Raymond 7500 7520 Reach-Fork® Trucks Schematics Manual SN 31001 and up - PDF DOWNLOAD

31,001 and Up

Issued: 22 Aug 2016

Publication: 1112860D

©2016 The Raymond Corporation.

Serial Numbers

Models

7500/7520

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

Schematics

Publication: 1112860D, Issued: 22 Aug 2016

Models 7500/7520 Reach-Fork ® Truck Schematics Figure 1-1. Power Distribution Diagram - Standard AC Lift

2

Publication: 1112860D, Issued: 22 Aug 2016

Models 7500/7520 Reach-Fork ® Truck Schematics Figure 1-2. Power Distribution Diagram - DC Lift

3

Publication: 1112860D, Issued: 22 Aug 2016

Models 7500/7520 Reach-Fork ® Truck Schematics Figure 1-3. Power Distribution Diagram - AC Lift with Regen Lower

4

JP B-

JP B+

JPS1-1

-2 -3 -4

-2

-1

JPF4-3 -4

-2

JPF1-1

-2

JPF3-1

TP4

A2

A1

-

MS

+

2

1

1

2

SA

JPS1-5

2

1

T°

FU5 (15A)

1

2

2

1 2 FU7 (15A/5A)

FU8 (15A/5A)

1

FU6 (15A)

MS-A2 TP4

MS-A1

STR-2

FU1 (150A)

STR

Publication: 1112860D, Issued: 22 Aug 2016

7

6

5

4

3

2

TP1

2

1

2

1

FU3 (675A)

MPC

1

-3

JPS1-10

FUSE/RELAY CARD

K3

2

JPS1-7

(500A)

FU2

CONTACTOR PANEL

K2

K4

Y

Y

K3

K2

X

X

K4

JPS1-8

MPC

STR

C

K1

K1

JPF2-8

JPF2-4 -6 -7 JPF4-7

-10

-8

-11

-12

-5

JPF4-13 -6

-2 -3 -5

JPF2-9

JPF4-15

JPF1-4

SPL-7

TS3-1

JPS14-1

TS1-1

TS1-1

JPS14-4

TS1-2

4

1

S1

KEYSWITCH

TS2-1

2

2 EPO 1

4

4

4

-8

JPL3 RED -2 RED/BLK -1

JPS10-4

-32

-2

BLUE

SPL-1

-31

-3

WHITE

LM

-7

W

1

TILT

1 2

SIDE 2 SHIFT

W

V B+

L VEL PHASE B

U

B-

-1

2

-

FAN-DU + FAN-TD +

-

-

2

FAN-FW2 +

JPB1-2

JX1-2 -5 4

STEER TILLER ENCODER

-NEG -IN -POS

H-1 H-2

JPS4-1

+

1

JPC22-18

-6

JPC18-12

-7 -13 -14 JPC24-24

JPC14-12

JPC14-6 JPC22-21

-6

SOL1

-10

JPC18-17

JPC20-14

-15

2

-1

JPS2-2

JPC18-16

JPC22-1

-14

-1

JPBR-2

-2

-5

0

JPC20-1

JPC22-19 JPC14-10 -2 -1 -8 -9

-1

-4

-3

-2

-5

JPC6-6

-8

NESTED_SWITCH

TILT_SOL

SIDESHIFT_SOL

REACH_SOL

B+K4 B+K2 B+K2 BATTERY_SENSE_IN

B+KEY

RELAY_ENABLE EPO_SENSE

L/H

FAN

BRAKE

HORN

SPEED_LIMIT_1

+12VP

B-F

DGND DGND

FU1_SENSE

NEUTRAL_PULSE

DGND

STEER_CURRENT

CW_PWM

CCW_PWM

+12V

MAIN_CONTACTOR

STR_CONTACTOR

DGND

BUS_1-

JPC18-11

-8

-12

-12 -7

DGND H_HTR

2

2

RED WHT BLU

JPDP-1 -2 -3

JPE4-1 -3 -2

JPC20-5 JPC10-8 JPC24-7

JPC20-7

TXD RXD DGND

VBUS D+ DDGND

DGND

+12VP STEER_LIMIT

DGND

CHANNELB_4

CHANNELA_4

+12VP

DGND

JPC3-1 -2 -3 -4

JP9-2 -3 -5

JP9A-2 -3 -5

-3

JPST-1 -2

JPC20-9 JPC22-22 -11

-4 JPC10-9

-10

JPC22-9

-3

JPC18-7 DGND

4

DGND

DGND

+5VP

DGND

+5VP

DGND

+5VP

+ 0

TABLE A 10A 15A

MODEL 75XX and 77XX REACH

STEERING

15A

5A 5A

2A FU8

FU7

AUX. POWER

S5

S4

S3

OPTION

-

+ 0

-

+ 0

-

H

AC LIFT & Standard AC Lift ELECTRIC

MODEL 77XX ONLY

HTR6

S9

S8

S7

S6

DGND

VR2

DGND +5VP

VR1

+5VP

+5VP

STEER MOTOR ENCODER

MODEL 77XX ONLY

-

+ 0 S11

BLK

-

+ 0 DS2

-

+ 0 DS1

JPDS-1 -2 JPC20-2 JPC22-8 +12VP DEADMAN DS1

+12VP DEADMAN DS2

2

2

-2

JPA-1

-7

+ 0 PRESS -

SOL3

SOL5B

SOL5T

JPY1-1 -2 -3

1

1

1

1

SPL-6

JPC20-4 JPC24-18 -6

-13

-12

-19

-20

-17

-18

-15

JPC20-16

JPC18-18

-11

JPC24-23

+12VP PRESSURE DGND

(B+K2)B+DUMP

DUMP

(B+K2)B+AUX2

AUX2

(B+K2)B+AUX1

AUX1

(B+K2)B+L/L

L/L

ALARM

DGND

AMBIENT_TEMP

THERM_EN

+12VP

SSHIFT_RIGHT

SOL2

-9

-9

4

-8

-8

-5

-6

-6

TILT_UP TILT_DOWN SSHIFT_LEFT

JPG1-2

-5

-5

JPC20-8

-11

-11

RETRACT

JPC10-3

-10 -4

-10 -4

LIFT

-13

-2

-2

P_HORN REACH

-3

4

JPH1-1

-3

JPC12-1

G

Figure 1-4. Electrical Schematic - Standard AC Lift (Sheet 1 of 6)

P_THROTTLE

+5VP

VEHICLE MANAGER

MAIN_CONT_SENSE

-3

-7

BUS_1+

+12VD

+12VP

DGND

CHANNEL_B_2

CHANNEL_A_2

+12V_EN2

DGND

CHANNEL_B_1

CHANNEL_A_1

+12V_EN1

F

JPC24-21

-4

-11

JPC14-5

JPC10-1

JPC18-6

-14

JPC22-13

-4

6

BRAKE

-

S12

JPD1-5 -6

-12 JPC10-7

JPC18-5

-5

TS3-2

HRN

BUS_1-

BLK

SOUNDER

-4

BLU

B-1 B-2

-2

WHT

-4

H

JPS4-3

-3

-2

JPD3-1

4

-3

RED

JPC22-5

JPC10-6

-3

JPB6-2

JPB3-2

JPB4-2

JPB2-2

-3

-2

JPS14-5

JPD1 DISPLAY -1 +12VD -4 +12VD DGND SOUNDER -2 BUS_1+

-1

-4

-4 JPE2-1

BLK

-2

-3

JPE1-1

-3

TS2 -2

2

SPL10

-

1

1

SPL9

FAN-FW +

FAN-T +

-35

-23

-11

JPB6-1

4

BUS _1-

BUS_1+

ID1

JPL1

4

1

JPB3-1

JPB4-1

JPB2-1

JPB1-1

B-

LPA

-3

-35

2 1 SPL12

BLU

-23

WHT

RED

-12 SPL11

E JPT1 -1

B+K3

LIFT POWER AMP

B+

L VEL PHASE A

L TEMP+

BUS_1-

BUS_1+

ID0

B+K3

CUSTOM OUT

L VEL SENSOR+

TPA

L I/0 GND

1 REACH 2

U

JPL1 -26

W

-4

V

U W

V

T TEMP+

T VEL PHASE B

T VEL PHASE A

T I/0 GND

T VEL SENSOR+

TRACTION POWER AMP

D

V

-1 JPL2

U

BLACK

MOTOR TEMPERATURE

LMT

LME

MOTOR VELOCITY RED

TM

-8 -7

-8

-3

-1

-31 -32

-4

-3 -2 JPT3 -2

RED RED/BLK

WHITE BLUE

MOTOR TEMPERATURE

TMT

TME

JPT1 -26 -7

JPS2

-5

-6

-4

JPT2

-1

RED BLACK

MOTOR VELOCITY

JPS1-11

FOR NOTES SEE SHEET 6.

JPF1-5

B

JPF1-6

A

-4 -5 -6 -7 -8

JPF3-3

PRIMARY CONTROL HANDLE DEADMAN SWITCH 1 DEADMAN SWITCH 2

STEER LIMIT SWITCH

Models 7500/7520 Reach-Fork ® Truck Schematics

FLASHWARE USB COMMUNICATIONS

JPF2-1

5

JP B-

-2

-1

JPF4-3 -4

-2

JPF1-1

-2

JPF3-1

A2

A1

TP2

1

-

+

TP4

MS

1

2

2

1

T°

FU5 (15A)

1

2

2

FU8 (15A/5A)

1

FU6 (15A)

A2

A1

2

1

2

1

S1

LM

FU7 (15A/5A)

JPS1-5

FU1 (100A)

STR

Publication: 1112860D, Issued: 22 Aug 2016

7

6

5

4

3

JPS1-1 -2 -3 -4

2

-

+

JPS1-6

LPC

FU3 (500A)

K3

JPS1-7

TP5

1

2

JPS1-10

FU2 (500A)

1

TPC

FUSE/RELAY CARD

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

1

CONTACTORPANEL

JPF1-5

JP B+

TP1

-3

2

JPF2-1

B

K2

K4

Y

Y

Y

K3

X

X

X

K4

K2

JPS1-9

LPC

STR

TPC

C

K1

K1

JPF1-6

A

SPL-7

JPS1-11 JPS1-8

JPF2-8

JPF2-4 -6 -7 JPF4-7

-10

-8

-11

-12

-5

JPF4-13 -6

-2 -3 -5

JPF2-9

JPF4-15

JPF1-4

4

BLUE

TS3-1

JPS14-1

TS1-1

TS1-1

JPS14-4

TS1-2

1

2

4

4

S1

EPO

KEYSWITCH

TS2-1

2

1

JPS10-4

SPL-1

REACH

2 SIDE SHIFT TILT

1

2

2

W

W

U V

1

T TEMP+

B+

B-

TPA

T VEL PHASE B

T VEL PHASE A

T I/O GND

T VEL SENSOR+ ID2

B+K3

4

SPL11

T°

2

-

FAN-DU + JPB3-1

-3 -4 -5

-6

-4 -5

-6

6

BUS_1-

BUS_1+

H

B-2

H-1 H-2

2

2

SOL1

SOL4

-1

1

1

JPS2-2

JPBR-2 -1

-3

-8

-POS

-4

JPC22-18

-15

-14

JPC18-12

-14 JPC24-24

-7 -13

JPC14-12

JPC22-21

JPC14-6

-10

-1

JPC18-17

JPC20-14

JPC18-16

JPC22-1

JPC14-10 -2 -1 -8 -9 JPC20-1

-19

JPC22-20

-10

JPC24-22

-8

-9

JPC18-11

JPC24-21

-11

JPC14-5

JPC10-1

-16

JPC22-15

-7

-NEG -IN

SOUNDER

BW2

BW1

-6

JPD1-5

B-1

JPD3-1

4

LM_A2 (ON LM)

LM_A1

-2

BRAKE

HRN

DGND SOUNDER

JPS4-1 -2

-3

-2

JPS14-5

4

+12VD

DISPLAY

-1

-4

-5

JX1-2

+12VD

TS3-2

JPB3-2

JPB5-2

JPB4-2

JPB2-2

JPB1-2

-3

-2

-4

JPD1-1

E

-3

TS2 -2

FAN-LM +

FAN-FW2 +

-

FAN-T + FAN-FW +

0

+

-2

JPZ-1

JPB5-1

-

S12

(ON LM)

1

1 2 SPL12

JPB4-1

JPB2-1

JPB1-1

4

-3

-35

-23

-12

-1

JPT1

JPS4-3

VANTAGE TRIGGER

BUS_1-

BUS_1+

TRACTION POWER AMP

V

1

4

U

-8

-8 -7

TM

-32

-31

-7

JPT1 -26

-3

-4

-3

-2 JPT3 RED -2 RED/BLK -1

-5

-4

WHITE

JPS2 -6

BLACK

MOTOR TEMPERATURE

TMT

TME

MOTOR VELOCITY JPT2 -1 RED

D F

NESTED_SWITCH

TILT_SOL

SIDESHIFT_SOL

REACH_SOL

B+K2 BATTERY_SENSE_IN

B+K4 B+K2

B+KEY

EPO_SENSE

RELAY_ENABLE

L/H

2nd_STAGE

FAN

BRAKE

HORN

SPEED_LIMIT_1

+12VP

B-F

DGND DGND

FU1_SENSE

FU3_SENSE

DGND

LIFT_MOT_TEMP

TRACTION_CONTACTOR

LIFT_CONTACTOR

STR_CONTACTOR

TPC_SENSE

DGND

BUS_1-

BUS_1+

+12VD

+12VP

BRUSH_WEAR_2

-5 -6 -8 -9 -12

-6 -8 -9 -12

JPC24-23 AMBIENT_TEMP

JPC9-2 -3 -5

DGND

RXD DGND

DDGND

VBUS D+

JPC3-1 -2 -3 -4

-3 JPC18-7

TXD

JPDS-1 -2 JPC20-2 JPC22-8 +12VP DEADMAN DS1

1

1

1

1

JPY1-1 -2 -3

JPC20-4 JPC24-18 -6

-13

-12

-19

-20

-17

-18

-15

JPC20-16

JPC18-18

+12VP PRESSURE DGND

(B+K2)B+AUXDUMP

AUXDUMP

(B+K2)B+AUX2

AUX2

(B+K2)B+AUX1

AUX1

(B+K2)B+L/L

L/L

ALARM

SPL-6

-5

-11

JPG1-2 JPC10-3

+ 0 DS1 -

2

2 + 0 PRESS -

SOL8

SOL5B

2

-2

JPA-1

2

-7

4

SOL5T

SOL2

-11

-11 -5

4

-10 -4

-10 -4

-13

-2

-2

-7

-3

JPC20-8

DGND

JPH1-1

-3

JPC12-1

G

HTR6

S9

S8

S7

S6

DGND

VR2

DGND +5VP

VR1

+5VP

+5VP

4

-

+ 0

+ 0

+ 0

S5

TABLE A AUX. POWER 2A OPTION 5A FU7 5A FU8

S4

S3

DC Lift

DGND

+5VP

DGND

+5VP

-

DC LIFT & HYDRAULIC STEERING MODEL 75XX REACH

DGND

+5VP DGND

H

10A 15A 15A

Figure 1-5. Electrical Schematic - DC Lift (Sheet 2 of 6)

THERM_EN

+12VP

H_HTR

DGND

SSHIFT_RIGHT

SSHIFT_LEFT

TILT_DOWN

TILT_UP

RETRACT

P_HORN REACH

LIFT

P_THROTTLE

+5VP

VEHICLE MANAGER BRUSH_WEAR_1

PRIMARY CONTROL HANDLE SWITCH 1

FOR NOTES SEE SHEET 6.

DEADMAN

Models 7500/7520 Reach-Fork ® Truck Schematics

FLASHWEAR USB COMMUNICATIONS

6

-

AM

+

-2

-1

JPF4-3 -4

-2

JPF1-1

-2

JPF3-1

A2

A1

+

-

MS

TP4

2

1

FU1 (150A)

2

2

1

T°

2

FU5 (15A)

1

1 2 FU7 (15A/5A)

FU8 (15A/5A)

1

FU6 (15A)

MS-A2 TP4

SA

MS-A1

STR-2

2

FU4 (100A)

1

2

1

AUX

2

1

2

1

FU3 (675A)

MPC

1

2

-3

X

Y

MPC

X

STR

X

Y

Y

AUX

FUSE/RELAY CARD

K3

(500A)

FU2

JPS1-7

Publication: 1112860D, Issued: 22 Aug 2016

JP B-

JPS1-1 -2 -3 -4

STR

JPS1-10

7

6

5

4

3

JP B+

1

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

2

JPF1-5

2

TP1

CONTACTOR PANEL

JPF2-1

B

K2

K4

K3

K4

K2

K1

K1

C

TM

JPS14-4

TS1-2

4

TS1-1

JPF2-8

JPF2-4 -6 -7 JPF4-7

-10

-8

-11

-12

-5

1

TS3-1

JPS14-1

JPF4-13 -6

-3 -5

-2

JPF4-15 TS1-1 JPF2-9

JPF1-4

SPL-7

S1

TS2-1

2

U

T VEL SENSOR+

W

V

1

SIDE 2 SHIFT

W B+

V

U

B-

BUS _1-

BUS_1+

ID1

B+K3

4

JPB6-1

JPB3-1

JPB4-1

JPB2-1

JPB1-1

B-

LPA

L VEL PHASE B

L VEL PHASE A

L I/0 GND

L TEMP+

TILT 2

1

B+

-35 1 2

1 2 SPL12

SPL11

-4 -5

-6

-5

-6

TS3-2

-4

- JPB6-2

- JPB3-2

H

HRN

BUS_1-

JPS4-3

-3

-3

FAN-TD +

FAN-DU +

- JPB4-2

- JPB2-2

- JPB1-2

-3

-2

JPS14-5

4

4

0

-

6

BRAKE

-NEG -IN -POS

+

S12

H-1 H-2

-1

JPBR-2

2

SOL1

-1

JPS2-2

-2

1

JPC22-18

-15

-14

JPC18-12

-7 -13 -14 JPC24-24

JPC14-12

JPC14-6 JPC22-21

-10

JPC18-17

JPC20-14

JPC18-16

JPC22-1

JPC20-1

-1 JPC22-20 -19 JPC14-10 -2 -1 -8 -9

-4

-3

-2

-5

JPC6-6

-8

JPC18-11

JPC18-9

JPC24-21

-3

-8

-11

JPC14-5

JPC10-1

JPC18-6

-14

-4

JPS4-1

SOUNDER

-4

-2

JPC22-13

JPC10-7

JPE2-1 -3

JPC18-5

-12

JPC22-5

JPC10-6

-4

-2

-3

JPE1-1

-7

-6

B-2

B-1

BLK

BLU

BLK

BLU

WHT

RED

STEER TILLER RED ENCODER WHT

JPD1 DISPLAY -1 JPD3-1 +12VD -4 +12VD DGND -2 SOUNDER -2 BUS_1+ JPD1-5

-1

-4

-5

JX1-2

E

-3

TS2 -2

FAN-T +

2

FAN-FW +

1

SPL10

FAN-FW2 +

-35

-23 SPL9 1 2

-11

JPL1 -1

VANTAGE -3 TRIGGER 4

BUS_1-

-23

-12

JPT1 -1

LIFT POWER AMP

TPA

ID0

B+K3

BUS_1+

L VEL SENSOR+

W

V

U

T TEMP+

T VEL PHASE B

T VEL PHASE A

T I/0 GND

1 REACH 2

KEYSWITCH

JPS10-4

2 EPO 1

4

4

MOTOR TEMPERATURE

4

-2 JPL3 -2 RED LMT RED/BLK -1

LM

-32

WHITE

-8

-31

-3

BLUE

-7

-4

JPL1 -26

W

V

LME BLACK

SPL-1

MOTOR VELOCITY -1 JPL2 RED

MOTOR TEMPERATURE

U

-8

-8 -7

-32

-3

-2 JPT3 RED -2 TMT RED/BLK -1 BLUE

-7 -31

-4

-3

WHITE

JPT1 -26

-5

JPS2 -6

-4

TME

BLACK

MOTOR VELOCITY JPT2 -1 RED

D TRACTION POWER AMP

F

NESTED_SWITCH

TILT_SOL

SIDESHIFT_SOL

REACH_SOL

B+K4 B+K2 B+K2 BATTERY_SENSE_IN

B+KEY

EPO_SENSE

RELAY_ENABLE

L/H

FAN

BRAKE

HORN

SPEED_LIMIT_1

+12VP

B-F

DGND DGND

NEUTRAL_PULSE FU4_SENSE FU1_SENSE

DGND

STEER_CURRENT

CW_PWM

CCW_PWM

+12V

MAIN_CONTACTOR

STR_CONTACTOR

AUX_CONTACTOR

MAIN_CONT_SENSE

DGND

BUS_1-

BUS_1+

+12VD

+12VP

DGND

CHANNEL_B_2

CHANNEL_A_2

+12V_EN2

DGND

CHANNEL_B_1

CHANNEL_A_1

+12V_EN1

JPC12-1

JPG1-2

1

+12VP

DDGND

VBUS D+

TXD RXD DGND

DGND

+12VP STEER_LIMIT

DGND

CHANNELB_4

CHANNELA_4

JPC3-1 -2 -3 -4

JP9-2 -3 -5

JP9A-2 -3 -5

JPST-1 -2

JPC20-9 JPC22-22

DGND

DGND

+5VP

DGND

+5VP

DGND

+5VP

-

+ 0

-

+ 0

-

+ 0

S5

S4

S3

H

AC LIFT & ELECTRIC STEERING MODEL 75XX AND 77XX LOWER REGEN

AC Lift with Regenerative Lower

MODEL 77XX ONLY

HTR6

S9

S8

S7

S6

DGND

VR2

DGND +5VP

VR1

+5VP

+5VP

STEER MOTOR ENCODER

4

MODEL 77XX ONLY

-

+ 0 S11

BLK

-4 JPC10-9

-3

WHT BLU

-2

-11

RED -3

DS2

DS1

JPE4-1

-

+ 0

-

+ 0

-10

-3

2

JPC22-9

JPDP-1 -2

JPC20-5 JPC10-8 JPC24-7 DGND

2

2

-2

+ 0 PRESS -

SOL6

-7

-13

-12

-9

JPA-1

JPC20-7

-3

+12VP DEADMAN DS2

SOL2

SOL5T

JPY1-1 -2 -3

JPDS-1 -2

JPC20-4 JPC24-18 -6

-13

-12

-19

JPC18-7 DGND

4

4

SOL5B 1 2

1

1

SPL-6

-5

JPC20-2 +12VP JPC22-8 DEADMAN DS1

+12VP PRESSURE DGND

(B+K2)B+AUXDUMP

AUXDUMP

(B+K2)B+AUX2

-20

-17 (B+K2)B+AUX1 AUX2

-18

-15

JPC20-16

JPC18-18

-11

JPC24-23

JPC10-3

JPC20-8

-7

-12

-9

-8

-6

-6 -8

-5

-4 -11

-4 -11 -5

-10

-2

-3

JPH1-1

-10

AUX1

(B+K2)B+L/L

L/L

ALARM

DGND

AMBIENT_TEMP

THERM_EN

+12VP

H_HTR

DGND

SSHIFT_RIGHT

SSHIFT_LEFT

TILT_DOWN

TILT_UP

RETRACT

REACH

P_HORN

LIFT

-2

P_THROTTLE -3

+5VP

G

Figure 1-6. Electrical Schematic - AC Lift with Regen Lower (Sheet 3 of 6)

VEHICLE MANAGER

PRIMARY CONTROL HANDLE

A

JPF1-6

FOR NOTES SEE SHEET 6.

JPS1-5 DEADMAN SWITCH 1

JPS1-6 DEADMAN SWITCH 2

Models 7500/7520 Reach-Fork ® Truck Schematics

JPS1-8 STEER LIMIT SWITCH

JPS1-9

USB COMMUNICATIONS FLASHWARE

JPS1-11

7

SPL-7

JPC18-18

PROX NESTED SWITCH

B+K2

CARD

BLK

BRN

BLU

BLK

BLU BRN

TP4

JPC22-18

FU16 (10A)

OVER THE MAST CABLE

NESTED SWITCH +12VP

VM

TS2-1

PHOTO BEAM LOWER

PHOTO BEAM UPPER

TS3-1

RCVR_2

RCVR_1

-4

-2

-3

JPC4-1

JPF2-8

S_THROTTLE

DGND

S_HORN

+5VP

FUSE/RELAY

VM

ALARM

B+K2

JPF1-6

SECONDARY CONTROL HANDLE

VM

FUSE/RELAY CARD

FU9 (10A)

-3

-2

COM

TS3 -1

-2

-6

JPX2-3

JPX2-8

JPX2-2

JPX2-1

JPX2-6

JPCS4-1

JPCS4-4

JPCS2-2

JPCS2-1

JPCS2-4

-2

-6

TS2 -1

NO

NC

FU40 (2A)

TS2-6

BLUE

BLACK

VM

H2

RLY-B

RLY

RLY-A

TP4(B-)

JPTL-2

JPTL-1

0

1

JPC22-18 NESTED SWITCH

VM

RTERM

RTERM

BUS_1-

BUS_1+

DGND

+12VD

OCSS

S23-2

S23-1

SPEED CUTOUT SWITCH

DGND

+12VD

DIN_0

DGND

+12VD

DIN_1

DOUT_1

+12VD

DOUT_0

+12VD

CAN I/O EXPANDER MODULE

-4

JPC10-2

JPD1-1

TILT PRESSURE SWITCH

JPX1-6

1

2

1

-35

JPT1-23

GND

+12VD

S18

TPA

BUS_1-

BUS_1+

Display

-2

-3 -3

-4

-4

JPS13-1

-2

-2

-3

-4

JPS11-1

JPHI-1

-2

-3

-4

JPE3-1

D

+12VP

-11

JPC24-23

THERM_EN

VM

DGND

VM AMBIENT-TEMP

SENSOR

JPC20-8 JPC10-3

-2

JPA-1

AMBIENT TEMPERATURE

2

SPL-12

JPX1-5 JPX1-3

SPL-11 2 1

-4

BLU

WHT

BLK

HTI DISPLAY

HEIGHT ENCODER

RED

HTI SYSTEM

JPX1-2

JPX1-4

JPX1-1

S23

3

TRAVEL LIGHTS #1 & 2

JPTL-1

JPTL-2

RLY-4

RLY-7

C

AUX START

DGND

AUX START

TS3-6

BROWN

JPX2-7

-

+

ALARM

D-y

D-x

JPX2-10

JPX2-5

JPX2-9

JPX2-4

VR3

JPCS4-3

JPCS3-2

JPCS3-1

S10

NESTED SWITCH

S14

BLU

EMTR_2 BRN

BLU

JPCS1-2

-

-2

+

0

JPCS1-1

3

-3

EMTR_1 BRN

JPH2-1

JPH3-1

SPL-6

B

Publication: 1112860D, Issued: 22 Aug 2016

7

6

5

4

3

2

TP1

TRAVEL LIGHT AND ALARM

A

Models 7500/7520 Reach-Fork ® Truck Schematics

0 -

T

TP4

-5

JPG1-2

-10

-9

-7

-6

-8

-5

-4

-3

-2

JPD2-1

B+

B-

(10A)

FU14

THERMAKIT CONTROL

B+

TP1

B+FU14

B+FU14

SEAT_HTR

SEAT_HTR

SEAT_HTR

SEAT_TC-

SEAT_TC+

DIAL-

DIAL+

THERM

B+FU14

THERM

B+FU14

THERM

B+FU14

JPHTD

JPHTD

JPHTD

-2

JPHTC-1

-2

JPHTB-1

-2

JPHTC-1

-2

JPHTB-1

-2

JPHTA-1

-

T°

o

HTR_BCK

HTR_BTM

HTR_TOP

DIAL

HTR4

TH3

HTR3

TH2

HTR1

TH1 FU13

T°

T°

T°

T°

T°

T°

B-FU8

+12V_CAMERA

B-FU8

VIDEO_IN

BUS_1-

BUS_1+

B-FU8

B+K1

VANTAGE POINT SYSTEM

VANTAGE POINT

COLD STORAGE COMFORT PACKAGE

DGND

TILT PRESS

DISPLAY

SBUSY

DATA

DGND

+5VP

CHANNEL B

CHANNEL A

DGND

+12VP

E

SEATS

HEATER SECONDARY HANDLE

FLOOR PAD

PRIMARY HANDLE

HTR2 8.25 WATT

-4

-3

-2

JPVS2-1

MODEL 7700 ONLY

?

TP1

MODEL 7500 ONLY

-4

-3

-2

JPVS3-1

-5

-7

-4

JPS14-1

-2

9.4

FU18 (2A)

-6

-2

JPVS1-1

F

CAMERA

TP4

FU19 (2A)

-3

-6

-5

-2

-1

JPS10-4

TP4

SPL-1

FU11 (10A)

JPF1-4

1 B+

RELAY CONTROL FUSE PANEL

FU12 (10A)

TP4

JPW3-1

JPW2-1

JPW1-1

+12VP

VM

TA CUSTOM OUT

+12VP CUSTOM INPUT 2

DGND

CUSTOM INPUT 1

JPC22-4

JPC20-3

-3

-2

JPS6-1

36V FAN

36V LIGHT

-

TS1

2

36V LIGHT

B-

+

JPF3-11 B-FU6 FUSE/ RELAY CARD

WL

- WHITE

-

0

+

JPW3-2

JPW2-2

JPW1-2

1 B+

JPF2-9

JPF1-4

AUX. POWER (KEY)

BLACK +

Options

HS TRAVEL SW

VM

S22

S21

S20

OR

JPW5-1

JPW5-2

HIGH SPEED TRAVEL SWITCH

TP1

JPT1-3

-17

-13

-5

SPL-1 JPC24-16

JPHE1-2

JPHE1-1

WARNING LIGHT & STROBE LIGHT

JPF4-15

TS1

2

JPF2-9

T-ENCODER

CUSTOM INPUT/OUTPUT

TP1

WORKING LIGHTS & FAN

B-

H

HEIGHT ENCODER HEATER OPTION

AUX. POWER (BATTERY)

G

S25

RELAY CONTROL FUSE PANEL

HTR_ENC

Figure 1-7. Electrical Schematic - Options (Sheet 4 of 6)

8

JRDP1-1

-6

-5

-3

-2

BATT+

BATT-

DGND

TXD

250V

2 AMP

FU35

-

0

+

-

0

RAYMOND VM

RXD

TS3-2

TS3-1

S15

JPF2-8

BATT+

TS3-2

TS3-1

S16

S15

JPF2-8

BATT-

JPC9-2

-5

-3

DGND

RXD

TXD

iPORT SUPPLIER WIRELESS MODULE

TS2-2

TS2-1

-4

-1

-4

-1

+

CONNECTOR TO

OVER THE MAST CABLE

FU15 (2A)

JPFL/LO-2

JPFL/UP-2

CONNECTOR TO

-2

-1

-7

-6

-5

-10

-9

-8

-4

JPFL1-3

TS2-2

TS2-1

-4

-

0

+

FORK LASER - MODEL 7520/7720

OVER THE MAST CABLE

FU15 (2A)

-1

JPFL-2

THIRD PARTY DEVICE

B(-)

B(+)

B(-)

RESET

+12VDC

B(-)

SET

+12VDC

TRIG(-)

TRIG(+)

-2

-1

-7

-3

-5

JPFL1-4

Publication: 1112860D, Issued: 22 Aug 2016

7

6

5

4

LASER MODULE

B(-)

B(+)

B(-)

TRIG(+)

+12VDC

TRIG(-)

AND NARROW 7520/7720

FORK LASER - MODEL 7500

TP1

3

LASER MODULE

B

TP4

2

A

VM

K2

K2

C

FU16 (10A)

FU5 (15A)

FU16 (10A)

FU5 (15A)

TP-4

TP-4

+12VP

+12VP

TP4

TP1

DGND

BATT GATE Rt SW

+12VP

DGND

LIFT CUTOUT SW

VM

B-

B+

HTR8-

HTR8+

HTR7-

HTR7+

TP1 (B+)

UPPER

UPPER

JPC24-3

JPC22-3

JPC20-10

JPC24-8

JPC22-7

JPC24-1

JPC22-6

JPC20-6

B-FU6 FUSE/ RELAY CARD

JPF3-12

-

+ 0 -

JPS16-1 -2 -3

-5

-2

-3

-2

JPS5-1

0

JPC9

+

-3

iPORT TRUCK VM

S58

S57

LEFT SIDE LOWER

-2

-3

RIGHT SIDE LOWER

JPS17-1

BATTERY GATE INTERLOCK

BATT GATE Lt SW

VM

TP4 (B-)

T-OCSS

2A

FU17

OPTIONAL HEATED PLATES FOR OCSS OPTION

D

RS-232

Models 7500/7520 Reach-Fork ® Truck Schematics

iWAREHOUSE-RED SYSTEM SEE INSTALLATION MANUAL FOR DETAILS

E

S27

LIFT CUTOUT SWITCH

-

0

+

5

F

H

Options - continued

G

Figure 1-8. Electrical Schematic - Options (con’t) (Sheet 5 of 6)

9

JPF3 JPF4 JPF4 JPG1 JPG1 JPHI JPH1 JPH2 JPH3 JPHE1 JPHTA JPHTB JPHTC JPHTD

JPA JPB+ JPBJPB1 JPB2 JPB3 JPB4 JPB5 JPB6 JPBR JPC2 JPC4 JPC6 JPC9 JPC9A JPC10 JPC12 JPC14 JPC18 JPC20 JPC22 JPC22 JPC24 JPC24 JPD1 JPD2 JPD3 JPDP JPDS JPE1 JPE2 JPE3 JPE4 JPF1 JPF1 JPF2 JPF2

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

5

B5 B6, C6,C7 G5 D6 G3 D3 G2,G3 B4 B3 H3 E4 E5,E6 E5,E6 E6

G4 A3 A4 E5 E5 E6 E6 E6 E6 E5 F7 A3 F4 G6 G6 F3 G3 F3 F5 G4-5 F E6,G2-4,H6 F D6,H3 E3 E2-3 E3 G6 G5 E2 E2 D2 G6 B5, C5 A2,H4 C5,C6,C7 H4,A7

B6

E5 C3 D2 H6 E5 D3 F4 F4 F5 F5 G3 D4 D4 F6 F6 F7 H3

H (HRN) 1,2,3 H2 4 HEIGHT ENCODER 4 HIGH SPEED TRAVEL SWITCH 4 HORN 1,2,3 HTI DISPLAY 4 HTR1 4 HTR2 4 HTR3 4 HTR4 4 1,2,3 HTR6 5 HTR7 5 HTR8 4 HTR_TOP 4 HTR_BTM 4 HTR_BCK 4 HTR_ENC

iPORT

H6 E5 E6 E6 E6 E6 E6 F7 B2,B4 B3 C3 B3 B3 B6 B5 B6 B5 B3 F6 G4 G6 F5 E6 B3,B5 C3,C5 D3 F2 G3 B7 B7 B7

B4,B5 B5 D6

4 4 1,2,3

EMITTER EMTR2 EPO

FAN 4 FAN-LM 2 1,2,3 FAN-T 1,2,3 FAN-FW 1,2,3 FAN-DU 1,2,3 FAN-FW2 1,3 FAN-TD FLASHWARE CONNECTION 1,2,3 4 FORK LASER 1,2,3 FU1 1,2,3 FU2 1,2,3 FU3 3 FU4 1,2,3 FU5 1,2,3 FU6 1,2,3 FU7 1,2,3 FU8 4 FU9 FU10 4 FU11 4 FU12 4 FU13 4 FU14 4 FU15 5 FU16 5 FU17 5 FU18 4 FU19 4 FU35 5 FU40 4 FUSE RELAY CARD 1,2,3,4

B2 G5 E3 G5

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

D DEADMAN SWITCH 1 DISPLAY MANAGER DS1

C

THERMAKIT CONTROL CONNECTOR THERMAKIT CONTROL CONNECTOR CONNECTOR FOR HTI DISPLAY PRIMARY HANDLE CONNECTOR SECONDARY HANDLE POTENTIOMETER CONNECTOR SECONDARY HANDLE HORN BUTTON CONNECTOR CONNECTOR FOR HEIGHT ENCODER HEATER CONNECTOR FOR PRIMARY HANDLE EXTERNAL HEATER CONNECTOR FOR FLOOR PAD HEATER/HEATED SEAT CONTROL DIAL CONNECTOR FOR SECONDARY HANDLE EXTERNAL HEATER/HEATED SEAT CONTROL SENSOR HEATED SEAT POWER CONNECTORS

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

CONNECTOR FOR AMBIENT TEMPERATURE SENSOR BATTERY + BATTERY CONNECTOR FOR FAN-T CONNECTOR FOR FAN-FW CONNECTOR FOR FAN-DU CONNECTOR FOR FAN-FW2 CONNECTOR FOR FAN-LM CONNECTOR FOR FAN-TD BRAKE CONNECTOR USB CONNECTOR ON VM SECONDARY HANDLE CONNECTOR ON VM ELECTRIC STEER CONNECTOR ON VM CONNECTOR ON VM FOR FLASHWARE CONNECTOR FOR FLASHWARE CAN; DIGITAL INPUTS & OUTPUTS CONNECTOR ON VM PRIMARY HANDLE CONNECTOR ON VM B+, B-, CAN COMMUNICATIONS CONNECTOR ON VM COIL DRIVERS CONNECTOR ON VM PROPORTIONAL COIL DRIVERS ON VM DIGITAL INPUTS CONNECTOR ON VM DIGITAL INPUTS CONNECTOR ON VM ANALOG INPUTS CONNECTOR ON VM ANALOG INPUTS CONNECTOR ON VM DISPLAY CONNECTOR DISPLAY CONNECTOR FOR HTI DISPLAY CONNECTOR FOR SOUNDER DEADMAN SENSOR CONNECTOR DEADMAN SWITCH CONNECTOR STEER TILLER ENCODER 1 CONNECTOR STEER TILLER ENCODER 2 CONNECTOR CONNECTOR FOR HEIGHT ENCODER STEER MOTOR ENCODER CONNECTOR B- AUX POWER, B+ POWER AMPS CONNECTOR ON FUSE/RELAY CARD B- AUX POWER, B+ POWER AMPS CONNECTOR ON FUSE/RELAY CARD B+ KEY SWITCH RELAYS CONNECTOR ON FUSE/RELAY CARD B+ KEY SWITCH RELAYS CONNECTOR ON FUSE/RELAY CARD

iPORT OPTION

HORN TRAVEL ALARM ENCODER FOR HTI HEIGHT SENSING HIGH SPEED TRAVEL SWITCH (S25) HORN REMOTE DISPLAY FOR HTI HEATER FOR CONTROL HANDLE (EXTERNAL LH) HEATER FOR CONTROL HANDLE (EXTERNAL RH) HEATER FOR FLOOR PAD HEATER FOR CONTROL HANDLE SECONDARY (EXTERNAL) HEATER FOR PRIMARY CONTROL HANDLE (INTERNAL) CONNECTOR FOR RIGHT SIDE OCSS HEATER OPTION CONNECTOR FOR LEFT SIDE OCSS HEATER OPTION HEATER FOR SEAT PAN TOP HEATER FOR SEAT PAN BOTTOM HEATER FOR SEAT BACK HEATER FOR HEIGHT ENCODER HEATER

OPERATOR COOLING FAN LIFT MOTOR COOLING FAN TRACTION AMPLIFIER COOLING FAN DASH PLATE COOLING FAN TRACTION MOTOR COOLING FAN SECOND DASH PLATE COOLING FAN TRACTION COMPARTMENT DOOR COOLING FAN CONNECTION POINT(S) FOR FLASHWARE FORK LASER CONNECTIONS POWER FUSE FOR STEER POWER FUSE FOR TRAVEL POWER FUSE FOR LIFT POWER FUSE FOR LIFT CONTROL FUSE FOR VEHICLE MANAGER B+ 15A CONTROL FUSE FOR VEHICLE MANAGER B- 15A CONTROL FUSE FOR AUX. POWER B+ 15A/5A CONTROL FUSE FOR AUX. POWER B- 15A/5A CONTROL FUSE FOR TRAVEL LIGHT & ALARM 10A CONTROL FUSE FOR COLD STORAGE COMFORT PACKAGE 50A CONTROL FUSE FOR WARNING LIGHT & STROBE 10A CONTROL FUSE FOR WORKING LIGHTS & FAN 10A THERMAL FUSE FOR CONTROL HANDLE HEATER (EXTERNAL) CONTROL FUSE FOR THERMAKIT 10A CONTROL FUSE FOR FORK LASER 2A CONTROL FUSE CARRIAGE FUSE 10A CONTROL FUSE FOR OCSS HEATER OPTION CONTROL FUSE FOR VANTAGE POINT CONTROL FUSE FOR HEIGHT ENCODER HEATER 2A CONTROL FUSE FOR IPORT 2A CONTROL FUSE FOR NESTED PROX. SW. RELAY CARD CONNECTION

EMITTER FOR OCSS EMITTER FOR OCSS EMERGENCY POWER OFF

SUPPRESSOR DIODE DEADMAN SWITCH 1 DISPLAY MANAGER DEADMAN SWITCH 1

AUXILIARY MOTOR AUXILIARY CONTACTOR AUXILIARY POWER (BATTERY) AUXILIARY POWER (KEY) AUXILIARY START SWITCH (S23) ELECTRIC BRAKE BRUSH WEAR INDICATOR (DC LIFT) BRUSH WEAR INDICATOR (DC LIFT) CONNECTOR FOR BRUSH WEAR INDICATOR 1 CONNECTOR FOR BRUSH WEAR INDICATOR 2 CUSTOMER INPUT

Publication: 1112860D, Issued: 22 Aug 2016

7

6

5

4

3

2

DESCRIPTION

B4 BE,C3 G5 H5 C3 E5 E2 E2 E2 E2 H3

B

ZONE

A

SHEET 3 AM 3 AUX 4 AUX POWER (BATTERY) 4 AUX POWER (KEY) AUXILIARY START SWITCH 4 1,2 BRAKE 2 BRUSH WEAR 1 2 BRUSH WEAR 2 BW1 2 BW2 2 CUSTOMER INPUT 4

IDENT.

LEGEND

Models 7500/7520 Reach-Fork ® Truck Schematics

KEY SWITCH PRIMARY HANDLE HORN SWITCH REACH SWITCH RETRACT SWITCH TILT UP SWITCH TILT DOWN SWITCH SHIFT LEFT SWITCH SHIFT RIGHT SWITCH SECONDARY HANDLE HORN SWITCH STEER LIMIT SWITCH 1st SPEED LIMITING SWITCH NESTED SWITCH TRIG(+) 7500, USED FOR LASER MODULE TRIGGER SET 7520, USED FOR LASER MODULE SET RESET 7520, USED FOR LASER MODULE SET TILT PRESSURE SWITCH WORKING LIGHT SWITCH WORKING LIGHT SWITCH OPERATOR COOLING FAN SWITCH AUX START SWITCH HIGH SPEED TRAVEL SWITCH LIFT CUTOUT SWITCH STEER AMPLIFIER

G5 E4 B6 C6 C6 B5 C6 C6

B3 B4 C4,C5,C6 G5 A4,A5 B4,B5 D7 C2 C6 G2 G3 G3 G3 G3 G3 G3 B3 G6 E5 B6,B7 C3 C4 C4 D3 H5 H5,H6 H6 C3 H6 E6

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

JPW1 JPW2 JPW3 JPW5 JPY1 JPZ JRDP1 K1 K2 K3 K4 KEYSWITCH LIFT CUTOUT SWITCH LIGHT LM LM LME LMT LPA LPC MPC MS OCSS PRESS RCVR 1 RCVR 2 REACH RLY S1 S3 S4 S5 S6 S7 S8 S9 S10 S11 S12 S14 S15 S15 S16 S18 S20 S21 S22 S23 S25 S27

E6 G4 G5 E5 E6 G5 G5 E6 E5 G5

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

SOL1 SOL2 SOL3 SOL3 SOL4 SOL5B SOL5T SOL6 SOL7 SOL8 SPL-1 SPL-1 SPL-2 SPL-6 SPL-7 SPL-9 SPL-10 SPL-11 SPL-12

C6 G4 B3 B3 C5,C5,C5,B2 E3 E3 E3 E3

D4 D7

1,3 1,2,3

SA SIDESHIFT

D4 B3 C3 C3 D3, D4 B3

F4 H5

F2,F3 G5, G5, G5, H5 G4

SPLICE FOR WARNING & STROBE LIGHT SPLICE FOR WARNING & STROBE LIGHT SPLICE FOR TRACTION RESISTOR SPLICE FOR TRAVEL LIGHT & ALARM SPLICE FOR TRAVEL LIGHT & ALARM SPLICE FOR CAN BUS_1+ LIFT SPLICE FOR CAN BUS_1- LIFT SPLICE FOR CAN BUS_1+ TRACTION SPLICE FOR CAN BUS_1- TRACTION

LOAD/HOLD SOLENOID LIFT/LOWER PROPORTIONAL SOLENOID PROPORTIONAL DUMP SOLENOID REGEN AUX. BOOST SOLENOID SECOND STAGE PUMP SELECT SOLENOID SOLENOID FOR AUX. OIL DIRECTION CONTROL SOLENOID FOR AUX. OIL DIRECTION CONTROL REGEN AUX. BOOST SOLENOID REGEN AUX. BOOST SOLENOID AUX. DUMP SOLENOID

SIDE SHIFT SOLENOID

LIFT PRESSURE SENSOR RECEIVER FOR OCSS RECEIVER FOR OCSS REACH SOLENOID RELAY FOR TRAVEL LIGHTS

OPERATOR COMPARTMENT SENSOR SYSTEM

MAIN POWER CONTACTOR-AC TRUCKS STEER MOTOR

AC LIFT MOTOR DC LIFT MOTOR LIFT MOTOR ENCODER LIFT MOTOR TEMPERATURE SENSOR LIFT POWER AMPLIFIER LIFT POWER CONTACTOR-DC

LIFT CUTOUT SWITCH (S27) WORK LIGHT

KEYSWITCH RELAY-OPTIONS KEYSWITCH RELAY-SOLENIODS, ATTACHMENTS, HORN KEYSWITCH RELAY, POWER AMPS KEYSWITCH RELAY-HEATERS KEYSWITCH (S1)

LIFT PRESSURE SENSOR CONNECTOR LIFT MOTOR TEMPERATURE SENSOR CONNECTOR CONNECTOR FOR THIRD PARTY DEVICES

CONNECTOR FOR WORKING LIGHT CONNECTOR FOR WORKING LIGHT CONNECTOR FOR OPERATOR FAN CONNECTOR FOR WARNING LIGHT & STROBE

CONNECTOR FOR TRIGGER FOR VISION SYSTEM

CONTACTOR PANEL INTERFACE CONNECTOR DRIVE UNIT INTERFACE CONNECTOR CONNECTOR FOR LIFT CUTOUT OPTION MAST SWITCH 1 INTERFACE CONNECTOR HIGH SPEED TRAVEL SWITCH INTERFACE CONNECTOR CUSTOMER INPUT CONNECTOR HTI INTERFACE CONNECTOR HTI DISPLAY INTERFACE CONNECTOR CONNECTOR FOR VANTAGE POINT DISPLAY RIGHT BATTERY GATE SWITCH LEFT BATTERY GATE SWITCH STEER LIMIT CONNECTOR CONNECTOR FOR TRAVEL LIGHT TRACTION AMP CONNECTOR TRACTION ENCODER CONNECTOR TRACTION TEMPERATURE SENSOR CONNECTOR CONNECTOR FOR VANTAGE POINT DISPLAY CONNECTOR FOR VANTAGE POINT CAMERA TRACTOR END CONNECTOR FOR VANTAGE POINT CAMERA CARRIAGE END

4

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

DESCRIPTION

JPVT1

D3 C3 C3 A2,B3,C3 D2 E6 E5 H6 H3 D2 D3 E2,C5,F2 E2 E2 H6 C2,C3 D2 D2 D3 F2 F2 F2

ZONE

E

JPS1 JPS2 JPS5 JPS4 JPS6 JPS10 JPS11 JPS13 JPS14 JPS16 JPS17 JPST JPTL JPT1 JPT2 JPT3 JPVS1 JPVS2 JPVS3

SHEET

D

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

JPL1 JPL2 JPL3

IDENT.

LEGEND

SOLENOID FOR TILT THERMOSTAT FOR PRIMARY CONTROL HANDLE HEATER (EXTERNAL) THERMOSTAT FOR FLOOR PAD HEATER THERMOSTAT FOR SECONDARY CONTROL HANDLE HEATER (EXTERNAL) THERMOSTAT FOR HEIGHT ENCODER HEATER

D6 D7 E6,F6 E5,F5 E5,F5 G3 D3

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

STR T TILT TH1 TH2 TH3 T-ENCODER TM

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

TS1 TS2 TS2 TS3 TS3

4

H4

G2 G3 B4 G6

WARNING LIGHT

VARIABLE RESISTOR FOR PRIMARY CONTROL HANDLE THROTTLE VARIABLE RESISTOR FOR LIFT/LOWER VARIABLE RESISTOR FOR SECONDARY CONTROL HANDLE THROTTLE VARIABLE RESISTOR FOR DEADMAN SENSOR

VANTAGE POINT CAMERA SYSTEM

FOR DEVICES CONNECTED TO THESE CONNECTORS SEE SHEET 4.

AC LIFT MODELS ONLY FOR DEVICES CONNECTED TO THESE CONNECTORS SEE SHEET 5.

4 5 6

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

USED ON FORE/AFT MODELS ONLY. 3

2. FOR FUSES FU7 AND FU8 SEE TABLE A.

KEY SWITCH OFF, EPO NOT DEPRESSED, NOT ON DEADMAN.

1. MAST IN FULLY LOWERED POSITION REACH CARRIAGE IN RETRACTED (NESTED) POSITION.

NOTES:

WL

VR1 VR2 VR3 VR4

E2,E3

B3 B3 G5,H5 C7, D7 B7 E7,C7 B3,B5

1,2,3 1,3

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

TERMINAL STRIP AUX POWER TERMINAL STRIP CARRIAGE FUNCTIONS TERMINAL STRIP CARRIAGE FUNCTIONS TERMINAL STRIP OVER THE MAST CABLE TERMINAL STRIP NESTED SWITCH

C3

4

TR TR-2

VANTAGE POINT

TRACTION POWER AMP. PRECHARGE RESISTOR SPLICE FOR TRACTION POWER AMP. PRECHARGE RESISTOR

B2 A3,E6,G5,G6 B2,B3 B2 B4 G4,G6 B2,B3 D2,D3

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

TP1 TP1 TP2 TP3 TP4 TP4 TP5 TPA TPC

TIE POINT ON B+ TIE POINT ON B+ TIE POINT ON AUXILIARY MOTOR FUSE TIE POINT ON LIFT MOTOR FUSE TIE POINT ON BTIE POINT ON BTIE POINT ON TRACTION MOTOR FUSE TRACTION POWER AMPLIFIER TRACTION POWER CONTACTOR-DC TRUCKS

C2 C2

1,2,3 1,2,3

TME TMT

TRACTION MOTOR ENCODER TRACTION MOTOR TEMPERATURE SENSOR

AC TRACTION MOTOR

AMBIENT TEMPERATURE SENSOR

STEER POWER CONTACTOR

STEER TILLER ENCODERS STEER POSITION FEEDBACK ENCODER

C3

1,3 1,3

DESCRIPTION

E2 G6

SHEET

H

STEER TILLER ENCODER STEER MOTOR ENCODER

ZONE

G

IDENT.

LEGEND

F

Figure 1-9. Electrical Schematic - Legend (Sheet 6 of 6)

10

2

1

1

1150 psi 2000 psi 3100 psi MAX

RV-4 SOL-3

PILOT LINES

COMPONENT BOUNDARIES

COMPONENT RELIEF SETTING

CFS (option)

RV-3

SOL-3

RETURN LINES

Publication: 1112860D, Issued: 22 Aug 2016

KEY

2

1

2

CV-1

2

1

4

1

2

SOL-5T

2

3

SOL-5B

4

1000 psi

3

1

RV-2

TANK

G3

P1

2

PRESSURE LINES

# 12

POD-1

1

700 psi

P1

M

RV-4 2000 psi

RV-1

ESS

Models 7500/7520 Reach-Fork ® Truck Schematics

2

LS-1

SOL-2

SOL-1

3

1

G2

CYL-P

G1

A2

A1

CYL-1

# 12

# 4 HOSE (7X00)

HTI (option)

2

4

TR

TC

RV1

SSL

SSR

RR

RC

FREE LIFT

TILT

REACH

SIDE SHIFT

Standard AC Lift

# 8 HOSE (7X00)

2

1

TILT

4

3

2

4

RV2

REACH

1

3

1

3

MAIN LIFT

A2

A1

SIDE SHIFT

Figure 1-10. Hydraulic Schematic - Standard AC Lift (Sheet 1 of 2)

11

2

1

A2

A1

2

2

4

2

1

2

1

3

4

TR

TC

SSL

SSR

825 PSI

1,600 PSI

3

CB-2

1

1

TILT

SIDE SHIFT

REACH

4

3

B

CB-1

Publication: 1112860D, Issued: 22 Aug 2016

A2

A1

T

CV-3 2 PSI

3

3

DEEP REACH WITH TILT AND SIDE SHIFT

Models 7500/7520 Reach-Fork ® Truck Schematics

TILT

2

1

RV-3 1,150 PSI

SIDE SHIFT

RR

RC

REACH

A2

A1

2

1

2

1

2

1

TR

TC

RV1

RR

RC

SSL

SSR

A2

A1

T

CV-3 2 PSI

A2

A1

2

4

1

3

TILT

REACH

1

3

B

2

2

4

CB-2

1

1

2

CB-1

DEEP REACH WITH TILT

TILT

REACH

OPTIONS FOR AUX FUNCTIONS

4

3

REACH

4

3

RV2

4

3

TILT

SIDE SHIFT

SINGLE REACH WITH TILT

TR

TC

825 PSI

1,600 PSI

3

3

RV-3 1,150 PSI

RR

RC

REACH

Standard AC Lift - Options

TILT

2

1

Figure 1-11. Hydraulic Schematic - Standard AC Lift (Sheet 2 of 2)

12

Publication: 1112860D, Issued: 22 Aug 2016

Models 7500/7520 Reach-Fork ® Truck Schematics

AC Lift with Regen Lower

Figure 1-12. Hydraulic Schematic - AC Lift with Regen Lower (Sheet 1 of 3)

13

1

3

1

3

4

2

1

S SL

TR

TC

S SR

4

2

CV- 3

3

2

4

1

3

A 1 c ar r i a g e

2

1

3

2

2

CB-2

3

3

CB-1

2

1

3

4

TC

1

2

Reach

TR

NOTE: Al l Auxil i ary ci rcuit ho ses ar e si ze #4

RR

RC

TILT

Til t

7 50 0/ 77 00 /7 52 0/ 77 2 0

Til t

Sid e Shi f t

1

1

REACH

A 2 c ar r i a g e

RV-3

2

4

2

1

RV-1

RR

RC

Deep Reach w it h Til t and Sid e Shi f t

SIDESHIFT

2

1

RV-2

S SL

4

S SR

Reach

Sin g le Reach wi t h Til t and Si de Shi ft

Publication: 1112860D, Issued: 22 Aug 2016

A2

A1

A2

A1

REACH

Sid e Shi f t

A2 1

A1

3

3

4

S SR

SIDESHIFT

NOTE: Al l Auxil i ary ci rcuit ho ses ar e size #4

4 2

1

A2

2

4

CV-3

1

3

TR

TC

2

2

CB-2

3

3

CB-1

1

1

A 2 c ar r i a g e

REACH

Deep Reach w i t h Ti lt

2

2

1

4

RR

RC

RV-1

Reach

Sin g le Reach wi t h Ti lt

A 1 c ar r i a g e

2

3

1

2

1

RV-2

S SL

A1

REACH

Models 7500/7520 Reach-Fork ® Truck Schematics

Side Shif t

TILT

TILT

Til t

RV-3

2

1

TILT

Til t

RR

RC

1

2

TR

Reach

App earan ce

AC Lift with Regen Lower

Li ne Fun ct i o n P r e s s u re R e t ur n Pi lo t Dr ain L oa d S ens e S u c ti o n Co mponen t

NOTE: Al l Auxil i ary ci rcu it ho ses ar e si ze #4

3

4

TC

Figure 1-13. Hydraulic Schematic - AC Lift with Regen Lower (Sheet 2 of 3)

14

Publication: 1112860D, Issued: 22 Aug 2016

Models 7500/7520 Reach-Fork ® Truck Schematics

AC Lift with Regen Lower

Figure 1-14. Hydraulic Schematic - AC Lift with Regen Lower (Sheet 3 of 3)

15

P3

M

P2

CV-1

R

P

Publication: 1112860D, Issued: 22 Aug 2016

P2

P1

M

2

E

L

T

S-RET

PWR BYND

CV-2

HYD STEER MOTOR FORE/AFT CONFIG SHOWN

CASE DRAIN

SOL-4 2ND STAGE

1

Models 7500/7520 Reach-Fork ® Truck Schematics

1

1

SOL-2

2

SOL-8 AUX DUMP

FILTER

1

LIFT/LOWER

TANK

2

PP

2

2

1

LOAD HOLD SOL-1

REL-1

1

2

CE-1

4

1

3

2

3

SOL-5T

SOL-5B

MAIN RELIEF

3

1 2

G2

LS-1

G1

A2

A1

HTI

CFS

CYL-P

CYL-1

A2

A1

2

4 2

3 1

REACH1

1

4

RV2

2

1

3

4

3

TILT

SIDE SHIFT

TR

TC

SSL

SSR

RV1

COMPONENT BOUNDARIES

RETURN AND PILOT LINES

PRESSURE LINES

TILT

REACH

SIDE SHIFT

DC Lift - Standard Reach

RR

RC

MAIN LIFT

16

FREE LIFT

Figure 1-15. Hydraulic Schematic - DC Lift - Standard Reach (Sheet 1 of 3)

P3

M

CV-1

L

P

Publication: 1112860D, Issued: 22 Aug 2016

P1

M

E

Models 7500/7520 Reach-Fork ® Truck Schematics

R

T

HYD STEER MOTOR DOCKSTANCE SHOWN. HOSES ARE REVERSE OF FORE/AFT.

CASE DRAIN

S-RET

PWR BYND

1

1

2

SOL-8 AUX DUMP

FILTER

2

2

COMPONENT BOUNDARIES

1

2

CE-1

4

1

3

2

3

SOL-5T

SOL-5B

MAIN RELIEF

REL-1

RETURN AND PILOT LINES

1

LOAD HOLD SOL-1

PRESSURE LINES

1

SOL-2 LIFT/LOWER

TANK

2

PP

3

1 2

G2

LS-1

G1

A2

A1

HTI

CFS

CYL-P

CYL-1

A2

A1

T

CV-3 2 PSI

A2

A1

2

4

2

4 2

1

2

3

4

TR

TC

SSL

SSR

825 PSI

1

CB-2

3

3

2

1,600 PSI

3

TILT

SIDE SHIFT

REACH

1

3

B

CB-1

MAIN LIFT

1

1

1,150 PSI

SIDE SHIFT

RR

RC

REACH

DC Lift - Deep Reach

TILT

2

1

FREE LIFT

Figure 1-16. Hydraulic Schematic - DC Lift - Deep-Reach (Sheet 2 of 2)

17

2

1

2

1

TILT

4

3

REACH

4

3

T

C V-3 2 PSI

2

1

A2

A1

2

4

2

3

1

2

1

TR

TC

SSL

SSR

825 PSI

4

CB-2

3

3

2

1,600 PSI

3

TI LT

SIDE SHIFT

REACH

4

3

B

CB-1

Publication: 1112860D, Issued: 22 Aug 2016

A2

A1

2

1

RV2

4

3

TR

TC

SSL

SSR

RV1

RR

RC

1

1

TI LT

2

1

TI LT

REACH

1,150 PSI

DEEP REACH WITH TILT AND SIDE SHIFT

A2

A1

SIDE SHIFT

SIDE SHIFT

RR

RC

SIDE SHIFT

SINGLE REACH WITH TILT AND SIDE SHIFT

Models 7500/7520 Reach-Fork ® Truck Schematics

REACH

A2

A1

1

3

REACH

1

2

4

2

4

RV2

2

1

3

4

3

TILT

SIDE SHIFT

TR

TC

RV1

RR

RC

SSL

SSR

SINGLE REACH WITH TILT

A2

A1

T

C V-3 2 PSI

A2

A1

2

4 2

1

CB-2

3

3

2

3

2

4

TI LT

REACH

1

3

B

CB-1

TR

TC

825 PSI

1,600 PSI

DEEP REACH WITH TILT

TI LT

REACH

1

1

TI LT

2

1

1,150 PSI

RR

RC

DC Lift - Aux Functions

REACH

Figure 1-17. Hydraulic Schematic - DC Lift - Aux Functions (Sheet 3 of 3)

18