Raymond 5400 5500 5600 Orderpicker Schematics Manual SN 00100 and Up - PDF DOWNLOAD

00100 and Up

Issued: 13 Jul 2015

Publication: 1123010B

©2015 The Raymond Corporation.

Serial Numbers

Models

5400, 5500, 5600

If you need assistance with your lift truck, or to order additional copies of this document, contact your local authorized Raymond Dealer. To locate your local authorized Raymond Dealer, 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.

Use with Maintenance Manual 1031794C

Schematics

2

1

T°

2

FU5 (15A)

2

JPF4-1, -2

1

FU8 (15A/5A)

1

FU6 (15A)

MSTP4

SA

FU7 (15A/5A) 1 2

-

MS+

TP2

JPF4-3, -4

JPF1-1, -2

JPF3-1, -2

+

MS

TP4

JPS1-5

TP2

FU1 (100A)

2

1

T°

Publication: 1123010B, Issued: 13 Jul 2015

JP B-

-3, -4

1

JPF3-3, -4

JPS1-1, -2

2

TP3

FUSE/ RELAY CARD

K3

T°

FU3 (500A)

LPC

JPF1-3

TPC

-9 -12 -11

JP B+

TP1

-5, -6, -7

T°

TP5

FU2 (350A)

X

X

LPC

TPC

Y

Y

JPS1-9

JPS1-11

JPS1-8

K1

K2 K4

K4 K3 K2 K1

JPS1-10

CONTACTOR PANEL

CONNECTED TO JPF4-14 ON 24V TRUCKS WITH AC LIFT.

JPF2-1

JPF1-5

1.

JPF1-6

JPF2-8

JPF4-7

JPF2-4 -3,-6,-7,

-10

-8

-11

-12

-5

1 JPF4-13 -14 -6

-5

JPF2-2

JPF2-9

JPF1-4 JPF4-15

-1

-2

LM

TM

V W

W

U V

U

-11

W

W

U V

ID0

ID1

V

U

-12

H

B-

LA

B-

TA

-1

HRN

-2

JP10-1

1

BRAKE

-NEG -IN -POS

B+K3

LPC SUPPLY (B+K3)

-1

-13

JPLA1 LPC -6 CONTACTOR

B+K3

JPTA1 TPC -6 CONTACTOR -13 TPC SUPPLY (B+K3)

L/H

JPS2 -24

JPS2 -11

1

JPS26 -4 -2 -3 -1 -6 -8

WARNING LIGHT

2

-1

JPBR-2

H-1 H-2

B-F

B+ESTOP

GUIDANCE MANAGER CARD (OPTION)

NOTES:

+

Models 5400/5500/5600 High-Level Orderpicker Lift Truck Schematics

JPT24-24

JPT14 -7,-13,-14

JPT14 -12

JPT18 -10 JPT14 -6 JPT22 -21

JPT20 -14

JPT18 -16

CD

BATTERY_SENSE_IN

CD

CD

CD

B-F

JPT20-19

DGND

JPT22 -19

-16

JPT20 -15

1

DGND

+5V

RF

2

1

1

2 FU10

2 FU9

FSUP

B-

TP4 B-

TP1 B+

-8

-6

JPC16 -1 -2 -3 -4

2 NO S56 1 NO

-2

-2

JPS29 -1

10 AMP POWER HOOKUP OPTION

FU31 (15A)

JPS30 -1

FU11 (10A)

FU12 (10A)

KEY SWITCH, EPO, BATTERY SENSE CONNECTOR ON FUSE/R

JPF4

1

B- CONNECTOR ON FUSE/RELAY CARD

JPF3

CONNECTOR ON TRUCK TRACKER FOR POWER

CONTACTOR PANEL INTERFACE CONNECTOR

PROPORTIONAL COIL DRIVERS CONNECTOR ON VM DIGITAL INPUTS CONNECTOR ON VM

JPT20 JPT22

TRACTION POWER CONTACTOR TERMINAL STRIP FOR SPARE POWER

TS12

AC LIFT

TIE POINT ON BTIE POINT ON TRACTION MOTOR FUSE

TP5 TPC

TIE POINT ON B+ TIE POINT ON LIFT MOTOR FUSE

TP3 TP4

TP2

AC TRACTION MOTOR TIE POINT ON STEER MOTOR FUSE

TP1

TM

TRACTION POWER AMPLIFIER

STEER POWER AMPLIFIER TA

SWITCH FOR FAN SA

SWITCH FOR FAN S56

S43

EPO SWITCH SWITCH FOR DOME LIGHTS

S41

KEY SWITCH SWITCH FOR WORKING LIGHTS

S21 S40

S1

STEER MOTOR

LIFT POWER CONTACTOR MS

AC LIFT MOTOR OR DC LIFT MOTOR LPC

LIFT POWER AMPLIFIER LM

LA

LIFT/LOWER SOLENOID

KEYSWITCH RELAY-AUX. VM POWER

K4

LOAD/HOLD SOLENIOD

KEYSWITCH RELAY-POWER AMPS

K3

L/L

KEYSWITCH RELAY-SOLENOIDS, ATTACHMENTS, HORN

K2

L/H

KEYSWITCH RELAY-OPTIONS

K1

JPTA1 TRACTION AMP CONNECTOR

ANALOG INPUTS CONNECTOR ON VM

COIL DRIVERS CONNECTOR ON VM

JPT18

JPT24

B+, B-, CAN COMMUNICATIONS CONNECTOR ON VM

JPT14

2

JPS30 CONNECTOR FOR 10 AMP POWER HOOKUP OPTION ON CAR

JPS29 CONNECTOR FOR 10 AMP POWER HOOKUP OPTION ON TRAC

JPS26 CONNECTOR FOR OVER THE MAST CABLE #2

JPS25 CONNECTOR FOR OVER THE MAST CABLE #1

JPS2

JPS1

JPLA1 LIFT AMP CONNECTOR

CONNECTOR ON C.C.C. FOR OVER THE MAST CABLE #2

CONNECTOR ON C.C.C. FOR SPARE POWER

B+ KEY SWITCH RELAYS CONNECTOR ON FUSE/RELAY CARD

JPC12

B- AUX POWER, B+ POWER AMPS CONNECTOR ON FUSE/REL

CONNECTOR ON C.C.C. FOR LIFT/LOWER BYPASS SWITCH

JPC6

JPF2

CONNECTOR ON C.C.C. FOR LIGHTS/FANS

JPC5

JPF1

CONNECTOR FOR BRAKE

JPBR

TS12-2

BATTERY CONNECTOR BATTERY CONNECTOR +

JPB+

CONNECTOR FOR WARNING LIGHT JPB-

JP10

H (HRN) HORN

JPC16

-4

15A B+ FUSE ON TRACTOR FOR 10A POWER HOOKUP OPTIO 15A B- FUSE ON TRACTOR FOR 10A POWER HOOKUP OPTION

10A B- FUSE ON CARRIAGE FOR 10A POWER HOOKUP OPTIO FU31

10A B+ FUSE ON CARRIAGE FOR 10A POWER HOOKUP OPTIO

FU11

-3

CONTROL FUSE FOR RF TERMINAL B- 2A

FU10

FU30

CONTROL FUSE FOR RF TERMINAL B+ 2A

FU9

-2

CONTROL FUSE FOR AUX. POWER B- 15A/5A

FU8

FU12

JPC6 -1

CONTROL FUSE FOR AUX. POWER B+ 15A/5A

FU7

POWER FUSE FOR LIFT CONTROL FUSE FOR VEHICLE MANAGER B- 15A

POWER FUSE FOR TRACTION

FU6

POWER FUSE FOR STEER

CONTROL FUSE FOR VEHICLE MANAGER B+ 15A

FU3 FU5

FU2

FU30 (15A)

COIL DRIVER CIRCUIT CONNECTOR ON FAN SUPPRESSOR

FU1

FSUP

CD

-3 -4

OTM CABLE

DESCRIPTION

BRAKE ELECTRIC BRAKE

IDENT.

-2

JPC5 -1

CARRIAGE CONTROL CARD

Figure 1. Power Distribution Diagram Sheet 1 (AC Lift)

JPC12 TS12-1 -1 -2

B+ 2 FAN

FSUP-6 -4 -3 -1

1

1

(OPTION)

NO

S21

WORK LTS

TERMINAL

S1

NC

2

WARNING LIGHT (OPTION)

5-

6+

SUPPRESSOR NETWORK

+12V

2,3,4

WORKING LIGHTS

S40 1 2

DOME LIGHTS

S43

1 FAN S41 2 1

2

VEHICLE MANAGER

5 AMP

SLR-2

SLL-2

5 AMP

-1, -8, -9

2

FL-2

JPT14-2, -10

L/L

FL-1

BALLAST

SLR-1

SLL-1

+ 5 AMP FL-1

FAN

BALLAST

-

LIGHTS AND FAN (OPTION)

SPL2-B+

+

Section A . Appendix

SPL1-B-

BALLAST

2

1

T°

2

FU5 (15A)

2

JPF4-1, -2

1

FU8 (15A/5A)

1

FU6 (15A)

MSTP4

SA

FU7 (15A/5A) 1 2

-

MS+

TP2

JPF3-3, -4

JPF4-3, -4

JPF1-1, -2

JPF3-1, -2

+

MS

TP4

JPS1-5

TP2

FU1 (100A)

-5, -6, -7

LPC

+

TP3

T°

FUSE/ RELAY CARD

K3

JPS1-6

T°

FU3 (500A)

S1 -

A2 LM

A1

2

1

Publication: 1123010B, Issued: 13 Jul 2015

JP B-

-3, -4

1

JPF1-3

T°

TP5

FU2 (350A)

LPC

TPC

Y

Y

JPS1-9

JPS1-11

JPS1-8

K1

K2 K4

K4 K3 K2 K1

JPS1-10

X

X

JPF2-8

JPF4-7

JPF2-4 -3,-6,-7,

-10

-8

-11

-12

-5

JPF4-13 -14 -6

-5

JPF2-2

JPF2-9

JPF1-4 JPF4-15

-2

TM

U V W

U V

ID1

W

-12

H

B-

TA

HRN

-2

JP10-1

BRAKE 1

-NEG -IN -POS

B+K3

-1

L/H 2

JPS2 -24

JPS2 -11

1

JPS26 -4 -2 -3 -1 -6 -8

2 STAGE SELECT SOL (OPTION)

WARNING LIGHT

-1

JPBR-2

H-1 H-2

B-F

B+ESTOP

GUIDANCE MANAGER CARD (OPTION)

TPC

-9 -12 -11

JPS1-1, -2

2

JPF2-1

JP B+

TP1

JPF1-6

JPTA1 -6 TPC CONTACTOR -13 TPC SUPPLY (B+K3)

JPF1-5

SLL-1

JPT24-24

JPT14 -7,-13,-14

JPT18-1

JPT14 -12

JPT18 -10 JPT14 -6 JPT22 -21

JPT20 -14

JPT18 -16

JPT20-19

1

CD

BATTERY_SENSE_IN

CD

CD

CD

CD

B-F

-1, -8, -9

CD

JPT14-2, -10

JPT22 -19

JPT18-9

-16

JPT20 -15

S40

WORKING LIGHTS

2

DOME LIGHTS

S43 1 FAN S41 2 1 2

VEHICLE MANAGER

5 AMP

SLR-2

SLL-2

5 AMP

JPT22-20

2

FL-2

DGND

L/L

FL-1

BALLAST

SLR-1

+ 5 AMP FL-1

FAN

BALLAST

-

LIGHTS AND FAN (OPTION)

DGND

+5V

+12V

2,3,4

1

1

2 FU10

FU9 1

2

(OPTION)

FSUP

FSUP-6 -4 -3 -1

WORK LTS

TERMINAL

RF

NO

S21 2

1

1

S1

NC

2

WARNING LIGHT (OPTION)

5-

6+

SUPPRESSOR NETWORK

1

2

FAN

B+

B-

TP4 B-

TP1 B+

-8

-6

-2

-2

JPS29 -1

10 AMP POWER HOOKUP OPTION

FU31 (15A)

JPS30 -1

FU12 (10A)

15A B- FUSE ON TRACTOR FOR 10A POWER HOOKUP OPTION

CONNECTOR FOR 10 AMP POWER HOOKUP OPTION ON TRACTOR CONNECTOR FOR 10 AMP POWER HOOKUP OPTION ON CARRIAG B+, B-, CAN COMMUNICATIONS CONNECTOR ON VM COIL DRIVERS CONNECTOR ON VM PROPORTIONAL COIL DRIVERS CONNECTOR ON VM DIGITAL INPUTS CONNECTOR ON VM ANALOG INPUTS CONNECTOR ON VM TRACTION AMP CONNECTOR

JPS30 JPT14 JPT18 JPT20 JPT22 JPT24 JPTA1

EPO SWITCH

TIE POINT ON B+

TRACTION POWER CONTACTOR TERMINAL STRIP FOR SPARE POWER

TPC TS12

DC LIFT

TIE POINT ON BTIE POINT ON TRACTION MOTOR FUSE

TP5

TIE POINT ON LIFT MOTOR FUSE TP4

TP3

TIE POINT ON STEER MOTOR FUSE

AC TRACTION MOTOR TP2

TM

STEER POWER AMPLIFIER

TP1

SWITCH FOR FAN

S56 SA

TRACTION POWER AMPLIFIER

SWITCH FOR FAN

S43

TA

SWITCH FOR DOME LIGHTS

S41

SWITCH FOR WORKING LIGHTS

KEY SWITCH S21 S40

S1

STEER MOTOR

LIFT POWER CONTACTOR MS

DC LIFT MOTOR

LIFT/LOWER SOLENOID

LPC

LOAD/HOLD SOLENIOD L/L LM

KEYSWITCH RELAY-AUX. VM POWER

KEYSWITCH RELAY-POWER AMPS

L/H

KEYSWITCH RELAY-SOLENOIDS, ATTACHMENTS, HORN K3 K4

K2

3

CONNECTOR FOR OVER THE MAST CABLE #2 JPS29

KEYSWITCH RELAY-OPTIONS

CONNECTOR FOR OVER THE MAST CABLE #1 JPS26

K1

CONNECTOR ON TRUCK TRACKER FOR POWER JPS25

CONTACTOR PANEL INTERFACE CONNECTOR JPS2

JPS1

KEY SWITCH, EPO, BATTERY SENSE CONNECTOR ON FUSE/RELA

B- CONNECTOR ON FUSE/RELAY CARD

JPF3 JPF4

CONNECTOR ON C.C.C. FOR OVER THE MAST CABLE #2

CONNECTOR ON C.C.C. FOR SPARE POWER

B+ KEY SWITCH RELAYS CONNECTOR ON FUSE/RELAY CARD

CONNECTOR ON C.C.C. FOR LIFT/LOWER BYPASS SWITCH

JPF2

CONNECTOR ON C.C.C. FOR LIGHTS/FANS JPC12

B- AUX POWER, B+ POWER AMPS CONNECTOR ON FUSE/RELAY C

CONNECTOR FOR BRAKE JPC6

JPF1

BATTERY CONNECTOR + JPC5

JPC16

BATTERY CONNECTOR JPBR

CONNECTOR FOR WARNING LIGHT JPBJPB+

JP10

H (HRN) HORN

15A B+ FUSE ON TRACTOR FOR 10A POWER HOOKUP OPTION

-4

10A B- FUSE ON CARRIAGE FOR 10A POWER HOOKUP OPTION FU31

CONTROL FUSE FOR RF TERMINAL B- 2A 10A B+ FUSE ON CARRIAGE FOR 10A POWER HOOKUP OPTION

CONTROL FUSE FOR RF TERMINAL B+ 2A

CONTROL FUSE FOR AUX. POWER B- 15A/5A FU9

FU8 FU10

FU30

FU11 (10A)

POWER FUSE FOR LIFT CONTROL FUSE FOR VEHICLE MANAGER B- 15A CONTROL FUSE FOR AUX. POWER B+ 15A/5A

CONTROL FUSE FOR VEHICLE MANAGER B+ 15A

FU6 FU7

FU5

POWER FUSE FOR STEER POWER FUSE FOR TRACTION

FU2 FU3

FU1

FU12

FU30 (15A)

COIL DRIVER CIRCUIT CONNECTOR ON FAN SUPPRESSOR

CD FSUP

-3

OTM CABLE

DESCRIPTION

BRAKE ELECTRIC BRAKE

IDENT.

FU11

JPC16 -1 -2 -3 -4

NO S56 NO

2

1

CARRIAGE CONTROL CARD

Figure 2. Power Distribution Diagram Sheet 2 (DC Lift)

-2

JPC6 -1

-3 -4

-2

JPC5 -1

JPC12 TS12-1 -1 -2 TS12-2

SPL2-B+

CONTACTOR PANEL

+

Models 5400/5500/5600 High-Level Orderpicker Lift Truck Schematics

SPL1-B-

BALLAST

JP B-

JPS1-2 -1 -4 -3

-2

JPF3-1

-2

-1

JPF4-3 -4

-2

JPF1-1

+

-

MS

TP4

SA

JPS1-5

TP2

FU1 (100A)

FU8 (15A/5A) 1 2

FU6 (15A) 1 2

MSTP4

MS+

TP2

1

T°

2

FU5 (15A)

1

2

1

LPC

TP3

T°

FUSE/ RELAY CARD

K3

T°

TP5

FU2 (350A)

X

X

LPC

TPC

Y

Y

K2

-7

MOTOR TEMPERATURE JPS1-9

LMT

K1

K4

JPF2-8

JPF2-4 -6 -7 JPF4-7

-10

-8

-12 -11

-5

-1 -2

LM

8

V W

W

H

B-

SERIAL Rx U

SERIAL Tx

+12V

ID1

ID0

L TEMP+

V

U

-29

-28

-25

-12

-11

-8

-8

LPC CONTACTOR

PROGRAM

HRN

-2

JP10-1

-14

1

L/H

-14

-1

-23 -35

-13

JPLA1 -6

BRAKE

-NEG -IN -POS

PROGRAM

B+K3

CURTIS LA AC LIFT AMPLIFIER

BUS+ BUS-

L VEL SENSOR - LPC L VEL PHASE A SUPPLY (B+K3) L VEL PHASE B

JPLA1 -26 L VEL SENSOR + -7

W

W

-32

-1

H-1 H-2

JPT14 -5

B+KEY

VEHICLE MANAGER

2

DETAIL B 11

JPS26 -4 -2 -3 -1 -6 -8 JPS30-1 -2

WARNING LIGHT

-1

JPBR-2

HORN

B-F

DGND DGND

FU1_SENSE

JPS29-1 -2

JPT14 -7 -13 -14 JPT24-24

B+K2 B+K2 B+K2 BATTERY_SENSE_IN

B+KEY

-15

JPT20 -16

JPT20-1 JPT22-1

+12VP

-10 JPT10-9

JPT2 VBUS -1 D+ -2 -3 DDGND -4

JPT9 TXD -2 RXD -3 DGND -5

DGND

JPT22-9

JPT20-7

+

0

1

-2

STEER MOTOR ENCODER

HOME SENSOR PROX

S10 + +VS -3 0 -2 OUT - GND -1

JPE4-1 RED -3 WHT -2 BLU -4 BLK

-3

L/L

-2

JPA7 -1

2

JPS8-3

-2

S10

-5 CARRIAGE DEADMAN JS27 JS31-1 -1

JPT22-8

-6 -1

JPS25 -2 -3

JPT22-7

JPS8-1 JPS8-2

F

JPS25 BRAKE DEADMAN -4

HOME JPT22 SENSE -3 DGND -11 JPT20 +12VF -9

CHANNELA_4 CHANNELB_4

NEUTRAL_PULSE

JPT18 -10 L/H JPT14 -6 RELAY_ENABLE JPT22 -21 EPO_SENSE JPT14 -12

L/L

+12VF 150_LIM

DGND

STEER_CURRENT (B+K2)B+L/L DGND

CW_PWM

CCW_PWM

+12VP

DGND

BUS_I+ BUS_I-

JPT20 -14 BRAKE

JPT18 -16

-1 JPT22 -19 JPT14 -10 -2 -1 -8 -9

-4

-3

-2

JPT6 -6 -5

-3

-11 -4

+12VP

DGND

+5V

+12V

BRAKE DEADMAN

B+K3

CURTIS TA AC TRACTION AMPLIFIER

CARRIAGE DEADMAN

V

-3 -7

-35

SERIAL Rx U

B-

BUS-

E

SERIAL Tx

+12V

ID1

ID0

V

-31

11

TM

-28 -29 U

-4

DETAIL A

JPF4-13 -14 -6

JPF2-2 -3 -5

JPF2-9

JPLA4 -6 -5

JPF1-4 JPF4-15

-3 LME WHITE BLUE -2 JPLA3 RED -2 RED/BLK -1

BLACK -4

MOTOR VELOCITY JPLA2 -1 RED

JPS1-11

JPS1-8

MOTOR TEMPERATURE

-11 -12

-8

-1

-25

-3

BLUE -2 RED JPTA3-2

DETAIL A 11

-4

SEE SHEET 5, D6

JPS4-5

D JPTA1 JPTA1 -26 T VEL -6 TPC SENSOR + CONTACTOR -7 T VEL SENSOR -13 TPC -31 T VEL PHASE A SUPPLY -32 T VEL PHASE B (B+K3) -8 -23 T TEMP+ BUS+

-1 -2

-5

WHITE -3

JPTA4 -6

BLACK -4

TMT RED/BLK

TME

K4 K3 K2 K1

JPS1-10

CONTACTOR PANEL

T°

FU3 (500A)

JPF1-3

TPC

FU7 (15A/5A) 1 2

2

Publication: 1123010B, Issued: 13 Jul 2015

7

6

5

4

3

JP B+

TP1

JPF3-3 -4 -5 -6 -7 -8 -12 -11

2

JPF1-5

NOTES: SEE PAGE 6.

JPF2-1

JPSC2-2

C

JPF1-6

JPS4-6 JPSC1-2 JPSC1-1

JPSC2-1

MOTOR VELOCITY JPTA2 -1 RED

HOME SENSOR USB

B

120 IN. LIMIT 150 IN. LIMIT COMMUNICATIONSFLASHWARE

A

+

B+KEY B+FU5

-6 -8

9

B+EPO B-FU8 B+FU7 B-FU6

JPC16 -1 -2 -3 -4

DGND

SEE SHEET 3

CARRIAGE CONTROL CARD

CARRIAGE DEADMAN

-6

BRAKE DEADMAN

-5

-4

JPC11 -1 +12V -2 BUS-3 BUS+

TABLE A AUX. POWER OPTION STD C.S. FU7 5A 15A 5A 15A FU8

G

AC LIFT

H

Figure 3. Electrical Schematic Sheet 1 (AC Lift)

OVER THE MAST CABLE

Models 5400/5500/5600 High-Level Orderpicker Lift Truck Schematics

OVER THE MAST CABLE

+

4

JP B-

-2

JPF3-1

-2

-1

JPF4-3 -4

-2

JPF1-1

+

-

MS

TP4

SA

JPS1-5

TP2

FU1 (100A)

2

2

1

T°

2

FU5 (15A)

FU7 (15A/5A) 1 2

1

FU8 (15A/5A)

1

FU6 (15A)

MSTP4

MS+

TP2

2

S1

LM

A2

A1

2

1

LPC

T°

FUSE/ RELAY CARD

K3

T°

JPS1-6

-

+

TP3

FU3 (500A) 2

JPF1-3

TPC

Publication: 1123010B, Issued: 13 Jul 2015

7

6

5

4

JPS1-2 -1 -4 -3

1

JPF3-3 -4 -5 -6 -7 -8 -12 -11

3

JP B+

TP1

T°

TP5

FU2 (350A)

X

X

LPC

TPC

JPF1-5

Y

Y

K2

-4 -3

-2

JPS1-9

JPS1-11

JPS1-8

K1

K4

JPF1-4 JPF4-15

JPF2-8

JPF2-4 -6 -7 JPF4-7

-10

-8

-11

-12

-5

-3 -5 JPF4 -13 -14 -6

JPF2-2

JPF2-9

DETAIL A

-2

-1

-7

-1

RED/BLK

-8

RED JPTA3 -2

BLUE

-5

RED

WHITE -3

JPTA4 -6

BLACK -4

JPTA2 -1

TM

11

U

B-

V W

W

SERIAL Rx U

SERIAL Tx

+12V

ID1

ID0

T TEMP+

H

BUS-

BUS+

TPC SUPPLY (B+K3)

-2

JP10-1

1

-NEG -IN -POS

BRAKE

HRN

PROGRAM

B+K3

L/H

-14

-1

-35

-23

-13

JPTA1 -6

CURTIS TA AC TRACTION AMPLIFIER

T VEL PHASE B

V

-29

-28

-25

-12

-11

-8

-32

TPC

D CONTACTOR

T VEL PHASE A

SENSOR +

T VEL SENSOR -

-7 -31

JPTA1 -26 T VEL

DETAIL B

JPS26 -4 -2 -3 -1 -6 -8 JPS30-1 -2

WARNING LIGHT

2

-1

JPBR-2

H-1 H-2

11

BUS_I-

JPT18 -10 JPT14 -6

JPT20 -14

JPT18 -16

JPT22 -20

-1 JPT22 -19 JPT14 -10 -2 -1 -8 -9

-4

-3

-2

JPT6 -6 -5

JPT18 -9

JPS29-1 -2

JPT14 -7 -13 -14 JPT24-24

JPT14 -12

L/L

+12VF 150_LIM

DGND

+5V

+12V

-2 -4

JPT10-9

VBUS D+ DDGND

JPT2 -1 -2 -3 -4

+

L/L

0

1

BLK

BLU

JPE4-1 RED -3 WHT -10

JPT22-9

JPT20-7

-2 -3

JPA7 -1 -11 JPT20 -9

2

+VS OUT GND

-2

JS27 -1

STEER MOTOR ENCODER

HOME SENSOR PROX

-

JPS8-3

-1

S10 + -3 0 -2

-2

JPS8-1 JPS8-2

JPT22 -3

-15

JPT20 -16

JPT20-1 JPT22-1

-5 JS31-1

JPS25 -4

JPT22-8

-6 -1

JPS25 -2 -3

F

JPT22-7

JPT9 TXD -2 RXD -3 DGND -5

DGND

CHANNELB_4

+12VP CHANNELA_4

+12VF

DGND

HOME SENSE

(B+K2)B+L/L

B+K2 B+K2 B+K2 BATTERY_SENSE_IN

B+KEY

EPO_SENSE

RELAY_ENABLE

L/H

BRAKE

HORN

FU3_SENSE

B-F

DGND DGND

FU1_SENSE

NEUTRAL_PULSE

DGND

STEER_CURRENT

CW_PWM

CCW_PWM

+12VP

LIFT_CONTACTOR

DGND

BUS_I+

-3

-4

+12VP

DGND

B+KEY

CARRIAGE DEADMAN

BRAKE DEADMAN

VEHICLE MANAGER

E

-11

JPT14 -5

JPT22-21

SEE SHEET 5, D6 JPS4-5 JPSC1-1

C

MOTOR TEMPERATURE

TMT

K4 K3 K2 K1

JPS1-10

CONTACTOR PANEL

JPF2-1

TME

JPF1-6

JPS4-6 JPSC1-2

MOTOR VELOCITY

HOME SENSOR

B

S10

-8

-6

9

JPC16 -1 -2 -3 -4

-6

-5

B+FU5

B+KEY

B+EPO B-FU8 B+FU7 B-FU6

DGND

SEE SHEET 3

CARRIAGE CONTROL CARD

CARRIAGE DEADMAN

BRAKE DEADMAN

JPC11 -1 +12V -2 BUS-3 BUS+ -4

G

DC LIFT

H

Figure 4. Electrical Schematic Sheet 2 (DC Lift)

TABLE A AUX. POWER OPTION STD C.S. 5A 15A FU7 5A 15A FU8

OVER THE MAST CABLE

2

A

120 IN. LIMIT 150 IN. LIMIT USB COMMUNICATIONSFLASHWARE

OVER THE MAST CABLE

Models 5400/5500/5600 High-Level Orderpicker Lift Truck Schematics

+

5

JPTA1-1

JPTA1-1

JPTA1-12

11

DETAIL B1

OPTIONS

JPBR-1

JPBR-2

DETAIL A2

11

H-2

+12VP

DGND

SENSOR 2

+12VP

DGND

SENSOR 1

JPT20-14

11

FOR TRACTION CONTROLLER

-2

DETAIL A1

JPTA1-12

JPTA1-11

VEHICLE MANAGER

-1

SPL2

JPTA4-2

JPLA1-1

JPLA1-1

JPLA1-11

-2

-3

-8

JPT24-9

11

C

ALTERNATE END OF AISLE

-1

JPT10 -7

JPS55

-3

-2

-2

JPT24-8

-1

-6

DETAIL B2

JPXBR-1

JPXBR-2

JPLA1-12

JPLA1-11

FOR LIFT CONTROLLER

-2

JPS54

-1

SPL1

JPLA4-2

JPLA4-1

JPT10

JPF1-6

JPTA4-1

JPF1-6

Publication: 1123010B, Issued: 13 Jul 2015

7

6

5

4

3

JPF1-6

JPF1-6

B

-8

-6

-4

-3

-2

S46A -1

OPTIONS

-3

+VS

B+FU5

B+KEY

B-FU6

B+EPO

FUSE/RELAY CARD (SEE SHEET 1 & 2)

JPF4-10

-8

-8

-6

-4

-4 JPF3-12

-6

-3

JPF4-8

-2

JPC16 -1 -3

9

-4

-4

-17

-3

-3

-17

-2

-2

-24

-24

JPC2

-16

-16

-1

-15

-15

-1

-1

-1

JPC15

-2

GND

OUT

S16

S15

JPS26 -1

-

+VS

GND

JPF4-15

-1

-3

0

+

-

OUT

JPF1-4

-2

-1

-5

-8

+ 0

-5

-4

-6

B+FU5

B+KEY

B-FU6

B+FU7

B-FU8

B+EPO

ETR/SHFT

DN ARROW

UP ARROW

DGND

+5.3V

DGND

-2 -3

-1 -3

1

-1

JPC7 -2

DGND +12VF

DGND

AUTO/MAN

HORN

DGND

L/L

+5.3V

DGND

TRAVEL

+5.3V

PGND

60" LIMIT

6-12VF

DGND

CARRIAGE DEADMAN

0 -

-3

S28 -1 -2 -3

-6

JPC3 -2 -1 -3

-2

-1

-3

-4

-6

-5

-7

-9

-8

JPC9

-

-2 -4

2 S1

S21

GND

OUT

+VS

GND

OUT

+VS

GND

OUT

+VS

GND

OUT

+VS

NO

NC

+ 0 -

S3 -3 -2 -1

2

GND

OUT

+VS

TRAVEL

S4

VR2

(OPTION)

HORN

S3

LIFT/LOWER

VR1

5

S28

S23

S2

S11

H

Figure 5. Electrical Schematic Sheet 3

CONTROL HANDLE

+

0

-1

-5

+

S2

-3 DGND

S23

+ 0 -

-3

+12VF

-2

+ 0 -

-1

2

1

-1

S11

1

STEERING ENCODER

JPC8 -2

-4

-3

-2

JPC6 -1

-6

-5

-4

-3

-2

-1

JPC21

-9

-8

-4

-3

-2

-1

JPC1

G

24" LIMIT

6-12VF

B+ KEY

B+ESTOP

B+KEY

B+F

CD

CD SUPPLY

CHB-E2

CHA-E2

DGND

+5.3V

DEADMAN

BRKDMAN

CHB

CHA

DGND

+5.3V

BRK DEADMAN

INPUT STEER ENCODER

CARRIAGE CONTROL CARD

CARRIAGE DEADMAN

BRAKE DEADMAN

DGND

+12V

BUS+

-1

BUS-

-3

F

-2

JPC11

JPF4-5

-3

S16

-2

JPS53B

-2

-3

-1

B+FU7

-7

S15

-3

DUAL ASC SWITCHES

JPT24-5

-2

-1

JPS53

-2

-1

JPS53

-5

-6

-4

B-FU8

LEFT

RIGHT

DGND

JPT18-4 JPT22-22

CARRIAGE DEADMAN

-3

-6 -1

-2

-5

-8

SEE

( SHEET ) 5 {

JPS25

JPS4

E

-7

JPT22

-3

-5

JPT14

-3

LEFT

-8

-7

-5

-3

S47B -1

-8

-6

-4

-3

-2

S47A -1

+12VP RAIL_SEN

DGND

+12V

BRAKE DEADMAN

VEHICLE MANAGER (SEE SHEET 1 & 2)

D

S46B -1

RIGHT

VEHICLE MANAGER RAIL SENSE

2

A

CARRIAGE CONTROL LIGHT DISPLAY CARD ALL PINS USED OPERATOR INTERFACE ALL PINS USED

OVER THE MAST CABLE

*INCLUDES CPU, CAN & ROM

Models 5400/5500/5600 High-Level Orderpicker Lift Truck Schematics

AISLE DETECT

CARRIAGE CONTROL LIGHT DISPLAY CARD OPERATOR INTERFACE CARD OVER THE MAST CABLE

EPO/ KEY 24" LIMIT DEADMAN SWITCHES

60" LIMIT CONTROL HANDLE/ AUTO MANUAL SW

6

-5

SHLD

FU35 2 AMP 125VDC BATT+BATT-

-3

RXD

-6

-7

-8

-6

-7

-8

Publication: 1123010B, Issued: 13 Jul 2015

ORIGINAL 10 AMP POWER HOOKUP OPTION

FU11 10 AMP

FU12 10 AMP

-5

-5

2

-4

-4

1

-3

TS12

-2

-3

JPC16 -1

CARD

CONTROL

CARRIAGE

-5

+6

JPC14 -2

2,3,4

1

JPC13 -2

-3

PGND

-3

SIDEGATE LEFT -1

+12VF

PGND

SIDEGATE RIGHT -1

+12VF

SUPPRESSOR NETWORK 1

1

2

2

S40 2

680Ù

WORKING LIGHTS

1

DOME LIGHTS

S41

FAN

S43

-2

IN PC5-2 BLACK

0

FU1

-

1

S43 FAN

1

1

2

2

-

SLL-1

SLR-1

2

FL-R

FL-L

FAN

DOME LIGHTS

S41

WORKING LIGHTS

S40

+

WHITE

RED

WHITE

RED

BLUE JP2-4

BLUE

BLACK

BLACK

BLUE JP1-4

BLUE

JP2-3

JP1-3

SENSOR PROX

GND

JPT12

-12

-6

LIFT -5 LOWER

VM

JPS26 -4 -2 -3 -1 -6 -8

2 EPO

-9

-3

JP1MPV -4

1

S22

STANDARD / FLUORESCENT

JP2-2

5 AMP

FU2

5 AMP JP1-2

FAN

MPV OPTION

+

-

JP2-1

JP1-1

+

3,5,6

4

SLR-2

SLL-2

FL-R

FL-L

-4

JP1-7

JP1-5

-1

-1

1

1

JP1-8

2

2

-4 -2 -3 -1 -6 -8

LGHT 2

-4

JP1-6

COLD STORAGE / INCANDESCENT

SUPPRESSOR NETWORK

BALLAST

-2

JPX1 -1

PC5-2

PC5-1

(10A)

FU12

(10A)

FU11

+1

IN PC5-1 WHITE

D

BULB

7

BATT+

PT9-2

TXD

CONNECTOR TO RAYMOND TM

iPORT SUPPLIER WIRELESS MODULE

-6

BATT-

DGND

-3

-5

TXD

-2

RXD

CONNECTOR TO THIRD PARTY DEVICE

JRDP1-1

-2

-2

10 AMP POWER HOOKUP OPTION

(15A)

FU31

-1

-1

C

BALLAST

-2

B-FU8 TS12-2

TS12-1 1

-2

HTR3 -1

HTRC 2 1

S81 2

FU21

-4

S111 (DOWN)

S112 (UP)

-1

FU13 (15A)

TP1 B+ 9

-8

-6

-4

-7 -8

-8

-7

-6

-5

-5 -6

-4

-4

-3

-2

JPS16 -1

OTM CABLE

1

5A

FUDM 2

+ 0 -

-2 -3

-

0

+

2

1

TS13

B+FU5

B+FUSEDS

B+KEY

B+EPO

B-FU6

B+FU7

B-FU8

B+EPO

B+FU12

B-FU13

-8

-6

-4

-3

-2

JPC16 -1

S15A

S15B

FUSE RELAY CARD HARNESS (P/N 1057487 AND 1057488)

FU12 (15A)

-2

-2

-3

JPSI26 -1

JPS26 -1

-3

HTRDM 2

2

1 S80

H

JC5-4 OF CONTROL HANDLE HEATER

JC5-3 OF CONTROL HANDLE HEATER

JC5-1 OF LIGHT & FAN PACKAGE

JC5-2 OF LIGHT & FAN PACKAGE

COLD STORAGE OPTION DEADMAN HEATER

1

-1

JPBGS1

-3

-2

-1

JPBGS2

HTR3 -1

HTR3 -2

G

BATTERY GATE SENSOR (OPTION)

-3

JPS16 -1 -2

JPT20-6

2

10A

1

JPT24-6

TP4 B-

MANAGER

VEHICLE

COLD STORAGE OPTION CARRIAGE CONTROL CARD HEATER

JPC12 -1

B+FU7

F

JPT22-6

E

6A SPARE -1

LGHT 1

-4

BULB

6

B-

TP4

(15A)

FU30

JPS29

JPS30

OTM CABLE

B

BULB

5

4

3

TP1

B+

TP1

2

TP4

A

SIDEGATE SWITCHES

Figure 6. Electrical Schematic Sheet 4

CARRIAGE GARD

Models 5400/5500/5600 High-Level Orderpicker Lift Truck Schematics

MAIN HARNESS

BULB

7

FLOW SENSOR

A B

B

A

P

JPB1-2

P

INTELLISPEED

Y

X

X

AUX SEL SOL

Y

NC

PRESS SW1

AUX L/H SOL

-6

-12

-3

-9

Y

JPF3-11

JPF2-4

JPF2-3

JPF2-8

2 STAGE SELECT SOL

JPT18-1

JPT18-5

JPT22-5

JPT18 -14 -15 -12

JPT18-7

JPT20-8 JPT4-3

JPT12 -5

JPT22-13 JPT22-14 JPT24-11 JPT24-19 JPT20-2

J1 -4

MAIN SEL SOL

X

-3

-1

-

JPB1-1

LIFT MOTOR FAN 36V EE ONLY

S124

GND F/S TEMP

JPY2 -1 -2

JPS51 -1 -2 -3 -4 -5

JPS57 -1 -2

VR IN1 SHLD

JPY6 -1 -2 -3

JPY1 -1 -2 -3 -4 -5

S124 + -3 O -2

VR IN2 SHLD

JPY7 -1 -2 -3

Publication: 1123010B, Issued: 13 Jul 2015

7

6

5

4

3

-

6

-2 -3 JPS16 -1

JPT24-3

JPT20-6

DGND

B-FU6

B+K4

B+K2

B+K2

JPS15 -2 -1

JPT20-17 JPT18-18

B+WG (B+K2)

)

HORN

ALARM_LIFT

B+ALARM (B+K2) ALARM_TRAVEL

SEE SHEET 1 & 2

(

-3

JPT24-7

DGND

B+K2

B-FU6

JPF2-2

JPF3-9

SEE SHEET 1

JPT20-19

JPT18-16

-2

H-1(+)

-

-

-

-1

JPS4 -5

JPS2 -11

JPS2 -24

-6

OUT GND

+VS

OUT GND

+VS

OUT GND

+VS

OUT GND

A TRAVEL ALARM

-

S100 + -3 -2 0

-1

S27 + -3 -2 0

-1

S24 + -3 -2 0

-1

+VS

D

S15 + -3 -2 0

JPS52-1

AL+ AL-

H-2(-)

-2

JPT24-1 JPT22-4

+12VP 180_LIM

JPT20 -18

-3

JPT24-6 JPS28 -1

-2

JPT22-6

TRVL CUTOUT DGND

+12VP

JPS10 -1

-3

JPT24-5

JPT22-2

-1

JPS53 -2

-3

JPT18-4 JPT22-22

JPT24-9

-2

JPT20-10

FUSE/RELAY CARD

2 STAGE SOL

DGND

PRESS_SW

MAIN SEL AUX SEL AUX L/H

DGND

-3

JPT24-8 JPS55 -1

-2

-2

JPT10 -7 -8

JPS54 -1

JPT10 -6

+12VP LIFT INHIB

DGND

RAIL_SEN

+12VP

DGND

+12VP SENSOR 2

DGND

+12VP SENSOR 1

VEHICLE MANAGER

LIFT DECEL

+12VP

DGND

LOWER

LIFT

FLOW A FLOW B DGND FS TEMP +12VP

+12VP P/T A DGND DGND

FLOW SENSOR LIFT PENDANT

JPS50 -1 JPT20-5 JPT24-18 -2 JPT24-10 -3

PRESSURE TRANSDUCER A LIFT DECEL

+ PRESS0 A

OPTIONS

AISLE DETECT

2

ALARM LIFT/LOWER

ALARM TRAVEL AUX MAST 24V HIGH PERFORMANCE LIFT

RAIL SENSE TRAVEL CUTOUT LIFT INHIBIT 180 IN. LIMIT ELECTRONIC HORN

FLOW MODULE

C

1 1

+

B-F

BUS+

BUS-

B+ESTOP

2

HRES

-

GUIDANCE MANAGER

JPW1 -1 -2 -3 -5 -6 -7 -8 -14 -15 -13

JPW2 -1 -2 -3 -5 -6 -7 -8 -14 -15 -13

JP1L -1 -2 -3 -5 -6 -7 -8 -14 -15

JP1T -1 -2 -3 -5 -6 -7 -8 -14 -15

WIRE GUIDANCE

H1

180 IN. LIMIT S100

S27

S24

S15

S47B -1 -3 -5 -7 -8

S47A -1 -2 -3 -4 -6 -8

S46B -1 -3 -5 -7 -8

S46A -1 -2 -3 -4 -6 -8

S34

RIGHT NEAR WIRE LEFT T0 T1 T2 T3 AGRD +12VF

RIGHT NEAR WIRE LEFT T0 T1 T2 T3 AGRD +12VF

LEFT

RIGHT

-1

S33

E

S32

+VS

S31 -2

LIFT

AUX LIFT & LOWER

DGND

2

2

-3

FU10

FU9

FSUP

1

-1

-3

-4

-6

FSUP-

1

DGND

-2 LOWER JPC20 -2 +12VF -1 AUX LIMIT

-1

-3

JPC19

WORK LTS

RF TERMINAL

-3

S34 -1 -2

LIFT -1

-2

-1

OUT GND

LOWER

-2

2

B+

1

2

NO

NO

1

FAN

+12VF B+KEY

B+FU7 B-FU8

JPC12 -1 -2

S56

B-

B+

+5.3V

DGND

PGND

-1 -2 -3 -4 -5 -6 -7 -8 -9

JPC18 -1 -2 -3 -4 -5 -6 -7 -8 -9

TS12-2

OPTIONS

TP4

TP1

CARRIAGE CONTROL CARD

-1 -2 -3 -4 -5 -6 -7 -8 -9

JPC17 -1 -2 -3 -4 -5 -6 -7 -8 -9

F

TS12-1

B-

SPL1-B-

6 4

AUX CARD SPL2-B+

AUX MAST SPARE POWER

SIDEGATE SWITCHES LOWER BYP INHIB /L/ BYP INHIB

B

+12VF

G

B+KEY

B-F

B-F

B+KEY

B+KEY

B-FU8

DGND

L/L INHIBIT BYP

PGND

-3

-3

+ 0 -

S61 -1 -2 -3

-1 -3

S1-2 (SHEET 3)

VM

iPORT TRUCK -2 -5

-3

JPC9

-4

-3

-2

JPC5 -1

JPC6-2

JPC12-2

-5

-6

7

-3 -3

+VS

S90

1

DA60

S7

1

6

A

B

K12

S7

S25

S61

S60

1

1

2

S75

SPL5

HTRH

CONTROL HANDLE HEATER

2

1

4

3

GND

OUT

+VS

GND

OUT

+VS

GND

OUT

K12

4

-

-2

JPC6

+ 0

S25 -1 -1

JPC4 -2

LOWER INHIBIT

+12VF

PGND

-

-2

JPC13 -2

SIDEGATE LEFT

+12VF

PGND

+ 0

S60 -1

H

Figure 7. Electrical Schematic Sheet 5

-1

JPC14 -2

SIDEGATE RIGHT

iWAREHOUSE-RED SYSTEM

A

RS-232

HIDDEN KEY SWITCH POWER OPTION SEE INSTALLATION MANUAL FOR DETAILS

Models 5400/5500/5600 High-Level Orderpicker Lift Truck Schematics

TRACTOR SENSOR LOAD SENSOR

-

+

8

60 INCH LIMIT SWITCH NOT USED ON INTELLISPEED TRUCKS.

OPR W/AUX LIFT OPTION.

REFERENCE POWER DISTRIBUTION DIAGRAMS D20009008 AND D20009239.

CONNECTED TO JPF4-14 ON 24V TRUCKS WITH AC LIFT. SEE FUSE RELAY CARD HARNESS ILLUSTRATION ON PAGE 4, APPLIES TO TRUCKS WITH INCANDESCENT LIGHT AND FAN PACKAGE BETWEEN S/N 5XX-XX-X01011 AND 5XX-XX-X04700

FOR MAIN HARNESS P/N 1040198/XXX USE DETAIL A1 AND B1; FOR MAIN HARNESS P/N 1109225/XXX USE DETAIL A2 AND B2 ON PAGE 3.

5

6

7

8

11

Publication: 1123010B, Issued: 13 Jul 2015

9

SCHEMATIC SHOWS TRUCK SWITCHED OFF, DEADMAN SWITCHED OFF, AND CARRIAGE FULLY LOWERED.

36V TRUCK ONLY.

350A FUSE REPLACES 500A FUSE ON SINGLE STAGE LIFT PUMP TRUCKS.

2

3.

1

NOTES:

5

5

5

5

JPC22

JPC23

JPB1

JPC19

5

5

JPC18

3,5

5

JPC17

JPC21

5

JPC16

JPC20

3

1,2,3

JPC15

5

3

JPC8

5

3

JPC7

JPC14

3,5

JPC6

JPC13

4,5

JPC5

3

5

JPC4

4,5

3

JPC3

1,2,3

3

JPC2

JPC12

E5

3

JPC1

JPC11

F2

1,2

JPBR

JPC9

A4

B7

F4

F4

F3,F3

F3

F2

F3

F2

G6,E6

E5

G2

G3

F2,F4

G2,E3

F6

F5

F5

F4,G3

B4,G5

G3

F6

D6

A3

D6

E5

D6

E6

1,2

4

JP1MPV

1,2

5

JP1L

H5

G2

JPB-

5

HTRH

JPB+

4

HTRDM

F2

F5

4

HTRC

F3,G3

D5

5

4

HTR3

1,2

5

HRES

D6

1,2

1,2

H (HRN)

E5

H2

JPA7

5

JP10 JP1

4

FUDM

H1

F3

F6

F6,B6

B6

F4

F4

B6

B6

B6

B6

B3

B3

B3

F6

D6

D5

D5

B6

ZONE

JP1T

4

5

FU10

FU21

5

FU9

4

1,2

FU8

FU13

1,2

FU7

4

1,2

FU6

4,4

1,2

FU12

1,2

FU5

FU11

1,2

FU3

FU1

FU2

5

1,2

FSUP

1,2

5

AL-

AL+

BRAKE

5

SHEET

2 STAGE SEL SOL

IDENT.

LEGEND

CONNECTOR FOR LIFT MOTOR FAN

CONNECTOR ON AUX CARD FOR AUX DEADMAN

CONNECTOR ON AUX CARD FOR AUX SLACK CHAIN

CONNECTOR ON C.C.C FOR SECONDARY STEER INPUT ENCODER

CONNECTOR ON AUX CARD FOR AUX LIMIT SWITCH

CONNECTOR ON AUX CARD FOR AUX LIFT & LOWER SWITCH

CONNECTOR ON C.C.C. FOR AUX CARD

CONNECTOR ON C.C.C. FOR AUX CARD

CONNECTOR ON C.C.C. FOR OVER THE MAST CABLE #2

CONNECTOR ON C.C.C. FOR LIGHT DISPLAY CARD

CONNECTOR ON C.C.C. FOR SIDEGATE SWITCHES

CONNECTOR ON C.C.C. FOR SIDEGATE SWITCHES

CONNECTOR ON C.C.C. FOR SPARE POWER

CONNECTOR ON C.C.C. FOR OVER THE MAST CABLE #1

CONNECTOR ON C.C.C. FOR CONTROL HANDLE

CONNECTOR ON C.C.C. FOR 24" LIMIT SWITCH

CONNECTOR ON C.C.C. FOR DEADMAN SWITCHES

CONNECTOR ON C.C.C. FOR LIFT/LOWER BYPASS SWITCH

CONNECTOR ON C.C.C. FOR LIGHTS/FANS

CONNECTOR ON C.C.C. FOR LOWER INHIBIT

CONNECTOR ON C.C.C. FOR 60" LIMIT SWITCH

CONNECTOR ON C.C.C. FOR DISPLAY CARD

CONNECTOR ON C.C.C. FOR STEERING ENCODER

CONNECTOR FOR BRAKE

BATTERY CONNECTOR +

BATTERY CONNECTOR -

CONNECTOR FOR HOME SENSOR PROX

CONNECTOR FOR WARNING LIGHT

CONNECTOR FROM TRACTOR W.G. ANTENNA TO FILTER CARD

EMERGENCY LIFT LOWER CONNECTION

CONNECTOR FROM LOAD W.G. ANTENNA TO FILTER CARD

CONTROL HANDLE HEATER

DEADMAN HEATER

C.C.C. HEATER

CONNECTOR FOR DEADMAN HEATER

ELECTRONIC HORN RESISTOR

HORN

ELECTRONIC HORN

CONTROL FUSE FOR COLD STORAGE DEADMAN HEATER, 5A

CONTROL FUSE FOR COLD STORAGE C.C.C. HEATER, 10A

CONTROL FUSE FOR EXTRA F/R HARNESS B-FU13 15A

CONTROL FUSE FOR EXTRA F/R HARNESS B+FU12 15A AND/OR FUSE FOR 10A POWER HOOKUP OPTION

10A FUSE FOR 10A POWER HOOKUP OPTION

CONTROL FUSE FOR RF TERMINAL B- 2A

CONTROL FUSE FOR RF TERMINAL B+ 2A

CONTROL FUSE FOR AUX. POWER B- 15A/5A

CONTROL FUSE FOR AUX. POWER B+ 15A/5A

CONTROL FUSE FOR VEHICLE MANAGER B- 15A

CONTROL FUSE FOR VEHICLE MANAGER B+ 15A

POWER FUSE FOR LIFT

POWER FUSE FOR TRACTION

POWER FUSE FOR STEER

CONNECTOR ON FAN SUPPRESSOR

ELECTRIC BRAKE

POSITIVE SIDE OF ALARM

NEGATIVE SIDE OF ALARM

TWO STAGE LIFT PUMP SOLENOID

DESCRIPTION

Models 5400/5500/5600 High-Level Orderpicker Lift Truck Schematics

1,2,3 1,2,5 1,2,3,5

JPF1 JPF2 JPF3

5 5 5

JPY2 JPY6 JPY7

1,2 1,2

L/H L/L

5

5

JPY1

1,2

4

JPX1

K12

3

K4

5

JPW2

1,2

5.

JPW1

JPXBR

K3

1,2

JPTA4

1,2

1,2

JPTA3

1,2

1,2

JPTA2

K2

B3

1,2

JPTA1

K1

B3

1,2,5

JPT24

F5

D6

H4

C6

B6

C6

C6

B3

B3

A5

B3

D6

D6 .

C2

C2

C2

D2

MULTI

MULTI

MULTI

1,2,5 1,2,3,5

MULTI

MULTI

C4

E6,B6,C3

F6

E5

C4,C5

F6

D4

D4,D3

B5

B5

B4

B6,D3

B6,D3

D3

D5

B3

B3

D4

F3

D7,E7

F2E3

D4

D5

D4

F4

D6

D5,D7

MULTI

C3

C3

C3

D3

MULTI

MULTI

MULTI

MULTI

JPT22

1,2,5

JPT18

ZONE F6

JPT20

5

JPT10

1,2,3

1,2,3,5

JPT9

JPT14

1,2

JPT6

JPT12

5 1,2

JPT4

1 1,2

JPT2

1,2

JPSC1 JPSC2

5

JPS52

5

5

JPS51

JPS59

5

JPS50

JPS58

5

JPS28

5

5

JPS27

JPS57

1,2

JPS26

3,5

1,2,3

JPS25

JPS55

1,2,3

JPS16

5

5

JPS15

3,5

5

JPS10

JPS54

5

JPS8

JPS53

5 1,2

JPS4

5

1

JPS2

1

JPLA4 1,2

JPLA3

JPS1

1

1

JPLA2

JPLA1

1,2,3

1,2

JPE4

JPF4

SHEET

IDENT.

DESCRIPTION

LIFT/LOWER SOLENOID

LOAD/HOLD SOLENIOD

HIDDEN KEY SWITCH RELAY

KEYSWITCH RELAY-AUX. VM POWER

KEYSWITCH RELAY-POWER AMPS

KEYSWITCH RELAY-SOLENOIDS, ATTACHMENTS, HORN

KEYSWITCH RELAY-OPTIONS

CONNECTOR ON FLOW MODULE TO FLOW SENSOR CHANNEL 2

CONNECTOR ON FLOW MODULE TO FLOW SENSOR CHANNEL 1

CONNECTOR ON FLOW MODULE TO FLOW SENSOR TEMPERATURE SENSOR

CONNECTOR ON FLOW MODULE

CONNECTOR FOR 10X AUX POWER

CONNECTOR FOR SEPERATE BRAKE HARNESS

CONNECTOR ON FILTER CARD FOR TRACTOR SENSOR

CONNECTOR ON FILTER CARD FOR LOAD SENSOR

CONNECTOR FOR TRACTION MOTOR ENCODER AND TEMPERATURE

TRACTION MOTOR TEMPERATURE SENSOR CONNECTOR

TRACTION MOTOR ENCODER CONNECTOR

TRACTION AMP CONNECTOR

ANALOG INPUTS CONNECTOR ON VM

DIGITAL INPUTS CONNECTOR ON VM

PROPORTIONAL COIL DRIVERS CONNECTOR ON VM

COIL DRIVERS CONNECTOR ON VM

B+, B-, CAN COMMUNICATIONS CONNECTOR ON VM

LIFT PENDANT CONNECTOR ON VM

CAN, DIGITAL INPUTS AND OUTPUTS CONNECTOR ON VM

CONNECTOR ON VM FOR FLASHWARE

ELECTRIC STEER CONNECTOR ON VM

CONNECTOR ON VM

USB CONNECTOR ON VM

SPLICE FOR CAN BUS

SPLICE FOR CAN BUS

CONNECTOR FOR SLACK CHAIN SWITCH

CONNECTOR FOR SLACK CHAIN SWITCH

CONNECTOR FOR LIFT CUTOUT

CONNECTOR FOR AISLE DETECT SENSOR 2

CONNECTOR FOR AISLE DECTECT SENSOR 1

CONNECTOR FOR RAIL SENSE SWITCH

CONNECTOR FOR LIFT/LOWER ALARM

CONNECTOR FOR FLOW MODULE

CONNECTOR FOR PRESSURE TRANSDUCER A

CONNECTOR FOR 180" LIMIT SWITCH

CONNECTOR FOR SPARE OVER THE MAST WIRES

CONNECTOR FOR OVER THE MAST CABLE #2

CONNECTOR FOR OVER THE MAST CABLE #1

CONNECTOR FOR TRAVEL CUTOUT SWITCH

CONNECTOR FOR TRAVEL ALARM

CONNECTOR FOR LIFT INHIBIT SWITCH

CONNECTOR FOR 120"/150" LIMIT SWITCH

CONNECTOR ON TRUCK TRACKER FOR POWER

CONTACTOR PANEL INTERFACE CONNECTOR

CONNECTOR FOR LIFT MOTOR ENENCODER/TEMP SENSOR CONNECTOR

LIFT MOTOR TEMPERATURE SENSOR CONNECTOR

LIFT MOTOR ENCODER CONNECTOR

LIFT AMP CONNECTOR

KEY SWITCH, EPO, BATTERY SENSE CONNECTOR ON FUSE/RELAY CARD

B- CONNECTOR ON FUSE/RELAY CARD

B+ KEY SWITCH RELAYS CONNECTOR ON FUSE/RELAY CARD

B- AUX POWER, B+ POWER AMPS CONNECTOR ON FUSE/RELAY CARD

CONNECTOR FOR STEER MOTOR ENCODER

IDENT.

ZONE

B3 B2

1,2 1,2 5,4 4 3 3

TP5 TPC TS12 TS13 VR1 VR2

F6

F6

G6

F5,F3

B4

1,2

TP4

B3

1,2

B3

B2

C2

C2

C3

D2

A2

B2

B5

B4

E7

E7

D4

H4

F2

H3

H5

H3

H2

F6

C6,D3

C6,D3

C5,D2

C5,D2

C4

C4

C5

E4

E3

E3

E2

E2

E2

B4

B4

F6

D4

H3

D3

F5

D6

F4

D3

F5

F4

H4

F7

F6

G5

F4

B6

B5

C4

C4

C3

C4,B3

D4

TP3

1,2

1,2 TP2

1,2 TP1

1,2

1,2

TMT

TME

TM

1,2

3

3

SPL1

TA

SPL2

1,2

5

4

4

5

5

4

4

5

5

5

5

3,5

3,5

3,5

3,5

4

4

4

5

5

5

5

5

5

5

5

3

5

5

5

3

4

3

5

3

1,2

5

3

3

3

3

5

1,2

1,2

1

1

1,2

1

SHEET

SA

S124

S112

S111

S100

S90

S81

S80

S75

S61

S60

S56

S47B

S47A

S46B

S46A

S43

S41

S40

S37

S36

S34

S33

S32

S31

S30

S29

S28

S27

S25

S24

S23

S22

S21

S15

S11

S10

S7

S4

S3

S2

S1

PRESS SW1

MS

LPC

LMT

LME

LM

LA

VARIABLE RESISTOR FOR LIFT/LOWER

VARIABLE RESISTOR FOR THROTTLE

TERMINAL STRIP FOR EXTRA F/R HARNESS

TERMINAL STRIP FOR SPARE POWER

TRACTION POWER CONTACTOR

TIE POINT ON TRACTION MOTOR FUSE

TIE POINT ON B-

TIE POINT ON LIFT MOTOR FUSE

TIE POINT ON STEER MOTOR FUSE

TIE POINT ON B+

TRACTION MOTOR TEMPERATURE SENSOR

TRACTION MOTOR ENCODER

AC TRACTION MOTOR

TRACTION POWER AMPLIFIER

9

BUTT SPLICE FOR TRACTION AMP TO FUSE RELAY C

BUTT SPLICE FOR LIFT AMP TO FUSE RELAY CARD

STEER POWER AMPLIFIER

LIFT DECEL SWITCH

MPV/EMERGENCY LIFT SWITCH

MPV/EMERGENCY LOWER SWITCH

180" LIMIT SWITCH

SECURITY START SWITCH

C.C.C. HEATER THERMOSTAT

DEADMAN HEATER THERMOSTAT

CONTROL HANDLE HEATER THERMOSTAT

SIDEGATE LEFT SWITCH

SIDEGATE RIGHT SWITCH

SWITCH FOR FAN

AISLE DETECT SENSOR 2

AISLE DETECT SENSOR 2

AISLE DETECT SENSOR 1

AISLE DETECT SENSOR 1

SWITCH FOR FAN

SWITCH FOR DOME LIGHTS

SWITCH FOR WORKING LIGHTS

SLACK CHAIN CARRIAGE #2

SLACK CHAIN CARRIAGE #1

AUX LIFT LIMIT SWITCH #1/REARGATE #1

AUX LOWER

AUX LIFT

AUX LIFT LEFTHAND DEADMAN

SLACK CHAIN (MAIN #2)

SLACK CHAIN (MAIN #1)

60" LIMIT SWITCH

TRAVEL CUTOUT SWITCH

LOWER INHIBIT SWITCH

LIFT INHIBIT SWITCH

DEADMAN SWITCH (CARRIAGE DEADMAN)

EMERGENCY POWER OFF

EPO SWITCH

RAIL SENSE SWITCH

24" LIMIT SWITCH

150" LIMIT SWITCH OR 120" LIMIT SWITCH

LIFT/LOWER INHIBIT BYPASS SWITCH

AUTO/MANUAL SWITCH

HORN SWITCH

DEADMAN SWITCH (BRAKE DEADMAN)

KEY SWITCH

PRESSURE SWITCH FOR 24V HI PERF LIFT

STEER MOTOR

LIFT POWER CONTACTOR

LIFT MOTOR TEMPERATURE SENSOR

LIFT MOTOR ENCODER

AC LIFT MOTOR OR DC LIFT MOTOR

LIFT POWER AMPLIFIER

DESCRIPTION

Figure 8. Electrical Schematic Legend

Publication: 1123010B, Issued: 13 Jul 2015

Models 5400/5500/5600 High-Level Orderpicker Lift Truck Schematics Figure 9. Hydraulic Schematic, Single Speed Lift

10

Publication: 1123010B, Issued: 13 Jul 2015

Models 5400/5500/5600 High-Level Orderpicker Lift Truck Schematics Figure 10. Hydraulic Schematic, Variable Speed Lift

11

Publication: 1123010B, Issued: 13 Jul 2015

Models 5400/5500/5600 High-Level Orderpicker Lift Truck Schematics Figure 11. Hydraulic Schematic, Variable Speed Lift with Auxiliary Lift

12