBJPB1 JPB3 JPB4 JPC3 JPC4 JPC6 JPC9 JPC10 JPC12 JPC12A JPC12B JPC14 JPC18 JPC20 JPC22 JPC24 JPD1 JPD2 JPDS JPFA

JPH1 JPH2 JPHT1

JPL1 JPL2 JPL3 JPL4-AC,-DC

CONNECTOR FOR WORKING LIGHT CONNECTOR FOR WORKING LIGHT CONNECTOR FOR WORKING LIGHT CONNECTOR FOR WORKING LIGHT CONNECTOR FOR WARNING LIGHT CONNECTOR FOR OCSS-UPPER LEFT EMITTER CONNECTOR FOR OCSS-UPPER RIGHT DETECTOR CONNECTOR FOR OCSS-LOWER RIGHT EMITTER CONNECTOR FOR OCSS-LOWER LEFT DETECTOR CONNECTOR FOR WARNING LIGHT CONNECTOR WEIGHT PRESSURE SENSOR OPTION KEYSWITCH RELAY-OPTIONS KEYSWITCH RELAY-SOLENIODS, ATTACHMENTS, HORN KEYSWITCH RELAY, POWER AMPS KEYSWITCH RELAY AC LIFT MOTOR LIFT MOTOR ENCODER LIFT MOTOR TEMPERATURE SENSOR

D2, D3/1&2 D2, D3/1&2 C2, C3/1&2 B3/3 B3/3 C3/3 B3/3 B2/3 F4/3 F5/3 F4/3 F4/3 B2/3 B4/3 C6/1&2 C7/1&2 C6/1&2 C7/1&2 D5/1 C4/1 C4/1

JPTL1, JPTR1 JPTL2, JPTR2 JPTL3, JPTR3 JPWL1 JPWL2 JPWL3 JPWL4 JPWL5 JPW1 JPW2 JPW3 JPW4 JPW5 JPY1 K1 K2 K3 K4 LM LME LMT

DC LIFT MOTOR B4/2 B4/3 D7/1&2 E7/1&2 H4/1&2 H4/1&2 H4/1&2 G4/1&2 G4/1&2 G4/1&2 G4/1&2 B2/3

S1 S2 S3 S4 S5 S6 S7 S8 S9 S10

KEY SWITCH DEADMAN SWITCH CONTROL HANDLE HORN SWITCH CONTROL HANDLE FUNCTION 4A SWITCH CONTROL HANDLE FUNCTION 4B SWITCH CONTROL HANDLE TILT UP SWITCH CONTROL HANDLE TILT DOWN SWITCH CONTROL HANDLE SHIFT LEFT SWITCH CONTROL HANDLE SHIFT RIGHT SWITCH REVERSE WORKING LIGHT SWITCH

LIFT PRESSURE SENSOR

LIFT POWER CONTACTOR B3/1&2 MP PRESS

SWITCHED BASED CONTROL HANDLE

TRACTION AMP CONNECTORS TRACTION MOTOR ENCODER CONNECTORS TRACTION MOTOR TEMPERATURE SENSOR CONNECTORS

D3/3

JPT1

LPC

CONTACTOR PANEL INTERFACE CONNECTOR STEERING POSITION SENSOR CONNECTOR HIGH SPEED LIMIT OPTION CONNECTOR LIFT LIMIT SWITCH OPTION CONNECTOR RIGHT BATTERY GATE SWITCH CONNECTOR LEFT BATTERY GATE SWITCH CONNECTOR MAST TILT SENSING OPTION CONNECTOR

iPORT SUPPLIER WIRELESS MODULE

F2/3 B4/1&2 F2/1&2 D3/3 D3/3 D3/3 D2/3

JPS1 JPS2 JPS5 JPS6 JPS13 JPS14

CONNECTOR FOR DEADMAN

JPRDP1

JPF1 JPF2 JPF3 JPF4

CONNECTOR FOR TEMPERATURE SENSOR BATTERY + BATTERY POWER AMP FAN OPTION CONNECTOR BRAKE CONNECTOR-LEFT BRAKE CONNECTOR-RIGHT

G3, G5/1 D5/3 D5/3

HTR6 HTR7 HTR8

USB CONNECTOR ON VM OPTIONAL LEVER #1 CONNECTOR CONNECTOR ON VM CONNECTOR ON VM FOR FLASHWARE CAN; DIGITAL INPUTS & OUTPUTS CONNECTOR ON VM HANDLE CONNECTOR ON VM CONNECTOR FOR LEVER OPTION HARNESS CONNECTOR FOR LEVER OPTION HARNESS B+, B-, CAN COMMUNICATIONS CONNECTOR ON VM COIL DRIVERS CONNECTOR ON VM PROPORTIONAL COIL DRIVERS ON VM

HEATER FOR CONTROL HANDLE (INTERNAL) HEATER FOR RIGHT SIDE OCSS PHOTO EYE HEATER FOR LEFT SIDE OCSS PHOTO EYE

E6/1&2 E6/1&2

HRN H

HORN TRAVEL ALARM

POWER FUSE FOR STEER POWER FUSE FOR TRAVEL POWER FUSE FOR LIFT

EMERGENCY POWER OFF (S21)

B3/1&2 B3/1&2 B3/1&2

C7/1&2

STEER MOTOR POSITIVE TERMINAL STEER MOTOR NEGATIVE TERMINAL

FU1 FU2 FU3

EPO

A4/1&2 A4/1&2

STEER POWER CONTACTOR

AMBIENT TEMPERATURE SENSOR

B5/3

FAN

OPERATOR'S COOLING FAN

DISPLAY AUDIBLE ALARM

THERMOSTAT FOR HEATERS FOR OCSS PHOTO EYES

D5/3 T-OCSS

WARNING LIGHT

B7/3 T

B2/3 WL

E5/1&2

G2, G4/1,G4/2 G2, G4/1,G4/2 E5/3 E6/3 E6/3 VR1 VR2 VR3 VR4 VR5

SOUNDER

TRACTION POWER CONTACTOR CONTROL HANDLE VARIABLE INPUT DEVICE FOR TRAVEL CONTROL HANDLE VARIABLE INPUT DEVICE FOR LIFT/LOWER LEVER #1 VARIABLE INPUT DEVICE LEVER #2 VARIABLE INPUT DEVICE LEVER #3 VARIABLE INPUT DEVICE

C3/1 TPC

TERMINAL STRIP FOR ACCESSORY POWER

TRACTION RIGHT MOTOR ENCODER TRACTION RIGHT TEMPERATURE SENSOR

C3/1&2 C3/1&2 TRE TRT

D6/1&2

TIE POINT ON B+ TIE POINT ON AUXILIARY MOTOR FUSE TIE POINT ON LIFT MOTOR FUSE TIE POINT ON BTIE POINT ON TRACTION MOTOR FUSE

B3/1&2 B3/1&2 B3/1&2 A5/1&2 B3/1&2

TS1

TRACTION MOTOR LEFT TRACTION MOTOR RIGHT

D3/1&2 D4/1&2 TP1 TP2 TP3 TP4 TP5

C2/1&2 C2/1&2 TML TMR

TRAVEL ALARM POSITIVE TERMINAL TRAVEL ALARM NEGATIVE TERMINAL TRACTION LEFT MOTOR ENCODER TRACTION LEFT TEMPERATURE SENSOR

E6/1&2 E6/1&2

OPTIONAL ANALOG HANDLE

FLEX CIRCUIT CONTROL HANDLE

CONTROL HANDLE HORN SWITCH CONTROL HANDLE ANALOG PUSHBUTTON FOR FUNCTION 4B CONTROL HANDLE ANALOG PUSHBUTTON FOR FUNCTION 4A CONTROL HANDLE TILT/SIDESHIFT JOYSTICK

TLE TLT

H2/1 H3/1 H3/1 G3/1

B4/1&2

H-1(+) H-2(-)

SW1 SW2 SW3 SW4

STR

SPLICE SPLICE SPLICE SPLICE SPLICE SPLICE SPLICE SPLICE SPLICE SPLICE SPLICE SPLICE

G6/1&2 G5/1&2 G5/1&2 G5/1&2 G5/1&2 G6/1&2 G6/1&2 G6/1&2 G6/1&2 G6/1&2 G6/1&2 H6/1&2 E4/1&2 F4/1&2 F4/1&2 D2/1&2 D4/1&2 D3/1&2 E5/1&2 E3/1&2 C5/1&2 F4/3 B3/3 E5/1

LOAD/HOLD SOLENOID LIFT/LOWER PROPORTIONAL SOLENOID DUMP SOLENOID PRIORITY BYPASS SOLENOID PROPORTIONAL RELIEF SOLENOID AUX SELECT SOLENOID SOLENOID FOR HIGH-SPEED ATTACHMENTS SOLENOID FOR HIGH-SPEED ATTACHMENTS SIDESHIFT LEFT SOLENOID SIDESHIFT RIGHT SOLENOID TILT SOLENOID HIGH SPEED ATTACHMENT 2 SOLENOID

C2/3

SOL1 SOL2 SOL3 SOL4 SOL5 SOL6 SOL7C SOL7R SOL9L SOL9R SOL10 SOL11 SPL1 SPL2 SPL3 SPL4 SPL5 SPL6 SPL7 SPL8 SPL9 SPL10 SPL11 SPL12

HIGH SPEED LIMIT SWITCH LIFT LIMIT SWITCH WORKING LIGHT SWITCH MAST TILT SWITCH OPTION BATTERY GATE SWITCHES SWITCH FOR OPERATOR'S FAN SWITCH FOR CLIPBOARD SPOTLIGHT OPTION STEER MOTOR SPOTLIGHT FOR CLIPBOARD

D3/3 D4/3 B2/3 D3/3 D2, D3/3 B5/3 C2/3 A4/1&2

S11 S12 S15 S18 S22A, S22B SF S35 SM SL

DESCRIPTION CONTROL HANDLE HORN SWITCH CONTROL HANDLE FUNCTION 4A SWITCH CONTROL HANDLE FUNCTION 4B SWITCH CONTROL HANDLE TILT UP SWITCH CONTROL HANDLE TILT DOWN SWITCH CONTROL HANDLE SHIFT LEFT SWITCH CONTROL HANDLE SHIFT RIGHT SWITCH

ZONE/SHEET G3/2&4 G3/2&4 G3/2&4 G4/2&4 G4/2&4 G4/2&4 G4/2&4

S3 S4 S5 S6 S7 S8 S9

IDENT.

AUX(+) AUX(-)

LEGEND DESCRIPTION

IDENT.

ZONE/SHEET

LEGEND

Figure 1-7. Electrical Schematic - Legend - Sheet 5 of 5

8

P2

M

P1

M

AC MOTOR

P

L

1

E

STEER VALVE

P1

Publication: 1193671B, Issued: 13 Jun 2016

TACH

R

T

SOL-3

S-RET

HYD STEER MOTOR

REL-1

SOL-4

Models 4150/4250 Stand-Up Counterbalanced Lift Truck Schematics

2

2

1

3

2

1

FILTER

SOL-5

AUX-P

1

CV1 2

100 PSI SPRING

G2

1

2

1

3

SOL-6

2

4

SSR

2

SOL-2

SOL-1

1

2 SOL-9R

1

1

SIDE SHIFT

2

1

1

CYL-P

SOL-7C

2

SOL-7R

2

SOL-9L

SSL

1

CYL1

G1

SOL-10

3

4 2

AC

AR

3

3

1

1

TC

TR

COMPONENT BOUNDARIES

RETURN AND PILOT LINES

PRESSURE LINES

MAIN LIFT

CB-2

2

2

CB-1

FREE LIFT

Model 4250 - AC LIFT

TILT

Shown with Integral Sideshift, attachment ready, and optional Lift Pressure Transducer

Figure 1-8. Hydraulic Schematic - Model 4250 - AC Lift (Sheet 1 of 3)

9

P2

M

P1

M

P

AC MOTOR

L

1

E

STEER VALVE

P1

Publication: 1193671B, Issued: 13 Jun 2016

TACH

R

T

2

SOL-3

S-RET

HYD STEER MOTOR

REL-1

SOL-4

Models 4150/4250 Stand-Up Counterbalanced Lift Truck Schematics

2

1

3

2

1

FILTER

SOL-5

AUX-P

1

CV1 2

100 PSI SPRING

G2

1

2

1

3

SOL-6

2

4

SSR

2

SOL-2

SOL-1

1

2 SOL-9R

1

2

1

1

CYL-P

SOL-7C

2

SOL-7R

2

1 SOL-9L

SSL

SIDE SHIFT

1

CYL1

G1

SOL-10

3

4 2

AC

AR

3

3

1

1

TC

TR

COMPONENT BOUNDARIES

RETURN AND PILOT LINES

PRESSURE LINES

MAIN LIFT

CB-2

2

2

CB-1

10

Model 4150 - DC LIFT

FREE LIFT

TILT

Shown with Integral Sideshift

Figure 1-9. Hydraulic Schematic - Model 4150 - DC Lift (Sheet 2 of 3

SSL

SSL

AR

AC

2

2

1

PR

2

2

1

PR

GR

GB

SIDE SHIFTING PUSH/PULL ATTACHMENT

RET

EXT

1

PB

PUSH/PULL CYLINDERS

4200-INTEGRAL SIDESHIFT SHOWN WITH 4250 INTEGRAL SIDESHIFT SHOWN WITH PUSH/PULL ATTACHMENT PUSH/PULL ATTACHMENT

RET

EXT

1

PB

SHEET RETAINER CYLINDER

SOL-11

AR

AC

Publication: 1193671B, Issued: 13 Jun 2016

SSR

SIDE SHIFT

SSR

SIDE SHIFT

PUSH/PULL CYLINDERS

Models 4150/4250 Stand-Up Counterbalanced Lift Truck Schematics

GR

GB

GRIPPER CYLINDERS

GRIPPER CYLINDERS 2

5 6 1 4 3

SSR

SSL

SIDE SHIFT

AR

AC

4200-

HIGH SPEED AUXILIARY FUNCTIONS

CARRIAGE MOUNTED SOLENOID USED FOR SELECTING BETWEEN TWO

AR

AC

SOL-11

CLAMP

OPEN

SSR

SSL

AR

AC

4

2

4

2

4

2

3

1

3

1

3

1

SOL-12 SIDESHIFT

SOL-13 AUX1

SOL-11 AUX2

D2

D1

C2

C1

B2

B1

CARRIAGE MOUNTED SOLENOID FOR SIDE SHIFT & 2 AUX FUNCTIONS

A2

HI FLOW AUX. 1

SIDE SHIFT

HI FLOW AUX. 2

11

Auxiliary Function Options

4250 CLAMP SIDESHIFT 4250 BOX BOXCLAMP CLAMPWITH WITHINTEGRAL INTEGRAL SIDESHIFT 4200-BOX WITH INTEGRAL SIDESHIFT

A1

Figure 1-10. Hydraulic Schematic - Auxiliary Function Options (Sheet 3 of 3)