7400 fixes

These are my personal tips, not found in manuals.
No longer work on raymonds, but if anyone has new info or tips please write me and I'll add it to this one list.

Part # for dead man switch is 7-590-003/001
Spring: 830-120
Bushings: 462-010

2V. Sometimes with 5G....,
EPO switch int open. Shuts down truck briefly.

57: often bad Battery drops too low too fast

Multiple codes intermittent at the same time: 4C,8L,45,G4 and 2V worse on bumps. Check K2 relay pins on fuse card. Card pins melt.

Unrequested lift while aux is used: Sol 3 stuck open.
Old software Also caused this.

61: possible prop out of adj

64: connection at VM JP14 plug, connection at ODI.

67; plug at VM loose
Mast did not nest fully,
Prox open.
Bad cushion
Stuck in main cyl.
Holds up mast, switch open 64; no pulses from encoder; bad connection
At VM. With code 61 can. often be dirt/filings in Prop.
Fork hang up: free lift starts dropping before main tellies nest: spun post on mast brg, tightens as it turns.

Relays lt to rt- K3,K2,K4,K1. (K1 is optional for Cold Storage,can be used at other slots to test)

Gland tool part #
223-001-813

Slow lift: valve, Sol3, (75%)sol 2 (15%) Pods1 valve (10%)
Slow aux; bad releif REL-2
Url; adjust Rel 2

8L. Wire at brake, (50%) relay,(20%) 8L with 4C- contacts at relay board (K2 relay)(20%). Pin at VM burned (10%)(JPC20-14)

8L with G4; power up slow, display shows "0/00" for date.....check K2 relay for burned lower pin. Replace board and 3 relays.

8C. Dead man switch bad or plastic stuck. terminals loose or harness open. Play in brake pedal bushing, worn. Brake spring weak.

Slow Aux: bad PODS-1, LS1 (under a/b) REL-2 or adjust REL2. (Filings in valve from something broken)

No Aux: k2 relay bad, LS1 valve. A/B dir valve

SLOW LOWER*
Clogged filter( 10%) solenoid 2 prop (60%)
LH valve Solenoid 1 (30%) plugged flow limiters, software conflict


G4; steer card possibly gone. Listen for neutral pulses..if none, steer card is shot

GD: worn brushes, worn radial rings. Toothed ring spins on drive unit. Prox way out of adj or too far from ring
Bad connection at plug near motor or VM
Check play at drive unit. No more than 120 thou. Drive with door off and check motor movement while plugging. Excess movement will cause steer binding. Look at underside of drive unit for wear marks
Grooves indicate binding and worn rings.
Sometimes steer motor coupler slips internally
Check clearance of steer prox. Close as possible without touching. You must adjust steer flag distance if the prox was removed. Go into "inputs" and test I90. At each end of travel the test I90 should read 8 deg each side. If 6 shows on one end and 11 at the other, GD will code. Adj as even as you can.
Also, caster housing bearing may seize and cause "snap" during turns. Steer Encoder gives an erratic signal ands codes out GD.

"Return control handle to neutral" message 85% time is secondary directional control handle plug at VM loose. Rarely the rear handle itself.

Oil leaks:
Right main Cyl at bottom block leaks in middle of weld. Left free lift same. Block must be removed snd re-welded or new Cyl tube installed.
Main Cyl is difficult to remove. Do not split cab from mast as manual says.