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Return
F-code
Section
C-code
Standard Codes
Version no
T-code
000
Standard Codes
B-Code
= Business area
F-Code
= Product family
T-Code
= Product type
C-Code
= Component function
Worksheet standard
W-Code = Working code
R-Code
= Reason code
SO-Code = Assortment
F-Code List
PS - Powered Pallet Stacker
T-Code List
Code
Model
395
RRX35
396
RRX45
397
RDX30
398
RSX40
399
RSX50
C-Code List
No Function Group
BT Prime-Mover, Inc.
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C-Code
Chassis
0000
Motors
1000
2000
3000
Steering System
4000
Electrical System
5000
2000-08-04
F-code
Section
C-code
Standard Codes
Version no
T-code
000
Return
6000
7000
8000
Options / Attachments
9000
2000-08-04
Table of Contents
Table of Contents
Standard Codes ............................................................................................. 1
Warning Symbols ......................................................................................... 15
Warning Levels ......................................................................................... 15
Prohibitory Symbols .................................................................................... 16
Ordinance Symbols .................................................................................. 16
Safety ............................................................................................................ 17
General Safety .......................................................................................... 17
Battery Safety ............................................................................................... 21
Static Safety .................................................................................................. 26
Welding Safety ............................................................................................. 27
Introduction, Service Manual ...................................................................... 29
Contents, Section M ..................................................................................... 31
Machine Information ................................................................................. 31
General Product Information ...................................................................... 33
Presentation of the Rider Trucks. ............................................................. 33
Main Components ..................................................................................... 42
Inch (SAE) and Metric Fasteners ...............................................................
Introduction ...............................................................................................
Nomenclature, Threads ............................................................................
Strength Identification ...............................................................................
Conversion of Metric and English Units ....................................................
45
45
46
47
55
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2001-10-12
Table of Contents
Planned Maintenance Procedures ............................................................ 76
Lubrication Chart ......................................................................................... 83
Oil and Grease Specifications ....................................................................
Approved Oils and Grease .......................................................................
Grease Location Points ............................................................................
Mast Adjustment Points ............................................................................
84
84
85
86
89
89
91
96
97
Chassis ......................................................................................................... 99
General ..................................................................................................... 99
Dash ........................................................................................................ 100
Motor Compartment Door ........................................................................ 101
Left-Hand Side Panel ............................................................................... 102
Operator Compartment Panel .................................................................. 103
Main Card Access Panel ......................................................................... 103
Battery Compartment ................................................................................. 105
Battery Retainer Plates ............................................................................ 106
Battery Rollers ......................................................................................... 106
Driver Controls ............................................................................................ 107
Brake Pedal, RSX40/RRX35 ........................................................................
Pedal Removal ........................................................................................
Pedal Bearing Replacement ....................................................................
Pedal Adjustment .....................................................................................
109
110
111
111
112
113
114
114
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2001-10-12
Table of Contents
Decal with Protective Sheet ..................................................................... 117
Decal without Protective Sheet ................................................................ 117
Steering Motor .............................................................................................
Removal ...................................................................................................
Installation ................................................................................................
Steering Motor Gear Replacement ..........................................................
121
121
121
122
125
125
125
126
155
155
159
161
165
174
176
178
179
179
181
182
183
183
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2001-10-12
Table of Contents
Brake Friction Plate ................................................................................. 184
Drive Wheel ..................................................................................................
Removal ...................................................................................................
Installation ................................................................................................
Tire Pressing Procedure ..........................................................................
185
186
186
187
189
191
193
195
197
215
217
218
219
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223
223
227
231
2001-10-12
Table of Contents
Brake Release .........................................................................................
Direction Selection ...................................................................................
Travel Request, Forks First .....................................................................
Travel Request, Forks Trailing .................................................................
Plug Braking ............................................................................................
12-Volt Power Supply ..............................................................................
7.35-Volt Power Supplies ........................................................................
Limit Switches ..........................................................................................
Height Indicator ........................................................................................
Drive Motor Brush Wear Indicator Switches ............................................
Pump Motor Brush Indicator Switch ........................................................
Safety Check ...........................................................................................
Shunt Power Cable ..................................................................................
237
239
241
245
250
254
255
258
262
264
265
266
268
277
277
278
279
280
281
282
283
284
285
286
287
289
289
290
291
292
293
294
295
296
297
298
299
300
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2001-10-12
Table of Contents
Circuit Diagram 2(12) ...............................................................................
Circuit Diagram 3(12) ...............................................................................
Circuit Diagram 4(12) ...............................................................................
Circuit Diagram 5(12) ...............................................................................
Circuit Diagram 6(12) ...............................................................................
Circuit Diagram 7(12) ...............................................................................
Circuit Diagram 8(12) ...............................................................................
Circuit Diagram 9(12) ...............................................................................
Circuit Diagram 10(12) .............................................................................
Circuit Diagram 11(12) .............................................................................
Circuit Diagram 12(12) .............................................................................
302
303
304
305
306
307
308
309
310
311
312
313
313
314
315
316
317
318
319
320
321
322
323
324
Battery ..........................................................................................................
Removal ...................................................................................................
Installation ................................................................................................
Battery Maintenance ................................................................................
Storage ....................................................................................................
Battery History Record .............................................................................
325
325
325
326
328
328
329
329
330
331
332
333
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2001-10-12
Table of Contents
General .................................................................................................... 337
Key Switch (S17) ..................................................................................... 337
Emergency Disconnect Switch (S21) ...................................................... 339
Battery Connector .......................................................................................
Location ...................................................................................................
Inspection ................................................................................................
Installation ................................................................................................
341
341
341
342
351
351
352
354
356
365
365
366
367
369
369
370
374
374
380
381
381
382
382
383
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2001-10-12
Table of Contents
Battery Discharge Indicator Parameter Adjustment .................................
A5 Jumper Harness Kit Installation (Serial numbers 28126000 - below)
Warning\Caution Codes ...........................................................................
Error Codes .............................................................................................
Programming Parameter .........................................................................
384
390
393
395
401
411
411
411
413
415
417
419
421
421
442
443
444
445
446
447
447
447
448
449
450
10
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2001-10-12
Table of Contents
Control Valve Assembly ............................................................................. 466
Repair ...................................................................................................... 468
Staging Cylinder, Three Stage Mast ..........................................................
Bearing Removal .....................................................................................
Disassembly ............................................................................................
Assembly .................................................................................................
Installation ................................................................................................
473
474
475
475
475
477
479
480
480
480
481
483
484
485
486
487
489
490
491
492
493
494
495
497
498
499
500
501
503
507
509
514
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2001-10-12
11
Table of Contents
Mounting Instructions ............................................................................... 529
Operation and Maintenance .................................................................... 530
Sideshifter, RRX35/45/RSX40/50/RDX30 ...................................................
Mounting Instructions ...............................................................................
Operation .................................................................................................
Maintenance ............................................................................................
Troubleshooting .......................................................................................
533
535
536
536
540
541
547
552
556
558
558
559
559
567
571
572
573
575
575
575
575
575
Forks ............................................................................................................
Removal ...................................................................................................
Inspection ................................................................................................
Installation ................................................................................................
577
579
579
580
12
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587
588
588
589
590
591
2001-10-12
Table of Contents
Programming ........................................................................................... 592
Load Backrest ............................................................................................. 601
Removal ................................................................................................... 604
Installation ................................................................................................ 604
BT Prime-Mover, Inc.
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2001-10-12
13
Table of Contents
14
Return
2001-10-12
F-code
PS
Version no
Section
C-code
Warning Symbols
T-code
001
Warning Symbols
Always follow the warnings given in this Service Manual
and on the truck to avoid accidents and incidents from
occurring.
1. Warning Levels
Warning levels
Warning texts are given in four levels and provide information
on the risks, describe the consequences, and instruct how to
avoid accidents.
DANGER
Warns that an accident will occur if the instructions are
not followed.
The consequences are serious personal injury or
possibly death, and/or extremely large material damage.
WARNING
Warns that an accident can occur if the instructions are
not followed.
The consequences are serious personal injury or
possibly death, and/or large material damage.
CAUTION
Warns that an accident can occur if the instructions are
not followed.
The consequences are personal injury and/or material
damage.
NOTE!
Marks the risk of an accident or breakdown if the
instructions are not followed.
BT Prime-Mover, Inc.
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2000-08-04
15
F-code
Section
C-code
PS
Prohibitory Symbols
Version no
T-code
001
Prohibitory Symbols
NO SMOKING
If smoking occurs in situations where a restriction against
smoking is stated, a serious accident can occur.
GENERAL PROHIBITION
If the prohibition is ignored, a serious accident can occur.
1. Ordinance Symbols
SAFETY SHOES
When the directive for safety shoes is given, safety shoes
shall always be worn to avoid personal injury.
PROTECTIVE GLASSES
When the directive for protective glasses is given,
protective glasses shall always be worn to avoid personal
injury.
16
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2000-08-04
F-code
Section
PS
Version no
C-code
Safety
T-code
001
Safety
1. General Safety
Do NOT operate or work on this truck unless trained,
qualified, and authorized to do so and have read the
Operators Manual.
BT Prime-Mover, Inc.
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2000-08-04
17
F-code
Section
C-code
PS
Safety
Version no
T-code
001
18
Return
lubrication,
maintenance,
and
2000-08-04
F-code
Section
PS
Version no
C-code
Safety
T-code
001
BT Prime-Mover, Inc.
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2000-08-04
19
F-code
Section
C-code
PS
Safety
Version no
T-code
001
20
Return
2000-08-04
F-code
Section
PS
Version no
C-code
Battery Safety
T-code
001
Battery Safety
WARNING As a battery is being charged, an explosive
gas mixture forms within and around each
cell. If the area is not properly ventilated,
this explosive gas can remain in or around
the battery for several hours after charging.
Be sure there are no open flames or sparks
in the charging area. An open flame or
spark can ignite this gas, resulting in
serious damage or injury.
WARNING Battery electrolyte is a solution of sulfuric
acid and water. Battery acid causes burns.
Should any electrolyte come in contact with
clothing or skin, flush the area immediately
with cold water. Should the solution get on
the face or in the eyes, flush the area with
cold water and receive medical attention
immediately.
Read, understand and follow procedures, recommendations
and specifications in the battery and battery charger manuals
from the manufacturer.
BT Prime-Mover, Inc.
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2000-08-04
21
F-code
Section
C-code
PS
Battery Safety
Version no
T-code
001
22
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2000-08-04
F-code
Section
PS
Version no
C-code
Battery Safety
T-code
001
Turn the key switch off before disconnecting the battery from
the truck at the battery connector. Do NOT break live circuits
at the battery terminals. A spark often occurs at the point
where a live circuit is broken.
BT Prime-Mover, Inc.
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2000-08-04
23
F-code
Section
C-code
PS
Battery Safety
Version no
T-code
001
Keep filler plugs firmly in place at all times except when the
electrolyte level is checked, when water is added to the cells
or when the specific gravity is checked.
Make sure vent holes in filler plugs are open to allow gas to
escape from the cells.
Vent Plug
24
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2000-08-04
F-code
Section
PS
Version no
C-code
Battery Safety
T-code
001
BT Prime-Mover, Inc.
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2000-08-04
25
F-code
Section
C-code
PS
Static Safety
Version no
T-code
001
Static Safety
Electronic circuit board and devices used on truck can be
damaged by the discharge of static electricity, called
electrostatic discharge.
Static charges can accumulate from normal operation of
truck as well as movement or contact between nonconductive materials such as, plastic bags, synthetic clothing,
synthetic soles on shoes, styrofoam coffee cups, etc.
Accumulated static can be discharged through human skin to
a circuit board or component by touching the parts. Static
discharge is also possible through the air when a charged
object is placed close to another surface at a different
electrical potential. Static discharge can occur without
seeing or feeling it.
Whenever working on or near static-sensitive electronics,
always use static discharge precautions.
1. Place a static discharge wrist strap around the wrist.
Connect the ground lead to the wrist strap connector.
2. Connect the ground clamp to an unpainted, ground
surface on truck frame.
3. If removing or installing static-sensitive components,
place them on a properly grounded static mat.
4. To transport static-sensitive components, including failed
components being returned, place the components in an
antistatic bag or box.
The wrist strap and associated accessories should be tested
monthly to verify they are working properly. A defective static
discharge wrist band will not alert that it is bad.
26
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2000-08-04
F-code
Section
PS
Version no
C-code
Welding Safety
T-code
001
Welding Safety
WARNING Flame cutting or welding on painted
surfaces may produce potentially harmful
fumes, smoke and vapors. Prior to
performing flame cutting or welding
operations, it is recommended that the
coating be removed in the vicinity where the
operation(s) will be performed.
WARNING Coating removal may be by mechanical
methods, chemical methods or a
combination of methods. Flame cutting and/
or welding operations should be carried out
only in well ventilated areas using local
exhaust if necessary.
Before working on truck, make sure of the following:
Fire protection equipment is nearby.
Know where the nearest eyewash station is located.
BT Prime-Mover, Inc.
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2000-08-04
27
F-code
Section
C-code
PS
Welding Safety
Version no
T-code
001
28
Return
2000-08-04
F-code
Section
C-code
M
Introduction, Service Manual
Version no
T-code
001
395/396/397/398/399
52761-8800
(563) 262-7700
This Service Manual is not a training manual. The information
contained in this service manual is intended as a guide to
help trained, qualified, and authorized technicians safely
service the truck.
The Service Manual is divided into four separate sections,
which cover needed information for servicing the truck types.
The main subject for each of the sections are as described
below.
SECTION
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SUBJECT
MACHINE INFORMATION
PLANNED MAINTENANCE
SERVICE INSTRUCTIONS
OPTIONS
2000-08-04
29
F-code
Section
C-code
M
Introduction, Service Manual
Version no
T-code
001
395/396/397/398/399
30
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2000-08-04
F-code
Section
C-code
M
Contents, Section M
Version no
T-code
001
Contents, Section M
1. Machine Information
BT Prime-Mover, Inc.
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M1.0
M2.0
M3.0
2000-08-04
31
F-code
Section
C-code
M
Contents, Section M
Version no
T-code
001
32
Return
2000-08-04
F-code
Section
C-code
M1.0
General Product Information
Version no
001
T-code
395/396/397/398/399
Forward
Right SIde
BT Prime-Mover, Inc.
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2000-08-04
33
F-code
Section
C-code
M1.0
General Product Information
Version no
T-code
001
395/396/397/398/399
Open
back
compartment
34
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2000-08-04
F-code
Section
C-code
M1.0
General Product Information
Version no
001
T-code
395/396/397/398/399
To transport/lift passengers.
RRX35
RRX45
RDX30
RSX40
RSX50
3500
(1587)
4500
(2041)
3000
(1360)
4000
(1814)
5000(
2267)
192-270
(4876-6858)
210-402
(5334-10210)
210-402
(5334-10210)
192-270
(4876-6858)
210-402
(5334-10210)
Operating
speed without
load, mph
24 Volt
6.0 mph
36 Volt
6.5 mph
Operating
speed with
load, mph
24 Volt
5.5 mph
36 Volt
6.0 mph
Service weight
without battery,
lb (kg)
Service weight
including
battery, lb (kg)
36 Volt
6.5 mph
36 Volt
6.5 mph
24 Volt
6.0 mph
36 Volt
6.5 mph
24 Volt
5.5 mph
36 Volt
6.0 mph
36 Volt
6.5 mph
36 Volt
6.0 mph
36 Volt
6.0 mph
36 Volt
6.0 mph
240 Mast
5595
(2537)
210 Mast
5915
(2682)
330 Mast
6945
(3150)
210 Mast
4645
(2106)
210 Mast
5530
(2508)
Above +
battery
weight
Above +
battery weight
Above +
battery weight
(2600 min)
Above +
battery weight
(2400 min)
Above +
battery weight
(2400 min)
The lifting capacity, lifting height, and weight of the truck can
be found on the truck data plate.
BT Prime-Mover, Inc.
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2000-08-04
35
F-code
Section
C-code
M1.0
General Product Information
Version no
T-code
001
395/396/397/398/399
(17 67.0
03 5
mm
)
40.5
(1028 mm) 31.0
(787 mm)
OALH
11.5
(292 mm)
Step
Height
3.0
(76 mm)
-3
Free Lift
2.0 (50 mm)
Battery
Roller 7.0 (177 mm)
Height
16.4
(416 mm)
9.1
(231 mm)
57.45
(1459 mm)
36
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2000-08-04
F-code
Section
C-code
M1.0
General Product Information
Version no
T-code
001
395/396/397/398/399
(17 69.5
65
mm
)
40.5
(1028 mm)
31.0
(787 mm)
OALH
11.5
(292 mm)
Step
Height
3.0
(76 mm)
-3
2.0
(50 mm)
Battery
Free Lift
16.4
(416 mm)
9.1
231 mm)
5.0
(127 mm)
60.0
(1524mm)
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2000-08-04
37
F-code
Section
C-code
M1.0
General Product Information
Version no
T-code
001
395/396/397/398/399
(17 69.5
65
mm
)
40.5
(1028 mm) 31.0
(787 mm)
46.0
(1168 mm)
A
48.0
(1219 mm)
95.0 (2413 mm)
7.0
(177 mm)
+4
11.5
(292 mm)
Step
Height
OALH
-3
Free Lift
Battery
Roller
Height
3.0
(76 mm)
16.4
(416 mm)
9.1
(231 mm)
60.0
(1524 mm)
38
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2000-08-04
F-code
Section
C-code
M1.0
General Product Information
Version no
001
T-code
395/396/397/398/399
Fork length
BT Prime-Mover, Inc.
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2000-08-04
39
F-code
Section
C-code
M1.0
General Product Information
Version no
T-code
001
395/396/397/398/399
Fork length
40
Return
2000-08-04
F-code
Section
C-code
M1.0
General Product Information
Version no
001
T-code
395/396/397/398/399
Legend
1
2
3
4
5
6
7
8
9
10
11
12
13
BT Prime-Mover, Inc.
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2000-08-04
41
F-code
Section
C-code
M1.0
General Product Information
Version no
T-code
001
395/396/397/398/399
2. Main Components
1
2
3
4
5
7
8
9
10
11
12
42
Return
Hydraulic valve:
The valves are located to provide easy access.
Battery:
24/36V with different capacities and weights.
Battery connector:
The truck is connected to the battery through the battery
connector. When charging the battery, do not connect the
battery charger to the battery connector at the truck
chassis.
Hydraulic unit:
Pump motor and hydraulic pump are an integrated unit.
Drive unit with brake:
Drive motor, gears, drive wheel and electrical brake
combined in the drive unit.
Electrical steering:
A servo steer motor drives a gear ring, enabling the drive
unit to be rotated through 360 degrees in either direction.
Data plate:
See Data Plate on page 41.
Cover:
Removable to provide access for servicing.
Pedal:
Brake pedal.
Control console:
The control console can be adjusted to a suitable height
and angle to obtain a comfortable working position. The
steering, hydraulic functions, horn, parking brake, preset
height, travel direction, key switch, and any extra
hydraulic functions are all controlled from this console.
The position of the console may be set in 1 of 3 positions;
forward facing, 45 degrees, or side stance.
Instrument panel:
This provides information on the trucks running hours,
time display, error codes, travel direction, parking brake,
steering angle and battery status.
Mast:
The mast is a clear view model.
2000-08-04
F-code
Section
C-code
M1.0
General Product Information
Version no
001
T-code
395/396/397/398/399
13 Electronics:
The electronics are in a protected compartment.
14 Control circuit fuse: (for fuse size and part number see
page 59)
15 Steering circuit fuse: (for fuse size and part number see
page 59)
16 Drive motor fuse: (for fuse size and part number see
page 59)
17 Pump motor fuse: (for fuse size and part number see
page 59)
18 Right foot pedal
An operator must keep all of his or her body in the
operators compartment at all times. The area of the
operators compartment in the truck is designed so that an
operator can do so. A red triangle (reminder light) will be
displayed on the instrument panel if the right foot pedal is
not depressed. This feature reinforces that the operator
must take advantage of the area of the operators
compartment and keep all of his or her body in the
compartment.
19 Emergency stop
The emergency stop switch will stop all control and power
functions.
BT Prime-Mover, Inc.
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2000-08-04
43
F-code
Section
C-code
M1.0
General Product Information
Version no
T-code
001
395/396/397/398/399
12
11
10
19
16
17
8
5
4
6
7
9
18
13
14
15
44
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2000-08-04
F-code
Section
C-code
M1.1
Inch (SAE) and Metric Fasteners
Version no
T-code
002
10
10
1. Introduction
Threaded fasteners such as bolts, nuts, cap screws, and
studs are made to specifications that describe the mechanical
strength and hardness of the fastener. A fastener used in a
design application is selected in accordance with its
specifications. Parts used on this truck are purchased from
many countries. Many of these fasteners are similar but
cannot be used as direct replacements.
Service persons must use replacement fasteners that have
the same specifications. Fasteners made to each
specification have identification marks for that specification.
This specification is commonly called grade for SAE
standards and property for metric standards. This section
describes the identification of some common fasteners.
The metric system used is described as SI (International
System of Units, also called SI in all languages). The SI
system of measurement is described in ISO Standard 1000,
1973.
BT Prime-Mover, Inc.
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2002-01-16
45
F-code
Section
C-code
M1.1
Inch (SAE) and Metric Fasteners
Version no
T-code
002
2. Nomenclature, Threads
The thread design is specified by a series of numbers and
letters for inch and metric fasteners (see figure below). The
diameter of the shank of the fastener is shown first in the
series, e.g. M12=12 mm, M20=20 mm (1/2=1/2 inch, 3/4=3/4
inch).
The number of threads per inch is normally not shown for inch
nomenclature and only the UNC (Unified National Coarse) or
UNF (Unified National Fine) is shown. This number of threads
per inch is not shown because a UNC or UNF fastener has a
standard number of threads per inch for a specific diameter.
The length of a shank is often indicated as part of the
description of a fastener. This length is shown in inches for
inch fasteners and in millimeters for metric fasteners.
A cap screw will have the following description:
A=
B=
C=
D=
46
Return
Inch
Metric
M12 x 1.75 x 50
A
B
C
Shank diameter
Number of threads per unit of length
Type of thread
Shank length
A = Thread size
B = Pitch
C = Length
2002-01-16
F-code
Section
C-code
M1.1
Inch (SAE) and Metric Fasteners
Version no
T-code
002
3. Strength Identification
The most common property classes for metric fasteners are
8.8 and 10.9. The property class is marked with a number on
the head of the cap screw or on a nut. Property classes less
then 8.8 are often not marked. Grades for inch bolts go from 2
to 8. Grade 2 fasteners normally do not have marks. The
following tables show the marks that identify the grades and
property classes for different fasteners.
WARNING When fasteners must be replaced the new
fasteners must be of the same strength or
greater than the original fasteners. The new
fasteners must also be the correct size.
NOTE!
BT Prime-Mover, Inc.
Return
2002-01-16
47
F-code
Section
C-code
M1.1
Inch (SAE) and Metric Fasteners
Version no
T-code
002
Types of
Fasteners
Metric Fasteners
Inch Fasteners
5.2
4.6*
4.8*
5.8*
8.8
4.6
4.8
5.8
8.8
9.8
10.9
12.9
9.8
10.9
12.9
Markings
for size
M5 and
Larger
Hex Head
Flange Screws
Same As Above
5
12 Point
Flange Screws
5.1
8.8
12.9
8.8
12.9
4.8*
9.8
4.8
9.8
SEMS
48
Return
2002-01-16
F-code
Section
C-code
M1.1
Inch (SAE) and Metric Fasteners
Version no
T-code
002
Types of
Fasteners
Inch Fasteners
Metric Fasteners
4.6*
4.6
5.2*
5*
9.8
9.8
8*
Hex Nuts
BT Prime-Mover, Inc.
Return
4.8
8.8
8.8
5.8
10.9 12.9
Markings
for size
M5 and
Larger
12.9
10.9
8.1
or
Studs
4.8* 5.8*
10
12
10
12
10
12
or
or
10
12
10
12
10
12
10
12
2002-01-16
49
F-code
Section
C-code
M1.1
Inch (SAE) and Metric Fasteners
Version no
T-code
002
Types of
Fasteners
Inch Fasteners
Metric Fasteners
10
10
or
All Metal Prevailing
Torque Nuts
G
9
10
or
9
10
or
50
Return
2002-01-16
F-code
Section
C-code
M1.1
Inch (SAE) and Metric Fasteners
Version no
T-code
002
Types of
Fasteners
Metric Fasteners
Inch Fasteners
10
10
or
Nylon Insert Prevailing Torque
Nuts
or
or
10
10
or
BT Prime-Mover, Inc.
Return
2002-01-16
51
F-code
Section
C-code
M1.1
Inch (SAE) and Metric Fasteners
Version no
T-code
002
Property, Class
8.8*
Property, Class
10.9**
Property, Class
12.9***
Nm
in-lb
Nm
in-lb
Nm
in-lb
5-6
8-10
20-25
44-53
71-88
177-221
7-8
12-14
30-35
62-71
106-124
------------
8-10
14-16
------------
71-88
124-142
------------
Nm
ft-lb
Nm
ft-lb
Nm
ft-lb
M8 x 1.25
M10 x 1.5
-----------40-45
-----------30-33
-----------60-65
22-26
44-48
34-40
70-75
26-30
52-55
M12 x 1.75
M14 x 2
70-80
110-125
30-33
52-59
100-110
155-180
74-81
114-133
115-130
180-210
85-96
133-155
M16 x 2
M20 x 2.5
170-190
340-380
125-140
251-280
240-270
450-500
177-199
332-369
280-320
550-600
207-236
406-443
M24 x 3
580-650
428-479
800-900
590-664
900-1050
664-774
M30 x 3.5
1150-1300
848-959
1600-1800
1180-1328
1850-2100
1364-1549
M36 x 4
2000-2250
1479-1660
2800-3150
2065-2323
3250-3700
2397-2729
M5 x 0.8
M6 x 1
M8 x 1.25
52
Return
2002-01-16
F-code
Section
C-code
M1.1
Inch (SAE) and Metric Fasteners
Version no
T-code
002
Torque Specification
Motor terminals
Loctite 243
Transmission case
Loctite 515
BT Prime-Mover, Inc.
Return
2002-01-16
53
F-code
Section
C-code
M1.1
Inch (SAE) and Metric Fasteners
Version no
T-code
002
Torque Specification
65 ft-lb
21 ft-lb
70 ft-lb
56 ft-lb
Loctite 243
54
Return
(88 Nm)
(28 Nm)
(95 Nm)
(76 Nm)
2002-01-16
F-code
Section
C-code
M1.1
Inch (SAE) and Metric Fasteners
Version no
T-code
002
By
To Get
Multiply
By
To Get
inches
6.451
centimeters (cm)
centimeters
0.155
inches (in)
feet
0.093
meters (m)
meters
10.764
feet (ft)
LINEAR
Multiply
By
To Get
Multiply
By
To Get
inches
25.4
millimeters(mm)
millimeter
0.039
inches (in)
feet
0.305
meters (m)
meter
3.280
feet (ft)
yards
0.914
meters (m)
meter
1.094
yards (yd)
miles
1.609
kilometers (km)
kilometer
0.621
miles (mi)
MASS
Multiply
By
To Get
Multiply
By
To Get
ounces (oz)
28.49
grams (g)
grams
0.035
ounces (oz)
pounds (lb)
0.454
kilograms (kg)
kilograms
2.205
pounds (lb)
907.18
kilograms (kg)
kilograms
0.001
0.907
metric ton
1.102
POWER
Multiply
By
To Get
Multiply
By
To Get
horsepower
0.746
kilowatts (kW)
kilowatts
1.34
horsepower(hp)
PRESSURE
Multiply
By
To Get
Multiply
By
To Get
pounds/in
6.895
kilopascal (kPa)
kilopascals
0.145
pounds/in
(psi)
pounds/in
0.007
megapascal (MPa)
megapascals
145.04
pounds/in
(psi)
BT Prime-Mover, Inc.
Return
2002-01-16
55
F-code
Section
C-code
M1.1
Inch (SAE) and Metric Fasteners
Version no
T-code
002
TEMPERATURE
Multiply
By
To Get
Multiply
By
To Get
(Fahrenheit
-32)
0.56
Celsius (C)
(Celsius x
1.8)
+32
Fahrenheit
(F)
TORQUE
Multiply
By
To Get
Multiply
By
To Get
inch pound
0.113
Newton meter
(Nm)
Newton
meter
8.851
inch pounds
in-lb
feet pound
1.356
Newton meter
(Nm)
Newton
meter
0.738
foot pounds
ft-lb
VELOCITY
Multiply
By
To Get
Multiply
By
To Get
miles/hour
1.609
kilometer/hour
(km/h)
kilometer/
hour
0.621
miles/hour
(mph)
VOLUME
56
Multiply
By
To Get
Multiply
By
To Get
inches
16.387
centimeters (cm)
centimeters
0.061
inches (in)
inches
0.016
liters
liters
61.024
inches (in)
quarts, U.S.
0.946
liters
liters
1.057
quarts, U.S.
(qt)
quarts, U.S.
0.83
quarts, Imp.
1.205
quarts, U.S.
(qt)
gallons, U.S.
3.785
liters
liters
0.264
gallons, U.S.
(gal)
gallons, U.S.
0.83
gallons, Imp.
1.205
gallons, U.S.
(gal)
ounces
29.57
milliliters (ml)
milliliters
0.034
ounces (oz)
Return
2002-01-16
F-code
PS
Section
C-code
M2.0
Technical Service Data
Version no
003
T-code
395/396/397/398/399
RDX30
RRX45 - RSX50
Series - DC
Series - DC
Series - DC
Duty factor
1 Hour Continuous
1 Hour Continuous
1 Hour Continuous
DRIVE MOTOR
Type
Power
TRANSMISSION/GEAR
Type
Gear ratio
17.57
17.57
17.57
Oil volume
1 gal (4 liters)
1 gal (4 liters)
1 gal (4 liters)
SAE 80W90
SAE 80W/90
ATF
BT Prime-Mover, Inc.
Return
2001-09-18
57
F-code
Section
C-code
PS
M2.0
Technical Service Data
Version no
T-code
003
395/396/397/398/399
MODEL
RRX35 - RSX40
RDX30
RRX45 - RSX50
WHEELS
Drive wheel
inch (mm)
240 Mast
3175 lb (1440 kg)
330 Mast
3595 lb (1630 kg)
402 Mast
3875 (1757 mm)
240 Mast
2385 lb (1081 mm)
330 Mast
2670 lb (1211 mm)
402 Mast
3184 lb(1444 mm)
Load wheel
6975 lbs
(3163807 g)
HYDRAULIC UNIT
Power
24 V 36 V - 9.8 Kw
13.1 hp
36 V -
36 V -
Revolutions/minute
at work pressure
2200 rpm
2550 rpm
2550 rpm
Duty factor
20% on 5 min.
cycles
Minimum brush
length
Minimum commutator
diameter
Minimum brush
spring tension
6.4 oz (180 g)
40 oz (1120 g)
40 oz (1120 g)
2450 psi
2400 psi
2450 psi
Pump displacement
24 V - 13 cc
36 V - 19 cc
36 V - 27 cc
36 V - 27 cc
Tank volume
58
Return
Sunoco TH
2001-09-18
F-code
PS
Section
C-code
M2.0
Technical Service Data
Version no
003
T-code
395/396/397/398/399
MODEL
RRX35 - RSX40
RDX30
ATF
Texaco 15
RRX45 - RSX50
FUSES
Drive motor circuit
Control circuit
Steering circuit
10A
part number 25275-12
BATTERIES
Dimension W x L x H
inches (mm)
Capacity (Max.
Amp-hrs.)
24 V - 1395
36 V - 1240
36 V - 1240
36 V - 1240
14.5 inch
1600 lb (726 mm)
2300 lb (1043 mm)
16.5 inch
2000 lb (907 mm)
2300 lb (1043 mm))
16.5 inch
2000 lb (907 mm)
2300 lb (1043 mm)
21.0 inch
2600 lb (1179 mm)
2900 lb (1315 mm)
16.5 inch
2000 lb (907 mm)
2300 lb (1043 mm)
21.0 inch
2400 lb (1089 mm)
2900 lb (1315 mm)
Weight Minimum
(Maximum)
DRIVING SPEEDS
Without load
24 V - 6.0 mph
36 V - 6.5 mph
36 V - 6.5 mph
36 V - 6.5 mph
24 V - 5.5 mph
36 V - 6.0 mph
36 V - 6.0 mph
36 V - 6.0 mph
BT Prime-Mover, Inc.
Return
2001-09-18
59
F-code
Section
C-code
PS
M2.0
Technical Service Data
Version no
T-code
003
395/396/397/398/399
MODEL
RRX35 - RSX40
RDX30
RRX45 - RSX50
LIFTING/LOWERING TIME
Lift without load
24 V - 60 fpm
36 V - 80 fpm
36 V - 94 fpm
36 V - 94 fpm
24 V - 40 fpm
36 V - 60 fpm
36 V - 60 fpm
36 V - 60 fpm
75 fpm
90 fpm
90 fpm
80 fpm
95 fpm
95 fpm
CURRENT READINGS
60
Return
Driving without
load
24 V - 140 amp
36 V - 140 amp
36 V - 150 amp
36 V - 150 amp
24 V - 160 amp
36 V - 165 amp
36 V - 170 amp
36 V - 170 amp
Lifting without
load
24 V 36 V - 240 amp
36 V - 320 amp
36 V - 320 amp
24 V 36 V - 415 amp
36 V - 570 amp
36 V - 570 amp
2001-09-18
F-code
PS
Version no
Section
C-code
M3.0
Ordering Spare Parts
T-code
001
BT Prime-Mover, Inc.
Return
2000-08-04
61
F-code
Section
C-code
PS
M3.0
Ordering Spare Parts
Version no
T-code
001
62
Return
2000-08-04
F-code
PS
Version no
Section
C-code
P
Contents, Section P
T-code
000
Contents, Section P
1. Planned Maintenance
BT Prime-Mover, Inc.
Return
P1.0
INTRODUCTION, MAINTENANCE
P2.0
SERVICE SCHEDULE
P3.0
LUBRICATION CHART
P4.0
2000-08-04
63
F-code
Section
C-code
PS
P
Contents, Section P
Version no
T-code
000
64
Return
2000-08-04
F-code
PS
Section
C-code
P1.0
Introduction, Maintenance
Version no
T-code
000
Introduction, Maintenance
The schedules of maintenance and lubrication given in this
section of the Service Manual cover up to one years
operation of a truck. These schedules are based on hourly
usage and can be adapted to suit most normal one shift
patterns. The following hourly usage figures have been used
when calculating the schedule:
Single shift, 30 hours per week usage
Double shift, 60 hours per week usage
Triple shift, 90 hours per week usage
The schedules are intended only as a guide, not as a rigid
structure. Operators of trucks may wish to adapt them to local
requirements; but it is emphasized that the schedules
represent minimum manufacturer requirements, and all items
should be included in a service program to ensure minimum
downtime and a high safety status of the equipment.
Use only spare parts approved by BT PrimeMover.
Always clean the equipment and carry out a full
safety check after service.
BT Prime-Mover, Inc.
Return
2000-08-04
65
F-code
Section
C-code
PS
P1.0
Introduction, Maintenance
Version no
T-code
000
66
Return
2000-08-04
F-code
PS
Section
C-code
P1.0
Introduction, Maintenance
Version no
T-code
000
BT Prime-Mover, Inc.
Return
2000-08-04
67
F-code
Section
C-code
PS
P1.0
Introduction, Maintenance
Version no
T-code
000
2. Lubricants
2.1. Standard
For reach trucks in their standard design under continuous
operation, the recommended ambient temperature is 23 F (5 C). These trucks should apply to the following guidelines:
Parked outside storage when not in use
Charging and maintenance work to be done
outside storage
2.2. Corrosion
In an environment where a damp, wet, or corrosive condition
exits, these trucks apply to the following guidelines:
All hardware coated with LPS Rust Inhibitor
during and/or after assembly
Sealed components (switches, push/pull
cables, sensors, etc.) where appropriate
Grease fittings provided on axle and other pivot
points
Plated pins, shafts and linkage where required
All electrical connections coated with Dow
Corning No. 4 compound during assembly
Lift chains coated with Libriplate chain
protectant
Components coated with LPS Cold Galvanize
where appropriate
Components (adjustable features, bearing
races, etc.) coated with Antisieze where
appropriate
Return
2000-08-04
F-code
PS
Section
C-code
P1.0
Introduction, Maintenance
Version no
T-code
000
BT Prime-Mover, Inc.
Return
2000-08-04
69
F-code
Section
C-code
PS
P1.0
Introduction, Maintenance
Version no
T-code
000
70
Return
2000-08-04
F-code
Section
PS
P2.0
Service Schedule
Version no
C-code
T-code
002
395/396/397/398/399
Service Schedule
1. Planned Maintenance Schedule
Item
0000
0000.1
0000.2
0000.3
0000.4
0640
0640.1
0640.2
0640.3
1700
1700.1
1700.2
1700.3
1700.4
1700.5
1700.6
1700.7
1700.8
2550
2550.1
3300
3300.1
3300.2
Work Required
Interval in Hours
Interval in Days/Weeks/Months
Chassis
Check truck identification plate for
legibility
Check for damage and cracks
Retighten truck body bolts (to
chassis)
Check cover screws
Operator Controls
Check travel direction/speed
selectors for operation
Check horn button for operation
Check hydraulic levers for
operation
Motors
Check for arcing due to poor
connections
Check tightness on all
connections
Clean motor of dirt and dust
Check torque of motor bolts
Check for abnormal noise in
motor bearings
Blow carbon, copper, and plastic
particle accumulations from the
motor using compressed air
Check electrical armature (see
page 138)
Check brushes (see page 135)
Drive Gear
Check for oil leakage
Brake
Clean dust and debris
Check brake shoes for wear
BT Prime-Mover, Inc.
Return
30
120
240
360
720
1440
4320
1d
1w
1m
2m
3m
6m
12 m
36 m
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
2000-08-04
71
F-code
Section
C-code
PS
P2.0
Service Schedule
Version no
T-code
002
395/396/397/398/399
Item
3300.3
3300.4
3500
3500.1
3500.2
3500.3
3500.4
4100
4100.1
4100.2
5110
5110.1
5110.2
5110.3
5110.4
5200
5200.1
5300
5300.1
5300.2
5300.3
5300.4
5300.5
5400
5400.1
5400.2
72
Return
Work Required
Interval in Hours
Interval in Days/Weeks/Months
Check correct clearance of
electrical brake and brake shoes
Check brake operation
Wheels
Remove all string, wrapping and
debris
Check all wheels for wear
Grease load wheel bearings
Grease caster and caster wheels
Steering Wheel
Check fasteners
Check ease of steering
Battery
Electrolyte level, 0.50-0.625 inch
(12-15 mm) above cell plates
Check all connections: battery,
battery and charger plugs
Check all cell and link covers
intact
Check battery specific gravity
Instrument Panel
Check battery indicator and hour
meter for correct operation
Electrical Control System
Check key switch
Check brake micro switch
Check control wiring harness for
proper routing
Examine negative cable and
wires from the battery to the main
electronic card (A5)
Check red emergency stop switch
for operation
Electrical Panel
Cleaning and mounting to
chassis
Check tightness on all
connections
30
120
240
360
720
1440
4320
1d
1w
1m
2m
3m
6m
12 m
36 m
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
2000-08-04
F-code
Section
PS
P2.0
Service Schedule
Version no
T-code
002
Item
5400.3
5400.4
5400.5
5400.6
5710
5710.1
6000
6000.1
6000.2
6000.3
6000.4
6000.5
6000.6
7100
7100.1
7100.2
7100.3
7100.4
7100.5
7100.6
7100.7
7100.8
7100.9
7210
7210.1
7210.2
7210.3
395/396/397/398/399
Work Required
Interval in Hours
Interval in Days/Weeks/Months
Check contactor tips
Check contactor tips for free
movements
Check all cable insulation for
damage
Check power safety control
system on the transistor regulator
(see page 363).
Electronic Card
Check for connections in harness
connectors
Hydraulic System
Check hoses and connections for
leakage
Check hoses for wear and
damage
Check oil tank for cracks, leaks
and mounting
Check correct oil level
Change hydraulic oil
Change hydraulic filter element
Mast
Check for damage and cracks
Retighten mast mounting bolts
Check clearance of rollers
Check lateral play of inner section
Check for wear on lift chains and
chain rollers
Check adjustment of lift chains
Clean & lube lift chains
Clean & lube mast columns
Lube chain sheaves
Side Shifter
Check torque of lower hook
mounting bolts
Inspect hydraulic hoses
Inspect cylinder and fittings
BT Prime-Mover, Inc.
Return
C-code
30
120
240
360
720
1440
4320
1d
1w
1m
2m
3m
6m
12 m
36 m
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
2000-08-04
73
F-code
Section
C-code
PS
P2.0
Service Schedule
Version no
T-code
002
395/396/397/398/399
Item
7210.4
7210.5
7210.6
7210.7
7310
7310.1
7310.2
7400.
7400.1
7400.2
7400.3
7400.4
7400.5
7400.6
7400.7
74
Return
Work Required
Interval in Hours
Interval in Days/Weeks/Months
Grease lower hook where pads
slide
Check thickness of upper pads
Check thickness of lower pads
Replace upper and lower pads
Lift Cylinder
Check for leakage
Check mounting
Lifting Device
Check clearance of fork carriage
Check fork carriage for damage
and cracks
Check forks for wear and cracks
Check reach attachment for
damage and cracks
Check reach attachment for
proper reach stroke and timing.
Check reach attachment for
damaged retract bumpers
Lube all grease fittings on reach
attachment
30
120
240
360
720
1440
4320
1d
1w
1m
2m
3m
6m
12 m
36 m
X
X
X
X
X
X
X
X
X
X
X
X
2000-08-04
F-code
Section
PS
P2.0
Service Schedule
Version no
002
C-code
T-code
395/396/397/398/399
7310
7100
5400
5300
7200
6000
7400
4110
5110
1700
3300
2550
5710
0000
3500
BT Prime-Mover, Inc.
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2000-08-04
75
F-code
Section
C-code
PS
P2.0
Service Schedule
Version no
T-code
002
395/396/397/398/399
1/2
Discharged battery
Return
2000-08-04
F-code
Section
PS
P2.0
Service Schedule
Version no
002
C-code
T-code
395/396/397/398/399
BT Prime-Mover, Inc.
Return
2000-08-04
77
F-code
Section
C-code
PS
P2.0
Service Schedule
Version no
T-code
002
395/396/397/398/399
2.2.4. Battery
Contact your battery dealer for specific instructions on care
and maintenance of the battery. An average battery will have
a specific gravity of 1.170 at the 80% discharged level.
However, there are many different batteries on the market.
Only the battery manufacturer can accurately determine the
fully charged and 80% charged levels. Contact the battery
manufacturer for this information.
2.2.5. Electrical Connections
Check that all electrical connections are clean and tight. Plugin connectors should be unplugged and plugged back in to
clean terminals. If the truck is equipped with any of the coldstorage, freezer use, or corrosive environment application
packages, the di-electric compound in the plug-in connectors
should be renewed.
2.2.6. Contactor Tips (NOT Sealed)
Inspect contactor tips for arcing, pitting, or burning. Minor
pitting of the tips is not a problem. However, if tips are pitted
through the tip to the copper bar, tips should be replaced. DO
NOT file tips. Replace tips only in complete sets. Some
contactors have concealed tips or fully sealed so tips cannot
be replaced.
2.2.7. Motor Brushes
The drive motor and pump motor are equipped with a brush
wear sensor which will indicate when brushes need replacing.
For minimum brush length see page 57. As a rule of thumb,
brushes should be replaced if brush spring is within 0.0625
inch (1.59 mm) of touching brush holder.
2.2.8. Drive Motor
Blow out drive motor fan and vents. Check for any signs of oil
on drive motor fan and air vents. Check for any damage to
fan or air vents.
WARNING Compressed air used for cleaning MUST
be reduced to less than 30 psi (206 kPa)
and then only with effective chip-guarding
and personal protective equipment worn.
78
Return
2000-08-04
F-code
Section
PS
P2.0
Service Schedule
Version no
002
C-code
T-code
395/396/397/398/399
BT Prime-Mover, Inc.
Return
2000-08-04
79
F-code
Section
C-code
PS
P2.0
Service Schedule
Version no
T-code
002
395/396/397/398/399
80
Return
2000-08-04
F-code
Section
PS
P2.0
Service Schedule
Version no
002
C-code
T-code
395/396/397/398/399
BT Prime-Mover, Inc.
Return
2000-08-04
81
F-code
Section
C-code
PS
P2.0
Service Schedule
Version no
T-code
002
395/396/397/398/399
82
Return
2000-08-04
F-code
Section
PS
P3.0
Lubrication Chart
Version no
C-code
T-code
001
395/396/397/398/399
Lubrication Chart
Pos. No.
Service Point
Interval/Running Hours
360 h
1
2
3
4
5
6
Wheel bearings
Mast beam
Lifting chains
Hydraulic system
Steering bearings
Drive gear
720 h
Lubricant
(See Approved Oils and
Grease on page 84)
1440 h
L
L
L
C
O
L
O
C
L= Lubrication
A
E
D
B
C
C
C = Check
O = Oil change
2
3
6
5
1
1
Truck Lubrication Points
BT Prime-Mover, Inc.
Return
2000-08-04
83
F-code
Section
C-code
PS
P4.0
Oil and Grease Specifications
Version no
T-code
001
395/396/397/398/399
Lubricant
Standard and
Corrosion
Continuous
Operation
Above
23 F (-5 C)
Cold Storage
Freezer
Continuous Operation
To 5 F (-15 C)
Intermittent Operation
To -13 F (-25 C)
Continuous
Operation
To -31 F
(-35 C)
Application
area
Bearings and
bushings
Hydraulic
system
Grease
Mystik JT-6
Mystik JT-6
Mobiltemp
SHC 32
Hydraulic oil
Sunoco TH
ATF
Texaco 15
SAE 80
SAE 80
ATF
Gears
# 10 W 40
# 10 W 40
# 10 W 40
Chains
Mast
columns,
Reach,
Sideshift
Mast
columns,
Reach,
Sideshift
Transmission
oil
Motor Oil
Grease
Molykote
200025 *
Molykote 200025
Molykote
200025
Grease
49670-00 *
49670-00
49670-00
84
Return
2000-08-04
F-code
Section
C-code
PS
P4.0
Oil and Grease Specifications
Version no
001
T-code
395/396/397/398/399
BT Prime-Mover, Inc.
Return
2000-08-04
85
F-code
Section
C-code
PS
P4.0
Oil and Grease Specifications
Version no
T-code
001
395/396/397/398/399
86
Return
2000-08-04
F-code
PS
Version no
Section
C-code
S
Contents, Section S
T-code
000
Contents, Section S
1. Service Instructions
NO FUNCTION GROUP
C-CODE
TROUBLESHOOTING GUIDELINES
0
CHASSIS
0000
MOTORS
1000
2000
3000
STEERING SYSTEM
4000
5000
HYDRAULIC SYSTEM
6000
7000
PERIPHERAL / INSTALLATION
8000
EQUIPMENT
9
BT Prime-Mover, Inc.
Return
OPTIONS / ATTACHMENTS
2000-08-04
9000
87
F-code
Section
C-code
PS
S
Contents, Section S
Version no
T-code
000
88
Return
2000-08-04
F-code
Section
C-code
PS
S0.0
Troubleshooting Guidelines
Version no
000
T-code
395/396/397/398/399
Troubleshooting Guidelines
1. General
Troubleshooting can be broken down into two sections: (1)
mechanical and (2) electrical circuits. Electrical circuits can
be further broken down into control circuit and power circuit.
Many hours of troubleshooting time can be saved by knowing
the exact operational symptoms. If the proper switch operates
for the chosen direction and speed, the problem can be found
in the controller or the power circuit of that function.
Voltage tests are made with the negative lead of the
voltmeter connected to battery negative if the negative lead is
connected to a negative terminal on the electrical panel. First,
verify the negative connection to the battery by touching the
positive meter lead to the positive battery post. The battery
voltage must be at least 25.2 volts for a 24 volt system. If the
battery voltage is below 22 volts (no load), the controller may
not operate properly. The battery voltage must be at least
37.8 volts for a 36 volt system. If the battery voltage is below
33 volts (no load), the controller may not operate properly.
Charge the battery before starting the troubleshooting
procedures.
When testing voltage, the positive side of any component
refers to the terminal on that component that is closest
electrically to the battery positive terminal. The negative
side of any component refers to the terminal on that
component that is farthest electrically from the battery
positive terminal. It is possible, and in many cases desirable,
to measure battery voltage at both the positive and negative
side of a component.
Rearward direction refers to travel in the direction of the
truck with the forks trailing. Forward direction refers to travel
with the forks first.
After the final test is completed, the truck should be repaired
and operating properly. If it is not, then verify test results and
possibly re-evaluate the failure symptoms. If truck is still not
repaired, then call your local authorized BT Prime-Mover
Dealer for assistance.
BT Prime-Mover, Inc.
Return
2000-08-04
89
F-code
Section
C-code
PS
S0.0
Troubleshooting Guidelines
Version no
T-code
000
395/396/397/398/399
Operating symptoms
90
Return
2000-08-04
F-code
Section
C-code
PS
S0.0
Troubleshooting Guidelines
Version no
000
T-code
395/396/397/398/399
2. Electrical
Many problems are caused by a faulty or dirty battery. Make
sure the battery is clean. Check the electrolyte level and state
of charge.
CAUTION Be sure to block truck whenever a
troubleshooting procedure requires turning
key switch (S17) ON. This will avoid
accidents caused by unexpected lift truck
travel.
CAUTION Unless otherwise directed, disconnect
battery connector when checking electrical
circuits or components with an ohmmeter.
Electrical current can damage the
ohmmeter.
For error code listings see pages 393, 394, 396. For
programming parameters see page 401. Visually inspect all
wiring and electrical components for the following:
BT Prime-Mover, Inc.
Return
2000-08-04
91
F-code
Section
C-code
PS
S0.0
Troubleshooting Guidelines
Version no
T-code
000
395/396/397/398/399
Accumulation of dirt
Breakdown in insulation
Bare wires
92
Return
Batteries
Motors
Heat sinks
Bus bars
Solenoids
Contactors
Terminal strips
Switches
2000-08-04
F-code
Section
C-code
PS
S0.0
Troubleshooting Guidelines
Version no
000
T-code
395/396/397/398/399
BT Prime-Mover, Inc.
Return
2000-08-04
93
F-code
Section
C-code
PS
S0.0
Troubleshooting Guidelines
Version no
T-code
000
395/396/397/398/399
94
Return
2000-08-04
F-code
Section
C-code
PS
S0.0
Troubleshooting Guidelines
Version no
000
T-code
395/396/397/398/399
BT Prime-Mover, Inc.
Return
2000-08-04
95
F-code
Section
C-code
PS
S0.0
Troubleshooting Guidelines
Version no
T-code
000
395/396/397/398/399
3. Hydraulic
NOTE!
For error code listings see pages 393, 394, and 396. For
programming parameters see page 401. If the hydraulic
pump assembly does not operate properly, the following
preliminary checks should be made:
96
Return
2000-08-04
F-code
Section
C-code
PS
S0.0
Troubleshooting Guidelines
Version no
000
T-code
395/396/397/398/399
4. Definitions
Auxiliary Function. A hydraulic function other than lift/lower.
Included on the truck is reach/retract, tilt, and sideshift. Some
auxiliary functions, or aux functions, are options not present
on every truck.
Continuity. A continuous and uninterrupted path between
two or more locations in an electrical circuit, typically having a
resistance of less than 1 ohm.
Brake Pedal Switch. The switch in the truck that must be
opened to allow lift truck operation. It is activated by the
operator stepping on the foot pedal thus engaging the brake
pedal. Travel is prohibited when the brake is applied.
High Speed Travel Limit. A reduced speed initiated when
the truck is driven and carriage is elevated above a certain
mast height. This is a feature that limits the speed of travel
with an elevated mast and helps prevent unstable load
conditions.
Mast Assembly. The elevating section of truck, bolts to the
truck section adjacent to the battery. The mast assembly
consists of column sections, carriage assembly, lift cylinders,
lift chains, etc.
Mast Switch. A switch on the mast upper position switch is
actuated when the carriage is above a certain height on the
mast. This switch regulates mast transition speeds.
Open Circuit. A lack of a continuous path between two or
more electrical connections. Generally, when such a circuit is
tested, it will have a resistance greater than ten megohms.
Overtemperature (Power Amplifier). Overtemperature
of
o
o
the motor power amplifier is from 185 F (85 C) and above.
At overtemperature the drive current limit is linearly
decreased from full set current down to zero. Plug current is
not reduced to provide full vehicle braking under all thermal
conditions.
Pulse Width Modulation. Pulse Width Modulation (PWM),
also called chopping, controls the speed of the motor by
switching the battery voltage to the motor on and off very
quickly.
BT Prime-Mover, Inc.
Return
2000-08-04
97
F-code
Section
C-code
PS
S0.0
Troubleshooting Guidelines
Version no
T-code
000
395/396/397/398/399
98
Return
2000-08-04
F-code
Section
PS
S0.1
Version no
C-code
0000
Chassis
T-code
002
395/396/397/398/399
Chassis
1. General
The chassis has several panels and covers that are
removable. During operation of the truck, the panels and
covers must be secured to the chassis. The purpose of bolton panels and covers is for access of components when
servicing the truck.
13
12
14
1
19
17
16
10
18
11
9
8
7
6
5
BT Prime-Mover, Inc.
Return
15
2001-09-20
99
F-code
Section
C-code
PS
Chassis
S0.1
0000
Version no
T-code
002
395/396/397/398/399
Item
No.
Description
Item
No.
Description
Item
No.
Description
Washer, flat
14
Screw
Panel, side
Nut
15
Panel, cover
Grill, fan
10
Door
16
Mount, console
Screw
11
17
Screw
Screw
12
Dash
18
Washer
13
Plug, hole
19
Plate, contactor
Latch
2. Dash
The dash is a one piece unit. It covers the motor
compartment, the drive and pump transistor regulators, and
contactors. The operator display is mounted on the dash. The
emergency stop switch is mounted on the truck. The key
switch, travel speed/directional selector, lift and lower switch,
horn switch, tilt switch and sideshifter switch are in the pod
(see page 107).
2.1. Removal
1. Park truck on a level surface and block.
2. Turn key switch OFF and disconnect battery
connector from the truck.
3. Remove the pod from the mount.
4. Remove hardware securing the dash to the frame.
5. Lift the cover up enough to disconnect the wiring
harness connections to the operator display.
6. Lift the dash off removing it from the truck.
100
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2001-09-20
F-code
Section
PS
S0.1
Version no
002
C-code
0000
Chassis
T-code
395/396/397/398/399
2.2. Removal
1. Install the dash on the truck.
2. Attach the harness connections to the operator
display.
3. Align the bolt holes in the cover with the ones in the
frame.
4. Secure dash to the frame.
5. Connect battery connector to the truck.
6. Return truck to service.
3.2. Installation
1. Set door (10) in place so hinge pins are securely
mounted in panel hinge.
CAUTION Do not force screw (5) past quarter turn or
latch can become loose.
2. Close door. Turn screw (5) counter clockwise one
quarter turn.
BT Prime-Mover, Inc.
Return
2001-09-20
101
F-code
Section
C-code
PS
Chassis
S0.1
0000
Version no
T-code
002
395/396/397/398/399
Control
Pod
102
Return
2001-09-20
F-code
Section
PS
S0.1
Version no
002
C-code
0000
Chassis
T-code
395/396/397/398/399
BT Prime-Mover, Inc.
Return
2001-09-20
103
F-code
Section
C-code
PS
Chassis
S0.1
0000
Version no
T-code
002
395/396/397/398/399
104
Return
2001-09-20
F-code
PS
Section
C-code
S0.2
0391
Battery Compartment
Version no
000
T-code
365/396/397/398/399
Battery Compartment
1
1
Item No.
Description
Bearing
Roller, battery
Shaft, battery
BT Prime-Mover, Inc.
Return
2000-08-04
105
F-code
Section
PS
S0.2
Battery Compartment
C-code
0391
Version no
T-code
000
365/396/397/398/399
Battery
Rollers
1.1. Inspection
Inspect battery retainer plates for bending or cracks. Replace
if necessary.
1.2. Removal
1. While lifting battery retainer plate upward, tilt edge
toward mast slightly forward to disengage tongue
on operator compartment end of battery retainer
plate.
2. Continue lifting until battery retainer plate is clear of
truck, then set aside.
1.3. Installation
1. Position battery retainer plate with tongued edges
on bottom and facing operator compartment.
2. The edge toward operator compartment should be
tilted in so that tongue engages with slot in back of
battery compartment.
3. Carefully lower battery retainer plate into position.
Move plate forward and backward until proper
engagement is noted.
2. Battery Rollers
2.1. Inspection
Inspect battery rollers to ensure they can turn freely. Clean off
electrolyte using a solution of 1 pound (0.45 kg) of baking
soda added to 1/2 gallon (3.7 liters) of hot water.
2.2. Replacement
Lift damaged roller from its slot and replace with a new.
106
Return
2000-08-04
F-code
Section
PS
S0.3
0640
Driver Controls
Version no
C-code
T-code
000
395/396/397/398/399
Driver Controls
The control console can be adjusted to a suitable height and
angle to obtain a comfortable working position. The steering,
hydraulic functions, horn, parking brake, preset height, travel
direction, key switch, and any extra hydraulic functions are all
controlled from the console. The position of the console may
be set in 1 of 3 positions; forward facing, 45 degrees, or side
stance. To remove console and/or the pod see page 215.
Dash
Steering
wheel
Pod
Lift &
lower
Reach
Tilt
Sideshifter
Horn
switch
Key switch
4
1 2 3
7 8
5 6
9 0
Travel speed /
direction selector
Console
BT Prime-Mover, Inc.
Return
Emergency
disconnect
switch
Spinner
2000-08-04
107
F-code
Section
C-code
PS
S0.3
Driver Controls
0640
Version no
T-code
000
395/396/397/398/399
108
Return
2000-08-04
F-code
Section
C-code
PS
S0.4
0642
Brake Pedal, RSX40/RRX35
Version no
T-code
000
395/396/397/398/399
2
1
4
3
8
13
14
15
10
11
Item
No.
Description
Item
No.
Pedal, brake
Bumper
11
Screw
Bearing, flanged
Plate
12
Mat, pedal
Bumper
Screw
13
Nut, twin
Bracket, brake
Screw
14
Switch, brake
Spring, return
10
Potentiometer
15
Screw
BT Prime-Mover, Inc.
Return
Description
2000-08-04
Item
No.
Description
109
F-code
Section
C-code
PS
S0.4
0642
Brake Pedal, RSX40/RRX35
Version no
T-code
000
395/396/397/398/399
1. Pedal Removal
1. Park the truck on a flat surface.
2. Turn key switch to OFF and disconnect battery at
battery connector. Check to make sure battery
retainer plates are in place.
3. Jack the rear of the truck (see page 66).
4. Looking into the operator's compartment, remove
the four screws from the right panel covering the
logic card. Take panel out and set to the side.
CAUTION Pinch point. Keep fingers clear of floor
board cutout while holding down left foot
brake pedal.
5. Push down on left foot brake pedal (1) with one
hand and remove the floor board by pulling up and
pivoting plate (7) toward motor compartment.
Release left foot brake pedal as the floor board
pivots up.
CAUTION Disconnect wire connections to right foot
pedal switch prior to removal of floor board.
6. Remove floor board and set to the side.
7. Remove the screws (11) holding the potentiometer
(10) and remove wires from the brake switch (14).
8. Loosen four mounting bolts holding brake pedal
assembly to the frame. Remove brake pedal
assembly from truck to service.
110
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2000-08-04
F-code
Section
C-code
PS
S0.4
0642
Brake Pedal, RSX40/RRX35
Version no
000
T-code
395/396/397/398/399
3. Pedal Adjustment
1. See Adjustment Procedures for Setting Brake
Switch and Brake Transducer on page 383.
2. When replacing pedal stop bumper (6) it should be
threaded down until the stop makes contact with
the bracket (4).
BT Prime-Mover, Inc.
Return
2000-08-04
111
F-code
Section
C-code
PS
S0.4
0642
Brake Pedal, RSX50/RRX45/RDX30
Version no
T-code
000
395/396/397/398/399
6
2
1
17
16
5
4
3
8
13
14
10
11
15
112
Return
2000-08-04
F-code
Section
C-code
PS
S0.4
0642
Brake Pedal, RSX50/RRX45/RDX30
Version no
T-code
000
395/396/397/398/399
Item
No.
Description
Item
No.
Pedal, brake
Plate
13
Nut, twin
Bearing, flanged
Screw
14
Switch, brake
Bumper
Screw
15
Screw
Bracket, brake
10
Potentiometer, brake
16
Cable, brake
Spring, return
11
Screw
17
Bumper
12
Mat, pedal
Description
Item
No.
Description
1. Pedal Removal
1. Park the truck on a flat surface.
2. Turn key switch to OFF and disconnect battery at
battery connector. Check to make sure battery
retainer plates are in place.
3. Jack rear of the truck.
4. Looking into the operator's compartment, remove
the four screws from the right panel covering the
logic card. Take panel out and set to the side.
CAUTION Pinch point. Keep fingers clear of floor
board cutout while holding down left foot
brake pedal.
5. Push down on the left foot brake pedal (1) with one
hand and remove the floor board by pulling up and
pivoting the plate (7) toward the motor
compartment. Release the left foot brake pedal as
the floor board pivots up.
CAUTION Disconnect wire connections to right foot
pedal switch prior to removal of floor board.
6. Remove floor board and set to the side.
BT Prime-Mover, Inc.
Return
2000-08-04
113
F-code
Section
C-code
PS
S0.4
0642
Brake Pedal, RSX50/RRX45/RDX30
Version no
T-code
000
395/396/397/398/399
3. Pedal Adjustment
1. See Adjustment Procedures for Setting Brake
Switch and Brake Transducer on page 383.
2. When replacing the pedal stop bumper (6) it should
be threaded down until the stop makes contact with
the bracket (4).
114
Return
2000-08-04
F-code
Section
PS
S0.5
0811
Overhead Guard
Version no
000
C-code
T-code
395/396/397/398/399
Overhead Guard
1
4
2
3
5
Item No.
1
2
3
4
5
BT Prime-Mover, Inc.
Return
2000-08-04
Description
Overhead guard
Bolt
Screw, cap
Nut
Post, overhead guard
115
F-code
Section
C-code
PS
S0.5
Overhead Guard
0811
Version no
T-code
000
395/396/397/398/399
116
Return
2000-08-04
F-code
Section
PS
S0.6
Version no
000
C-code
0851
Decals
T-code
365/396/397/398/399
Decals
Remove and replace any decals that are damaged. Replace
any missing decals. Remove a damaged decal by using a
sharp edge to peel decal from the surface. Use caution not to
scratch or damage the paint on truck when removing the
decal. Replacement of warning decals are free from BT
Prime-Mover.
Using the required cleaning solution, thoroughly clean the
surface of truck before applying a new decal. Allow the
surface to completely dry, be sure that there is no residue.
Touch up paint in the area of the decal, as required.
BT Prime-Mover, Inc.
Return
2000-08-04
117
F-code
Section
C-code
PS
Decals
S0.6
0851
Version no
T-code
000
365/396/397/398/399
14
12
13
Inches
Serial Number
Model
Cap. (Lbs.)
Truck Wt.
Less Batt. (Lbs.)
DC Voltage
Use UL Class
Battery Type
Type
Attachment
Max.
Back Tilt
C
B
Truck as rated at factory conforms to requirements of Part III of ASME B561-1993
306040-000
BT Prime-Mover, Inc.
Muscatine, IA 52761
10
5
11
118
Return
2000-08-04
F-code
Section
PS
S0.6
Version no
T-code
000
Item
No.
Description
Item
No.
C-code
0851
Decals
365/396/397/398/399
Description
Decal, BT
Decal, Warning
Plate, Data
Decal, sideshifter
10
Plate, UL
11
Box, Manual
12
Decal, Warning
13
Decal, Warning
14
BT Prime-Mover, Inc.
Return
2000-08-04
119
F-code
Section
C-code
PS
Decals
S0.6
0851
Version no
T-code
000
365/396/397/398/399
120
Return
2000-08-04
F-code
Section
PS
S1.0
1730
Steering Motor
Version no
000
C-code
T-code
395/396/397/398/399
Steering Motor
The steering motor is located in the lower right section of the
motor compartment, to the right of the drive motor and
beneath the control valve.
1. Removal
WARNING Block all wheels to prevent truck from
rolling.
1. Park truck on a level surface. Block truck to
prevent accidental movement.
2. Turn the key switch OFF and disconnect battery
connector from the truck.
3. Remove motor compartment door (see page 101)
to access steering motor.
4. Disconnect steering motor from main electrical
harness.
5. Use a 0.24 inch (6 mm) Allen wrench to remove
four bolts securing steering motor to truck frame.
The rubber gasket should remain on each bolt.
Spacer
2. Installation
1. Make sure rubber spacer and two O rings are on
the end of steering motor.
2. Apply a little grease so the motor will slide into
frame without cutting O rings.
BT Prime-Mover, Inc.
Return
2000-08-04
121
F-code
Section
C-code
PS
S1.0
Steering Motor
1730
Version no
T-code
000
395/396/397/398/399
3.2. Installation
1. Apply Loctite 243 to steer motor shaft. Slide
steering gear onto steering motor shaft.
2. Install mounting bolt in steering gear.
3. Torque gear mounting bolt to 88 in-lb (10 Nm).
4. Return steering motor to lift truck following the
installation procedure on page 121.
122
Return
2000-08-04
F-code
Section
PS
S1.1
Version no
001
C-code
1740
Fan Motor
T-code
395/396/397/398/399
Fan Motor
The main fan motor in the truck cools the upper electrical
compartment. An optional operator cooling fan is also
available.
1.1. Removal
1. Turn key switch OFF and disconnect battery
connector from the truck.
1.2. Installation
1. Install fan assembly by inserting four screws (2)
through the truck frame from the mast side.
2. Install four nuts (3) from the electrical compartment
side.
3. Connect electrical connections to the main wiring
harness.
4. Install dash.
BT Prime-Mover, Inc.
Return
2001-03-15
123
F-code
Section
C-code
PS
Fan Motor
S1.1
1740
Version no
T-code
001
395/396/397/398/399
2. Operator Fan
The operator fan is located in the compartment with the
overhead light on the left side of the overhead guard. The
operator fan/overhead light is an option, therefore, it may not
be on your particular truck.
124
Return
2001-03-15
F-code
Section
C-code
PS
S1.2
1750
Motor Maintenance Schedule/Troubleshooting
Version no
001
T-code
395/396/397/398/399
Motor Maintenance
Schedule/Troubleshooting
1. General Information
A routine maintenance schedule with recorded findings is the
best way to reduce costly shut-downs and repair of
equipment during operating hours. The goal of any
maintenance program, long-life and trouble-free operations is
related to the time spent making inspections and correcting
minor problems as they occur. The drive motor and pump
motor are both equipped with brush sensors. When brushes
are in need of replacement, a warning code C16 for the pump
motor and C-17 for the drive motor will show on the dash
display.
2. Operating Conditions
Operating environment of reach truck motors varies
widely: The following recommendations should be applied as
actual conditions dictate.
Normal Service:
Severe Service:
Extreme Service:
yChemical Processing
yFreezer operation
yProcessing plants (poultry, meat)
BT Prime-Mover, Inc.
Return
2000-08-04
125
F-code
Section
C-code
PS
S1.2
1750
Motor Maintenance Schedule/Troubleshooting
Version no
T-code
001
395/396/397/398/399
3. Troubleshooting
When a motor has trouble in operation, a reasonable decision
has to be made as to the proper corrective course of action. A
review of the many troubleshooting guides has been
conducted and have been reduced to a few which seem to be
the most effective Symptom/Cause relationships and are
listed on tables 1 and 2.
126
Return
Table 1
Table 2
2000-08-04
F-code
Section
C-code
PS
S1.2
1750
Motor Maintenance Schedule/Troubleshooting
Version no
001
T-code
395/396/397/398/399
Immediate Causes
Primary Faults
Sparking
1-2-3-43-44-45-46-49-59-60
7-12-31-33
7-12-30-32
7-12-30-32
8-9-11
6-14-15-16-17-18-19-20-21-28
29
25-27-28-29-38-39-40-41-42
7-13-23-34
51-52
See Chattering or Noisy Brushes
55-57-59
50
Overcommutation
Undercommutation
Too rapid reversal of current
7-12-31-33
7-12-30-32
7-12-30-32
Glowing
Embedded copper
Severe sparking
Imperfect contact with
commutator
Wrong brush grade
11-14-15-16-51-52
54-58
Embedded copper
Faulty machine adjustment
Severe load condition
Bad service condition
Wrong brush grade
2-3
43-46-47-48-49
59-61
Flashover at Brushes
Machine condition
Bad load condition
Lack of attention
14-35
38-39-41-53
5-11
Chattering or Noisy
BT Prime-Mover, Inc.
Return
2000-08-04
127
F-code
Section
C-code
PS
S1.2
1750
Motor Maintenance Schedule/Troubleshooting
Version no
T-code
001
395/396/397/398/399
Immediate Causes
Primary Faults
Looseness in machine
Vibration
Chattering
Sluggish brush movement
Rough or Uneven Surface
1-2-3-4-17
5-44-60
Eccentric Surface
1-19-22-52
Sparking
17
Sparking
Copper or foreign material in
brush face
Glowing
2-25
2-3-43-44-45-46-47-48-49-59-61
Sparking
Flashover
2-3-7-12-30-31-32-33
5-11-14-35-38-39-41-53
Sparking
25-37
Sparking
7-12-30-57-60
Flat Spot
Sparking
Flashover
Lack of attention
19-23-25-41-53
5-11-14-35-38-39-41-53
1-5-11
Discoloration of Surface
High temperature
Atmospheric condition
Wrong brush grade
Embedded copper
Bad service condition
Wrong brush grade
Rapid Commutator
Wear with Blackened Surface
Burning
Severe sparking
2-3-11-14
See Sparking
Rapid Commutator
Wear with Bright Surface
Copper Dragging
43-45-47-49
61
39-52-58-59
128
Return
2000-08-04
F-code
Section
C-code
PS
S1.2
1750
Motor Maintenance Schedule/Troubleshooting
Version no
001
T-code
395/396/397/398/399
Immediate Causes
Primary Faults
Heating in Windings
38-41-42-53
18-19-20-21-27-28-29
8-19-22-25-27-28-29-37
38-41-42
7-8-9-12-20-33-45-57
10-11-36-43-45-49-58-59
See specific surface fault in
evidence
6-24
56
38-41-42
7-10-11-12-26
See Sparking
See Streaking or Threading of
Surface
See Copper in Brush Face
57-58-59-61-62
Heating at Commutator
Heating at Brushes
BT Prime-Mover, Inc.
Return
2000-08-04
7-13-23-24
129
F-code
Section
C-code
PS
S1.2
1750
Motor Maintenance Schedule/Troubleshooting
Version no
T-code
001
395/396/397/398/399
2.
High mica
3.
Feather-edge mica
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
130
Return
14.
15.
16.
17.
Commutator loose
18.
19.
20.
21.
22.
Dynamic unbalance
23.
2000-08-04
F-code
Section
C-code
PS
S1.2
1750
Motor Maintenance Schedule/Troubleshooting
Version no
001
T-code
395/396/397/398/399
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
BT Prime-Mover, Inc.
Return
38.
Overload
39.
40.
41.
Plugging
42.
Dynamic braking
43.
44.
Contaminated atmosphere
45.
Contact poisons
46.
47.
2000-08-04
131
F-code
Section
C-code
PS
S1.2
1750
Motor Maintenance Schedule/Troubleshooting
Version no
T-code
001
395/396/397/398/399
49.
50.
Silicone contamination
Disturbing External Condition
132
Return
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
2000-08-04
F-code
Section
PS
S1.3
Version no
001
C-code
1750
Motor Repair
T-code
395/398
Motor Repair
1. Disassembly
1. Remove motor from truck (for pump motor see
page 141 and for drive motor see page 149).
2. Remove band from end head commutator of
motor.
3. Use a brush hook to reach into the motor and lift
brush springs. Pull brushes out of brush holders.
Either position brushes outside the motor or
remove brush retaining screws and remove
brushes from motor.
4. Scribe or center punch locating marks in the end
head and frame. Although locating marks are not
always necessary, they can save time when the
motor does not have locating pins.
5. Remove commutator end head retaining screws.
Most motors have a slip fit bearing at the
commutator end allowing the end head to be
removed with very little trouble. On motors that
have a shaft extension on both ends of the
armature, the attachment on the commutator end
of the shaft must be removed before the end head
can be separated from the motor.
6. Remove drive end head retaining screws, if
necessary. Some smaller pump motors retain the
drive end head with the motor through bolts.
Separate the armature and head assembly as an
assembly from the frame and field coil assembly.
CAUTION Use caution and DO NOT damage the
armature during removal. If the shaft,
coupling or spline is damaged when
removing the end head, the armature or the
drive spline usually has to be replaced.
7. Separate the armature from the drive end head by
pressing the armature out of the drive end bearing.
On some of the larger motors, the end head and
bearing will have to be removed with a puller.
BT Prime-Mover, Inc.
Return
2002-01-09
133
F-code
Section
C-code
PS
S1.3
Motor Repair
1750
Version no
T-code
001
395/398
Puller
Propane torch
Use Loctite on
this area of shaft
134
Return
2002-01-09
F-code
Section
PS
S1.3
Version no
001
C-code
1750
Motor Repair
T-code
395/398
2. Motor Inspection
A good planned maintenance program will save many hours
of future down time on a piece of equipment. Maintenance
schedules should consist of periodic routine inspections of
motors, battery and wiring circuitry.
BT Prime-Mover, Inc.
Return
2002-01-09
135
F-code
Section
C-code
PS
S1.3
Motor Repair
1750
Version no
T-code
001
395/398
segments
GOOD UNDERCUT
0.04 inch deep
mica
segments mica
segments
BAD UNDERCUT
Brushes should be inspected for uneven wear and signs of
overheating such as discolored brush shunts and brush
springs. See Table 1. Unsatisfactory Brush Performance on
page 127. Check the brush holders for physical damage and
make sure they are not loose on the end head or the brush
holder plate. Check the brush springs for correct alignment on
the brush. A brush spring that does not apply equal pressure
on the center of the brush will cause the brush to wear
unevenly. Check for correct clearance and freedom of brush
movement in the holder. If any of the brushes are worn to the
point that replacement is necessary, the complete brush set
should be replaced. Do not replace just one or two brushes.
When brush service is required on the motor, lift brush spring
over holding bracket before removing brush.
136
Return
2002-01-09
F-code
Section
PS
S1.3
Version no
001
C-code
1750
Motor Repair
T-code
395/398
BT Prime-Mover, Inc.
Return
2002-01-09
137
F-code
Section
C-code
PS
S1.3
Motor Repair
1750
Version no
T-code
001
395/398
2.3. Bearings
After the motor has been disassembled, it is recommended
that new bearings are installed. Bearings may have been
damaged during removal. Although the bearings may appear
and feel good, the bearing races could be brinelled and fail
within a relatively short period of service.
138
Return
2002-01-09
F-code
Section
PS
S1.3
Version no
001
C-code
1750
Motor Repair
T-code
395/398
BT Prime-Mover, Inc.
Return
2002-01-09
139
F-code
Section
C-code
PS
S1.3
Motor Repair
1750
Version no
T-code
001
395/398
2.6. Assembly/Testing
Refer to the following drawing whenever a bearing is installed
into an end head or shaft.
Press Ram
Bearings
Inner Race
End Head
Armature
Shaft
Snap Ring
140
Return
2002-01-09
F-code
Section
PS
S1.4
Version no
C-code
1750
Pump Motor
T-code
001
395/398
Pump Motor
1. Mounting Points
1
2
3
4
5
6
Item
No.
1
2
Description
Lift Pump Assembly
Screw
Item
No.
Description
Item
No.
3
4
5
6
Description
Washer, flat
Shock, mount
Return
2002-01-09
141
F-code
Section
C-code
PS
S1.4
Pump Motor
1750
Version no
T-code
001
395/398
1.1. Removal
WARNING Block all wheels to prevent truck from
rolling.
1. Park the truck on a level surface and make sure all
wheels are blocked to prevent accidental
movement.
Pump
Motor
Motor
Bracket
Mounting
Bolts
Suction (Supply)
Hose To Pump
Lift
Pump
142
Return
2002-01-09
F-code
Section
PS
S1.4
Version no
001
C-code
1750
Pump Motor
T-code
395/398
1.2. Installation
1. Place lift pump and motor assembly with bracket
onto truck frame. Make sure four rubber grommet
shock mounts (6) are in the bracket mounting
holes.
2. Align suction tube flange with reservoir hose. Slide
reservoir hose onto flange as the pump and motor
assembly is installed into the truck. Install hose
clamp at the flange. Be sure clamp is tightened to
prevent leakage. If a leak is found later, the drive
motor will have to be removed to access the
clamps.
3. Install mounting bolts (4) to secure the motor/pump
into position. Insert bolts through the large washer
(5), then through the bracket mounting plate into
truck frame. Torque bolts to 14-18 ft-lb (19-24 Nm)
using a 9/16 inch (13 mm) socket and extension if
needed.
4. Install control valve on the bracket.
5. Install hydraulic line from the pump to the control
valve.
6. Install pump motor electrical power cables to the
motor, following the markings on the cables.
Tighten terminal nuts using a M10 wrench. Torque
motor cable securing nuts to 100-120 in-lbs (11.213.6 Nm). Use a second wrench on the stud
terminal securing nut to avoid twisting the stud.
7. Attach brush wear indicator connections using
needle nosed pliers. Connectors are male and
female with one large and one small.
BT Prime-Mover, Inc.
Return
2002-01-09
143
F-code
Section
C-code
PS
S1.4
Pump Motor
1750
Version no
T-code
001
395/398
144
Return
2002-01-09
F-code
Section
PS
S1.4
Version no
C-code
1750
Pump Motor
T-code
001
395/398
2. Repair
See Motor Repair on page 133.
RRX35/RSX40
12 11
7
8
10
9
14
13
ROTATION
C.C.W.C.E.
Counterclockwise
when viewed from
commutator end.
BT Prime-Mover, Inc.
Return
2002-01-09
145
F-code
Section
C-code
PS
S1.4
Pump Motor
1750
Version no
T-code
001
395/398
Item
No.
146
Description
Item
No.
Description
Retaining ring
Set, spring
Bearing
10
Lead assembly
Fan
11
Bearing
Armature assembly
12
Spring Washer
13
Head assembly
Set, brush
14
Headband assembly
Return
2002-01-09
F-code
Section
PS
S1.4
Version no
C-code
1750
Pump Motor
T-code
001
395/398
RRX45/RDX30/RSX50
15
12
14
11
10
13
Item
No.
ROTATION
C.C.W.C.E.
Counterclockwise
when viewed from
commutator end.
BT Prime-Mover, Inc.
Return
Description
Item
No.
Description
Retaining ring
Bearing
10
11
Bearing
Fan
12
Washer, wave
13
14
Band
Brush
15
Spring, brush
2002-01-09
147
F-code
Section
C-code
PS
S1.4
Pump Motor
1750
Version no
T-code
001
395/398
148
Return
2002-01-09
F-code
Section
PS
S1.4
Version no
001
C-code
1760
Drive Motor
T-code
395/396/397/398/399
Drive Motor
1. Mounting Points
23
22
21
20
19
18
17
16
14
15
Item
No.
14
15
16
17
18
BT Prime-Mover, Inc.
Return
Description
Item
No.
Ring, retainer
Ring, retainer
Bearing
Ring, seal
Sleeve
19
20
21
22
23
2002-01-09
Description
O-ring
Screw, cap
Drive Motor Assembly
Brake Assembly
Sensor Assembly
149
F-code
Section
C-code
PS
S1.4
Drive Motor
1760
Version no
T-code
001
395/396/397/398/399
1.1. Removal
WARNING There is no brake on the truck when drive
motor is removed from transmission
assembly. Block all wheels to prevent truck
from rolling.
1. Park the truck on a level surface and make sure all
wheels are blocked to prevent accidental
movement.
2. Turn key switch OFF and disconnect battery
connector from the truck.
3. Remove motor compartment door, left side panel,
and side panel to allow access to drive motor.
4. Remove four power cables. An 11/16 inch (17 mm)
wrench is required to loosen terminal nuts for the
field and armature connections. Note cable
numbers and terminal locations for use in
reassembly.
5. Disconnect the drive motor brush sensor, two
speed/directional sensors, temperature sensor,
and brake assembly connectors.
6. Using a 9/16 inch (13 mm) socket, remove the six
drive motor mounting bolts (20). A 24 inch (609
mm) extension is helpful to access the two bolts
behind the drive motor.
7. Attach a lifting tool to lift the drive motor. (Using two
eye bolts screwed into the top of the brake
assembly (two empty holes used for the brake
manual release screws), attach a piece of chain
(about 20 inches (508 mm) long) with a S hook at
each end to each of the eye bolts.)
8. Attach a hoist to the lifting tool attached to the top
of the brake assembly.
9. Gently lift the drive motor out of the transmission.
(It may be necessary to rock the drive motor gently
to loosen it from the transmission.)
10. Cap top of the transmission
contamination of transmission fluid.
150
Return
to
prevent
2002-01-09
F-code
Section
PS
S1.4
Version no
001
C-code
1760
Drive Motor
T-code
395/396/397/398/399
1.2. Installation
1. Remove cap from the top of transmission.
2. Lower drive motor straight down onto transmission.
The drive motor terminals and brush motor sensor
should be facing out.
3. Remove chain, S hooks, and eye bolts from brake
assembly.
NOTE!
BT Prime-Mover, Inc.
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2002-01-09
151
F-code
Section
C-code
PS
S1.4
Drive Motor
1760
Version no
T-code
001
395/396/397/398/399
2. Repair
See Motor Repair on page 133.
1
3
2
4
13
7
8
9
14
6
5
10
15
16
11
12
25
16
26
27
17
28
29
30
152
Return
18
2002-01-09
F-code
Section
PS
S1.4
Version no
T-code
001
Item No.
Item No.
Description
395/396/397/398/399
Item No.
Description
Screw
Set, brush
17
End head,
drive
Band, head
10
Set, spring
18
Screw
Fan unit
11
Bearing
25
Ring, seal
Guard, fan
12
Retainer
26
O ring
Field coil
13
27
Sleeve
14
Stud, terminal
28
Bearing
End head,
commutator
15
Armature
29
Ring, retainer
Plate, brush
16
Key, woodruff
30
Ring, retainer
BT Prime-Mover, Inc.
Return
Description
C-code
1760
Drive Motor
2002-01-09
153
F-code
Section
C-code
PS
S1.4
Drive Motor
1760
Version no
T-code
001
395/396/397/398/399
154
Return
2002-01-09
F-code
Section
PS
S2.0
2550
Transmission
Version no
000
C-code
T-code
395/396/397/398/399
Transmission
1. Mounting Points
13
12
11
8
10
9
Item
No.
7
8
9
10
BT Prime-Mover, Inc.
Return
Description
Transmission assembly
Drive wheel assembly
Screw, set
Gasket, EE
2002-01-09
Item
No.
Description
11
12
13
Plate, EE
Screw, EE
Screw, cap
155
F-code
Section
C-code
PS
S2.0
Transmission
2550
Version no
T-code
000
395/396/397/398/399
1.2. Removal
1. Park truck on a level surface.
2. Turn key switch OFF and disconnect battery
connector from the truck.
CAUTION Any misalignment of tire and hub while tire
is being pressed onto hub can cause
damage to hub. For this reason, chamfers
have been provided on the outside edge of
hub and on the end of the inside diameter
of tires metal insert. The chamfers help to
center hub and tire during the pressing
operation and reduce the possibility of
misalignment. To prevent damage, hub
must be installed on circular ram with its
chamfered side up.
3. Jack the rear of truck so the drive and caster
wheels are approximately 1 inch (25.4 mm) off the
floor. Block truck in this position.
4. Drain transmission fluid.
156
Return
2002-01-09
F-code
Section
PS
S2.0
2550
Transmission
Version no
000
C-code
T-code
395/396/397/398/399
1.3. Installation
1. Place transmission in drive tire and slide
transmission, in the tire cradle, beneath the truck.
Using a hoist, lower the truck frame onto the
transmission. Be careful not to pinch hands
between the transmission and the truck frame.
2. Line grease fittings up with the indentations in the
frame.
3. The half-moon shaped piece mounted to the top
surface of the transmission should be toward the
left so that the sensors will read the wheel position
correctly.
4. Guide the transmission, with one hand through the
hole in the truck frame, while lowering the frame
onto the transmission.
NOTE!
BT Prime-Mover, Inc.
Return
157
F-code
Section
C-code
PS
S2.0
Transmission
2550
Version no
T-code
000
395/396/397/398/399
158
Return
2002-01-09
F-code
Section
PS
S2.0
2550
Transmission
Version no
C-code
T-code
000
395/396/397/398/399
2. Repair
Before disassembly of parts, thoroughly clean the outside of
the assembly with a cleaning solution or other non-corrosive
cleaning fluid and air dry parts. Refer to Parts Book for any
up-dates of transmission.
31
30
8
10
29
42
39
11
12
38
40
35
41
32
24
13
20
14
19
17
33
36
16
15
37
22
21
26
27
18
23
25
BT Prime-Mover, Inc.
Return
34
2002-01-09
28
159
F-code
Section
C-code
PS
S2.0
Transmission
2550
Version no
T-code
000
395/396/397/398/399
160
Return
Item
No.
Description
Item
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Transmission assembly
Gear, ring
Kit, spare parts (Bearing)
Kit, spare parts (Sealing)
Kit, spare parts (Helical gear)
Kit, spare parts (Wheel shaft)
Kit, spare parts (Bevel gear)
Gear, wheel
Gear, wheel
Nut
Bearing
Kit, shim
Kit, shim
Bearing
O-ring
Screw
Axle
Washer, copper
Bearing
Kit, shim
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
Screw
Bearing
Washer
Spacer
Ring, sealing
Ring, locking
Plug, drain
Nut (not part of item #1)
Washer, locking (not part of item #1)
Washer (not part of item #1)
Screw
Gear, bevel
Screw
Plug, fill
Keeper
Cover
Case
Bearing
Screw
O-ring
21
Cover ring
42
Breather
Description
2002-01-09
F-code
Section
PS
S2.0
2550
Transmission
Version no
C-code
T-code
000
395/396/397/398/399
3. Disassemble
1. Remove transmission
page 155).
from
the
truck
(see
Remove
eight
screws
retaining the cover and
remove cover.
BT Prime-Mover, Inc.
Return
2002-01-09
161
F-code
Section
C-code
PS
S2.0
Transmission
2550
Version no
T-code
000
395/396/397/398/399
162
Return
2002-01-09
F-code
Section
PS
S2.0
2550
Transmission
Version no
000
C-code
T-code
395/396/397/398/399
BT Prime-Mover, Inc.
Return
2002-01-09
163
F-code
Section
C-code
PS
S2.0
Transmission
2550
Version no
T-code
000
395/396/397/398/399
Remove
washer,
spacer, outer bearing
cone and seal from the
axle shaft.
164
Return
2002-01-09
F-code
Section
PS
S2.0
2550
Transmission
Version no
000
C-code
T-code
395/396/397/398/399
4. Assembly
1. Position the transmission case with the axle output
side up.
BT Prime-Mover, Inc.
Return
2002-01-09
165
F-code
Section
C-code
PS
S2.0
Transmission
2550
Version no
T-code
000
395/396/397/398/399
166
Return
2002-01-09
F-code
Section
PS
S2.0
2550
Transmission
Version no
000
C-code
T-code
395/396/397/398/399
BT Prime-Mover, Inc.
Return
2002-01-09
167
F-code
Section
C-code
PS
S2.0
Transmission
2550
Version no
T-code
000
395/396/397/398/399
168
Return
2002-01-09
F-code
Section
PS
S2.0
2550
Transmission
Version no
000
C-code
T-code
395/396/397/398/399
Install nut on pinion shaft (see page 159 and page 160).
BT Prime-Mover, Inc.
Return
2002-01-09
169
F-code
Section
C-code
PS
S2.0
Transmission
2550
Version no
T-code
000
395/396/397/398/399
170
Return
2002-01-09
F-code
Section
PS
S2.0
2550
Transmission
Version no
000
C-code
T-code
395/396/397/398/399
Washer
Spacer
Install spacer on
the axle shaft.
BT Prime-Mover, Inc.
Return
2002-01-09
171
F-code
Section
C-code
PS
S2.0
Transmission
2550
Version no
T-code
000
395/396/397/398/399
Install washer
on axle shaft.
172
Return
2002-01-09
F-code
Section
PS
S2.0
2550
Transmission
Version no
000
C-code
T-code
395/396/397/398/399
BT Prime-Mover, Inc.
Return
2002-01-09
173
F-code
Section
C-code
PS
S2.0
Transmission
2550
Version no
T-code
000
395/396/397/398/399
5.1. Disassembly
1. Drain transmission oil by removing drain plug (28).
Remove copper washer (18) from drain plug.
2. Remove transmission
page 155).
from
the
truck
(see
174
Return
from
axle
(17)
or
2002-01-09
F-code
Section
PS
S2.0
2550
Transmission
Version no
000
C-code
T-code
395/396/397/398/399
5.2. Assembly
1. Place drive axle outer bearing (23) in the
transmission case (38).
NOTE!
BT Prime-Mover, Inc.
Return
2002-01-09
175
F-code
Section
C-code
PS
S2.0
Transmission
2550
Version no
T-code
000
395/396/397/398/399
6. Leakage
When there is leakage from the transmission top cover,
proceed as follows:
176
Return
2002-01-09
F-code
Section
PS
S2.0
2550
Transmission
Version no
000
C-code
T-code
395/396/397/398/399
BT Prime-Mover, Inc.
Return
2002-01-09
177
F-code
Section
C-code
PS
S2.0
Transmission
2550
Version no
T-code
000
395/396/397/398/399
7. Wheel Bolt
1. Drain transmission oil by removing drain plug (28).
2. Remove transmission from truck.
3. Remove drive axle from the transmission case.
4. Press or drive out the damaged bolt from the drive
axle rim.
NOTE!
178
Return
2002-01-09
F-code
PS
Section
C-code
S3.0
3370
Electromagnetic Brake
Version no
T-code
001
395/396/397/398/399
Electromagnetic Brake
13
Item No.
11
10
7
4
Description
Brake assembly
Coil
Armature
Hub
Plate, friction
Plate, mounting
Spacer, adjustable
Spring
10
Washer
11
12
Screw
13
Spacer
1. Removal
5
12
BT Prime-Mover, Inc.
Return
2000-08-04
179
F-code
Section
C-code
PS
S3.0
3370
Electromagnetic Brake
Version no
T-code
001
395/396/397/398/399
180
Return
2000-08-04
F-code
PS
Version no
001
Section
C-code
S3.0
3370
Electromagnetic Brake
T-code
395/396/397/398/399
2. Installation
WARNING Block all wheels to prevent truck from
rolling.
1. Be sure truck is securely blocked with key switch
OFF and the battery at the battery connector
disconnected.
WARNING The magnetic coil (2) and armature (3) are
under pressure. DO NOT remove retaining
screws (9) without the manual release
screws (11) in place.
WARNING The two manual release screws (11) must
be fully tightened before removing three
brake retaining screws (9). Screws (11) are
used as a tool for braking. Size of the screw
is 8 mm x 1.25 thread x 37.5 mm. Refer to
Section 3000 of the Parts Book for the part
number of screw (11).
2. Fully tighten two manual release screws (11).
3. Remove three screws (9) holding brake parts and
set aside, ensuring all parts are clean and dry.
Avoid making adjustable spacers (7) if possible,
thus maintaining correct axial air gap when
reassembled. The mounting plate is secured to
drive motor with screw (9).
4. Secure brake hub (4) to motor shaft. It should not
interfere with mounting plate (6).
5. Slide friction plate (5) onto hub spline and up to
mounting plate (6).
6. Place armature (3) and coil (2) of brake over
mounting plate (6) and line up screws (9). Carefully
secure in place.
7. Once brake is fully secured in position, remove
manual release screws (11) and washers (10) and
set aside.
BT Prime-Mover, Inc.
Return
2000-08-04
181
F-code
Section
C-code
PS
S3.0
3370
Electromagnetic Brake
Version no
T-code
001
395/396/397/398/399
3. Adjustments
NOTE!
1. Turn
Allen
head
retaining
screws
(9)
counterclockwise to loosen one at a time to allow
adjustment of threaded spacers (7).
2. Using an 9/16 (14 mm) open end wrench, the
brass nut on threaded spacers (7) can now be
threaded in or out of magnet. This changes the
relative position of armature and end plate, thus
changing the air gap.
Turn the brass nut to the left (clockwise) to
increase air gap. Turn the brass nut to the right
(counter-clockwise) to decrease the air gap.
NOTE!
182
Return
2000-08-04
F-code
PS
Section
C-code
S3.0
3370
Electromagnetic Brake
Version no
001
T-code
395/396/397/398/399
BT Prime-Mover, Inc.
Return
2000-08-04
183
F-code
Section
C-code
PS
S3.0
3370
Electromagnetic Brake
Version no
T-code
001
395/396/397/398/399
5.2. Installation
NOTE!
6.2. Replacement
If brake friction plate needs replacement, remove and install
new plate.
184
Return
2000-08-04
F-code
Section
PS
S3.1
Version no
C-code
3530
Drive Wheel
T-code
001
395/396/397/398/399
Drive Wheel
4
5
2
1
3
BT Prime-Mover, Inc.
Return
Item No.
Description
Item No.
Nut
Tire
Washer, spherical
Wheel, drive
2000-08-04
Description
185
F-code
Section
C-code
PS
S3.1
Drive Wheel
3530
Version no
T-code
001
395/396/397/398/399
1. Removal
1. Park the truck on a level surface.
2. Turn key switch to OFF and disconnect battery at
battery connector. Check to make sure battery
retainer plates are in place.
3. Jack rear of truck so drive and caster wheels are
approximately 1 inch (25.4 mm) off the ground.
Block truck in this position.
4. Remove seven wheel retaining nuts (4) and
spherical washers (5). Pull tire (2) and drive wheel
(3) from transmission drive axle hub.
5. Press tire (1) from drive wheel (2).
2. Installation
1. Press drive tire on wheel hub. This is usually done
while pressing off old tire. Press hub to the center
of tire (2).
2. Install drive tire assembly on transmission axle
hub. The seven drive tire wheel nuts should be
torqued to 95 ft-lb (129 Nm).
186
Return
2000-08-04
F-code
Section
PS
S3.1
Version no
001
C-code
3530
Drive Wheel
T-code
395/396/397/398/399
Circular
Ram
Press
Table
BT Prime-Mover, Inc.
Return
2000-08-04
187
F-code
Section
C-code
PS
S3.1
Drive Wheel
3530
Version no
T-code
001
395/396/397/398/399
7. Begin pressing new tire onto hub and old tire off
the hub. Run the press slowly for the first few
inches of travel, because this is the critical stage of
the operation. If tire begins to cock to one side,
stop press and realign the tire. A sharp jar with a
soft-headed mallet will usually realign tire on hub.
8. Release the press. Remove wheel, tire assembly,
and old tire from press table. Inspect wheel and tire
assembly.
9. Install wheel assembly following the procedure for
the specific type of wheel.
188
Return
2000-08-04
F-code
Section
C-code
PS
S3.2
3540
Non-Braking Caster Wheel, RRX35/RSX40
Version no
002
T-code
395/398
3
6
4
7
8
9
17
10
11
12
19
20
18
13
14
17
15
16
BT Prime-Mover, Inc.
Return
2000-08-04
189
F-code
Section
C-code
PS
S3.2
3540
Non-Braking Caster Wheel, RRX35/RSX40
Version no
T-code
002
395/398
Item No.
190
Return
Description
Item No.
Description
Locknut
11
Screw, cap
Lockwasher
12
Nut
Ring, Nilos
13
Pivot, caster
Bearing
14
Bearing, thrust
Screw, cap
15
Caster assembly
Nut
16
Block, pivot
Guide, spring
17
Fitting, grease
Spring
18
Bushing
Screw, set
19
Washer
10
Nut
20
Screw, cap
2000-08-04
F-code
Section
C-code
PS
S3.2
3540
Non-Braking Caster Wheel, RRX35/RSX40
Version no
T-code
002
395/398
1. Caster Pivot
1.1. Removal
1. Park the truck on a flat surface.
2. Turn key switch to OFF and disconnect battery at
battery connector. Check to make sure battery
retainer plates are in place.
3. Jack the rear of truck (see page 66).
4. Remove the main electronic card panel (see
page 103).
5. Remove floor board.
WARNING Secure caster pivot before removing
mounting bolts (20). Serious injury could
occur if failure to comply with this
requirement.
6. Turn and secure transmission to access mounting
bolts (20).
NOTE!
(16)
closest
to
battery
Return
2000-08-04
191
F-code
Section
C-code
PS
S3.2
3540
Non-Braking Caster Wheel, RRX35/RSX40
Version no
T-code
002
395/398
192
Return
2000-08-04
F-code
Section
C-code
PS
S3.2
3540
Non-Braking Caster Wheel, RRX35/RSX40
Version no
002
T-code
395/398
2. Thrust Bearing
2.1. Removal
1. Park the truck on a flat surface.
2. Turn key switch to OFF and disconnect battery at
battery connector. Check to make sure battery
retainer plates are in place.
3. Jack the rear of the truck.
4. Remove main electronic card panel.
5. Remove floor board.
NOTE!
BT Prime-Mover, Inc.
Return
2000-08-04
193
F-code
Section
C-code
PS
S3.2
3540
Non-Braking Caster Wheel, RRX35/RSX40
Version no
T-code
002
395/398
2.2. Installation
1. The truck must be properly blocked at this time.
2. Install the race (4) in caster pivot (13) and thrust
bearing (14) on caster assembly.
3. Install caster assembly in caster pivot (13).
4. Install bearing (4), Nilos ring (3), lockwasher (2)
and locknut (1).
5. Tighten locknut (1) while turning caster wheel
assembly until tight, then back off 0.250 turn.
6. Bend lockwasher tab (2) up to secure locknut (1).
NOTE!
194
Return
2000-08-04
F-code
Section
C-code
PS
S3.2
3540
Non-Braking Caster Wheel, RRX35/RSX40
Version no
002
T-code
395/398
3. Caster Springs
3.1. Adjustment
5.375-5.50 inch
(136.5-139.7 mm)
3.2. Removal
1. Park the truck on a flat surface.
New Free Length
is 7 inch (178 mm)
BT Prime-Mover, Inc.
Return
2000-08-04
195
F-code
Section
C-code
PS
S3.2
3540
Non-Braking Caster Wheel, RRX35/RSX40
Version no
T-code
002
395/398
3.3. Installation
1. Install caster springs.
2. Install adjusting bolts (5).
3. Lower truck to the floor and remove hoist.
5.375-5.50 inch
(136.5-139.7 mm)
Mast Height
Battery
Compartment
192
210
240
270
0.375
inch
0.375
inch
0.375
inch
0.375
inch
0.375
inch
0.375
inch
0.375
inch
0.375
inch
0.375
inch
0.375
inch
300
330
0.375
inch
0.250
inch
0.250
inch
0.375
inch
0.250
inch
0.250
inch
360
402
0.250
inch
0.250
inch
196
Return
2000-08-04
F-code
Section
C-code
PS
S3.2
3540
Non-Braking Caster Wheel, RRX35/RSX40
Version no
002
T-code
395/398
4. Caster Stops
4.1. Adjustment.
1. Park truck on a flat surface.
2. Turn key switch to OFF and disconnect battery
connector from the truck and securely block truck.
3. Remove main electronic card panel.
5.375-5.50 inch
(136.5-139.7 mm)
BT Prime-Mover, Inc.
Return
2000-08-04
197
F-code
Section
C-code
PS
S3.2
3540
Non-Braking Caster Wheel, RRX35/RSX40
Version no
T-code
002
395/398
198
Return
2000-08-04
F-code
Section
C-code
PS
S3.3
3540
Non-Braking Caster Assembly, RRX35/RSX40
Version no
T-code
002
395/398
1
3
4
4
Item No.
BT Prime-Mover, Inc.
Return
Description
Item No.
Wheel, caster
Lockwasher
Bracket, caster
Locknut
Ring, Nilos
Fitting, grease
Bearing
Cap, wheel
2000-08-04
Description
199
F-code
Section
C-code
PS
S3.3
3540
Non-Braking Caster Assembly, RRX35/RSX40
Version no
T-code
002
395/398
1. Removal
NOTE!
2. Installation
1. Install Nilos ring (3) on axle.
2. Install caster wheel assembly.
3. Install Nilos ring (3), lockwasher (5) and locknut
(6).
4. Tighten locknut (6) while turning caster wheel until
wheel becomes tight.
5. Back off locknut (6) until caster wheel turns freely.
and lockwasher (5) tab are aligned.
6. Bend lock washer (5) tab to secure locknut (6).
7. Grease as needed.
8. Replace wheel cap (8).
200
Return
2000-08-04
F-code
Section
C-code
PS
S3.4
3540
Braking Caster Wheel, RRX45/RDX30/RSX50
Version no
002
T-code
396/397/399
26
23
4
6
24
23
7
9
17
21
22
10
11
12
20
19
13
18
14
16
BT Prime-Mover, Inc.
Return
15
17
2000-08-04
201
F-code
Section
C-code
PS
S3.4
3540
Braking Caster Wheel, RRX45/RDX30/RSX50
Version no
T-code
002
396/397/399
Item No.
202
Return
Description
Item No.
Description
Locknut
14
Bearing, thrust
Lockwasher
15
Caster assembly
Ring, Nilos
16
Block
Bearing
17
Fitting, grease
Screw, cap
18
Bushing
Nut
19
Washer
Guide, spring
20
Screw, cap
Spring
21
Shaft
Screw, set
22
Bracket
10
Nut
23
Bearing, flanged
11
Screw, cap
24
Pin, roll
12
Nut
25
Pivot
13
Pivot, caster
26
Screw, cap
2000-08-04
F-code
Section
C-code
PS
S3.4
3540
Braking Caster Wheel, RRX45/RDX30/RSX50
Version no
002
T-code
396/397/399
1. Removal
1.1. Caster Brake Adjustment
1. Park the truck on a flat surface.
2. Turn key switch to OFF and disconnect battery
connector from the truck. Check to make sure the
battery retainer plates are in place.
3. Jack the rear of the truck (see page 66).
4. Remove main electronic card panel (page 103).
CAUTION Pinch point. Keep fingers clear of floor
board cutout while holding down left foot
brake pedal.
CAUTION Disconnect wire connections to right foot
pedal switch prior to removal of floor board.
5. Remove floor board.
6. Total travel of the left foot brake pedal from up to
down is 3.5 inch (89 mm). The pedal setpoint is 50
percent down or 1.8 inch (45.7 mm). This can be
felt by a change in force at the pedal by the spring
tension.
Spring
Rod
Adjusting
Nut
BT Prime-Mover, Inc.
Return
2000-08-04
203
F-code
Section
C-code
PS
S3.4
3540
Braking Caster Wheel, RRX45/RDX30/RSX50
Version no
T-code
002
396/397/399
204
Return
2000-08-04
F-code
Section
C-code
PS
S3.5
3540
Braking Caster Assembly, RRX45/RDX30/RSX50
Version no
T-code
001
396/397/399
16
15
13
9
14
2
11
10
13
12
9
10
11
1
4
4
BT Prime-Mover, Inc.
Return
2000-08-04
205
F-code
Section
C-code
PS
S3.5
3540
Braking Caster Assembly, RRX45/RDX30/RSX50
Version no
T-code
001
396/397/399
Item No.
206
Return
Description
Item No.
Description
Wheel, caster
Ring, E
Bracket, caster
10
Brake assembly
Ring, Nilos
11
Screw, cap
Bearing
12
Nut
Lockwasher
13
Washer
Locknut
14
Pivot, brake
Fitting, grease
15
Spring
Cap, wheel
16
Plunger, brake
2000-08-04
F-code
Section
C-code
PS
S3.5
3540
Braking Caster Assembly, RRX45/RDX30/RSX50
Version no
001
T-code
396/397/399
1. Removal
NOTE!
BT Prime-Mover, Inc.
Return
2000-08-04
207
F-code
Section
C-code
PS
S3.5
3540
Braking Caster Assembly, RRX45/RDX30/RSX50
Version no
T-code
001
396/397/399
2. Installation
1. Slide spring (15) in caster bracket (2) and install
brake plunger (16).
2. Install washer (13) on brake plunger (16) and slide
brake pivot (14) on brake plunger (16) against
washer (13)
3. Install second washer (13) on brake plunger
against brake pivot (14). Secure assembly together
with nut (12) and install a second nut (12) to lock in
place.
4. Install brake assembly (10) with cap screws (11).
5. Move brake pivot (14) around to install E ring (9) on
both brake assembles (10
6. Install Nilos ring (3) on axle.
7. Install caster wheel assembly.
8. Install Nilos ring (3), lockwasher (5) and locknut
(6).
9. Tighten locknut (6) while turning caster wheel until
wheel becomes tight.
10. Back off locknut (6) until caster wheel turns freely
and lock washer (7) tabs are aligned.
11. Bend lock washer (5) tab to secure locknut (6).
12. Grease as needed.
13. Replace wheel cap (8).)
1
2
3
4
208
Return
Item No.
Description
Cam
Plate
Lever
Clip
Spring
Shoe
2000-08-04
F-code
Section
C-code
PS
S3.6
3550
Load Wheels, Sizes 4 X 3, 5 X 4, and 5 X 3
Version no
T-code
000
398/399
11
3
10
6
7
8
9
8
7
6
RSX40/50
(Wheel Sizes 4 X 3 and 5 X 4)
Item No.
BT Prime-Mover, Inc.
Return
Description
Item No.
Description
Axle
Washer, 18 gauge
Toe box
Bearing
Plate, rocker
Wheel, load
Ring, retainer
10
Nut
Fitting, grease
11
Bolt, shoulder
Washer, 10 gauge
2000-08-04
209
F-code
Section
C-code
PS
S3.6
3550
Load Wheels, Sizes 4 X 3, 5 X 4, and 5 X 3
Version no
T-code
000
398/399
11
3
4
10
5
6
7
8
9
8
7
6
RRX35/45/RDX30
(Wheel Sizes 5 X 4 and 5 X 3)
Item No.
210
Return
Description
Item No.
Description
Axle
Washer, 18 gauge
Toe box
Bearing
Plate rocker
Wheel, load
Ring, retainer
10
Nut
Fitting, grease
11
Bolt, shoulder
Washer, 10 gauge
Master Service Manual
2000-08-04
F-code
Section
C-code
PS
S3.6
3550
Load Wheels, Sizes 4 X 3, 5 X 4, and 5 X 3
Version no
000
T-code
398/399
1. Removal
1. Park the truck on a flat surface.
2. Lower carriage fully.
3. Turn key switch to OFF and disconnect battery
connector from the truck. Check to make sure the
battery retainer plates are in place.
WARNING Block all wheels to prevent truck from
rolling.
4. Hoist truck so load wheels are approximately 2
inches (50.8 mm) off the floor and securely block.
5. Remove retainer ring (4) from the axles.
6. Drive the axle back out through the wheels.
Remove rocker plate (3). Remove two washers (6
and 7) on each side of the wheel. Axle (1) is
welded into the rocker plate. Remove the load
wheel (9) from the toe box (2).
7. Inspect bearings (8).
BT Prime-Mover, Inc.
Return
2000-08-04
211
F-code
Section
C-code
PS
S3.6
3550
Load Wheels, Sizes 4 X 3, 5 X 4, and 5 X 3
Version no
T-code
000
398/399
2. Installation
1. Pack bearings with grease.
2. Install bearings in the load wheel.
3. Install load wheel assembly in toe box (2).
NOTE!
212
Return
2000-08-04
F-code
Section
C-code
PS
S3.7
3550
Load Wheels, Size 10.5 X 3.5
Version no
T-code
000
398/399
1
10
2
3
4
11
RRX35/45/RDX30
(Wheel Size 10.5 X 3.5)
Item No.
1
2
3
4
5
6
BT Prime-Mover, Inc.
Return
Description
Toe box, right hand
Washer, 10 gauge
Washer, 18 gauge
Bearing
Tire, load
Wheel
2001-09-21
Item No.
Description
7
8
9
10
11
213
F-code
Section
C-code
PS
S3.7
3550
Load Wheels, Size 10.5 X 3.5
Version no
T-code
000
398/399
1. Removal
1. Park the truck on a flat surface.
2. Lower carriage fully.
3. Turn key switch to OFF and disconnect battery
connector from the truck. Check to make sure the
battery retainer plates are in place.
WARNING Block all wheels to prevent truck from
rolling.
4. Hoist truck so load wheels are approximately 2
inches (50.8 mm) off the floor and securely block.
5. Remove toe box retaining nuts (9) and bolts (10).
6. Remove right toe box (2) and load wheel (9).
7. Grease as needed.
2. Installation
1. Inspect and replace bearings as needed.
2. Install load wheel assembly on toe box axle (1).
3. Install toe box (2).
4. Install toe box assembly on support arm. Apply
Loctite #243 to nuts (10) and bolts (11).
5. Remove blocking and lower truck to the floor.
6. Connect battery connector to the truck.
7. Test operation of load wheel and truck.
8. Return truck to service.
214
Return
2001-09-21
F-code
Section
C-code
PS
S4.0
4110
Steering Arm / Wheel / Lever
Version no
001
T-code
395/396/397/398/399
29
9
10
2
1
26
28
12
24
11
25
23
13
27
19
14
15
22
20
31
32
21
18
17
16
BT Prime-Mover, Inc.
Return
2000-08-04
215
F-code
Section
C-code
PS
S4.0
4110
Steering Arm / Wheel / Lever
Version no
T-code
001
395/396/397/398/399
Item
No.
216
Return
Description
Item
No.
Description
Item
No.
Description
12
O ring
23
Lever
13
Bearing, ball
24
O ring
Screw
14
Housing, bearing
25
Screw, set
Washer, spring
15
Ring, retainer
26
Coupler
Nut
16
Screw
27
Washer
Cap, spinner
17
Motor
28
Screw
Nut
18
Bolt, carriage
29
Grip, hand
Washer
19
Washer
30
Cushion
Spinner
20
Lever assembly
31
Screw
10
Steering wheel
21
Console
32
Spacer
11
Ring, retainer
22
Arm
2000-08-04
F-code
Section
C-code
PS
S4.0
4110
Steering Arm / Wheel / Lever
Version no
001
T-code
395/396/397/398/399
1. Control Pod
1.1. Removal
1. Park truck on level surface.
2. Turn key switch to OFF and disconnect battery
connector from the truck. Block truck.
3. Remove dash retaining screws (see page 100).
4. Remove adjusting lever (23) and washer (27).
5. Lift pod assembly.
6. Lift dash approximately 6 inch (152.4 mm) to
access controls pod's wiring harness connectors.
7. Disconnect harness and remove control pod.
1.2. Installation
1. Route control pod wiring harness through dash.
2. Connect control pod harness to trucks main wiring
harness.
3. Install adjusting lever (23) and washer (27).
4. Install dash.
BT Prime-Mover, Inc.
Return
2000-08-04
217
F-code
Section
C-code
PS
S4.0
4110
Steering Arm / Wheel / Lever
Version no
T-code
001
395/396/397/398/399
2. Steering Wheel
2.1. Removal
1. Park truck on level surface.
2. Turn key switch to OFF and disconnect battery at
battery connector and securely block truck.
3. Remove control pod.
4. Remove screws (28) on lower control pod panel (1)
and remove panel.
5. Remove four screws (16).
6. Remove steering wheel (10). Inspect and replace
bearing as needed.
2.2. Installation
1. Install steering wheel (10) in upper control pod
panel (2).
2. Align holes on steering wheel mount and install
four screws (16). Check steering wheel for ease of
turning.
3. Install lower control pod panel (1) and install
screws (28).
4. Install control pod.
5. Connect battery connector to the truck. Turn key
switch to ON.
6. Test operation of steering wheel (10) and truck.
218
Return
2000-08-04
F-code
Section
C-code
PS
S4.0
4110
Steering Arm / Wheel / Lever
Version no
001
T-code
395/396/397/398/399
3. Steering Tach
3.1. Removal
1. Park truck on level surface
2. Turn key switch to OFF and disconnect battery at
battery connector and securely block truck.
3. Remove control pod.
4. Remove screws (28) and remove lower control pod
panel (1).
5. Remove steering wheel (10).
6. Loose setscrew (25) and remove coupler (26).
7. Electrically disconnect steering tach motor (17)
wires from wiring harness. Remove four screws
(31) holding tach motor (17).
3.2. Installation
1. Install steering tach motor (17) and secure with
four screws (31).
2. Connect steering tach motor (17) wires from wiring
harness.
3. Install coupler (26) and tighten set screw (25).
4. Install steering wheel (10).
5. Install lower control pod panel (1) and tighten
screws (28).
6. Install control pod.
BT Prime-Mover, Inc.
Return
2000-08-04
219
F-code
Section
C-code
PS
S4.0
4110
Steering Arm / Wheel / Lever
Version no
T-code
001
395/396/397/398/399
220
Return
2000-08-04
F-code
Section
PS
S4.1
4180
Steering Bearing
Version no
C-code
T-code
001
395/396/397/398/399
Steering Bearing
3
2
Item No.
BT Prime-Mover, Inc.
Return
Description
Bearing
Breather
Screw
O ring
Transmission assembly
2000-08-04
221
F-code
Section
C-code
PS
S4.1
Steering Bearing
4180
Version no
T-code
001
395/396/397/398/399
1. Removal
NOTE!
2. Installation
1. Install new O ring (4), making sure it is positioned
before installing breather (2). Install breather (2).
2. Install new steer bearing (1).
3. Install
transmission
mounting
plate
and
transmission in truck and torque six mounting
screws to 50-59 ft-lb (68-80 Nm).
4. Install drive motor.
O ring Location
NOTE: Photo is a representation
of transmission assembly.
222
Return
2000-08-04
F-code
PS
Version no
002
Section
C-code
S5.0
5000
Electrical Functions
T-code
395/396/397/398/399
Electrical Functions
1. General
The braking, steering, and travel control systems on the
reach truck are electrically controlled and monitored. The lift/
lower and auxiliary function systems are electrically controlled
and hydraulically operated. See Electrical Schematics
page 277, page 289, page 301, or page 313 and Hydraulic
Schematics page 442.
The control system of the reach truck consists of the following
components: movable ergonomic control pod; main electronic
card containing steer control; drive motor transistor regulator;
pump motor transistor regulator; steering components; and
brake. An operator instrument panel displaying direction of
travel, drive wheel indicator, actual time, hourmeter/error
code, parking brake indicator, right foot switch indicator, and
parameter set mode. For a listing of error codes see pages
page 393 and page 394. For a listing of parameters see
page 401. For information on the fuses and their location see
page 347.
R11
R12 R13
R14
3 4
1 2
7 8
5 6
9 0
Travel Direction
R1
Hydraulic Control
The first hydraulic lever (R11) is used for lift and lower.
Pulling rearward on the lever causes the mast to lift. Pushing
forward on the lever causes the mast to lower. The second
BT Prime-Mover, Inc.
Return
2002-01-09
223
F-code
Section
PS
S5.0
Electrical Functions
C-code
5000
Version no
T-code
002
395/396/397/398/399
A5
The
main
electronic
card
(A5)
contains
three
microprocessors. One microprocessor operates as a master
and the other two as slaves. The three microprocessors
share various digital and analog input functions. The
microprocessors monitor the state of switches, sensors,
control pod functions, system functions, and other input
devices. The master microprocessor makes decisions based
on the information received from its inputs and the two slave
processors. The results of the decisions are communicated to
the slaves. All three microprocessors share in control of
digital and analog outputs. Output devices controlled include:
solenoids; contactors; motor controllers; steer motor; brake;
and optional equipment.
The main electronic card (A5) performs diagnostic tests at
start-up and during truck operation. The diagnostic tests
assist in repair by identifying problems and minimizing truck
downtime. For any identified problems, the operator is alerted
by a visible tool bar icon and error code numbers displaying
on the operator display. An audible alarm is sounded when
an error is detected. A history log records error codes by date
and time.
The main electronic card (A5) contains a clock/calendar chip
with an internal battery. The combination of a chip and battery
allows clock and date settings to remain in memory when the
trucks battery is disconnected.
224
Return
2002-01-09
F-code
PS
Version no
002
Section
C-code
S5.0
5000
Electrical Functions
T-code
395/396/397/398/399
BT Prime-Mover, Inc.
Return
2002-01-09
225
F-code
Section
C-code
PS
S5.0
Electrical Functions
5000
Version no
T-code
002
395/396/397/398/399
K10
K10
A1
F1
A2
M1
F55
ARMATURE
A1
K11
A5
S21
34
101
902
40
K13
M1
K11
B7
2
15
ACC
RELAY 1
B+
44
K13
8
M
1
805
64
Y1
803
51
K11
802
808
36V only
501
S48
43 111
52
K13
22
F51
25
F50
S108
21
S21
24
S17
49 102
22 809
901
LEGEND
Pressure Oil
Return Oil
Electric Positive
Electric Negative
LED Off (Not Lit)
LED Input (Lit)
LED Output (Lit)
226
Return
2002-01-09
F-code
PS
Version no
002
Section
C-code
S5.0
5000
Electrical Functions
T-code
395/396/397/398/399
2. Start Up
With the battery connected to the reach truck, wire #1
connects battery voltage to the battery terminal of the main
contactor (K10), the control fuse (F50), the steer servo fuse
(F51), and the accessory fuse (F55). Control fuse F50 and
wire #21 connect voltage to the main electronic card (A5)
connector pin 808 (and connector pin 501 for 36V trucks),
and the positive terminal of one section of the emergency
disconnect (S21) switch. Steer servo fuse (F51) and wire #25
connects battery positive to the main electronic card (A5)
connector pin 901 (steer servo). Accessory fuse (F55) and
wire #15 connects battery voltage to the accessories relay(s).
The main electronic card (A5) and steer servo are powered
when the battery is connected. Wire #40 is battery negative.
BT Prime-Mover, Inc.
Return
2002-01-09
227
F-code
Section
C-code
PS
S5.0
Electrical Functions
5000
Version no
T-code
002
395/396/397/398/399
K10
F3
A2
K10
B+
A1
F1
A2
B+
M1 ARMATURE
F55
2
K11
K11
M1
44
B7
A1
15
ACC
RELAY 1
S21
34
A5
101
M
1
805
64
Y1
803
51
K11
802
808
36V only
501
S48
43 111
52
K13
22
25
F50
21
S108
S21
24
40
K13
K13
8
F51
902
S17
49 102
22
809
901
LEGEND
Pressure Oil
Return Oil
Electric Positive
Electric Negative
LED Off (Not Lit)
LED Input (Lit)
LED Output (Lit)
228
Return
2002-01-09
F-code
PS
Version no
002
Section
C-code
S5.0
5000
Electrical Functions
T-code
395/396/397/398/399
BT Prime-Mover, Inc.
Return
2002-01-09
229
F-code
Section
C-code
PS
S5.0
Electrical Functions
5000
Version no
T-code
002
395/396/397/398/399
A5
40
40
F51
25
60
M6
902 (OV)
901
903 +
A6
Tx + 303
Rx+
Tx - 304
Rx-
M
61
62
U1
503 IN -
G
63
LEGEND
904 -
502 IN +
Steering Components
Pressure Oil
Return Oil
Electric Positive
Electric Negative
LED Off (Not Lit)
LED Input (Lit)
LED Output (Lit)
230
Return
2002-01-09
F-code
PS
Version no
002
Section
C-code
S5.0
5000
Electrical Functions
T-code
395/396/397/398/399
3. Steering Components
3.1. Steering System
The steering system is electrically controlled. The input is a
tachometer (DC generator (U1) connected to the steering
wheel. The faster the steering wheel is turned, the higher the
voltage is produced by the tachometer (U1). The direction of
tachometer (U1) rotation determines the polarity of the signal.
The tachometer (U1) is connected to the main electronic card
(A5) by wire #62 to input 503 (-) and by wire #63 to input 502
(+). The master processor on the main electronic card (A5)
processes the tachometer signal and communicates the
result to the steer slave processor. The steer slave processor
controls the steer chopper to obtain the appropriate output
voltage and polarity to drive the steer motor (M6). The steer
motor is connected to the main electronic card (A5) through
wire #60 output 903 (+) and wire #61 output 904 (-). Current
through the main electronic card (A5) connector pins 903 (+)
and 904 (-) determines the steer motor direction. Electrical
power for the steer motor is supplied through wire #1 to fuse
(F51) and through wire #25 to the main electronic card (A5) at
connector pin 901. The negative is wire #40 connected to the
main electronic card (A5) connector pin 902.
The main electronic card (A5) monitors the steer system. If a
fault is sensed in the steer tachometer, steer controller, steer
motor, or wiring, an error code will appear on the Operator
Display (A6) indicating the steering problem.
Three parameters can be modified to adjust the steering for
custom control. Parameter 1 adjusts speed sensitive steering
(reduced steering sensitivity at high speed). Parameter 2
adjusts steering sensitivity (tachometer response). Parameter
11 adjusts steer direction (backward or forward).
Turning the steering wheel clockwise directs B- current to the
steer motor through a series of steps:
The steer tachometer determines the rate and direction of
steer wheel rotations.
Turning the steer tachometer clockwise sends 0 to +2.9
volts (depending upon the rate of rotation of the steering
wheel) to the main electronic card (A5) at input 502 with
respect to connector pin 503.
BT Prime-Mover, Inc.
Return
2002-01-09
231
F-code
Section
PS
S5.0
Electrical Functions
C-code
5000
Version no
T-code
002
395/396/397/398/399
The main electronic card (A5) interprets the input from the
steer tachometer (depending upon the sensitivity setting
selected) and instructs the steer motor to rotate clockwise
(direction parameter 11 set to forward) by supplying Bvoltage through wire #60 from output 903 to the steer
motor with respect to wire #61, connector pin 904.
The drive wheel steers in a counter-clockwise direction
turning the forks of a moving, forks leading truck to the
right.
Turning the steering wheel counter-clockwise directs B+
current to the steer motor through a series of steps:
The steer tachometer determines the rate and direction of
steer wheel rotations.
Turning the steer tachometer counter-clockwise sends 0 to
-2.9 volts (depending upon the rate of rotation of the
steering wheel) to the main electronic card (A5) at input
502 with respect to connector pin 503.
The main electronic card (A5) interprets the input from the
steer tachometer (depending upon the sensitivity setting
selected) and instructs the steer motor to rotate
counterclockwise (direction parameter 11 set to forward)
by supplying B+ voltage through wire #60 from output 903
to the steer motor with respect to wire #61, connector pin
904.
The drive wheel steers in a clockwise direction turning the
forks of a moving, forks leading truck to the left.
232
Return
2002-01-09
F-code
PS
Version no
002
Section
C-code
S5.0
5000
Electrical Functions
T-code
395/396/397/398/399
BT Prime-Mover, Inc.
Return
2002-01-09
233
F-code
Section
C-code
PS
S5.0
Electrical Functions
5000
Version no
T-code
002
395/396/397/398/399
A5
F53
67
31
810 12V +
811 -
32
S66
58
204
STEERING ANGLE A
S67
22
S65
59
57
203
STEERING ANGLE B
202
STEER WHEEL POSITION
40 902 (OV)
40
LEGEND
Pressure Oil
Return Oil
Electric Positive
Electric Negative
LED Off (Not Lit)
LED Input (Lit)
LED Output (Lit)
234
Return
2002-01-09
F-code
PS
Version no
002
Section
C-code
S5.0
5000
Electrical Functions
T-code
395/396/397/398/399
BT Prime-Mover, Inc.
Return
2002-01-09
235
F-code
Section
C-code
PS
S5.0
Electrical Functions
5000
Version no
T-code
002
395/396/397/398/399
K10
K10
A1
F1
A2
B+
ARMATURE
M1
44
B34
7
2
A1
R3
22
101
29
FIELD
K11
K13
M1
K11
K13
8
A5
S21
65
30
M
1
902
504 +7.35V
511
510 OV
805
64
Y1
51
K11
802 52
K13
803
F50
808
36V only
501
S48
43
111
S108
49
102
21
S21
24
S17
22
40
809
LEGEND
Pressure Oil
Brake Release
Return Oil
Electric Positive
Electric Negative
LED Off (Not Lit)
LED Input (Lit)
LED Output (Lit)
236
Return
2002-01-09
F-code
PS
Version no
002
Section
C-code
S5.0
5000
Electrical Functions
T-code
395/396/397/398/399
4. Brake Release
Brake release occurs when the brake pedal is fully
depressed. The emergency switch (S21) ON, key switch
(S17) ON and the brake pedal fully depressed (down) causes
the brake switch (S48) to open removing the input to the main
electronic card (A5) terminal 111 (wire #43). The brake
potentiometer (R3) output goes to a lower voltage than when
the brake pedal is released (up). The main electronic card
(A5) senses the decrease in voltage at terminal 511 (wire
#65). The main electronic card (A5) responds by turning on
output 805 (wire #64) sending current to the magnetic brake
coil (Y1), lighting the main electronic card (A5) 805 LED. The
energizing of the brake coil (Y1) causes the brake pressure
plate to move from the brake friction plate, releasing the
brake and allowing the truck to travel.
BT Prime-Mover, Inc.
Return
2002-01-09
237
F-code
Section
C-code
PS
S5.0
Electrical Functions
5000
Version no
T-code
002
395/396/397/398/399
K10
K10
A1
F1
3
A2
B+
M1
44
B-
2
K11
29
R1
K13
K13
M1
K11
50
30
M
1
101
34
A1
29
22
R3
F50
65
36V only
S48
21
S108
S21
24
S17
43
49
22
A6
123
Rx +
Rx -
LEGEND
Pressure Oil
A5
S21
124
902
40
504 +7.35V
505 +3.65V
510 OV
805
64
Y1
803
51
K11
802
52
K13
511
808
501
111
102
809
303 Tx +
304 Tx -
Direction Selection
Return Oil
Electric Positive
Electric Negative
LED Off (Not Lit)
LED Input (Lit)
LED Output (Lit)
238
Return
2002-01-09
F-code
PS
Version no
002
Section
C-code
S5.0
5000
Electrical Functions
T-code
395/396/397/398/399
5. Direction Selection
4
1 2 3
7 8
5 6
9 0
BT Prime-Mover, Inc.
Return
2002-01-09
239
F-code
Section
C-code
PS
S5.0
Electrical Functions
5000
Version no
T-code
002
395/396/397/398/399
+
K10
K10
A1
F1
3
A2
M1
B+
ARMATURE
2
A1
FIELD
K11
K11
M1
A5
44
B7
36
10
11
35
6
S21
34
29
R1
8
1
610
611
609 -
37
K13
K13
50
30
M
1
22
R3
F50
65
36V only
S48
43
21
S108
S21
24
S17
49
22
S60
101
39
902
40
504 +7.35V
505 +3.65V
510 OV
805
64
Y1
803
51
K11
802
808
501
52
K13
511
111
102
809
104
LEGEND
Pressure Oil
Return Oil
Electric Positive
Electric Negative
LED Off (Not Lit)
LED Input (Lit)
LED Output (Lit)
240
Return
2002-01-09
F-code
PS
Version no
002
Section
C-code
S5.0
5000
Electrical Functions
T-code
395/396/397/398/399
Return
2002-01-09
241
F-code
Section
PS
S5.0
Electrical Functions
C-code
5000
Version no
T-code
002
395/396/397/398/399
242
Return
2002-01-09
F-code
PS
Version no
002
Section
C-code
S5.0
5000
Electrical Functions
T-code
395/396/397/398/399
BT Prime-Mover, Inc.
Return
2002-01-09
243
F-code
Section
C-code
PS
S5.0
Electrical Functions
5000
Version no
T-code
002
395/396/397/398/399
+
K10
K10
A1
F1
A2
B+
ARMATURE
M1
A1
FIELD
K11
K11
M1
A5
B7
10 36
44
101
34 S21
11
A
6 35
29
K13
K13
R1
8
610
611
609 -
37
50
30
M
1
22
R3
F50
902
40
504 +7.35V
505 +3.65V
510 OV
805
64
Y1
803
51
K11
802
808
501
43
111
49
102
22
809
52
K13
65
511
36V only
S48
21
S108
S21
24
S17
S60
LEGEND
39
104
Pressure Oil
Return Oil
Electric Positive
Electric Negative
LED Off (Not Lit)
LED Input (Lit)
LED Output (Lit)
244
Return
2002-01-09
F-code
PS
Version no
002
Section
C-code
S5.0
5000
Electrical Functions
T-code
395/396/397/398/399
Return
2002-01-09
245
F-code
Section
PS
S5.0
Electrical Functions
C-code
5000
Version no
T-code
002
395/396/397/398/399
246
Return
2002-01-09
F-code
PS
Version no
002
Section
C-code
S5.0
5000
Electrical Functions
T-code
395/396/397/398/399
BT Prime-Mover, Inc.
Return
2002-01-09
247
F-code
Section
PS
S5.0
Electrical Functions
C-code
5000
Version no
T-code
002
395/396/397/398/399
248
Return
2002-01-09
F-code
Section
PS
Version no
T-code
002
+
K10
395/396/397/398/399
K10
A1
F1
3 B+
A2
ARMATURE
M1
A1
K11
K11
FIELD
M1
A5
B7
8
10
A
44 S21
34
38
36
35
37
11
29
K13
K13
R1
8
M
1
R3
101
103
610
902
609 611
65
40
504 +7.35V
50 505 +3.65V
30
22
F50
C-code
S5.0
5000
Electrical Functions
805
510 OV
803
511
64
Y1
51
K11
52
K13
802
21
S21
24
S17
LEGEND
810 +
22
808 811 36V only
501
S48
43
111
102
S108
49
105
22
201
809
S125
S64
23
56
Plug Braking
Pressure Oil
Return Oil
Electric Positive
Electric Negative
LED Off (Not Lit)
LED Input (Lit)
LED Output (Lit)
BT Prime-Mover, Inc.
Return
2002-01-09
249
F-code
Section
PS
S5.0
Electrical Functions
C-code
5000
Version no
T-code
002
395/396/397/398/399
8. Plug Braking
CAUTION Releasing the brake pedal while on an
incline will cause the truck to move.
There are two methods of plug braking available on the reach
truck. The first method is using the directional/speed control
lever. The second method is accomplished through raising
the brake pedal and is detailed second.
Return
2002-01-09
F-code
PS
Version no
002
Section
C-code
S5.0
5000
Electrical Functions
T-code
395/396/397/398/399
the drive transistor regulator (A1) input pin 11. The current
limit signal ranges from 0 volts to approximately 4.5 volts and
controls the plugging force.
Plug braking force is regulated with the direction/speed
control lever movement. The greater the movement of the
control lever, the higher the current limit signal voltage and
the greater the plug braking force. Both speed and current
limit signals are measured with respect to the main electronic
card (A5) output 609 (wire #35).
Return
2002-01-09
251
F-code
Section
PS
S5.0
Electrical Functions
C-code
5000
Version no
T-code
002
395/396/397/398/399
252
Return
2002-01-09
F-code
PS
Version no
002
Section
C-code
S5.0
5000
Electrical Functions
T-code
395/396/397/398/399
BT Prime-Mover, Inc.
Return
2002-01-09
253
F-code
Section
PS
S5.0
Electrical Functions
C-code
5000
Version no
T-code
002
395/396/397/398/399
105
S125
32
31 F53
S64
67
811 810 +
56
201
S66
204
S67
203
205
U10
206
LEGEND
Pressure Oil
Return Oil
Electric Positive
Electric Negative
LED Off (Not Lit)
LED Input (Lit)
LED Output (Lit)
254
Return
2002-01-09
F-code
PS
Version no
002
29
R1
50
30
Section
C-code
S5.0
5000
Electrical Functions
T-code
395/396/397/398/399
A5
504 +7.35V
505 Speed/Direction
510 OV
R3
511 Brake
R11
506 Lift/Lower
R12
507 Reach/Retract
R13
508 Tilt
R14
509 Sideshift
BT Prime-Mover, Inc.
Return
2002-01-09
255
F-code
Section
PS
S5.0
Electrical Functions
C-code
5000
Version no
T-code
002
395/396/397/398/399
256
Return
2002-01-09
F-code
Section
PS
C-code
S5.0
5000
Electrical Functions
Version no
T-code
002
395/396/397/398/399
S45
22 40
A5
106
S31
207
107
79
22 40
29
504 7.35 V
50
R1
505 6.35V
30
201
31
32
LEGEND
Pressure Oil
A1
501 OV
610
35
10
56
S64
Return Oil
Electric Positive
Electric Negative
LED Off (Not Lit)
LED Input (Lit)
LED Output (Lit)
BT Prime-Mover, Inc.
Return
2002-01-09
257
F-code
Section
PS
S5.0
Electrical Functions
C-code
5000
Version no
T-code
002
395/396/397/398/399
258
Return
2002-01-09
F-code
PS
Section
C-code
S5.0
5000
Electrical Functions
Version no
T-code
002
395/396/397/398/399
S45
22 40
A5
106
207
79
S31
107
22 40
88
40
Y10
LEGEND
Pressure Oil
A2
804
10
75
702
Return Oil
Electric Positive
Electric Negative
LED Off (Not Lit)
LED Input (Lit)
LED Output (Lit)
BT Prime-Mover, Inc.
Return
2002-01-09
259
F-code
Section
PS
S5.0
Electrical Functions
C-code
5000
Version no
T-code
002
395/396/397/398/399
260
Return
2002-01-09
F-code
Section
PS
C-code
S5.0
5000
Electrical Functions
Version no
T-code
002
395/396/397/398/399
A8
3+
+5
4 OV
-2
A7
A5
125
+7
40
22
F52
6 OV
-3
4+
+1
126
127
128
-5
402 403 +
404 -
106
S45
67
F53
31
405 +
U10
+
207
810 12 Volt Supply
98
205 A
99
206 B
32
811
LEGEND
Pressure Oil
Return Oil
Electric Positive
Electric Negative
LED Off (Not Lit)
LED Input (Lit)
LED Output (Lit)
BT Prime-Mover, Inc.
Return
2002-01-09
261
F-code
Section
PS
S5.0
Electrical Functions
C-code
5000
Version no
T-code
002
395/396/397/398/399
Return
2002-01-09
F-code
PS
Version no
002
Section
C-code
S5.0
5000
Electrical Functions
T-code
395/396/397/398/399
BT Prime-Mover, Inc.
Return
2002-01-09
263
F-code
Section
PS
S5.0
Electrical Functions
C-code
5000
Version no
T-code
002
395/396/397/398/399
K10
SA2
A1
F1
M1
SA1
K10
3
B+
ARMATURE
2
FIELD
K11
K13
M1
K13
K11
44
B7
34
S21
A5
101
902
40
803 51
K11
802 52 K13
41
LEGEND
42
Pressure Oil
208
209
Return Oil
Electric Positive
Electric Negative
264
Return
2002-01-09
F-code
Section
PS
C-code
S5.0
5000
Electrical Functions
Version no
T-code
002
395/396/397/398/399
A2
14 F3
B - 40
9 B+
ARMATURE
M3A
SA2
FIELD
M3F
10
SA1
A5
77
78
LEGEND
Pressure Oil
210
211
Return Oil
Electric Positive
Electric Negative
LED Off (Not Lit)
BT Prime-Mover, Inc.
Return
2002-01-09
265
F-code
Section
C-code
PS
S5.0
Electrical Functions
5000
Version no
T-code
002
395/396/397/398/399
+ K10
K10
A2
F1
3 B+
A2
M1
ARMATURE
2 A
K11
K11
B7
A1
A5
44
S21
34
101
902
40
FIELD
K13
M1
K13
8
LEGEND
Pressure Oil
Return Oil
Safety Check A
Electric Positive
Electric Negative
LED Off (Not Lit)
LED Input (Lit)
LED Output (Lit)
266
Return
2002-01-09
F-code
Section
PS
C-code
S5.0
5000
Electrical Functions
Version no
T-code
002
395/396/397/398/399
+ K10
K10
A2
F1
3 B+
A2
M1
ARMATURE
2 A
K11
K11
B7
A1
A5
44
S21
34
101
902
40
FIELD
K13
M1
K13
8
LEGEND
Pressure Oil
Safety Check B
Return Oil
Electric Positive
Electric Negative
LED Off (Not Lit)
LED Input (Lit)
LED Output (Lit)
BT Prime-Mover, Inc.
Return
2002-01-09
267
F-code
Section
PS
S5.0
Electrical Functions
C-code
5000
Version no
T-code
002
395/396/397/398/399
Shunt Wire
+
40
A5
606 606 -(+)
607 607 - (-)
608
608 +
LEGEND
Pressure Oil
Return Oil
Electric Positive
Electric Negative
LED Off (Not Lit)
LED Input (Lit)
LED Output (Lit)
268
Return
2002-01-09
F-code
PS
Version no
002
Section
C-code
S5.0
5000
Electrical Functions
T-code
395/396/397/398/399
List of Symbols
Symbol
Designation
Function
A1
Drive Motor
A2
Pump Motor
A5
Electronic card
Main Card
A6
Electronic card
Display
A7
Electronic card
Height Preset
A8
Electronic card
Height Indication
A60
Drive module
Electronic unit
A61
Drive module
Electronic unit
A62
Drive module
Electronic unit
BT
Battery
C1
Capacitor
Suppressor H1
E1
Light
Overhead Guard
E3
Light
Work
E4
Light
Work
E21
Heater
A1/A2
E22
Heater
Lever
E23
Heater
Lever
E24
Heater
E25
Heater
E26
Heater
A5
Fuse
Drive Motor
F1
BT Prime-Mover, Inc.
Return
Remark
24/36 Volt
Horn
250 Amp
2002-01-09
269
F-code
Section
C-code
PS
S5.0
Electrical Functions
5000
Version no
T-code
002
395/396/397/398/399
List of Symbols
Symbol
270
Designation
Function
Remark
F3
Fuse
Pump Motor
RRX35/RSX40
425A 24V/355A 36V
RRX45/RDX30/RSX50
250A 36V
F4
Fuse
Pump Motor
RRX45/RDX30/RSX50
250A 36V
F50
Fuse
Control Circuit
10 Amp
F51
Fuse
Steering Motor
30 Amp
F52
Fuse
1/4 Amp
F53
Fuse
1/4 Amp
F54
Fuse
Display Power
1/4 Amp
F55
Fuse
Relay 1
10 Amp
F81
Fuse
10 Amp
F82
Fuse
10 Amp
H1
Horn
Alarm
H2
Flashing light
Light
option
H3
Traction
Alarm
option
K10
Contactor
Main Contactor
K11
Contactor
Directional
K13
Contactor
Directional
K34
Contactor
Bypass Lift
M1
Motor
Drive Motor
M3
Motor
Pump Motor
M6
Motor
Steering Motor
M11
Fan
Drive
Return
RRX45/RDX30/RSX50
2002-01-09
F-code
PS
Version no
002
Section
C-code
S5.0
5000
Electrical Functions
T-code
395/396/397/398/399
List of Symbols
Symbol
Designation
Function
Remark
M12
Fan
Electronics
M13
Fan
Overhead guard
R1
Potentiometer
Travel
R3
Potentiometer
Brake
R11
Potentiometer
R12
Potentiometer
R13
Potentiometer
R14
Potentiometer
R20
Resistor
Plug-in Module
R21
Resistor
Output Load
R22
Resistor
Output Load
S17
Switch
Key
S18
Switch
Horn
S21
Switch
Emergency stop
S31
Switch
Speed Limit
S33
Switch
S45
Inductive sensor
Carriage Sensor
S48
Switch
S60
Thermostat
Drive Temperature
S64
Inductive sensor
Drive Speed
S65
Inductive sensor
S66
Inductive sensor
Steer Angle A
S67
Inductive sensor
Steer Angle B
S96
Switch
Fan
Push Button
S97
Switch
Work Light
Push Button
BT Prime-Mover, Inc.
Return
2002-01-09
Push Button
271
F-code
Section
C-code
PS
S5.0
Electrical Functions
5000
Version no
T-code
002
395/396/397/398/399
List of Symbols
Symbol
272
Designation
Function
Remark
S99
Switch
Light
Push Button
S108
Switch
Right Foot
S111
Switch
A1 & A2 Thermostat
S112
Switch
S113
Switch
A5 Thermostat
S125
Inductive sensor
Drive Direction
SA1
Switch
SA2
Switch
U1
Tachometer
Steering
U10
Pulse sensor
Height Counter
V101
Zener diode
Voltage Regulator
Battery Connector
Y1
Brake coil
Parking Brake
Y10
Valve
Lift/Lower
Y10-2
Valve
Lift Of Forks
Y10-3
Valve
Y12
Valve
Direction A
Y13
Valve
Direction B
Y14
Valve
Reach Out
Y15
Valve
Reach In
Y16
Valve
Sideshift
Y17
Valve
Tilt
Return
2002-01-09
F-code
Section
PS
C-code
S5.0
5000
Electrical Functions
Version no
T-code
002
395/396/397/398/399
A2
R14
K10
3 4
1 2
7 8
5 6
9 0
S17
R12 R13
2
3
R11
U1
A1
R1
K34
1
2
3
4
A1
1
2
3
4
F1
F3
A2
K10
K11
K13
RRX35/RSX40
Y14
Y15
Y17
Y16
BT Prime-Mover, Inc.
Return
2002-01-09
273
F-code
Section
C-code
PS
S5.0
Electrical Functions
5000
Version no
T-code
002
395/396/397/398/399
M3
S125
S64
Y13
A5
H1
Y1
M11
S65
M1
S60
M6
CONTROL
FUSES
S48
274
Return
R3
2002-01-09
F-code
PS
Version no
000
Section
C-code
S5.1
5000
Electrical Symbols
T-code
395/396/397/398/399
Electrical Symbols
Electrical Symbols
Symbol
BT Prime-Mover Inc.
Return
Symbol
Description
Battery
Brake (coil)
Contactor
Diode
Emergency stop
Fuse
Horn
Inductive sensor
(normally closed)
Inductive sensor
(normally open)
Key switch
Magnet switch
(normally closed)
Magnet switch
(normally open)
Motor
Potentiometer
A1
Description
A2
Service Manual
2001-03-15
275
F-code
Section
PS
S5.1
Electrical Symbols
C-code
5000
Version no
T-code
000
395/396/397/398/399
Electrical Symbols
Symbol
Description
Push button switch
(normally closed)
Symbol
Description
Push button switch
(normally open)
Resistor
Switch
Switch
(normally closed)
Switch
(normally open)
Valve
276
Return
Service Manual
2001-03-15
F-code
Section
C-code
PS
5.2
5000
Electrical Schematics (Serial numbers 27163000-28105000)
Version no
002
T-code
395/396/397/398/399
Legend
BT Prime-Mover, Inc.
Return
2000-08-04
277
F-code
Section
C-code
PS
5.2
5000
Electrical Schematics (Serial numbers 27163000-28105000)
Version no
T-code
002
395/396/397/398/399
278
Legend
Return
2000-08-04
F-code
Section
C-code
PS
5.2
5000
Electrical Schematics (Serial numbers 27163000-28105000)
Version no
002
T-code
395/396/397/398/399
BT Prime-Mover, Inc.
Return
15A
Legend
Input
2000-08-04
279
F-code
Section
C-code
PS
5.2
5000
Electrical Schematics (Serial numbers 27163000-28105000)
Version no
T-code
002
395/396/397/398/399
280
Return
Legend
2000-08-04
F-code
Section
C-code
PS
5.2
5000
Electrical Schematics (Serial numbers 27163000-28105000)
Version no
002
T-code
395/396/397/398/399
S108
Legend
BT Prime-Mover, Inc.
Return
2000-08-04
281
F-code
Section
C-code
PS
5.2
5000
Electrical Schematics (Serial numbers 27163000-28105000)
Version no
T-code
002
395/396/397/398/399
282
Legend
Return
2000-08-04
F-code
Section
C-code
PS
5.2
5000
Electrical Schematics (Serial numbers 27163000-28105000)
Version no
002
T-code
395/396/397/398/399
BT Prime-Mover, Inc.
Return
RRX45
RDX30
RSX50
RRX45
RDX30
RSX50
Legend
2000-08-04
283
F-code
Section
C-code
PS
5.2
5000
Electrical Schematics (Serial numbers 27163000-28105000)
Version no
T-code
002
395/396/397/398/399
284
Legend
Return
2000-08-04
F-code
Section
C-code
PS
5.2
5000
Electrical Schematics (Serial numbers 27163000-28105000)
Version no
002
T-code
395/396/397/398/399
Legend
BT Prime-Mover, Inc.
Return
2000-08-04
285
F-code
Section
C-code
PS
5.2
5000
Electrical Schematics (Serial numbers 27163000-28105000)
Version no
T-code
002
395/396/397/398/399
286
Legend
Return
2000-08-04
F-code
Section
C-code
PS
5.2
5000
Electrical Schematics (Serial numbers 27163000-28105000)
Version no
002
T-code
395/396/397/398/399
Legend
BT Prime-Mover, Inc.
Return
2000-08-04
287
F-code
Section
C-code
PS
5.2
5000
Electrical Schematics (Serial numbers 27163000-28105000)
Version no
T-code
002
395/396/397/398/399
288
Return
2000-08-04
F-code
Section
C-code
PS
5.3
5000
Electrical Schematics (Serial numbers 28105001-28126000)
Version no
000
T-code
395/396/397/398/399
Legend
BT Prime-Mover, Inc.
Return
2000-08-04
289
F-code
Section
C-code
PS
5.3
5000
Electrical Schematics (Serial numbers 28105001-28126000)
Version no
T-code
000
395/396/397/398/399
290
Legend
Return
2000-08-04
F-code
Section
C-code
PS
5.3
5000
Electrical Schematics (Serial numbers 28105001-28126000)
Version no
000
T-code
395/396/397/398/399
Legend
Input
BT Prime-Mover, Inc.
Return
2000-08-04
291
F-code
Section
C-code
PS
5.3
5000
Electrical Schematics (Serial numbers 28105001-28126000)
Version no
T-code
000
395/396/397/398/399
292
Return
Legend
2000-08-04
F-code
Section
C-code
PS
5.3
5000
Electrical Schematics (Serial numbers 28105001-28126000)
Version no
000
T-code
395/396/397/398/399
Legend
S108
BT Prime-Mover, Inc.
Return
2000-08-04
293
F-code
Section
C-code
PS
5.3
5000
Electrical Schematics (Serial numbers 28105001-28126000)
Version no
T-code
000
395/396/397/398/399
294
Legend
Return
2000-08-04
F-code
Section
C-code
PS
5.3
5000
Electrical Schematics (Serial numbers 28105001-28126000)
Version no
000
T-code
395/396/397/398/399
BT Prime-Mover, Inc.
Return
RRX45
RDX30
RSX50
RRX45
RDX30
RSX50
Legend
2000-08-04
295
F-code
Section
C-code
PS
5.3
5000
Electrical Schematics (Serial numbers 28105001-28126000)
Version no
T-code
000
395/396/397/398/399
296
Legend
Return
2000-08-04
F-code
Section
C-code
PS
5.3
5000
Electrical Schematics (Serial numbers 28105001-28126000)
Version no
000
T-code
395/396/397/398/399
Legend
BT Prime-Mover, Inc.
Return
2000-08-04
297
F-code
Section
C-code
PS
5.3
5000
Electrical Schematics (Serial numbers 28105001-28126000)
Version no
T-code
000
395/396/397/398/399
298
Legend
Return
2000-08-04
F-code
Section
C-code
PS
5.3
5000
Electrical Schematics (Serial numbers 28105001-28126000)
Version no
000
T-code
395/396/397/398/399
Legend
BT Prime-Mover, Inc.
Return
2000-08-04
299
F-code
Section
C-code
PS
5.3
5000
Electrical Schematics (Serial numbers 28105001-28126000)
Version no
T-code
000
395/396/397/398/399
Legend
300
Return
2000-08-04
F-code
Section
C-code
PS
5.4
5000
Electrical Schematics (Serial numbers 28126001-31285000)
Version no
000
T-code
395/396/397/398/399
Legend
BT Prime-Mover, Inc.
Return
2002-02-07
301
F-code
Section
C-code
PS
5.4
5000
Electrical Schematics (Serial numbers 28126001-31285000)
Version no
T-code
000
395/396/397/398/399
302
Legend
Return
2002-02-07
F-code
Section
C-code
PS
5.4
5000
Electrical Schematics (Serial numbers 28126001-31285000)
Version no
000
T-code
395/396/397/398/399
Legend
Inputs
BT Prime-Mover, Inc.
Return
2002-02-07
303
F-code
Section
C-code
PS
5.4
5000
Electrical Schematics (Serial numbers 28126001-31285000)
Version no
T-code
000
395/396/397/398/399
304
Return
Legend
2002-02-07
F-code
Section
C-code
PS
5.4
5000
Electrical Schematics (Serial numbers 28126001-31285000)
Version no
000
T-code
395/396/397/398/399
Legend
S108
BT Prime-Mover, Inc.
Return
2002-02-07
305
F-code
Section
C-code
PS
5.4
5000
Electrical Schematics (Serial numbers 28126001-31285000)
Version no
T-code
000
395/396/397/398/399
306
Legend
Return
2002-02-07
F-code
Section
C-code
PS
5.4
5000
Electrical Schematics (Serial numbers 28126001-31285000)
Version no
000
T-code
395/396/397/398/399
Legend
BT Prime-Mover, Inc.
Return
2002-02-07
307
F-code
Section
C-code
PS
5.4
5000
Electrical Schematics (Serial numbers 28126001-31285000)
Version no
T-code
000
395/396/397/398/399
308
Legend
Return
2002-02-07
F-code
Section
C-code
PS
5.4
5000
Electrical Schematics (Serial numbers 28126001-31285000)
Version no
000
T-code
395/396/397/398/399
Legend
BT Prime-Mover, Inc.
Return
2002-02-07
309
F-code
Section
C-code
PS
5.4
5000
Electrical Schematics (Serial numbers 28126001-31285000)
Version no
T-code
000
395/396/397/398/399
310
Legend
Return
2002-02-07
F-code
Section
C-code
PS
5.4
5000
Electrical Schematics (Serial numbers 28126001-31285000)
Version no
000
T-code
395/396/397/398/399
BT Prime-Mover, Inc.
Return
Legend
2002-02-07
311
F-code
Section
C-code
PS
5.4
5000
Electrical Schematics (Serial numbers 28126001-31285000)
Version no
T-code
000
395/396/397/398/399
Legend
312
Return
2002-02-07
F-code
Section
C-code
PS
5.5
5000
Electrical Schematics (Serial numbers 31285001-UP)
Version no
000
T-code
395/396/397/398/399
Legend
BT Prime-Mover, Inc.
Return
2002-02-07
313
F-code
Section
C-code
PS
5.5
5000
Electrical Schematics (Serial numbers 31285001-UP)
Version no
T-code
000
395/396/397/398/399
314
Legend
Return
2002-02-07
F-code
Section
C-code
PS
5.5
5000
Electrical Schematics (Serial numbers 31285001-UP)
Version no
000
T-code
395/396/397/398/399
Legend
BT Prime-Mover, Inc.
Return
2002-02-07
315
F-code
Section
C-code
PS
5.5
5000
Electrical Schematics (Serial numbers 31285001-UP)
Version no
T-code
000
395/396/397/398/399
316
Return
Legend
2002-02-07
F-code
Section
C-code
PS
5.5
5000
Electrical Schematics (Serial numbers 31285001-UP)
Version no
000
T-code
395/396/397/398/399
Legend
BT Prime-Mover, Inc.
Return
2002-02-07
317
F-code
Section
C-code
PS
5.5
5000
Electrical Schematics (Serial numbers 31285001-UP)
Version no
T-code
000
395/396/397/398/399
318
Legend
Return
2002-02-07
F-code
Section
C-code
PS
5.5
5000
Electrical Schematics (Serial numbers 31285001-UP)
Version no
000
T-code
395/396/397/398/399
Legend
BT Prime-Mover, Inc.
Return
2002-02-07
319
F-code
Section
C-code
PS
5.5
5000
Electrical Schematics (Serial numbers 31285001-UP)
Version no
T-code
000
395/396/397/398/399
320
Legend
Return
2002-02-07
F-code
Section
C-code
PS
5.5
5000
Electrical Schematics (Serial numbers 31285001-UP)
Version no
000
T-code
395/396/397/398/399
Legend
BT Prime-Mover, Inc.
Return
2002-02-07
321
F-code
Section
C-code
PS
5.5
5000
Electrical Schematics (Serial numbers 31285001-UP)
Version no
T-code
000
395/396/397/398/399
322
Legend
Return
2002-02-07
F-code
Section
C-code
PS
5.5
5000
Electrical Schematics (Serial numbers 31285001-UP)
Version no
000
T-code
395/396/397/398/399
Legend
BT Prime-Mover, Inc.
Return
2002-02-07
323
Return
324
Section
Version no
T-code
000
395/396/397/398/399
Legend
F-code
PS
5.5
5000
Electrical Schematics (Serial numbers 31285001-UP)
C-code
2002-02-07
F-code
Section
PS
S5.5
Version no
000
C-code
5110
Battery
T-code
395/396/397/398/399
Battery
CAUTION Before working on the battery, review
Battery Safety, beginning on page 21.
Batteries may weigh more than 2,900
pounds (1315 kg). Use extreme care during
replacement. Use a suitable battery
replacement device or hoist for lifting.
Battery
Connector
1. Removal
WARNING Block all wheels to prevent truck from
rolling.
1. After the truck is stopped and brake pedal is
returned to full up position, turn key switch to the
OFF position.
Battery
Roller
Battery
Retainer
Plate
2. Installation
1. With a fully charged and tested battery on the lifting
device, position the lifting device at the truck
according to the manufacturers recommendations.
2. Position the battery in the compartment. Be sure
the battery has no more than 0.50 inch (13 mm) of
free play movement in the battery compartment.
3. Install the battery retainer plate (see page 106).
4. Move lifting device from the area.
5. Connect battery connector to the truck, turn key
switch ON, and test operation of truck.
BT Prime-Mover, Inc.
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2000-08-04
325
F-code
Section
C-code
PS
Battery
S5.5
5110
Version no
T-code
000
395/396/397/398/399
3. Battery Maintenance
The following information does not supercede or replace
information supplied by the battery and battery charger
manufacturer. Read, understand, and follow the procedures
in the manual supplied with the battery and battery charger.
Notify your supervisor if there are any concerns or questions
regarding battery safety or procedures.
326
Return
2000-08-04
F-code
Section
PS
S5.5
Version no
000
C-code
5110
Battery
T-code
395/396/397/398/399
3.3. Charging
OSHA regulations require that battery charging installations
be located in areas designated for that specific purpose. Such
areas must provide for flushing and neutralizing spilled
electrolyte, fire protection, protecting charging equipment
from damage by trucks and adequate ventilation of fumes
from gassing batteries.
To charge a battery, direct current is passed through the
battery cells in the direction opposite that of discharge.
Charging time is 5% to 20% longer than discharge time.
BT Prime-Mover, Inc.
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2000-08-04
327
F-code
Section
C-code
PS
Battery
S5.5
5110
Version no
T-code
000
395/396/397/398/399
4. Storage
Before storing battery, make sure the electrolyte is at the
proper level in all the cells, the filler plugs are tight, and the
battery is fully charged. Store battery in a clean, cool, dry
location away from radiators and other sources of heat.
Check electrolyte level and specific gravity every 30 days
during storage. Whenever specific gravity is less than 1.230,
charge the battery.
328
Return
2000-08-04
F-code
Section
PS
5.6
5121
Light Assemblies
Version no
C-code
T-code
000
395/396/397/398/399
Light Assemblies
1. Overhead Guard Lights (Option)
The overhead guard lights are mounted in a compartment on
the left side of overhead guard. Switches for the lights are
located in the switch cluster below the key switch on the pod.
1.1. Removal
1. Turn the key switch OFF and disconnect battery
connector from the truck.
2. From the top of the overhead guard, remove four
screws securing light/fan assembly.
3. Lower light/fan assembly enough to disconnect it
from the harness.
4. Remove light/fan assembly from truck.
5. Repair or replacement of light is achieved by
removing four screws in the side of light/fan dash
assembly to detach hanger bracket from the top of
the dash.
Item No.
1
Description
Bezel light
Light, dome
Tie, wire
1.2. Installation
1. Reassemble light/fan dash assembly. Be sure clip
nuts are positioned over mounting holes for
attachment to overhead guard.
2. Reconnect harness connections.
3. Install mounting screws through the top of
overhead guard to secure assembly.
4. Connect battery connector to the truck.
BT Prime-Mover, Inc.
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2000-08-04
329
F-code
Section
C-code
PS
5.6
Light Assemblies
5121
Version no
T-code
000
395/396/397/398/399
2.1. Removal
1. Turn the key switch OFF and disconnect battery
connector from the truck.
2. Disconnect electrical connection at warning light.
3. Remove two hex head screws (1) securing light
assembly (2) to overhead guard bracket (4).
4. Replace light bulb or light assembly as required.
Item No.
3
Description
Screw
Light
Bulb
Bracket, mounting
Alarm, travel
Screw
Fitting
330
Return
2000-08-04
F-code
Section
PS
5.6
5121
Light Assemblies
Version no
000
C-code
T-code
395/396/397/398/399
2.2. Installation
1. Secure light assembly to overhead guard bracket
(4) with two hex head screws (1).
2. Reconnect wiring harness.
3. Connect battery connector to the truck.
4. Test operation of warning lights, then return truck
to service.
3.1. Removal
1. Turn the key switch OFF and disconnect battery
connector from the truck.
2. Disconnect electrical connection at working light.
3. Remove screws
overhead guard.
securing
light
assembly
to
3.2. Installation
1. Secure light assembly to overhead guard.
2. Reconnect wiring harness.
3. Connect battery connector to the truck.
4. Test operation of working lights, then return truck
to service.
BT Prime-Mover, Inc.
Return
2000-08-04
331
F-code
Section
PS
5.6
Light Assemblies
C-code
5121
Version no
T-code
000
395/396/397/398/399
4.1. Removal
1. Turn the key switch OFF and disconnect battery
connector from the truck.
2. Disconnect electrical connection at travel/back-up
alarm.
3. Remove two hex head screws (6) securing travel/
back-up alarm (5) to the overhead guard bracket
(4).
4. Replace alarm assembly as required.
4.2. Installation
1. Secure travel/back-up alarm assembly to overhead
guard bracket (4) with two hex head screws (6).
2. Reconnect wiring harness.
3. Connect battery connector to the truck.
4. Test operation of alarm, then return truck to
service.
332
Return
2000-08-04
F-code
Section
PS
5.6
5121
Light Assemblies
Version no
C-code
T-code
000
395/396/397/398/399
2
3
6
Item No.
BT Prime-Mover, Inc.
Return
Description
Bracket, fan
Shroud, fan
Screw
Screw
Console, overhead
Tie, wire
2000-08-04
333
F-code
Section
PS
5.6
Light Assemblies
C-code
5121
Version no
T-code
000
395/396/397/398/399
5.1. Removal
1. Turn the key switch OFF and disconnect battery
connector from the truck.
2. From the top of the overhead guard, remove four
screws (5) securing light/fan assembly.
3. Lower light/fan assembly enough to disconnect
from harness.
4. Remove light/fan assembly from truck.
5. Repair or replacement of fan is achieved by
removing four screws (5) in the light/fan console
assembly to detach hanger bracket (1) from the top
of console (6).
5.2. Installation
1. Reassemble light/fan console assembly.
2. Reconnect harness connections.
3. Install mounting screws (5) through the top of
overhead guard to secure assembly.
4. Connect battery connector to the truck.
5. Test operation of light assembly, then return truck
to service.
334
Return
2000-08-04
F-code
Section
PS
S5.7
Version no
000
C-code
5160
Horn
T-code
395/396/397/398/399
Horn
1. Removal
1. Turn the key switch OFF and disconnect battery
connector from the truck.
2. Open motor compartment door to access the horn.
Item No.
2
Description
Horn
Screw
Capacitor
Clamp
2. Installation
1. Attach horn to truck frame and tighten mounting
bolt (2).
2. Attach three wires.
3. Connect battery connector to the truck and test
operation.
4. Close motor compartment door.
BT Prime-Mover, Inc.
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2000-08-04
335
F-code
Section
C-code
PS
Horn
S5.7
5160
Version no
T-code
000
395/396/397/398/399
336
Return
2000-08-04
F-code
PS
Version no
000
Section
C-code
S5.9
5311
Start/Stop Switches
T-code
395/396/397/398/399
Start/Stop Switches
1. General
Refer to the electrical schematics to identify the electrical
circuit location of switches (see applicable electrical
schematics page 277, page 289, page 301 or page 313).
1.1. Test/Inspection
Examine the switch for signs of arcing, overheating,
discoloration, cracking, or other physical damage. Replace
switch if necessary.
To test switch, isolate it from the electrical circuit. Remove all
connections from switch, making sure all wires are labeled
and identified for reconnection.
Use an ohmmeter set to a low resistance scale to measure
resistance across the switch. In a closed position, the switch
should be less than 1 ohm. In an open position, the switch
should show a resistance greater than 10 megohms.
Key Switch
4
2 3
7 8
5 6
9 0
2.1. Inspection
With battery plugged in and key switch in the ON position, the
battery voltage B+ should be present on both terminals of
switch. Test key switch (S17) with an ohmmeter after
removing from the electrical system. In the OFF position, the
ohmmeter should read greater than 10 megohms. In the ON
position, the ohmmeter should read less than 1 ohm. Replace
switch if readings are not within ranges.
BT Prime-Mover, Inc.
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2000-08-04
337
F-code
Section
PS
S5.9
Start/Stop Switches
C-code
5311
Version no
T-code
000
395/396/397/398/399
2.2. Removal
1. Turn the key switch OFF and disconnect battery
connector from the truck.
2. Remove pod. Remove bottom half of pod see
page 215).
3. Disconnect wires from the bottom of key switch.
4. Remove mounting nut from stem of key switch.
5. Remove key switch.
2.3. Installation
1. Install new key switch and tighten locking nut.
2. Connect wires to terminals.
3. Connect battery connector to the truck and check
operation.
4. Turn the key switch OFF and disconnect battery
connector from the truck.
5. Install bottom half of pod. Install pod.
6. Connect battery connector to the truck.
338
Return
2000-08-04
F-code
PS
Version no
000
Section
C-code
S5.9
5311
Start/Stop Switches
T-code
395/396/397/398/399
3.1. Inspection
With the battery plugged in and the emergency disconnect
switch in the out position, battery voltage B+ should be
present on both terminals of the switch. Test the emergency
disconnect switch with an ohmmeter after removing it from
the electrical system. In the OFF position, the ohmmeter
should read greater than 10 megohms. In the ON position,
ohmmeter should read less than 1 ohm. Replace switch if
readings are not within ranges.
3.2. Removal
1. Turn the key switch OFF and disconnect battery
connector from the truck.
2. Lift the dash up to gain access of electrical
harness.
3. Disconnect the electrical harness from the base of
the emergency disconnect switch.
4. Use a small phillips head screwdriver to loosen two
screws in the backside of the dash.
5. Press two halves of the emergency disconnect
switch together and turn counter-clockwise to
disconnect the switch body from the dash.
6. Finish removing two screws.
7. Repair or replace switch as necessary.
BT Prime-Mover, Inc.
Return
2000-08-04
339
F-code
Section
PS
S5.9
Start/Stop Switches
C-code
5311
Version no
T-code
000
395/396/397/398/399
3.3. Installation
1. Place switch operator down through the opening in
the frame.
2. Attach the switch body to operator from the
backside of the frame.
3. Turn the halves clockwise to engage the latches.
4. Secure the base of the emergency disconnect
switch to the back of the frame with two screws.
5. Reconnect electrical harness to the base of the
emergency disconnect switch.
6. Position dash and secure in place.
7. Connect battery connector to the truck.
8. Test truck operation, then return to service.
340
Return
2000-08-04
F-code
PS
Version no
000
Section
C-code
S5.8
5190
Battery Connector
T-code
395/396/397/398/399
Battery Connector
2
1
4
Item No.
Description
Connector, SB-350
Cap screw
Cable, Negative
Cable, Positive
1. Location
The battery connector is located on the right side of the truck,
above the battery.
f
Battery
Connector
2. Inspection
1. Turn the key switch OFF and disconnect battery
connector from the truck.
2. Check battery connector for damaged cables.
BT Prime-Mover, Inc.
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2000-08-04
341
F-code
Section
PS
S5.8
Battery Connector
C-code
5190
Version no
T-code
000
395/396/397/398/399
3. Installation
The cables to either half of the connector have a lip on the
forward end. This lip snaps over a spring-loaded retainer
which is part of the connector.
To remove a cable from the connector, push retainer down
while pulling battery cable towards the rear and out of the
connector.
NOTE!
342
Return
2000-08-04
F-code
PS
Version no
000
Section
C-code
S5.10
5332
Mast Switch (S31)
T-code
395/396/397/398/999
1. General
Refer to the electrical schematic to identify the electrical
circuit location of the switch (see applicable electrical
schematic on page 277, page 289, page 301 or page 313).
1.1. Test/Inspection
Examine switch for signs of arcing, overheating,
discoloration, cracking, or other physical damage. Replace
switch if necessary.
To test switch, isolate it from the electrical circuit. Remove all
connections from switch, making sure all wires are labeled
and identified for reconnection.
For trucks with serial numbers before 27272000, use an
ohmmeter set to a low resistance scale to measure
resistance across the switch. In a closed position, the switch
should be less than 1 ohm. In an open position, the switch
should show a resistance greater than 10 megohms.
For trucks with serial numbers after 27272000, the switch
(S31) senses the presence or absence of the lower mast tie
bar on the inner column. When the inner columns are
elevated, and the load is above freelift, the absence of the
lower mast tie bar is detected. Speed limit mast switch (S31)
turns ON supplying voltage to the main electronic card input
107. When the mast is lowered and the presence of the lower
mast tie bar is detected, the speed limit switch turns OFF
removing voltage to the main electronic card. For electrical
operation see page 258 and/or 260.
BT Prime-Mover, Inc.
Return
2001-08-20
343
F-code
Section
PS
S5.10
Mast Switch (S31)
C-code
5332
Version no
T-code
000
395/396/397/398/999
Item No.
344
Return
Description
Bracket, switch
Switch, limit
Bracket, switch
Sensor
2001-08-20
F-code
PS
Version no
000
Section
C-code
S5.10
5332
Mast Switch (S31)
T-code
395/396/397/398/999
1.2. Adjustment
1. Raise empty carriage until the bottom of tie bar is
even with bottom of mast switch.
2. Secure the carriage with blocks and a hoist to
prevent any movement.
3. Loosen jam nut securing the mast switch to the
mast.
4. Adjust switch to 0.187 inch (4.76 mm) between the
tie bar and the face of the switch. Allowable
tolerance is +0.0625 inch (1.59 mm) and -0 mm.
5. Tighten jam nut.
6. Check clearance with jam nut tightened.
7. Remove blocks and hoist.
8. Place a maximum capacity load on forks. Verify
that the tie bar does not contact switch under
normal working conditions.
9. Adjust the clearance as necessary to achieve
proper clearance when fully loaded.
10. Remove the load from forks.
11. Test the truck operation to verify normal travel
speed with mast lowered.
BT Prime-Mover, Inc.
Return
2001-08-20
345
F-code
Section
PS
S5.10
Mast Switch (S31)
C-code
5332
Version no
T-code
000
395/396/397/398/999
1.3. Removal
1. Raise the empty carriage until the bottom of the tie
bar is above the mast switch.
2. Secure the carriage with blocks and a hoist to
prevent any movement.
3. Turn the key switch OFF and disconnect battery
connector from the truck.
4. Disconnect switch from the harness.
5. Loosen jam nut securing mast switch to mast.
6. Remove mast switch from mast.
1.4. Installation
1. Install new mast switch.
2. Tighten jam nut to secure switch.
3. Attach wiring harness.
4. Connect battery connector to the truck.
5. Adjust switch following the procedure on page 345.
6. Return truck to service.
346
Return
2001-08-20
F-code
PS
Section
C-code
S5.11
5391
Control Cable and Harness
Version no
T-code
000
395/396/397/398/399
1. Fuses
Examine the fuse for signs of overheating, discoloration,
cracking, or other physical damage. Replace fuse if
damaged.
F81
F82
F55
F54
F53
Fuse
No.
Amp
F1
250
F3
425
355
250
F52
F50
F4
F51
F50
15/
10
F51
30
Steering Circuit
F52
1/4
F53
1/4
F54
1/4
F55
10
F81
10
F82
10
F1
F3 or F4
BT Prime-Mover, Inc.
Return
Function
2000-08-04
347
F-code
Section
C-code
PS
S5.11
5391
Control Cable and Harness
Version no
T-code
000
395/396/397/398/399
2. Wiring
2.1. Harness
When working on the truck, use care around the wiring
harnesses.
348
Return
2000-08-04
F-code
PS
Section
C-code
S5.11
5391
Control Cable and Harness
Version no
000
T-code
395/396/397/398/399
Evidence of overheating
Nicks in insulation
BT Prime-Mover, Inc.
Return
2000-08-04
349
F-code
Section
C-code
PS
S5.11
5391
Control Cable and Harness
Version no
T-code
000
395/396/397/398/399
350
Return
2000-08-04
F-code
Section
PS
S5.12
Version no
000
C-code
5441
Contactors
T-code
395/396/397/398/399
Contactors
1. General
1.1. Resistance Testing
Visually inspect the contactor for any signs of burning or
physical damage.
1. Turn the key switch OFF and disconnect battery
connector from the truck.
2. Disconnect the two wires from the base of
contactor.
3. Connect one lead of ohmmeter to the lead from
contactor. Connect the other lead to the lead from
contactor.
4. The reading should be between 20 and 40 ohms. If
it is not, replace contactor.
Severe Pitting
BT Prime-Mover, Inc.
Return
2000-08-04
351
F-code
Section
C-code
PS
S5.12
Contactors
5441
Version no
T-code
000
395/396/397/398/399
2. Direction Contactors
4
3
Item No.
352
Return
Description
Item No.
Description
Contactor assembly
Base
Screw
Kit, service
Contactor
2000-08-04
F-code
Section
PS
S5.12
Version no
000
C-code
5441
Contactors
T-code
395/396/397/398/399
2.1. Removal
1. Turn the key switch OFF and disconnect battery
connector from the truck.
2. Remove dash (see page 100).
3. Disconnect cables by removing hex nuts. Identify
cables and their location. Label, if necessary, for
proper installation.
4. Remove contactor coil wires by pulling the wire
connector. Note their locations and label if
necessary.
5. Remove two screws (2) holding contactor to
mounting panel.
6. Remove contactor from contactor panel.
2.2. Installation
1. Position contactor over the holes in the mounting
panel. Attach with screws.
2. Attach coil wires by sliding connector onto
appropriate spade terminal.
3. Attach cables to appropriate lugs and tighten
securely.
4. Connect battery connector to the truck.
5. Turn key switch ON and test truck operation.
6. Turn the key switch OFF. Disconnect battery
connector from the truck.
7. Install dash.
8. Connect battery connector to the truck.
BT Prime-Mover, Inc.
Return
2000-08-04
353
F-code
Section
C-code
PS
S5.12
Contactors
5441
Version no
T-code
000
395/396/397/398/399
Item No.
354
Return
Description
Contactor
Kit, service
Screws
2000-08-04
F-code
Section
PS
S5.12
Version no
000
C-code
5441
Contactors
T-code
395/396/397/398/399
3.1. Removal
1. Turn the key switch OFF and disconnect battery
connector from the truck.
2. Remove dash.
3. Disconnect cables by removing hex nuts. Identify
cables and their location. Label, if necessary, for
proper installation.
4. Remove contactor coil wires by pulling the wire
connector. Note their locations and label if
necessary.
5. Remove two screws (3) holding the contactor to
the mounting panel.
6. Remove contactor from contactor panel.
3.2. Installation
1. Position contactor over holes in mounting panel.
Attach with screws (3).
2. Attach coil wires by sliding connector onto the
appropriate spade terminal.
3. Attach cables to appropriate lugs and tighten
securely.
4. Connect battery connector to the truck.
5. Turn key switch ON and test truck operation.
6. Turn key switch OFF.
connector from the truck.
Disconnect
battery
7. Install dash.
8. Connect battery connector to the truck.
BT Prime-Mover, Inc.
Return
2000-08-04
355
F-code
Section
C-code
PS
S5.12
Contactors
5441
Version no
T-code
000
395/396/397/398/399
4. Main Contactor
2
3
Item No.
356
Return
Description
Screws
Contactor
Cover, bridge
Kit, service
2000-08-04
F-code
Section
PS
S5.12
Version no
000
C-code
5441
Contactors
T-code
395/396/397/398/399
4.1. Removal
1. Turn the key switch OFF and disconnect battery
connector from the truck.
2. Remove dash.
3. Disconnect cables by removing hex nuts. Identify
cables and their location. Label, if necessary, for
proper installation.
4. Remove contactor coil wires by pulling wire
connector. Note their locations and label if
necessary.
5. Remove two screws (1) holding contactor to
mounting panel.
6. Remove contactor from contactor panel.
4.2. Installation
1. Position contactor over the holes in mounting
panel. Attach with screws (1).
2. Attach coil wires by sliding connector onto
appropriate spade terminal.
3. Attach cables to appropriate lugs and tighten
securely.
4. Connect battery connector to the truck.
5. Turn the key switch ON and test truck operation.
6. Turn the key switch OFF. Disconnect battery
connector from the truck.
7. Install dash.
8. Connect battery connector to the truck.
BT Prime-Mover, Inc.
Return
2000-08-04
357
F-code
Section
PS
S5.12
Contactors
C-code
5441
Version no
T-code
000
395/396/397/398/399
358
Return
2000-08-04
F-code
PS
Section
C-code
S5.13
5460
Transistor Panel (Drive)
Version no
T-code
000
395/396/397/398/399
3
4
1
Item No.
NOTE!
BT Prime-Mover, Inc.
Return
Description
Screw
Lockwasher
Nut
Screw
Screw
2000-08-04
359
F-code
Section
C-code
PS
S5.13
5460
Transistor Panel (Drive)
Version no
T-code
000
395/396/397/398/399
1. Motor Connections
The transistor regulator for the drive has four connections for
power cables, as set out in the table below.
Terminal Number
Function
B-
Battery minus
B+
Battery plus
Connection
Supply voltage
Safety test
Not used
Not Used
Not Used
Plug braking
360
Return
Function
Not Used
10
11
LED No.
Color
Green
Supply voltage
Yellow
Upper/lower temperature
Red
Red
Function
2000-08-04
F-code
Section
PS
C-code
S5.13
5460
Transistor Panel (Lift)
Version no
000
T-code
395/396/397/398/399
3
4
Item No.
BT Prime-Mover, Inc.
Return
Description
Screw
Lockwasher
Nut
Screw
Screw
2000-08-04
361
F-code
Section
PS
S5.13
Transistor Panel (Lift)
C-code
5460
Version no
T-code
000
395/396/397/398/399
The transistor regulator for the lift has four connections for
power cables, as set out in the table below.
Terminal Number
Function
B-
Battery minus
B+
Battery plus
Connection
362
Supply voltage
Not Used
Liftreg. current
Liftreg. voltage
Liftreg. temp
Return
Function
Not Used
10
11
LED No.
Color
Green
Supply voltage
Yellow
Upper/lower temperature
Red
Red
Function
2000-08-04
F-code
PS
Version no
000
Section
C-code
S5.13
5460
Transistor Panel (Lift)
T-code
395/396/397/398/399
BT Prime-Mover, Inc.
Return
2000-08-04
363
F-code
Section
PS
S5.13
Transistor Panel (Lift)
C-code
5460
Version no
T-code
000
395/396/397/398/399
364
Return
2000-08-04
F-code
Section
PS
S5.14
5511
Micro Switches
Version no
000
C-code
T-code
395/396/397/398/399
Micro Switches
1. General
To identify the electrical schematic for circuit location of
switches, see applicable electrical schematic page 277,
page 289, page 301 or page 313. Examine switch for signs of
arcing, overheating, discoloration, cracking, or other physical
damage. Replace switch if necessary.
To test switch, isolate it from the electrical circuit. Remove all
connections from the switch, making sure all wires are
labeled and identified for reconnection. Use an ohmmeter set
to a low resistance scale to measure resistance across the
switch. In a closed position, the switch should be less than 1
ohm. In an open position, the switch should show a
resistance greater than 10 megohms. With the battery
plugged in and the key switch in the ON position, equal
voltage should be present on both terminals of the switch.
BT Prime-Mover, Inc.
Return
2000-08-04
365
F-code
Section
PS
S5.14
Micro Switches
C-code
5511
Version no
T-code
000
395/396/397/398/399
Lift Limit
Override
Switch
2.1. Removal
1. Turn the key switch OFF and disconnect battery
connector from the truck.
2. Loosen pod and remove lower control pod panel to
allow access to wiring harness connection at
switch cluster.
3. Pull two wires off tabs on back of switch.
4. Unscrew nut securing switch in switch cluster.
5. Lift switch from switch cluster.
2.2. Installation
1. Place a new switch in the switch cluster.
2. Secure switch with nut.
3. Attach two wires to tabs on back of switch.
4. Secure pod to truck.
5. Connect battery connector to the truck.
6. Check operation of truck, then return truck to
service.
366
Return
2000-08-04
F-code
Section
PS
S5.14
5511
Micro Switches
Version no
000
Operator
Light
Switch
C-code
T-code
395/396/397/398/399
Operator
Fan
Switch
Working
Light
Switch
3.1. Removal
1. Turn the key switch OFF and disconnect battery
connector from the truck.
2. Loosen the pod and remove lower control pod
panel to allow access to wiring harness connection
at the switch cluster.
3. Pull two wires off the tabs on the back of switch.
4. Unscrew nut securing the switch in the switch
cluster.
5. Lift switch from the switch cluster.
3.2. Installation
1. Place a new switch in the switch cluster.
2. Secure switch with nut.
3. Attach two wires to the tabs on the back of the
switch.
4. Secure pod to truck.
5. Connect battery connector to the truck.
6. Check operation of truck, then return truck to
service.
BT Prime-Mover, Inc.
Return
2000-08-04
367
F-code
Section
PS
S5.14
Micro Switches
C-code
5511
Version no
T-code
000
395/396/397/398/399
368
Return
2000-08-04
F-code
PS
Version no
001
Section
C-code
S5.15
5710
Main Electronic Card
T-code
395/396/397/398/399
BT Prime-Mover, Inc.
Return
2001-10-31
369
F-code
Section
PS
S5.15
Main Electronic Card
C-code
5710
Version no
T-code
001
395/396/397/398/399
Two allen
bolts holding
A5 logic card
to the frame.
Four screws
holding cover on
A5 logic card.
370
Return
2001-10-31
F-code
PS
Version no
001
Section
C-code
S5.15
5710
Main Electronic Card
T-code
395/396/397/398/399
Logic chip
extractor tool.
Wrist strap on
the end of the
static strap.
BT Prime-Mover, Inc.
Return
2001-10-31
371
F-code
Section
PS
S5.15
Main Electronic Card
C-code
5710
Version no
T-code
001
395/396/397/398/399
A5 logic chip
to be removed
and replaced.
NOTE!
Return
2001-10-31
F-code
PS
Version no
001
Section
C-code
S5.15
5710
Main Electronic Card
T-code
395/396/397/398/399
NOTE!
BT Prime-Mover, Inc.
Return
2001-10-31
373
F-code
Section
PS
S5.15
Main Electronic Card
C-code
5710
Version no
T-code
001
395/396/397/398/399
3. Removal
1. Turn key switch OFF and disconnect battery
connector from the truck.
2. Remove main
page 103).
electronic
card
panel
(see
4. Installation
1. Place the main electronic card unit against the
outside wall of the chassis. Align mounting holes.
2. Secure the main electronic card to the truck frame
with four Allen head screws.
3. Reconnect all electrical cables to the main
electronic card.
4. Connect battery connector to the truck.
5. Perform RV2
page 382).
adjustment
procedure
(see
374
Return
2001-10-31
F-code
PS
Section
Version no
T-code
001
36 Volt Resistor
24 Volt Jumper
101
to
111
201
to
211
C-code
S5.15
5710
Main Electronic Card
395/396/397/398/399
RV2
301
to
304
402
to
405
501
to
511
601
to
611
701
to
710
801
to
811
901
to
904
LED No.
Connection
101
101
Drive chopper - OK
102
102
103
103
Plug braking
104
104
105
105
Drive direction
106
106
107
107
Speed reduction
111
111
Brake switch
BT Prime-Mover, Inc.
Return
Function
2001-10-31
375
F-code
Section
C-code
PS
S5.15
Main Electronic Card
5710
Version no
T-code
001
395/396/397/398/399
LED No.
376
Color
Function
TX
Green
RX
Green
Terminal
Number
LED No.
Connection
201
201
Drive measuring
202
202
203
203
Steering angle A
204
204
Steering angle B
205
205
Height counter A
206
206
Height counter B
207
207
Height reference
208
208
209
209
210
210
211
211
Function
Terminal Number
Connection
Function
301
Display power +
302
Display power -
303
TX positive display
304
TX negative display
Terminal Number
Connection
402
403
404
405
Return
Function
2001-10-31
F-code
Section
PS
Version no
T-code
001
395/396/397/398/399
Terminal
Number
LED No.
Connection
501
501
502
Steering/tach +
503
Steering/tach -
504
Positive 7.35 V
505
506
Lift/lower potentiometer
507
Reach/retract potentiometer
508
Tilt potentiometer
509
Sideshifter potentiometer
510
Function
Zero Voltage
511
Terminal Number
Connection
601
602
603
604
606
607
608
Battery indicator +
609
Speed/current reference -
610
611
Current limit +
BT Prime-Mover, Inc.
Return
C-code
S5.15
5710
Main Electronic Card
Function
2001-10-31
377
F-code
Section
C-code
PS
S5.15
Main Electronic Card
5710
Version no
T-code
001
395/396/397/398/399
Terminal
Number
LED No.
Connection
Function
701
702
703
704
704
Fork lift
705
705
Direction A
706
706
Direction B
707
707
Reach out
708
708
Reach in
709
709
sideshifter
710
710
Tilt
711
711
Spare 2A
Terminal
Number
LED No.
Connection
801
801
Spare 2B
802
802
803
803
804
804
Fork lower
805
805
Brake coil
808
+24/36 Volt
809
INP. +24/36 V
810
811
Sensor feed -
Function
806
807
378
Return
2001-10-31
F-code
PS
Version no
001
Terminal
Number
LED No.
901
902
Zero Voltage
903
+ steer motor
904
- steer motor
LED
Color
STEER PWR
Green
STEER OK
Green
Steering OK
Switch
395/396/397/398/399
Function
SW 1
SW 2
SW 3
Potentiometer
BT Prime-Mover, Inc.
T-code
Function
Green
Return
C-code
S5.15
5710
Main Electronic Card
Connection
POWER
RV2
Section
Function
Adjustment of lowering speed (see page 382)
2001-10-31
379
F-code
Section
C-code
PS
S5.15
Main Electronic Card
5710
Version no
T-code
001
395/396/397/398/399
SW1
SW2
5. Display
SW3
NOTE!
Parameters
Running time
Return
I H G FE
D
Master Service Manual
2001-10-31
F-code
Section
PS
Version no
T-code
001
SW1
SW2
SW3
C-code
S5.15
5710
Main Electronic Card
395/396/397/398/399
6. Time
It is possible to program the clock. The hour character
window (B) will flash after pressing SW3. Press SW3 again
and the minutes will flash.
1. Change time by stepping up using SW2 and down
using SW1.
2. Save the values and display the function by
pressing SW3.
3. Exiting this function can be done in three ways;
Value
Hours
09=9h
Minutes
35=35 min.
7. Effect on Truck
All hydraulic functions except fork lowering are stopped.
BT Prime-Mover, Inc.
Return
2001-10-31
381
F-code
Section
PS
S5.15
Main Electronic Card
C-code
5710
Version no
T-code
001
395/396/397/398/399
8. Running time
When running time reading is shown, the character box (E) is
illuminated. The time is shown as follows:
Character
Time
Key time
Total running time
Drive motor time
Pump motor time
382
Return
2001-10-31
F-code
PS
Version no
001
Section
C-code
S5.15
5710
Main Electronic Card
T-code
395/396/397/398/399
BT Prime-Mover, Inc.
Return
Set parameter 12 at 4
2001-10-31
383
F-code
Section
PS
S5.15
Main Electronic Card
C-code
5710
Version no
T-code
001
395/396/397/398/399
Return
2001-10-31
F-code
PS
Version no
001
Section
C-code
S5.15
5710
Main Electronic Card
T-code
395/396/397/398/399
BT Prime-Mover, Inc.
Return
2001-10-31
385
F-code
Section
C-code
PS
S5.15
Main Electronic Card
5710
Version no
T-code
001
395/396/397/398/399
Parameter
13 Value
Operating Light
Duty Battery Voltage/
Cell
Operating Medium
Duty Battery Voltage/
Cell
Operating Heavy
Duty Battery Voltage/
Cell
RRX35/RSX40
RRX35/45/RSX40/50/RDX30
RRX45/RDX30/RSX50
2.09
1.94
1.87
2.03
1.88
1.81
1.96
1.81
1.74
1.89
1.73
1.66
1.81
1.66
1.57
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
BATTERY EXCEEDS
FULL DISCHARGE
23
24
25
1.74
1.59
1.52
26
27
NOT VALID
28
386
Return
29
1.67
1.53
30
Force Reset
Force Reset
Force Reset
2001-10-31
F-code
PS
Version no
001
Section
C-code
S5.15
5710
Main Electronic Card
T-code
395/396/397/398/399
OPEN
CELL
VOLTAGE
OPEN
CELL
VOLTAGE
OPEN
CELL
VOLTAGE
OPEN
CELL
VOLTAGE
OPEN
CELL
VOLTAGE
10 MINIMUM
GREEN
25.00
25.00
25.00
25.00
25.00
9 MAXMUM
GREEN
24.79
24.83
24.86
24.90
24.94
9 MINIMUM
GREEN
24.58
24.65
24.73
24.80
24.88
8 MAXMUM
GREEN
24.36
24.48
24.59
24.70
24.81
8 MINIMUM
GREEN
24.15
24.30
24.45
24.60
24.75
7 MAXMUM
GREEN
23.94
24.13
24.31
24.50
24.69
7 MINIMUM
GREEN
23.73
23.95
24.18
24.40
24.63
6 MAXMUM
GREEN
23.51
23.78
24.04
24.30
24.56
6 MINIMUM
GREEN
23.30
23.60
23.90
24.20
24.50
5 MAXMUM
GREEN
23.09
23.43
23.76
24.10
24.44
5 MINIMUM
GREEN
22.88
23.25
23.63
24.00
24.38
4 MAXMUM
YELLOW
22.66
23.08
23.49
23.90
24.31
4 MINIMUM
YELLOW
22.45
22.90
23.35
23.80
24.25
3 MAXMUM
YELLOW
22.24
22.73
23.21
23.70
24.19
3 MINIMUM
YELLOW
22.03
22.55
23.08
23.60
24.13
2 MAXMUM
RED
21.81
22.38
22.94
23.50
24.06
2 MINIMUM
RED
21.60
22.20
22.80
23.40
24.00
1 MAXMUM
RED
21.39
22.03
22.66
23.30
23.94
1 MINIMUM
RED
21.18
21.85
22.53
23.20
23.88
1.8
1.85
1.9
1.95
2.0
BAR
LEVEL
BT Prime-Mover, Inc.
Return
2001-10-31
387
F-code
Section
C-code
PS
S5.15
Main Electronic Card
5710
Version no
T-code
001
395/396/397/398/399
10 MINIMUM
GREEN
37.50
37.50
37.50
37.50
37.50
9 MAXMUM
GREEN
37.18
37.24
37.29
37.35
37.41
9 MINIMUM
GREEN
36.86
36.98
37.09
37.20
37.31
8 MAXMUM
GREEN
36.54
36.71
36.88
37.05
37.22
8 MINIMUM
GREEN
36.23
36.45
36.68
36.90
37.13
7 MAXMUM
GREEN
35.91
36.19
36.47
36.75
37.03
7 MINIMUM
GREEN
35.59
35.93
36.26
36.60
36.94
6 MAXMUM
GREEN
35.27
35.68
36.06
36.45
36.84
6 MINIMUM
GREEN
34.95
35.40
35.85
36.30
36.75
5 MAXMUM
GREEN
34.63
35.14
35.64
36.15
36.68
5 MINIMUM
GREEN
34.31
34.88
35.44
36.00
36.56
4 MAXMUM
YELLOW
33.99
34.61
35.23
35.85
36.47
4 MINIMUM
YELLOW
33.68
34.35
35.03
35.70
36.38
3 MAXMUM
YELLOW
33.36
34.09
34.82
35.55
36.28
3 MINIMUM
YELLOW
33.04
33.83
34.61
35.40
36.19
2 MAXMUM
RED
32.72
33.56
34.41
35.25
36.09
2 MINIMUM
RED
32.40
33.30
34.20
35.10
36.00
1 MAXMUM
RED
32.08
33.04
33.99
34.95
35.91
1 MINIMUM
RED
31.76
32.77
33.79
34.80
35.81
1.8
1.85
1.9
1.95
2.0
388
Return
OPEN CELL OPEN CELL OPEN CELL OPEN CELL OPEN CELL
VOLTAGE
VOLTAGE
VOLTAGE
VOLTAGE
VOLTAGE
BAR LEVEL
2001-10-31
F-code
PS
Version no
001
Section
C-code
S5.15
5710
Main Electronic Card
T-code
395/396/397/398/399
BT Prime-Mover, Inc.
Return
2001-10-31
389
F-code
Section
PS
S5.15
Main Electronic Card
C-code
5710
Version no
T-code
001
395/396/397/398/399
electronic
card
panel
(see
Return
2001-10-31
F-code
PS
Version no
001
Section
C-code
S5.15
5710
Main Electronic Card
T-code
395/396/397/398/399
Harness End
A5 Connector End
Wire 39
Wire 22
Wire 39
Input 104
No longer used
Tie wire back
Key Lock
Harness Bundle
Wire 22
Connector 100
(Connector Plug-in # 1)
308035-000
Jumper Harness
A5 Control Module
A5 Logic Box
Connector 800
(Connector Plug-in # 8)
Input 809
Wire 22
Wire 22
Key Lock
Wire 22
Wire 22
BT Prime-Mover, Inc.
Return
2001-10-31
391
F-code
Section
PS
S5.15
Main Electronic Card
C-code
5710
Version no
T-code
001
395/396/397/398/399
10. Replace A5 logic box with new logic box. Install the
main harness to the A5 logic box, plug the battery
into the truck. Check the parameter settings and
adjust as needed.
11. Check the operation of the truck to be sure it
performs properly.
12. Install main electronic card panel (see page 103).
392
Return
2001-10-31
F-code
Section
PS
C-code
S5.15
5710
Main Electronic Card
Version no
T-code
001
395/396/397/398/399
Error
Warning
Comment
10
Not used
11
12
Not used
13
16
17
18
19
Default Par
Not used
20
Not used
21
22
23
24
27
28
BT Prime-Mover, Inc.
Return
2001-10-31
393
F-code
Section
C-code
PS
S5.15
Main Electronic Card
5710
Version no
T-code
001
395/396/397/398/399
Comment
52
O Lift Error
53
O Tilt Error
54
O Dir A Error
55
O Dir B Error
56
O sideshifter Error
57
O Spare In Error
Unused output/input
58
59
O Reach In Error
60
61
63
64
90
91
92
93
95
394
Return
2001-10-31
F-code
PS
Section
Version no
T-code
001
SW1
SW2
SW3
C-code
S5.15
5710
Main Electronic Card
395/396/397/398/399
Error
Error
BT Prime-Mover, Inc.
Return
2001-10-31
395
F-code
Section
PS
S5.15
Main Electronic Card
C-code
5710
Version no
T-code
001
395/396/397/398/399
Comment
100
101
Not used
102
110
111
112
113
115
116
117
120
122
123
124
125
126 *
127
130
131 *
132 *
133 *
121 *
140
* If these error codes are displayed, parameter 13 may need to be properly set (see Battery Discharge Indicator
Parameter Adjustment on page 384).
396
Return
2001-10-31
F-code
PS
Version no
001
Section
C-code
S5.15
5710
Main Electronic Card
T-code
395/396/397/398/399
Green
Yellow
Red
Red
BT Prime-Mover, Inc.
Return
2001-10-31
397
F-code
Section
PS
S5.15
Main Electronic Card
C-code
5710
Version no
T-code
001
395/396/397/398/399
398
Return
2001-10-31
F-code
PS
Version no
001
Section
C-code
S5.15
5710
Main Electronic Card
T-code
395/396/397/398/399
BT Prime-Mover, Inc.
Return
2001-10-31
399
F-code
Section
PS
S5.15
Main Electronic Card
C-code
5710
Version no
T-code
001
395/396/397/398/399
400
Return
2001-10-31
F-code
PS
Version no
001
SW1
SW2
SW3
Section
C-code
S5.15
5710
Main Electronic Card
T-code
395/396/397/398/399
BT Prime-Mover, Inc.
Return
Truck handling.
Modifying specific truck parameters will
change the driving characteristics of the
truck. Do not change any parameters
without the necessary knowledge.
2001-10-31
401
F-code
Section
C-code
PS
S5.15
Main Electronic Card
5710
Version no
T-code
001
395/396/397/398/399
Parameter
Name
Value
Range
Default
Inc
1-6
1-Least sensitivity
5-Most sensitivity
6-Test curve
Steer Wheel
Par
0-2
0-Least sensitivity
2-Most sensitivity
10-100%
100
% of maximum speed
Red Speed
Par
10-100%
40
% of maximum speed
Accel Par
10-100%
50
% of maximum
acceleration
Acceleration reduction.
Reach Scale
Par
10-100%
80
% of maximum reach
speed
Spare Scale
Par
10-100%
20
0-100%
100
Spec Height
Par
0-531
Special height
10
60-177 inch
90
11
0-1
0-Backward (Eur.)
1-Forward (US) (see table)
Steer direction.
12
1-4
Displayed timer.
13
Battery Par
1-30
12
1-Shallow discharge
29-Deep discharge
30-Force BDI to full charge
battery indication (not a
permanent parameter)
Battery type.
402
Return
Values
Comment
2001-10-31
F-code
PS
Version no
001
Section
C-code
S5.15
5710
Main Electronic Card
T-code
395/396/397/398/399
Parameter
Name
Value
Range
Default
Inc
Values
0-36V Std (RRX35/RSX40)
1-24V Std (RRX35/RSX40)
2-36V HD (RRX45/RDX30/
RSX50)
Comment
14
Pump Type
Par
0-2
15
Clock Year
0-99
Clock year.
16
Clock Day
0-31
Clock day.
17
Clock Month
0-12
Clock month.
BT Prime-Mover, Inc.
Return
2001-10-31
403
F-code
Section
PS
S5.15
Main Electronic Card
C-code
5710
Version no
T-code
001
395/396/397/398/399
Parameter
Name
Value
Range
Default
Inc
1-6
1-Least sensitivity
5-Most sensitivity
6-Test curve
Steer Wheel
Par
0-2
0-Least sensitivity
2-Most sensitivity
10-100%
100
% of maximum speed
Red Speed
Par
10-100%
40
% of maximum speed
Accel Par
10-100%
50
% of maximum
acceleration
Acceleration reduction.
Reach Scale
Par
10-100%
80
% of maximum reach
speed
Spare Scale
Par
10-100%
20
0-100%
Spec Height
Par
0-531
Special height
10
60-177
90
11
0-1
0-Backward (Eur.)
1-Forward (US) (see table)
Steer direction.
12
1-4
Displayed timer.
13
Battery Par
1-30
20
1 -Shallow discharge
29-Deep discharge
30-Force BDI to full charge
battery indication (not a
permanent parameter)
Battery type.
404
Return
Values
Comment
2001-10-31
F-code
Section
PS
C-code
S5.15
5710
Main Electronic Card
Version no
T-code
001
395/396/397/398/399
Parameter
Name
Value
Range
Default
Inc
Values
Comment
14
Pump Type
Par
0-2
15
Clock Year
0-99
Year
Current year.
16
Clock Day
0-31
Day
Day
Current day.
17
Clock Month
0-12
Month
Month
Current month.
BT Prime-Mover, Inc.
Return
Mast Height
(inch)
RRX35/RSX40
RRX45/RDX30/RSX50
192
192
210
210
210
240
240
240
270
270
270
300
300
330
330
360
360
402
402
2001-10-31
405
F-code
Section
PS
S5.15
Main Electronic Card
C-code
5710
Version no
T-code
001
395/396/397/398/399
RRX35/RSX40
RRX45/RDX30/RSX50
192
72
210
78
76
240
90
88
270
102
100
300
111
330
123
360
135
402
152
406
Return
Standard - Forward
(U.S. style)
2001-10-31
F-code
PS
Version no
001
Section
C-code
S5.15
5710
Main Electronic Card
T-code
395/396/397/398/399
Parameter
Name
Value
Range
Default
Inc
1-6
1-Least sensitivity
5-Most sensitivity
6-Test curve
Steer Wheel
Par
0-3
0-Least sensitivity
3-Most sensitivity
10-100%
100
% of maximum speed
Red Speed
Par
10-100%
40
% of maximum speed
Accel Par
10-100%
50
% of maximum
acceleration
Acceleration reduction.
Reach Scale
Par
10-100%
80
% of maximum reach
speed
Spare Scale
Par
10-100%
Spare parameter.
Not used
0-100%
Spare parameter.
Not used.
Spec Height
Par
0-531
Special height.
10
60-177
90
11
0-1
0-Backward (Eur.)
1-Forward (US) (see table)
Steer direction.
12
1-4
Displayed timer.
13
Battery Par
1-30
15
1 -Shallow discharge
29-Deep discharge
30-Force BDI to full charge
battery indication (not a
permanent parameter)
Battery type.
14
Pump Type
Par
0-2
BT Prime-Mover, Inc.
Return
Values
2001-10-31
Comment
407
F-code
Section
PS
S5.15
Main Electronic Card
C-code
5710
Version no
T-code
001
395/396/397/398/399
Parameter
Name
Value
Range
Default
Inc
Values
Comment
15
Option Par
0-5
Options.
16
Clock Year
0-99
Year
Current year.
17
Clock Day
0-31
Day
Day
Current day.
18
Clock Month
0-12
Month
Month
Current month
408
Return
Mast Height
(inch)
RRX35/RSX40
RRX45/RDX30/RSX50
192
192
210
210
210
240
240
240
258
258
270
270
270
300
300
330
330
360
360
390
390
402
402
2001-10-31
F-code
PS
Version no
001
Section
C-code
S5.15
5710
Main Electronic Card
T-code
395/396/397/398/399
RRX35/RSX40
RRX45/RDX30/RSX50
192
198
198
210
240
258
258
270
285
285
300
321
321
330
360
390
390
402
BT Prime-Mover, Inc.
Return
Mast Height
(inch)
RRX35/RSX40
RRX45/RDX30/RSX50
192
72
210
78
75
240
90
87
258
95
270
102
99
300
111
330
123
360
135
390
147
402
151
2001-10-31
409
F-code
Section
PS
S5.15
Main Electronic Card
C-code
5710
Version no
T-code
001
395/396/397/398/399
RRX35/RSX40
RRX45/RDX30/RSX50
192
198
74
210
240
258
98
95
270
285
105
300
321
119
330
360
390
402
Standard - Forward
(U.S. style)
410
Return
All Trucks
None
Travel Alarm
Backup Alarm
2001-10-31
F-code
PS
Section
C-code
S5.16
5751
Switches and Sensors
Version no
000
T-code
395/396/397/398/399
1.1. Test/Inspection
Examine switch for signs of arcing, overheating,
discoloration, cracking, or other physical damage. Replace
switch if you see such damage.
-
+
1
1/2
Brake
Pedal
Right
Foot
Pedal
BT Prime-Mover, Inc.
Return
2000-08-04
411
F-code
Section
C-code
PS
S5.16
5751
Switches and Sensors
Version no
T-code
000
395/396/397/398/399
2.1. Removal
1. Turn the key switch OFF and disconnect battery
connector from the truck.
2. Remove floor board.
3. Remove two screws (1) securing switch (2) to twin
nut (3) at switch bracket.
2.2. Installation
f
3
2
412
Return
Description
Screw, machine
Switch, brake
Nut, twin
2000-08-04
F-code
PS
Version no
000
Section
C-code
S5.16
5751
Switches and Sensors
T-code
395/396/397/398/399
Forks
Mast
Sensor
BT Prime-Mover, Inc.
Return
2000-08-04
413
F-code
Section
C-code
PS
S5.16
5751
Switches and Sensors
Version no
T-code
000
395/396/397/398/399
3.1. Adjustment
1. Raise empty carriage until the top of the staging
switch is even with the top of staging column.
2. Secure carriage with blocks and a hoist to prevent
any movement.
3. Loosen switch mounting bracket screws.
4. Adjust switch to 0.187 inch (4.75 mm). Allowable
tolerance is +0.0625 inch (1.59 mm) and -0 mm.
5. Tighten switch mounting bracket screws.
6. Check clearance with screws tight.
7. Remove blocks and hoist.
8. Test mast operation to verify proper operation of
staging switch.
3.2. Removal
1. Raise empty carriage until the top of the staging
switch is even with the top of the staging column.
2. Secure carriage with blocks and a hoist to prevent
any movement.
3. Turn key switch OFF and disconnect battery
connector from the truck.
4. Disconnect switch from the wiring harness.
5. Remove switch mounting bracket screws.
3.3. Installation
1. Install switch on mounting bracket.
2. Tighten switch mounting bracket screws.
3. Connect switch to wiring harness.
4. Connect battery connector to the truck.
5. Adjust switch.
6. Return truck to service.
414
Return
2000-08-04
F-code
PS
Section
C-code
S5.16
5751
Switches and Sensors
Version no
000
T-code
395/396/397/398/399
4.1. Adjustment
CAUTION Adjustment of sensor with wheel nuts
facing inward will result in shearing of
sensor when the drive wheel is rotated.
1. Position drive wheel with wheel nuts facing
outward.
2. Turn key switch OFF and disconnect battery at
battery connector.
3. Remove dash, motor compartment door, and left
hand panel to allow access to drive unit.
4. Loosen jam nut securing the sensor to the frame.
5. Turn wheel direction sensor by hand in a clockwise
direction until it contacts the drive unit housing.
6. Back sensor out by turning
counterclockwise 1-1/4 turns.
the
sensor
BT Prime-Mover, Inc.
Return
2000-08-04
415
F-code
Section
C-code
PS
S5.16
5751
Switches and Sensors
Version no
T-code
000
395/396/397/398/399
4.2. Removal
1. Turn key switch OFF and disconnect battery
connector from the truck.
2. Disconnect sensor at the main wiring harness.
3. Loosen jam nut securing the sensor to the frame.
4. Turn sensor counterclockwise to remove it from the
frame.
4.3. Installation
1. Install sensor in the frame.
2. Tighten by hand in a clockwise direction until it just
contacts the drive unit housing.
3. Set the proper sensor distance by turning the
sensor counterclockwise 1-1/4 turns.
4. Tighten jam nut securing the sensor to the frame.
5. Reconnect sensor electrical connection to the main
wiring harness.
6. Install dash, motor compartment door, and left
hand panel to drive unit.
7. Connect battery connector to the truck.
8. Return truck to service.
416
Return
2000-08-04
F-code
PS
Section
C-code
S5.16
5751
Switches and Sensors
Version no
000
T-code
395/396/397/398/399
The steer proximity sensors (S66 and S67) are located on the
truck frame in front of the drive unit and accessed from the
battery compartment. The steer proximity sensors work as a
pair in conjunction with switch S65 to detect drive wheel
direction and position information from the top of drive unit.
Steering
sensors
optional
mounting
styles
5.1. Adjustment
1. Remove battery from truck.
2. Center a steering gear tooth crest on the face of
wheel angle sensor to be adjusted.
3. Loosen jam nut.
4. Adjust sensor to 0.089 inch (2.26 mm) between
sensor and steering gear tooth crest. Tolerance is
0.002 inch (+0 mm, -0.05 mm).
NOTE!
Return
2000-08-04
417
F-code
Section
C-code
PS
S5.16
5751
Switches and Sensors
Version no
T-code
000
395/396/397/398/399
5.2. Removal
1. Turn the key switch OFF and disconnect battery
connector from the truck.
2. Disconnect sensor from wiring harness.
3. Remove jam nut securing sensor to truck frame.
4. Remove sensor from truck.
5.3. Installation
1. Place new sensor in truck frame.
NOTE!
418
Return
2000-08-04
F-code
PS
Section
C-code
S5.16
5751
Switches and Sensors
Version no
000
T-code
395/396/397/398/399
6.1. Removal
1. Turn the key switch OFF and disconnect battery
connector from the truck.
2. Disconnect drive motor speed and/or directional
sensor from main wiring harness.
3. Remove cap screw (10) securing sensor to spacer
(8).
4. Remove sensor from spacer. Note the wire ends
and location for reassembly.
Item No.
BT Prime-Mover, Inc.
Return
Description
Spacer
10
Screw, cap
11
Nut, sensor
12
Screw
13
14
2000-08-04
419
F-code
Section
C-code
PS
S5.16
5751
Switches and Sensors
Version no
T-code
000
395/396/397/398/399
6.2. Installation
1. Install sensor (9 or 13) in spacer (8). Be sure the
wire ends and location match the ones noted in
removal. Sensors that are improperly installed will
result in an error code appearing when truck is
returned to service.
2. Install cap screw (10).
3. Reconnect sensor to main harness assembly.
4. Connect battery connector to truck.
5. Test operation of truck before returning to service.
420
Return
2000-08-04
F-code
Section
PS
S6.0
6000
Hydraulic System
Version no
000
C-code
T-code
395/396/397/398/399
Hydraulic System
WARNING DO NOT use your hands to check for
hydraulic leakage. Use a piece of
cardboard or paper to search for leaks.
Escaping fluid under pressure can
penetrate the skin causing injury. Relieve
pressure before disconnecting hydraulic or
other lines. Tighten all connections before
applying pressure. Keep hands and body
away from pinholes and nozzles which
eject fluids under high pressure.
1. Operation
See RRX35 Hydraulic Schematic on page 442, RRX45
Hydraulic Schematic on page 443, RDX30 Hydraulic
Schematic on page 444, RSX40 Hydraulic Schematic on
page 445, or RSX50 Hydraulic Schematic on page 446. For
a listing of error codes see page 393 and page 394. For a
listing of parameters see page 402, page 404, or page 407.
For a listing on the fuses and their location see page 347.
NOTE!
BT Prime-Mover, Inc.
Return
2001-11-08
421
F-code
Section
C-code
PS
S6.0
Hydraulic System
6000
Version no
T-code
000
395/396/397/398/399
506
507
R14
508 509
701
74
702
75
6
(-)
A5
703
76
10
11
40
10
B-
A2
B+
M3
(+)
Supply
LEGEND
Pressure Oil
Return Oil
Electric Positive
Electric Negative
LED Off (Not Lit)
LED Input (Lit)
LED Output (Lit)
422
Return
2001-11-08
F-code
Section
PS
S6.0
6000
Hydraulic System
Version no
000
C-code
T-code
395/396/397/398/399
1.1. Supply
A voltage from lift (R11), reach (R12), sideshift (R14), or tilt
(R13) on the control pod to the main electronic card (A5)
initiates a pump request to the pump transistor regulator (A2).
The electronic card (A5) turns on speed request output 702
(wire #75) to a level proportional to the control handle
request. This signal is sent to the pump transistor regulator
(A2) input pin 10. A current limit signal is also sent from the
main electronic card (A5) output 703 (wire #76) to the pump
transistor regulator (A2) input pin 11 limiting the current from
the pump transistor regulator (A2) to the motor. Both speed
request and current limit signals range from 0 volts to
approximately 4.5 volts and are measured with respect to
main electronic card (A5) output 701 (wire #74). The pump
transistor regulator sends the amplified signal to the pump
motor (M3) commanding pumping.
Hydraulic functions can be performed by using the brake
pedal, the right foot pedal, or both. By depressing the right
foot pedal and releasing the brake pedal setting the parking
brake, hydraulic functions can be performed with the truck
parked in position.
Oil is pumped by the pump from the hydraulic tank into the
hydraulic system. The pump is used for both the lift and
auxiliary functions. Appropriate solenoids are activated,
opening valves and the hydraulic functions are performed. If
the pressure in the system increases to the preset value of
the relief valve, it will open directing oil back to the hydraulic
tank. The lowering function is powered by gravity and
proportionally controlled. Returned oil is filtered at the
hydraulic tank.
BT Prime-Mover, Inc.
Return
2001-11-08
423
F-code
Section
PS
S6.0
Hydraulic System
C-code
6000
Version no
T-code
000
395/396/397/398/399
1.2. Lifting
With the key switch ON and brake pedal and/or right foot
switch depressed, by pulling potentiometer (R11) back
causes output voltage to be different than when in the neutral
position. The main electronic card (A5) senses this change in
voltage at input 506 (wire #82). The main electronic card (A5)
responds by enabling voltage to the lift valve coil (Y10-2)
output 704 (wire 89). The lift speed can be infinitely varied to
the maximum lift speed.
Oil is fed from the pump to the lift valve (Y10) and from the
valve to the free lift and main lift cylinders. The free lift
cylinder, having less weight on it, will lift first. After the free lift
cylinder has reached full extension, the main lift cylinders will
begin to lift. If the pressure in the system increases to the
relief valves preset value, oil flows back to the hydraulic tank.
LEGEND
Pressure Oil
Return Oil
Electric Positive
Electric Negative
LED Off (Not Lit)
LED Input (Lit)
LED Output (Lit)
29
30
R11
A5
804
88
506
704
(-)
89
2
3
Y10-3
40
Y10-2
Lifting
424
Return
2001-11-08
F-code
Section
PS
S6.0
6000
Hydraulic System
Version no
C-code
T-code
000
395/396/397/398/399
1.3. Lowering
With the key switch ON and brake pedal and/or right foot
switch depressed, by pushing forward potentiometer (R11)
causes output voltage to be different than when in the neutral
position. The main electronic card (A5) senses this change in
voltage at input 506 (wire #82). The main electronic (A5) card
enables voltage to the proportional lower solenoid coil (Y103) from output 804 (wire 88). The lowering speed is regulated
by the proportional lowering valve (Y10-3) in direct proportion
to the voltage from (R11). Proportional lower solenoid coil
(Y10-3) is normally closed. Oil flows from the cylinders
through the valve, returning to the hydraulic tank. A reach, tilt,
or sideshift function can be performed while lowering.
LEGEND
Pressure Oil
Return Oil
Electric Positive
Electric Negative
LED Off (Not Lit)
LED Input (Lit)
LED Output (Lit)
29
30
R11
A5
82
804
88
506
704
89
2
3
Y10-3
(-)
40
Y10-2
Lowering
BT Prime-Mover, Inc.
Return
2001-11-08
425
F-code
Section
C-code
PS
S6.0
Hydraulic System
6000
Version no
T-code
000
395/396/397/398/399
LEGEND
Pressure Oil
Return Oil
Electric Positive
Electric Negative
LED Off (Not Lit)
LED Input (Lit)
LED Output (Lit)
29
Y14
30
83
A5
707
507 708
706
705
(-)
Y15
R12
40
92
93
91
90
Y13
Y12
Reach
426
Return
2001-11-08
F-code
Section
PS
S6.0
6000
Hydraulic System
Version no
000
C-code
T-code
395/396/397/398/399
1.4. Reach
Reach extends the forks away from the mast assembly. With
the key switch ON and brake pedal and/or right foot switch
depressed, by pushing forward potentiometer (R11) causes
output voltage to be different than when in the neutral
position. The main electronic card (A5) senses this change in
voltage at input 506 (wire #82). The main electronic (A5) card
responds by:
Enabling voltage to the direction A solenoid coil (Y12) from
output 705 (wire #90).
Enabling the reach solenoid(s) (Y14) and (Y15) on the
reach carriage from outputs 707 (wire #92) and 708 (wire
#93).
Sending a speed request to the pump transistor regulator.
The extend speed can be infinitely varied to the maximum
extend speed. The maximum speed is configured by
Reach Scale Parameter 6. The truck voltage and reach
model is configured by pump type parameter 14.
The speed request signal to the pump transistor regulator
provides the PWM frequency rate to pulse the pump motor.
Oil is fed through direction A (Y12) valve, through reach valve
(Y14) to the rear ports on the reach cylinders, and drives the
pistons outwards. The oil flows from the front ports of the
cylinders, through reach valve (Y15) to direction A (Y12)
valve, and back to the hydraulic tank.
BT Prime-Mover, Inc.
Return
2001-11-08
427
F-code
Section
PS
S6.0
Hydraulic System
C-code
6000
Version no
T-code
000
395/396/397/398/399
LEGEND
Pressure Oil
Return Oil
Electric Positive
Electric Negative
LED Off (Not Lit)
LED Input (Lit)
LED Output (Lit)
29
R12
83
A5
707
507 708
706
705
(-)
Y15
Y14
30
40
92
93
91
90
Y13
Y12
Retract
428
Return
2001-11-08
F-code
Section
PS
S6.0
6000
Hydraulic System
Version no
000
C-code
T-code
395/396/397/398/399
1.5. Retract
Retract withdraws the forks toward the mast assembly. With
the key switch ON and brake pedal and/or right foot switch
depressed, by pulling forward potentiometer (R11) causes
output voltage to be different than when in the neutral
position. The main electronic card (A5) senses this change in
voltage at input 506 (wire #82). The main electronic (A5) card
responds by:
Enabling voltage to the direction B solenoid coil (Y13) from
output 706 (wire #91).
Enabling the reach solenoid(s) (Y14) and Y15) on the
reach carriage from outputs 707 (wire #92) and 708 (wire
#93).
Sending a speed request to the pump transistor regulator.
The retract speed can be infinitely varied to the maximum
retract speed. The maximum speed is configured by
Reach Scale Parameter 6. The truck voltage and reach
model is configured by Pump Type Parameter 14.
The speed request signal to the pump transistor regulator
provides the PWM frequency rate to pulse the pump motor.
Oil is fed through direction B (Y13) valve, through Reach2
(Y15) valve to the front ports on the reach cylinders, and
drives the pistons inwards. The oil flows from the rear ports of
the cylinders, through Reach1 (Y14) valve to direction B
(Y13) valve, and back to the hydraulic tank.
BT Prime-Mover, Inc.
Return
2001-11-08
429
F-code
Section
C-code
PS
S6.0
Hydraulic System
6000
Version no
T-code
000
395/396/397/398/399
LEGEND
Pressure Oil
Return Oil
Electric Positive
Electric Negative
LED Off (Not Lit)
LED Input (Lit)
LED Output (Lit)
1800 PSI
0.020
300 PSI
29
30
83
Y14
A5
707
507 708
706
705
(-)
40
Y15
R12
92
93
91
90
Y13
Y12
Reach Relief
430
Return
2001-11-08
F-code
Section
PS
S6.0
6000
Hydraulic System
Version no
C-code
T-code
000
395/396/397/398/399
LEGEND
Pressure Oil
Return Oil
Electric Positive
Electric Negative
LED Off (Not Lit)
LED Input (Lit)
LED Output (Lit)
1800 PSI
0.020
300 PSI
29
Y14
30 R12
83
A5
507
707
708
706
705
Y15
92
93
91
90
(-) 40
Y12
Y13
Reach Impact
BT Prime-Mover, Inc.
Return
2001-11-08
431
F-code
Section
C-code
PS
S6.0
Hydraulic System
6000
Version no
T-code
000
395/396/397/398/399
LEGEND
Pressure Oil
Return Oil
Electric Positive
Electric Negative
LED Off (Not Lit)
LED Input (Lit)
LED Output (Lit)
Y17
29
30
R13
84
A5
710
508
706
705
(-)
40
94
91
90
Y13
Y12
Tilt Up
432
Return
2001-11-08
F-code
Section
PS
S6.0
6000
Hydraulic System
Version no
000
C-code
T-code
395/396/397/398/399
1.8. Tilt Up
Fork tilt allows the operator to raise or lower the tips of the
forks. Standard fork tilt is 4 up and 3 down.
With the key switch ON and the brake pedal and/or right foot
pedal depressed, by pulling back potentiometer (R13) causes
voltage to be different at the main electronic (A5) card input
508 (wire #84). The main electronic (A5) card responds by:
Enabling voltage to the direction B solenoid coil (Y13) from
output 706 (wire #91).
Enabling the tilt solenoid (Y17) on the reach carriage from
output 710 (wire #94).
Sending a speed request to the pump transistor regulator.
The tilt speed can be infinitely varied to the maximum tilt
speed.
The speed request signal to the pump transistor regulator
provides the PWM frequency rate to pulse the pump motor.
Oil is fed through direction B (Y13) valve, to the tilt (Y17)
valve, to the rear port of the tilt cylinder, driving the piston
outward. The oil flows from the front port of the cylinder, to
the direction B (Y13) valve, returning to the hydraulic tank.
BT Prime-Mover, Inc.
Return
2001-11-08
433
F-code
Section
C-code
PS
S6.0
Hydraulic System
6000
Version no
T-code
000
395/396/397/398/399
LEGEND
Pressure Oil
Return Oil
Electric Positive
Electric Negative
LED Off (Not Lit)
LED Input (Lit)
LED Output (Lit)
29
30
Y17
R13
84
A5
94
710
508
706
705
(-)
40
91
90
Y13
Y12
Tilt Down
434
Return
2001-11-08
F-code
Section
PS
S6.0
6000
Hydraulic System
Version no
000
C-code
T-code
395/396/397/398/399
BT Prime-Mover, Inc.
Return
2001-11-08
435
F-code
Section
C-code
PS
S6.0
Hydraulic System
6000
Version no
T-code
000
395/396/397/398/399
LEGEND
Pressure Oil
Return Oil
Electric Positive
Electric Negative
LED Off (Not Lit)
LED Input (Lit)
LED Output (Lit)
29
30
Y16
R14
84
A5
709
509
706
705
(-)
40
95
91
90
Y13
Y12
436
Return
2001-11-08
F-code
Section
PS
S6.0
6000
Hydraulic System
Version no
000
C-code
T-code
395/396/397/398/399
BT Prime-Mover, Inc.
Return
2001-11-08
437
F-code
Section
C-code
PS
S6.0
Hydraulic System
6000
Version no
T-code
000
395/396/397/398/399
LEGEND
Pressure Oil
Return Oil
Electric Positive
Electric Negative
LED Off (Not Lit)
LED Input (Lit)
LED Output (Lit)
29
30
Y16
R14
84
A5
709
509
706
705
(-)
40
95
91
90
Y13
Y12
438
Return
2001-11-08
F-code
Section
PS
S6.0
6000
Hydraulic System
Version no
000
C-code
T-code
395/396/397/398/399
BT Prime-Mover, Inc.
Return
2001-11-08
439
F-code
Section
C-code
PS
S6.0
Hydraulic System
6000
Version no
T-code
000
395/396/397/398/399
Symbol
Designation
1-2
Cylinder
Staging
Cylinder
Free lift
Cylinder
Reach/retract
Cylinder
Tilt
Cylinder
Sideshifter
11-12
Valve
13
Valve
14
Valve
Relief
A2
Pump transistor
Pump motor
A5
Electronic card
Main card
Filter
Main filter
M3
Motor
Pump motor
Pump
Hydraulic pump
R11
Potentiometer
R12
Potentiometer
R13
Potentiometer
R14
Potentiometer
Y10
Valve
Lift/lower
Y10-2
Valve
Lift
Y10-3
Valve
Lower of Forks
440
Return
Function
Remarks
2001-11-08
F-code
Section
PS
S6.0
6000
Hydraulic System
Version no
000
Symbol
Designation
Y12
Valve
Direction A
Y13
Valve
Direction B
Y14
Valve
Reach out
Y15
Valve
Reach in
Y16
Valve
Sideshifter
Y17
Valve
Tilt
BT Prime-Mover, Inc.
Return
Function
2001-11-08
C-code
T-code
395/396/397/398/399
Remarks
441
F-code
Section
C-code
PS
S6.0
Hydraulic System
6000
Version no
T-code
000
395/396/397/398/399
Y10-2
Y10-3
442
Return
2001-11-08
F-code
Section
PS
S6.0
6000
Hydraulic System
Version no
000
C-code
T-code
395/396/397/398/399
4
Y10-2
Y10-3
BT Prime-Mover, Inc.
Return
2001-11-08
443
F-code
Section
C-code
PS
S6.0
Hydraulic System
6000
Version no
T-code
000
395/396/397/398/399
4
Y10-2
Y10-3
444
Return
2001-11-08
F-code
Section
PS
S6.0
6000
Hydraulic System
Version no
000
C-code
T-code
395/396/397/398/399
Y10-2
Y10-3
BT Prime-Mover, Inc.
Return
2001-11-08
445
F-code
Section
C-code
PS
S6.0
Hydraulic System
6000
Version no
T-code
000
395/396/397/398/399
Y10-2
Y10-3
446
Return
2001-11-08
F-code
Section
PS
S6.1
6112
Hydraulic Fluid
Version no
000
C-code
T-code
395/396/397/398/399
Hydraulic Fluid
1. Hydraulic Fluid Selection
Before adding or changing hydraulic fluid, determine the
environment and usage of truck. To make proper oil/lubricant
selection see page 84.
BT Prime-Mover, Inc.
Return
2000-08-04
447
F-code
Section
C-code
PS
S6.1
Hydraulic Fluid
6112
Version no
T-code
000
395/396/397/398/399
3. System Draining
1. Lower the carriage fully, tilt forks down completely
and retract reach mechanism fully.
2. Turn key switch OFF and disconnect battery
connector from the truck.
3. Remove dash and open motor compartment door
(see page 100).
4. Use female half of the diagnostic fitting (24 inch
hose) and direct the hydraulic fluid into a waste
container with a capacity greater than 5 gallons (19
liters).
5. Connect battery connector to the truck and turn key
switch ON.
6. Operate lift until air in the system is heard.
7. Turn the key switch OFF and disconnect battery
connector from the truck.
8.
9.
448
Return
2000-08-04
F-code
Section
PS
S6.1
6112
Hydraulic Fluid
Version no
000
C-code
T-code
395/396/397/398/399
4. Refilling System
1. If reservoir was removed for flushing, install
reservoir.
2. Install hydraulic filter.
3. Fill hydraulic reservoir through bleeder cap/fill hole.
Be sure to use proper grade of fluid. The reservoir
holds 5 gallons (19 liters) of fluid.
4. Connect battery connector to the truck and turn key
switch ON.
5. Bleed hydraulic system (see page 450).
6. Install dash and secure motor compartment door.
BT Prime-Mover, Inc.
Return
2000-08-04
449
F-code
Section
C-code
PS
S6.1
Hydraulic Fluid
6112
Version no
T-code
000
395/396/397/398/399
450
Return
2000-08-04
F-code
Section
PS
S6.1
6112
Hydraulic Fluid
Version no
000
C-code
T-code
395/396/397/398/399
BT Prime-Mover, Inc.
Return
2000-08-04
451
F-code
Section
C-code
PS
S6.1
Hydraulic Tank
6112
Version no
T-code
000
395/396/397/398/399
Hydraulic Tank
1
Item No.
452
Return
Description
2000-08-04
F-code
Section
PS
S6.1
6112
Hydraulic Tank
Version no
000
C-code
T-code
395/396/397/398/399
1. Removal
1. Lower carriage fully and retract reach mechanism
fully.
2. Remove dash (see page 100).
3. Drain hydraulic system (see page 448).
4. Remove left side panel (see page 102).
5. Turn the key switch OFF and disconnect battery
connector from the truck.
6. Remove drive motor and brake assembly.
7. Remove pump and motor.
8. Disconnect hydraulic hose to mast. Plug ends to
prevent contamination.
9. Disconnect hydraulic hose to control valve. Plug
end to prevent contamination.
10. To remove reservoir, tilt truck end of reservoir up.
Pull reservoir back, away from mast. Once the front
of reservoir has cleared front truck frame, lift the
reservoir out.
11. Remove hydraulic filter adapter.
BT Prime-Mover, Inc.
Return
2000-08-04
453
F-code
Section
C-code
PS
S6.1
Hydraulic Tank
6112
Version no
T-code
000
395/396/397/398/399
2. Installation
1. Install hydraulic filter adapter.
2. Install hydraulic filter.
3. Angle mast end of reservoir down and push
forward to truck frame. Let truck end of reservoir
drop straight down at this point.
4. Install pump and motor assembly.
5. Connect hoses to reservoir.
6. Fill hydraulic reservoir.
7. Install drive motor and brake assembly.
8. Install left side panel.
9. Connect battery connector to the truck.
10. Bleed hydraulic system (see page 450).
11. Test operate truck.
12. Turn key switch OFF and disconnect battery
connector from the truck. Install dash. Connect
battery connector to the truck.
454
Return
2000-08-04
F-code
Section
PS
S6.1
6112
Hydraulic Tank
Version no
000
BT Prime-Mover, Inc.
Return
2000-08-04
C-code
T-code
395/396/397/398/399
455
F-code
Section
C-code
PS
S6.2
6131
Hydraulic Filter Assembly
Version no
T-code
000
395/396/397/398/399
1, 2
3, 4
5, 6
12
10
Item No.
456
Return
Description
Item No.
Description
Screw
O-ring
Washer
Ring
Screw
10
Element, filter
Washer
11
U-gasket
Plate
12
Gasket, tank
Gasket
13
Cap, filter
Filter assembly
2000-08-04
F-code
PS
Section
C-code
S6.2
6131
Hydraulic Filter Assembly
Version no
000
T-code
395/396/397/398/399
1. Hydraulic Filter
1.1. Removal
NOTE!
1.2. Installation
1. Snap filter onto blue cover.
2. Install cap and filter assembly in hydraulic tank.
3. Test operate truck.
4. Check hydraulic fluid level and refill as needed.
5. Replace dash.
6. Connect battery connector to the truck.
7. Return to service.
BT Prime-Mover, Inc.
Return
2000-08-04
457
F-code
Section
C-code
PS
S6.2
6131
Hydraulic Filter Assembly
Version no
T-code
000
395/396/397/398/399
2.2. Installation
1. Clean all parts thoroughly. Clean mating surface of
the hydraulic tank.
2. Align collar mounting holes with hydraulic tank
holes. Torque four mounting screws to 44.4 in-lb
(5.01 Nm).
3. Install cap and filter.
4. Check fill level fluid in the hydraulic tank.
5. Connect battery connector to the truck.
6. Bleed hydraulic system.
7. Test operate truck.
8. Turn key switch OFF and disconnect battery
connector from the truck.
9. Install dash.
458
Return
2000-08-04
F-code
PS
Section
Version no
000
BT Prime-Mover, Inc.
Return
2000-08-04
C-code
S6.2
6131
Hydraulic Filter Assembly
T-code
395/396/397/398/399
459
F-code
Section
C-code
PS
S6.3
Hydraulic Pump
6141
Version no
T-code
000
395/396/397/398/399
Hydraulic Pump
1. Removal
Remove pump motor (see page 141). Remove hydraulic
pump from pump motor.
2. Repair
Contact your local BT Prime-Mover distributor for repair
procedures on the hydraulic pump.
Pump
Motor
Hydraulic
Pump
460
Return
2000-08-04
F-code
Section
PS
S6.4
6211
Control Valve
Version no
000
C-code
T-code
395/396/397/398/399
Control Valve
To
Mast
1. Removal
1. Turn key switch OFF and disconnect battery
connector from the truck.
To
Reservoir
To
Pump
To Aux.
Functions
Y13 DIRB
2. Installation
1. Apply thread locking compound to three mounting
bolts.
2. Tighten using a 1/2 inch (13 mm) socket.
3. Attach hoses to control valve in the following order:
- Control valve to reservoir
- Return hose to mast 1-1/8 inch (28.58 mm)
- Control valve to lift pump 1-1/8 inch (28.58
mm)
BT Prime-Mover, Inc.
Return
461
F-code
Section
C-code
PS
S6.4
Control Valve
6211
Version no
T-code
000
395/396/397/398/399
462
Return
F-code
Section
PS
S6.4
6211
Control Valve
Version no
000
FUNCTION
MALFUNCTION
Lifting Function
C-code
T-code
395/396/397/398/399
POSSIBLE CAUSE
POSSIBLE REPAIR
Unintentionally lift
during the actuation
of auxiliary
functions.
BT Prime-Mover, Inc.
Return
463
F-code
Section
C-code
PS
S6.4
Control Valve
6211
Version no
T-code
000
395/396/397/398/399
FUNCTION
Lowering
Function
MALFUNCTION
Forks do not drop
or drop too slow.
POSSIBLE CAUSE
POSSIBLE REPAIR
Forks lower
unintentionally.
2.Proportional pre-pressure
reducing valve sticks or does
not operate smoothly.
464
Return
F-code
Section
PS
S6.4
6211
Control Valve
Version no
000
FUNCTION
Auxiliary
Functions
Main control
valve (general)
BT Prime-Mover, Inc.
Return
MALFUNCTION
Auxiliary functions
(reach, tilt,
sideshift) do not
operate or operate
too slowly.
C-code
T-code
395/396/397/398/399
POSSIBLE CAUSE
POSSIBLE REPAIR
465
F-code
Section
C-code
PS
S6.4
6211
Control Valve Assembly
Version no
T-code
000
395/396/397/398/399
1
17
2
18
3
4
4a
20
4b
13
14
19
5
6
15
21
22
10
23
11
12
16
24
25
29A
29
49
26
27 47
28
20
30
31
32
47
33
53
48
41
40
46
40
20
36
41
20
43
37
466
Return
41
50
51
F-code
PS
Version no
000
Item
No.
Description
1
Valve assembly, control
2
Plug
3
O ring
4
Insert
4a
O ring
4b
Seal ring
5*
Rod
6*
Screw (torque 8.85 ft-lb (12 Nm)
7*
Pin
8*
Valve core
9*
Seal
10*
Return Spring
11*
Spring
12*
Seal
13*
Screw (torque 5.9 ft-lb (8 Nm)
14
Seal
15*
Spring
16*
Damping insert
17
Screw
18
Nut
19
Screw
20
Ring, seal
21
Disc
22
Spring
23
Guide spring
* Not sold separately (NSS)
BT Prime-Mover, Inc.
Return
Section
C-code
S6.4
6211
Control Valve Assembly
T-code
395/396/397/398/399
Item
No.
Description
24
25
26
27
28*
29*
29A*
30*
31
32*
33*
36
37
40
41*
43*
46*
47
48
49
50
51
52
53
Piston
Spring
Spring
Sleeve
Ball
Screw
Screw
Screw (torque 8.85 ft-lb (12 Nm)
Seal
Spring
Guide, ball
Locknut
Screw
Seal
Plug
Screw
Plug (torque11.06 ft-lb (15 Nm)
O ring
Valve, assembly
Plate, end
Washer
Screw (torque14.75 ft-lb (20 Nm)
Solenoid, double
Valve assembly
467
F-code
Section
C-code
PS
S6.4
6211
Control Valve Assembly
Version no
T-code
000
395/396/397/398/399
3. Repair
3.1. Proportional Pre-Pressure Reducing
Valve
1. Remove three screws and lift off double solenoid
block (52) from valve block.
2. Remove O ring seal (3) and screw out valve insert
(4) from solenoid block.
3. Check piston in valve insert (4) for smooth
operation.
4. Inspect valve insert (4) and O ring seals (3) and
replace if necessary.
5. Screw in valve insert (4) with O ring seals (3).
Make sure piston in the valve insert operates
smoothly when assembled.
6. Install outer seal and mount double solenoid
solenoid block (52).
468
Return
F-code
PS
Version no
000
Section
C-code
S6.4
6211
Control Valve Assembly
T-code
395/396/397/398/399
Relief Pressure
Test Port
(beneath
reservoir hose)
BT Prime-Mover, Inc.
Return
469
F-code
Section
C-code
PS
S6.4
6211
Control Valve Assembly
Version no
T-code
000
395/396/397/398/399
470
Return
F-code
PS
Section
C-code
S6.4
6211
Control Valve Assembly
Version no
000
T-code
395/396/397/398/399
insert
or
BT Prime-Mover, Inc.
Return
471
F-code
Section
C-code
PS
S6.4
6211
Control Valve Assembly
Version no
T-code
000
395/396/397/398/399
472
Return
F-code
Section
C-code
PS
S6.5
6610
Staging Cylinder, Three Stage Mast
Version no
T-code
001
395/396/397/398/399
3
1
2
4
10
11
12
13
16
15
Item No.
Description
Item No.
Description
Screw
Ring, wear
Washer, seal
10
Piston
11
Ring, retainer
12
Rod, cylinder
Plugger assembly
13
O ring
Spring
14
Bearing
Plug
15
Seal, rod
O ring
16
Wiper
BT Prime-Mover, Inc.
Return
14
2002-01-15
473
F-code
Section
C-code
PS
S6.5
6610
Staging Cylinder, Three Stage Mast
Version no
T-code
001
395/396/397/398/399
1. Bearing Removal
1. Park the truck on a level surface and apply the
brake.
2. Fully extend the cylinders to inspect rod (12) for
gouges or pits. If gouges or pits are detected,
remove cylinder for repair.
DANGER Securely block columns to prevent
lowering. If not blocked, unexpected
movement could occur resulting in personal
injury or death.
3. Lift mast so inner column is raised approximately
12 inches (305 mm). Securely block mast.
4. Remove bolts from top end of staging cylinder
rods. Lower cylinder rods hydraulically.
5. Turn key switch to OFF and disconnect battery
connector from the truck.
WARNING Compressed air used for cleaning MUST
be reduced to less than 30 psi (205 kPa)
and then only with effective chip guarding
and personal protective equipment.
6. Clean the exterior of the lift cylinder.
474
Return
2002-01-15
F-code
Section
C-code
PS
S6.5
6610
Staging Cylinder, Three Stage Mast
Version no
001
T-code
395/396/397/398/399
2. Disassembly
1. Remove bearing (14) from the cylinder tube.
2. Remove and discard rod wiper (16), seal (15),
wear ring (9) and O ring (13) from the bearing (14).
Discard seal (15). Use care NOT to damage the
inside of the bearing.
3. Assembly
1. Install new bearing (14), seal (15), wear ring (9), O
ring (13) and rod wiper (16).
2. The lip of the wiper must face outward.
3. It is not necessary to replace wear ring (9), unless
the cylinder was removed for rod repair.
4. Installation
1. Install bearing in the cylinder tube.
2. Raise cylinder rods hydraulically.
3. Install bolts in the top end of the staging cylinder.
4. Connect battery connector to the truck.
5. Test for proper operation.
BT Prime-Mover, Inc.
Return
2002-01-15
475
F-code
Section
C-code
PS
S6.5
6610
Staging Cylinder, Three Stage Mast
Version no
T-code
001
395/396/397/398/399
476
Return
2002-01-15
F-code
Section
C-code
PS
S6.6
6620
Freelift Cylinder, Three Stage Mast
Version no
001
T-code
395/396/397/398/399
3
15
14
13
7
12
6
11
5
10
BT Prime-Mover, Inc.
Return
2000-08-04
477
F-code
Section
C-code
PS
S6.6
6620
Freelift Cylinder, Three Stage Mast
Version no
T-code
001
395/396/397/398/399
Item
No.
Item
No.
Description
Washer, seal
Screw
10K
O ring
Tube cylinder
11K
Ring, back-up
Ring, retainer
12
Bearing
Plunger assembly
13K
Ring, guide
Spring
14K
Seal
Ring, guide
15K
Wiper
7K
8
Description
Piston
Rod cylinder
478
Return
2000-08-04
F-code
Section
C-code
PS
S6.6
6620
Freelift Cylinder, Three Stage Mast
Version no
001
T-code
395/396/397/398/399
1. Removal
1. Park the truck on a level surface and apply the
brake.
2. Fully extend cylinder to inspect rod (9) for gouges
or pits. If gouges or pits are detected, cylinder must
be removed for repair.
DANGER Securely block columns to prevent
lowering. If not blocked, unexpected
movement could occur resulting in personal
injury or death.
3. Lift carriage/reach and securely block.
4. Lower cylinder so chains, hoses, and electric
cables are loose.
5. Turn key switch to OFF and disconnect battery
connector from the truck.
6. Remove chains, hoses, and electric cables from
the crosshead.
7. Remove crosshead from cylinder rod.
WARNING Compressed air used for cleaning MUST
be reduced to less than 30 psi (205 kPa)
and then only with effective chip guarding
and personal protective equipment.
8. Clean the exterior of the lift cylinder.
BT Prime-Mover, Inc.
Return
2000-08-04
479
F-code
Section
C-code
PS
S6.6
6620
Freelift Cylinder, Three Stage Mast
Version no
T-code
001
395/396/397/398/399
2. Disassembly
1. Remove bearing (12) from the cylinder tube (3).
2. Remove and discard seal (14), back-up ring (11),
O ring (10), rod wiper (15) and ring guide (13) from
bearing (12). Use care NOT to damage the inside
of the bearing (12).
3. Assembly
1. Install new back-up ring (11), O ring (10), seal (14)
rod wiper (15) and guide ring (13).
2. The lip of the wiper must face outward.
4. Installation
1. Install crosshead, chains, hoses and electric
cables.
2. Connect battery connector to the truck.
3. Test for proper operation.
480
Return
2000-08-04
F-code
PS
Section
C-code
S6.7
6650
Reach Cylinder Assembly
Version no
T-code
002
395/396/397
10
11
12
13
14
15
24
25
23
21
20 19
18
17
16
22
1
6
2
6
3
BT Prime-Mover, Inc.
Return
2000-08-04
481
F-code
Section
C-code
PS
S6.7
6650
Reach Cylinder Assembly
Version no
T-code
002
395/396/397
Item
No.
Description
Item
No.
Description
Reach cylinder
assembly, right
10K
Ring, guide
19Q
Piston
Reach cylinder
assembly, left
11K
Seal
20K
Ring, guide
Pin, roll
12K
Wiper
21Q
Nut, lock
Pin, clevis
13Q
Rod cylinder
22K
Retainer
Pin, clevis
14
Nut
23
Fitting, grease
15
Clevis
24
7K
O ring
16
Spacer
25
Bearing
8K
Ring, backup
17K
Ring, backup
Bearing
18K
O ring
NOTE!
482
Description
Return
Item
No.
2000-08-04
F-code
PS
Section
Version no
002
C-code
S6.7
6650
Reach Cylinder Assembly
T-code
395/396/397
1. Removal
1. Park the truck on a level surface and apply the
brake.
2. Extend the reach about 1/2-3/4 of the total reach.
3. Block and chain the reach mechanism to prevent
movement of the reach mechanism.
4. Relieve pressure on the reach cylinders.
5. Remove hoses from the reach cylinder.
6. Remove roll pins (3). Remove front mounting pins
(4).
7. Raise reach assembly above full freelift. Remove
roll pins (3). Remove rear cylinder mounting pins
(5).
8. Remove reach cylinder from truck.
9. Turn key switch to OFF. Disconnect battery
connector from the truck.
BT Prime-Mover, Inc.
Return
2000-08-04
483
F-code
Section
C-code
PS
S6.7
6650
Reach Cylinder Assembly
Version no
T-code
002
395/396/397
2. Disassembly
WARNING Compressed air used for cleaning MUST
be reduced to less than 30 psi (206 kPa),
and then only with effective chip-guarding
and personal protective equipment.
NOTE!
484
Return
2000-08-04
F-code
PS
Section
Version no
002
C-code
S6.7
6650
Reach Cylinder Assembly
T-code
395/396/397
3. Inspection
WARNING Compressed air used for cleaning MUST
be reduced to less than 30 psi (206 kPa),
and then only with effective chip-guarding
and personal protective equipment.
1. Carefully clean all parts in a cleaning solution and
position them on a clean work surface.
2. Check piston rod for damage. Look for gouges,
scratches, corrosion, or evidence of unusual wear.
Minor surface damage can be repaired by use of
fine abrasion cloth or stoning. Be extremely careful
to not remove chrome plating. Deeper damage will
require replacement of rod assembly. Make sure
the threads on the rod are free of damage.
3. Check cylinder bore for any damage. Parts with
deep gouges or pitted surfaces will require
replacement.
4. Check threaded section of cylinder tube to be sure
threads have not been damaged.
BT Prime-Mover, Inc.
Return
2000-08-04
485
F-code
Section
C-code
PS
S6.7
6650
Reach Cylinder Assembly
Version no
T-code
002
395/396/397
4. Assembly
1. Install new O ring (7), back-up ring (8), ring guide
(10), seal (11), and rod wiper (12) in bearing
assembly (9). The lip of the wiper must face
outward.
2. Install new ring guide (20), back-up rings (17) and
(8) on piston (19).
3. Apply clean hydraulic fluid to rod cylinder (13).
Coat inside of cylinder tube and bearing assembly
with clean fluid.
4. Carefully slide spacer (16) (if used) and bearing
assembly (9) onto cylinder rod. Be sure rod end
does not cut or nick wiper upon installation.
5. Install cylinder assembly consisting of the rod (13),
piston (19) and lock nut (21) into cylinder tube (23
or 24). Be careful not to nick or cut piston seals on
the edge of cylinder tube or when sliding over
groove within tube. Torque cylinder piston lock nut
(21) to 47.94 ft-lb (65 Nm).
6. Install bearing assembly into cylinder tube. Use
care not to nick or cut seals upon installation.
7. Install retainer (22).
8. Check installation by making sure piston rod
assembly moves smoothly within tube assembly
without binding.
9. Install bearing (25).
486
Return
2000-08-04
F-code
PS
Section
C-code
S6.7
6650
Reach Cylinder Assembly
Version no
002
T-code
395/396/397
5. Installation
1. Connect battery connector to the truck. Turn key
switch to ON.
2. Raise reach to full freelift height. Install reach
cylinder rear cylinder mounting pins (5). Secure
mounting pins with roll pins (3).
3. Lower reach assembly. Install reach cylinder front
mounting pins (4). Secure mounting pins with roll
pins (3).
4. Connect correct hydraulic hoses to reach cylinders.
5. Remove blocking and chains.
6. Fill hydraulic reservoir with new clean oil.
7. Operate reach to remove air from hydraulic hoses
and check operation of the whole hydraulic system.
CAUTION DO NOT use your hands to check for
hydraulic leakage. Use a piece of
cardboard or paper to search for leaks.
Escaping fluid under pressure can
penetrate the skin causing injury. Relieve
pressure before disconnecting hydraulic or
other lines. Tighten all connections before
applying pressure. Keep hands and body
away from pinholes and nozzles which
eject fluids under high pressure.
8. After running the hydraulic system, check and fill
hydraulic reservoir with new clean oil.
BT Prime-Mover, Inc.
Return
2000-08-04
487
F-code
Section
C-code
PS
S6.7
6650
Reach Cylinder Assembly
Version no
T-code
002
395/396/397
488
Return
2000-08-04
F-code
Section
C-code
PS
S6.8
6660
Tilt Cylinder Assembly, RRX35/RSX40/RSX50
Version no
T-code
002
395/398/399
11
8
7
5
12
10
1
2
3
4
BT Prime-Mover, Inc.
Return
Item
No.
Description
Item
No.
Seal
11
O Ring
Bushing
Bearing, cylinder
12
Ring, back-up
Retainer, cylinder
Ring, back-up
13
Retainer
Screw, cap
O Ring
14
Tube, cylinder
Wiper
10
Rod, cylinder
Description
2000-08-04
Item
No.
Description
489
F-code
Section
C-code
PS
S6.8
6660
Tilt Cylinder Assembly, RRX35/RSX40/RSX50
Version no
T-code
002
395/398/399
1. Removal
1. Park the truck on a level surface and apply the
brake.
2. Raise reach approximately 12 inches (305 mm)
and block so reach will not lower.
3. Pivot carriage upward and block to prevent
carriage/reach from lowering.
4. Turn key switch to OFF. Disconnect battery
connector from the truck.
5. Relieve pressure on tilt cylinder assembly (1).
6. Remove retainer (3) and cap screws (4) securing
cylinder to carriage/reach.
7. Remove hydraulic
assembly (1).
hoses
from
tilt
cylinder
490
Return
2000-08-04
F-code
Section
C-code
PS
S6.8
6660
Tilt Cylinder Assembly, RRX35/RSX40/RSX50
Version no
002
T-code
395/398/399
2. Disassembly
WARNING Compressed air used for cleaning MUST
be reduced to less than 30 psi (206 kPa),
and then only with effective chip-guarding
and personal protective equipment.
NOTE!
Perform
procedures
in
a
clean
environment. Make sure all parts are
cleaned before disassembly and kept clean
during assembly.
BT Prime-Mover, Inc.
Return
2000-08-04
491
F-code
Section
C-code
PS
S6.8
6660
Tilt Cylinder Assembly, RRX35/RSX40/RSX50
Version no
T-code
002
395/398/399
3. Inspection
WARNING Compressed air used for cleaning MUST
be reduced to less than 30 psi (206 kPa),
and then only with effective chip-guarding
and personal protective equipment.
1. Carefully clean all parts in a cleaning solution and
position on a clean work surface
2. Check cylinder rod (10) for damage. Look for
gouges, scratches, corrosion, or evidence of
unusual wear. Minor surface damage can be
repaired by the use of fine abrasion cloth or
stoning. Be extremely careful not to remove the
chrome plating. Deeper damage will require
replacement of piston rod assembly. Make sure
threads on rod are free of damage.
3. Check cylinder bore for any damage. Parts with
deep gouges or pitted surfaces will require
replacement.
4. Check threaded section of cylinder tube to be sure
threads have not been damaged.
492
Return
2000-08-04
F-code
Section
C-code
PS
S6.8
6660
Tilt Cylinder Assembly, RRX35/RSX40/RSX50
Version no
002
T-code
395/398/399
4. Assembly
1. Install new seals (6), O ring (9), backup ring (8),
and rod wiper (5) in bearing assembly. The lip of
the wiper must face outward.
2. Install new O ring (11) and back-up ring (12) on
cylinder rod (10).
3. Apply clean hydraulic fluid to cylinder rod
assembly. Coat the inside of the cylinder barrel and
bearing assembly with clean fluid.
4. Carefully slide bearing assembly on cylinder rod.
Be sure rod end does not cut or nick wiper (5) and
seal (6) upon installation.
5. Install rod into cylinder barrel. Be careful not to nick
or cut piston seals on the edge of cylinder barrel or
when sliding over groove within barrel.
6. Install bearing assembly into cylinder barrel. Use
care not to nick or cut seals upon installation.
7. Check installation by making sure cylinder rod
assembly moves fairly easy within barrel assembly
without binding.
8. Install bearing fastening ring and retainer.
BT Prime-Mover, Inc.
Return
2000-08-04
493
F-code
Section
C-code
PS
S6.8
6660
Tilt Cylinder Assembly, RRX35/RSX40/RSX50
Version no
T-code
002
395/398/399
5. Installation
1. Install cylinder on reach front frame.
2. Install retainer (3) and secure with four cap screws
(4).
3. Properly connect correct hydraulic hoses to front
and rear of tilt cylinder.
4. Remove blocking and chains.
5. Fill hydraulic reservoir with new clean oil.
6. Connect battery connector to the truck.
WARNING DO NOT use your hands to check for
hydraulic leakage. Use a piece of
cardboard or paper to search for leaks.
Escaping fluid under pressure can
penetrate the skin causing injury. Relieve
pressure before disconnecting hydraulic or
other lines. Tighten all connections before
applying pressure. Keep hands and body
away from pinholes and nozzles which
eject fluids under high pressure.
7. Operate tilt to remove air from hydraulic hoses and
check operation of whole hydraulic system.
8. After running the hydraulic system, check and fill
hydraulic reservoir with more new clean oil.
494
Return
2000-08-04
F-code
Section
C-code
PS
S6.9
6660
Tilt Cylinder Assembly, RRX45/RDX30
Version no
T-code
001
396/397
23
22
21 20
18
19
24
25
26
9
12
13
16
11
15 14
17
10
5
6
1
4
2
3
2
BT Prime-Mover, Inc.
Return
2000-08-04
495
F-code
Section
C-code
PS
S6.9
6660
Tilt Cylinder Assembly, RRX45/RDX30
Version no
T-code
001
396/397
Item
No.
496
Description
Item
No.
Description
Item
No.
Description
Pin, roll
10
Retainer
19
Ring, sealing
Washer
11
Nut, lock
20
Bearing
Bearing
12
Washer, flat
21
Ring, guide
Pin
13
Ring, guide
22
Seal, rod
Pin
14
Piston
23
Wiper, rod
Pin, roll
15
O ring
24
Rod, cylinder
Tilt cylinder
assembly
16
Ring, sealing
25
Nut
Bearing
17
O ring
26
Clevis
Tube, cylinder
18
O ring
Return
2000-08-04
F-code
Section
C-code
PS
S6.9
6660
Tilt Cylinder Assembly, RRX45/RDX30
Version no
001
T-code
396/397
1. Removal
1. Park the truck on a level surface and apply the
brake.
2. Raise reach approximately 12 inches (304 mm)
and block so reach will not lower.
3. Pivot carriage upward and block to prevent
carriage/reach from lowering.
4. Turn key switch to OFF and disconnect battery
connector from the truck.
5. Relieve pressure on tilt cylinder.
6. Remove hydraulic hoses from tilt cylinder and mark
their position.
7. Remove roll pin (6) and top mounting pin (5).
Remove tilt cylinder from truck.
8. Repeat procedure on other side of truck as
needed.
BT Prime-Mover, Inc.
Return
2000-08-04
497
F-code
Section
C-code
PS
S6.9
6660
Tilt Cylinder Assembly, RRX45/RDX30
Version no
T-code
001
396/397
2. Disassembly
WARNING Compressed air used for cleaning MUST
be reduced to less than 30 psi (206 kPa),
and then only with effective chip-guarding
and personal protective equipment.
NOTE!
498
Return
2000-08-04
F-code
Section
C-code
PS
S6.9
6660
Tilt Cylinder Assembly, RRX45/RDX30
Version no
001
T-code
396/397
3. Inspection
WARNING Compressed air used for cleaning MUST
be reduced to less than 30 psi (206 kPa),
and then only with effective chip-guarding
and personal protective equipment.
1. Carefully clean all parts in a cleaning solution and
position on a clean work surface
2. Check piston rod (24) for damage. Look for
gouges, scratches, corrosion or evidence of
unusual wear. Minor surface damage can be
repaired by use of fine abrasion cloth or stoning.
Be extremely careful not to remove the chrome
plating. Deeper damage will require replacement of
piston rod assembly. Make sure threads on rod are
free of damage.
3. Check cylinder bore for any damage. Parts with
deep gouges or pitted surfaces will require
replacement.
4. Check threaded section of cylinder tube (9) to be
sure threads have not been damaged.
BT Prime-Mover, Inc.
Return
2000-08-04
499
F-code
Section
C-code
PS
S6.9
6660
Tilt Cylinder Assembly, RRX45/RDX30
Version no
T-code
001
396/397
4. Assembly
1. Install new guide ring (21), seal (22) and rod wiper
(23) in gland assembly. The lip of the wiper must
face outward.
2. Install new piston seals (15) and (17), guide ring
(13), and sealing ring (16) on piston (14).
3. Install piston (14) on rod (24).
4. Install nut (11) on cylinder rod (24). Torque cylinder
piston nut to 60-65 ft-lb (81-88 Nm).
5. Apply clean hydraulic fluid to piston rod assembly.
Coat inside of cylinder tube (9)
and gland
assembly with clean fluid.
6. Carefully slide gland assembly onto piston cylinder
rod (24). Be sure rod end does not cut or nick wiper
(23) and seal (22) upon installation.
7. Install piston and rod into cylinder tube (9). Be
careful not to nick or cut piston seals on the edge
of cylinder tube or when sliding over groove within
tube.
8. Install gland assembly into cylinder tube (9). Use
care not to nick or cut seals are upon installation.
9. Install retainer (10).
10. Check installation by making sure piston rod
assembly moves fairly easy within tube assembly
without binding.
11. Install bearing (20).
12. If removed, install roller bearing and clevis
assembly.
500
Return
2000-08-04
F-code
Section
C-code
PS
S6.9
6660
Tilt Cylinder Assembly, RRX45/RDX30
Version no
001
T-code
396/397
5. Installation
1. Install tilt cylinder on carriage/reach front frame.
Secure with mounting pin (5) with roll pin (6).
2. Properly connect correct hydraulic hoses to the top
and bottom of tilt cylinder.
3. Remove blocking and chains.
4. Fill hydraulic reservoir with new clean oil.
5. Connect battery connector to the truck.
6. Operate tilt to remove air from hydraulic hoses and
check operation of the whole hydraulic system.
WARNING DO NOT use your hands to check for
hydraulic leakage. Use a piece of
cardboard or paper to search for leaks.
Escaping fluid under pressure can
penetrate the skin causing injury. Relieve
pressure before disconnecting hydraulic or
other lines. Tighten all connections before
applying pressure. Keep hands and body
away from pinholes and nozzles which
eject fluids under high pressure.
7. After running the hydraulic system, check and fill
hydraulic reservoir with new clean oil.
BT Prime-Mover, Inc.
Return
2000-08-04
501
F-code
Section
C-code
PS
S6.9
6660
Tilt Cylinder Assembly, RRX45/RDX30
Version no
T-code
001
396/397
502
Return
2000-08-04
F-code
Section
PS
S7.0
7110
Mast, 3 Stage
Version no
C-code
T-code
001
395/396/397/398/399
Mast, 3 Stage
RRX35/RSX40
33
27
32
34
5
34
35
29
30
31
28
28
10
3
1
7
4
11
22
14
12
15
26
3
21
20
13
14
15
23
38
36
37 36
17
40
25
24
BT Prime-Mover, Inc.
18
5
Return
17 19
2000-08-04
16
39
503
F-code
Section
C-code
PS
S7.0
Mast, 3 Stage
7110
Version no
T-code
001
395/396/397/398/399
Item
No.
504
Description
Item
No.
Description
Item
No.
Description
Anchor, chain
15
Nut, jam
29
Sheave, chain
16
Line, hydraulic
30
Bearing, roller
Pin, cotter
17
Screw, cap
31
Race, inner
Pin, chain
18
Column, Intermediate
32
Lockwasher
Shim
19
Bracket
33
Screw, cap
Bearing
20
Screw, cap
34
Fitting, grease
Staging cylinder
assembly
21
Lockwasher
35
Shaft
22
Sheave
36
Spacer
Column, inner
23
Screw, cap
37
Sheave, hose
10
24
Washer, flat
38
Screw, cap
11
Freelift cylinder
assembly
25
Screw, cap
39
Shaft, sheave
12
Pin, anchor
26
Column, outer
40
Sheave, hydraulic,
and electrical
13
Pin, cotter
27
Shaft
14
Nut
28
Washer, shim
Return
2000-08-04
F-code
Section
PS
S7.0
7110
Mast, 3 Stage
Version no
C-code
T-code
001
395/396/397/398/399
RRX45/RSX50/RDX30
28
29
30
5
31
6
24
25
26
27
24
10
6
1
7
4
11
18
14
37
15
19
12
13
3
14
15
22
38
17
4
16
23
5
6
20
32
33
32
21
35
34
BT Prime-Mover, Inc.
Return
36
2000-08-04
505
F-code
Section
C-code
PS
S7.0
Mast, 3 Stage
7110
Version no
T-code
001
395/396/397/398/399
Item
No.
506
Description
Item
No.
Description
Item
No.
Description
Anchor, chain
14
Nut
27
Race, inner
15
Nut, jam
28
Lockwasher
Pin, cotter
16
Line, hydraulic
29
Screw, cap
Pin, chain
17
Screw, cap
30
Fitting, grease
Shim
18
Column, Intermediate
31
Shaft
Bearing
19
Bracket
32
Spacer
Staging cylinder
assembly
20
Screw, cap
33
Sheave, hose
21
Shaft, sheave
34
Screw, cap
Column, inner
22
Column, outer
35
Washer, shim
10
23
Screw, cap
36
Sheave, hydraulic,
and electrical
11
Freelift cylinder
assembly
24
Washer, shim
37
Manifold
12
Pin, anchor
25
Sheave, chain
38
Screw
13
Pin, cotter
26
Bearing, roller
Return
2000-08-04
F-code
Section
PS
S7.0
7110
Mast, 3 Stage
Version no
001
C-code
T-code
395/396/397/398/399
BT Prime-Mover, Inc.
Return
2000-08-04
507
F-code
Section
C-code
PS
S7.0
Mast, 3 Stage
7110
Version no
T-code
001
395/396/397/398/399
508
Return
2000-08-04
F-code
Section
PS
S7.0
7110
Mast, 3 Stage
Version no
001
C-code
T-code
395/396/397/398/399
Plate
BT Prime-Mover, Inc.
Return
2000-08-04
509
F-code
Section
C-code
PS
S7.0
Mast, 3 Stage
7110
Version no
T-code
001
395/396/397/398/399
2.2. Disassembly
1. Lower mast assembly to a horizontal position
before work can begin.
2. Remove lift chain anchors, lift chain, attachment
hydraulic hoses, and electrical cable from the
mast.
3. Remove freelift chain anchor, two cotter pins, and
two cylinder anchor pins from inner column. Pull
straight up to remove freelift cylinder assembly.
NOTE!
510
Return
2000-08-04
F-code
Section
PS
S7.0
7110
Mast, 3 Stage
Version no
001
C-code
T-code
395/396/397/398/399
2.3. Assembly
WARNING Compressed air used for cleaning MUST
be reduced to less than 30 psi (206 kPa),
and then only with effective chip-guarding
and personal protective equipment.
1. Thoroughly clean all parts and air dry.
2. Install mast roller bearing on both intermediate and
outer columns.
3. Assemble intermediate column in outer column.
Slide columns together.
4. Determine amount of shims required. Pry inner
column to one side and slip shims between bearing
and web on mast. Add shims by hand until no more
can be added.
5. Divide shims as equally as possible between the
two bearings. Install shims under the bearings.
6. Extend intermediate column through the outer
column as far as it will go under normal operation.
Check bearing shimming as column is extended.
Remove shims as required if tight spots are
encountered where an assembler cannot roll the
mast by hand.
Check for excessive bearing clearance with
columns in the fully extended position. Pry column
to one side and check with a 0.030 inch (0.76 mm)
shim. Maximum clearance must not exceed 0.030
inch (0.76 mm).
7. Assemble inner column in intermediate column.
Slide columns together.
8. Determine amount of shims required. Pry inner
column to one side and slip shims between bearing
and web on the mast. Add shims by hand until no
more can be added.
9. Divide shims as equally as possible between the
two bearings. Install shims under bearings.
10. Extend inner column through the intermediate
column as far as it will go under normal operation.
BT Prime-Mover, Inc.
Return
2000-08-04
511
F-code
Section
C-code
PS
S7.0
Mast, 3 Stage
7110
Version no
T-code
001
395/396/397/398/399
Return
2000-08-04
F-code
Section
PS
S7.0
7110
Mast, 3 Stage
Version no
001
C-code
T-code
395/396/397/398/399
2.4. Installation
1. Install mast using a hoist.
2. Install side mounting plates. Torque mounting plate
bolts to 85 ft-lb (115 Nm).
3. Install two mast bolts in the middle of the battery
box. Torque bolts to 400 ft-lb (543 Nm).
4. Install two bolts at the base of overhead guard
post. Torque to 25 ft-lb (34 Nm).
5. Connect hydraulic hoses to lift cylinders.
6. Hydraulically lift up inner column enough to install
reach carriage assembly.
7. Connect all electrical connectors.
8. Adjust lift chains.
Loosen jam nut and tighten staging chains equally
until the top of the rails are level in the fully lowered
position. Retighten jam nut and torque to 200 ft-lb
(271 Nm).
Freelift chains should be adjusted in the fully
lowered position. Adjust chains until the top of forks
are 2.0 inches (50 mm) off the floor.
9. Grease all chain sheaves.
10. Bleed any air from cylinders.
11. Connect battery connector to the truck. Test
operations of mast and unit.
BT Prime-Mover, Inc.
Return
2000-08-04
513
F-code
Section
C-code
PS
S7.0
Mast, 3 Stage
7110
Version no
T-code
001
395/396/397/398/399
3. Lift Chain
Lift chains are very important components of the truck. The
chain system on the mast was designed for efficient, reliable
transmission of lifting force from the hydraulic cylinder to the
forks. Safe, uninterrupted use of the truck depends on proper
care and maintenance of lift chains.
After 100 hours of truck operation, lift chains should be
inspected and lubricated. When operating in unfamiliar
corrosive environment, inspect chains every 50 hours.
514
Return
2000-08-04
F-code
Section
PS
S7.0
7110
Mast, 3 Stage
Version no
001
T-code
395/396/397/398/399
3.3.1. Wear
As the chain flexes on and off the sheaves, the joints
gradually wear. The stretch a chain develops in service is
due to material being worn off the pin on the outside diameter
and the pitch hole inside diameter on the inside plates.
Chain
Wear
Scale
New Chain
C-code
BT Prime-Mover, Inc.
Return
2000-08-04
515
F-code
Section
C-code
PS
S7.0
Mast, 3 Stage
7110
Version no
T-code
001
395/396/397/398/399
516
Return
2000-08-04
F-code
Section
PS
S7.0
7110
Mast, 3 Stage
Version no
001
C-code
T-code
395/396/397/398/399
Rusty joints
Return
2000-08-04
517
F-code
Section
C-code
PS
S7.0
Mast, 3 Stage
7110
Version no
T-code
001
395/396/397/398/399
Protruding Pins
MA0633.ill
MA0000.ill
Turned Pins
518
Return
2000-08-04
F-code
Section
PS
S7.0
7110
Mast, 3 Stage
Version no
001
C-code
T-code
395/396/397/398/399
Prevent corrosion
BT Prime-Mover, Inc.
Return
2000-08-04
519
F-code
Section
C-code
PS
S7.0
Mast, 3 Stage
7110
Version no
T-code
001
395/396/397/398/399
Lubricate
520
Return
2000-08-04
F-code
Section
PS
S7.0
7110
Mast, 3 Stage
Version no
001
C-code
T-code
395/396/397/398/399
BT Prime-Mover, Inc.
Return
2000-08-04
521
F-code
Section
C-code
PS
S7.0
Mast, 3 Stage
7110
Version no
T-code
001
395/396/397/398/399
522
Return
2000-08-04
F-code
Section
PS
C-code
7.1
7170
Lifting Gear (Crosshead)
Version no
T-code
000
395/396/397/398/399
RRX35/RSX40
4
5
6
3
7
9
3
10
6
5
4
3
2
1
Freelift Cylinder
Item
No.
BT Prime-Mover, Inc.
Return
Description
Item
No.
Description
Fitting, grease
Sheave, chain
Ring, retainer
Head, sheave
Shim
Race
Shaft
Bearing, roller
10
Screw, set
2000-08-04
523
F-code
Section
C-code
PS
7.1
7170
Lifting Gear (Crosshead)
Version no
T-code
000
395/396/397/398/399
RRX45/RSX50/RDX30
3
4
5
6
8
7
9
3
10
6
5
4
3
2
1
Item
No.
524
Return
Description
Item No.
Description
Fitting, grease
Sheave, chain
Ring, retainer
Head, sheave
Shim
Race
Shaft
Bearing, roller
10
Screw, set
2000-08-04
F-code
PS
Version no
000
Section
C-code
7.1
7170
Lifting Gear (Crosshead)
T-code
395/396/397/398/399
BT Prime-Mover, Inc.
Return
2000-08-04
525
F-code
Section
C-code
PS
7.1
7170
Lifting Gear (Crosshead)
Version no
T-code
000
395/396/397/398/399
1.2. Disassembly
1. Remove retaining ring (2) from one end of the
lifting gear assembly.
2. Slide shim (3), bearing roller and race (5 and 4),
chain sheave (6) and the second shim (3) off the
shaft (9).
3. Repeat steps 1 and 2 for the opposite side.
4. Loosen set screw (10) in the side of the sheave
head (7).
5. Remove shaft (9) from sheave head (7) releasing
the hydraulic/electric sheave (8).
1.3. Assembly
1. Place hydraulic/electric sheave (8) into the sheave
head.
2. Insert shaft (9) into sheave head (7), through the
hydraulic/electric sheave (8).
3. Secure shaft in position with a set screw (10).
4. Install one shim (3), one chain sheave (6) with
bearing assembly (5, 4), a second shim (3), and a
retaining ring (2) on shaft (9).
5. Repeat step 4 for the opposite side.
6. Install a grease fitting (1) in each end of the shaft
(9).
1.4. Installation
1. Place lifting gear assembly on top of freelift
cylinder.
2. Tighten set screw (10) in the base of sheave head
(7) to secure the lifting gear to the cylinder.
3. Grease chain sheaves. Install chains, hoses, and
electric cables.
4. Connect battery connector to the truck.
5. Remove blocking and test for proper operation.
526
Return
2000-08-04
F-code
Section
C-code
PS
7.2
7210
Sideshifter, RRX35/45/RDX30
Version no
T-code
000
395/396/397
Sideshifter, RRX35/45/RDX30
21
20
19
18
15
17
16
X
14
2
15
3
13
4
5
7
8
12
11
10
Serial Number
RRX35 27091000 - 28075000
RRX45 27091000 - 28266000
RDX30 27091000 - 28266000
BT Prime-Mover, Inc.
Return
2000-08-04
527
F-code
Section
C-code
PS
7.2
7210
Sideshifter, RRX35/45/RDX30
Version no
T-code
000
395/396/397
Item
No.
528
Description
Item
No.
Description
Item
No.
Slide, top
Screw, set
Anchor, cylinder
10
Screw
Spacer
11
Lockwasher
Fitting
12
Frame, sideshifter
Ring, retainer
13
Nut
Slide, lower
14
Spacer
21
Ring, retainer
Nut
15
Cylinder assembly
Hook, lower
Return
16K
Description
17
18K
19
20K
Spacer, nylon
Spacer
Seal, gland
Retainer, wiper
Wiper, rod
2000-08-04
F-code
Section
C-code
PS
7.2
7210
Sideshifter, RRX35/45/RDX30
Version no
T-code
000
395/396/397
1. Mounting Instructions
1.1. Installation
WARNING Clean the fork carriage and inspect to be
sure it is free of damage or grooves before
installing the sideshift carriage. Apply
grease to the fork carriage frame where the
lower pads slide.
1. Remove lower
assembly.
hooks
(8)
from
sideshifter
BT Prime-Mover, Inc.
Return
2000-08-04
529
F-code
Section
C-code
PS
7.2
7210
Sideshifter, RRX35/45/RDX30
Version no
T-code
000
395/396/397
530
Return
2000-08-04
F-code
Section
C-code
PS
7.2
7210
Sideshifter, RRX35/45/RDX30
Version no
000
T-code
395/396/397
2.3. Cylinder
1. The hydraulic cylinder (15) is basically a nonserviceable style, with the exception of the gland O
ring. It is recommended that a leaking or defective
cylinder be replaced.
2. If the cylinder rod becomes scored, a minimal
amount of scoring may be removed by polishing
with a fine emery cloth. Deep scoring requires that
the cylinder (15) be replaced.
BT Prime-Mover, Inc.
Return
2000-08-04
531
F-code
Section
C-code
PS
7.2
7210
Sideshifter, RRX35/45/RDX30
Version no
T-code
000
395/396/397
532
Return
2000-08-04
F-code
Section
C-code
PS
S7.3
7210
Sideshifter, RRX35/45/RSX40/50/RDX30
Version no
001
T-code
395/396/397/398/399
Sideshifter, RRX35/45/RSX40/50/RDX30
1
2
25
24
21
23
22
20
19
18 17
16
26
15
14
29
3
X
7
28
10
27
13
12
BT Prime-Mover, Inc.
Return
11
2000-08-04
Serial Number
RRX35 28075001 - UP
RRX45 28266001 - UP
RSX40 28308000 - UP
RSX50 28308000 - UP
RDX30 28266001 - UP
533
F-code
Section
C-code
PS
S7.3
7210
Sideshifter, RRX35/45/RSX40/50/RDX30
Version no
T-code
001
395/396/397/398/399
Item
No.
Description
Item
No.
Description
Item
No.
Description
Screw
11
Hook, lower
21
Bracket
12
Pad, lower
22
Support
13
23
Seal
Pad, upper
14
Cap, right
24
Seal
Frame
15
Body, cylinder
25
Rod
16
Seal
26
Cylinder
Bolt, stop
17
Piston
27
Washer
18
O-ring
28
Screw
19
Ring
29
Restrictor, flow
10
Washer, lower
hook
20
Bushing
534
Return
2000-08-04
F-code
Section
C-code
PS
S7.3
7210
Sideshifter, RRX35/45/RSX40/50/RDX30
Version no
001
T-code
395/396/397/398/399
1. Mounting Instructions
1.1. Installation
NOTE!
BT Prime-Mover, Inc.
Return
2000-08-04
535
F-code
Section
C-code
PS
S7.3
7210
Sideshifter, RRX35/45/RSX40/50/RDX30
Version no
T-code
001
395/396/397/398/399
NOTE!
2. Operation
Always operate lift truck controls in a smooth manner.
Sudden movements of sideshifter at high lifts can
compromise stability of truck, as well as cause damage to
overall system.
3. Maintenance
Maintenance on sideshifter unit should be performed on a
regular basis to receive the best performance from the unit.
(See Planned Maintenance Schedule on page 71.)
Perform the following every 100-hour maintenance:
Check torque of lower hook mounting bolts (6)
Inspect hydraulic hoses for wear
Inspect cylinder (26) and fittings for wear or leaks
In addition to the 100-hour maintenance procedures
perform the following:
Grease lower hook (11) where the pads (12) slide.
Check thickness of upper pads (4). If thickness
measures 0.0625 inch (1.5 mm) or less, replace
upper pads.
Check thickness of lower pads (12). If thickness
measures 0.020 inch (5 mm) or less, replace lower
pads.
Perform the following procedures every 2000 hours.
Replace upper (4) and lower (12) pads.
NOTE!
536
Return
2000-08-04
F-code
Section
C-code
PS
S7.3
7210
Sideshifter, RRX35/45/RSX40/50/RDX30
Version no
001
T-code
395/396/397/398/399
BT Prime-Mover, Inc.
Return
2000-08-04
537
F-code
Section
C-code
PS
S7.3
7210
Sideshifter, RRX35/45/RSX40/50/RDX30
Version no
T-code
001
395/396/397/398/399
538
Return
2000-08-04
F-code
Section
C-code
PS
S7.3
7210
Sideshifter, RRX35/45/RSX40/50/RDX30
Version no
001
T-code
395/396/397/398/399
3.4. Cylinder
1. Remove sideshifter carriage from truck. See
Carriage Removal on page 537.
2. Remove cylinder from cylinder support. Loosen
locking screws (1). Remove brackets (2). Lift
cylinder assembly (26) from cylinder support.
3. Secure body of cylinder in a vice equipped with soft
jaws. The bracket slots should be facing upwards.
4. Use a wrench to turn cap (22) until ring (21) comes
out. Turn ring, slowly removing cap. Check that
seal passes through recess (press seals through
recess with a screwdriver).
NOTE!
5. Reassemble cylinder.
6. Secure cylinder in cylinder support (3) using
brackets (2) and screws (1).
NOTE!
Return
2000-08-04
539
F-code
Section
C-code
PS
S7.3
7210
Sideshifter, RRX35/45/RSX40/50/RDX30
Version no
T-code
001
395/396/397/398/399
4. Troubleshooting
Below are three symptoms and the corrective actions to be
taken for each.
4.1. No Sideshifting
1. Check that input pressure is not greater than 3200
psi (22063 kPa). Average working pressure should
be 1000 psi (6895 kPa). Recommended oil flow is
2 gallons (9 liters) per minute and should be a
minimum of 1 gallon (4 liters) per minute.
2. Check carriage frame for damage.
3. Check relationship of lower hook (11) to truck
carriage.
4. Check for leaks in hydraulic circuit or cylinder.
Return
2000-08-04
F-code
Section
PS
C-code
S7.4
7241
Single Reach, RRX35
Version no
T-code
002
395
22
21
39
10
24
25
19
12
13
14
Reach
Cylinders
Tilt
Cylinder
7
6
40
1
1
42
46
44
43
15
18
38 34
41
45
37
20
16 17
23
2
26
11
27
34
28
29
38
36
30
33
35
32
33
31
BT Prime-Mover, Inc.
Return
2001-09-10
541
F-code
Section
PS
S7.4
Single Reach, RRX35
Version no
T-code
002
395
Item
No.
542
C-code
7241
Description
Item
No.
Description
Item
No.
Description
Nut, lock
17
Screw
33
Bearing
Washer
18
Cover, valve
34
Bumper
Frame, rear
19
Manifold
35
Shim
Screw
20
Frame, forward
36
Screw, cap
Arm, left
21
Pin, roll
37
Manifold
Bushing
22
Pin
38
Shim
Fitting, grease
23
Bushing
39
Shaft
Arm, inner
24
Bar, fork
40
Nut
Valve, control
25
Screw, cap
41
Clamp
10
Screw
26
Shaft, pivot
42
Screw
11
Bushing
27
Arm, right
43
Washer
12
Plug, wear
28
Washer, flat
44
Bracket
13
Bearing
29
Nut, jam
45
14
Washer
30
Set, bearing
46
Bushing
15
Clamp, poly
31
Screw
16
Cover
32
Cap
Return
2001-09-10
F-code
Section
PS
Version no
T-code
002
395
19
18
5
8
12
7
10
13
21
22
16
11
9
45 46
Reach
Cylinders
24
44
42
Tilt
Cylinder
7
23
26
36
40
35
36
38
23
25
34
41
39
14 15
2
43 1
20
17
7
6
C-code
S7.4
7241
Single Reach, RRX35
33
27
35
28
29
32
37
31
32
30
BT Prime-Mover, Inc.
Return
2001-09-10
543
F-code
Section
PS
S7.4
Single Reach, RRX35
Version no
T-code
002
395
Item
No.
544
C-code
7241
Description
Item
No.
Description
Item
No.
Description
Screw, cap
17
Frame, forward
33
Bushing
Pin
18
Pin, roll
34
Screw
Frame, rear
19
Pin
35
Bumper
Screw
20
Bushing
36
Shim
Arm, left
21
Bar, fork
37
Shim
Bushing
22
Screw, cap
38
Screw, cap
Fitting, grease
23
Washer
39
Manifold
Bushing
24
Washer
40
Screw
Arm, inner
25
Pin
41
Clamp
10
Control, valve
26
Arm, right
42
Washer
11
Screw
27
Washer, flat
43
Bracket
12
Cover, valve
28
Nut, jam
44
Nut
13
Clamp, poly
29
Set, bearing
45
Cap, bearing
14
Cover
30
Screw
46
Bearing
15
Screw
31
Cap
16
Manifold
32
Bearing
Return
2001-09-10
F-code
Section
PS
Version no
T-code
002
395
19
18
6
2
1
5
48
8
12
7
10
13
14 15
9
45 46
Reach
Cylinders
47
24
23
42
26
36
44
41
40
36
38
35
34
39
21
22
16
11
43
20
17
C-code
S7.4
7241
Single Reach, RRX35
Tilt
Cylinder
7
6
23
25
1
33
27
35
28
29
32
37
31
32
30
BT Prime-Mover, Inc.
Return
2001-09-10
545
F-code
Section
PS
S7.4
Single Reach, RRX35
Version no
T-code
002
395
Item
No.
546
C-code
7241
Description
Item
No.
Description
Item
No.
Description
Screw, cap
17
Frame, forward
33
Bushing
Pin
18
Pin, roll
34
Screw
Frame, rear
19
Pin
35
Bumper
Screw
20
Bushing
36
Shim
Arm, left
21
Bar, fork
37
Shim
Bushing
22
Screw, cap
38
Screw, cap
Fitting, grease
23
Washer
39
Manifold
Bushing
24
Washer
40
Screw
Arm, inner
25
Pin
41
Clamp
10
Control, valve
26
Arm, right
42
Washer
11
Screw
27
Washer
43
Bracket
12
Cover, valve
28
Nut, jam
44
Nut
13
Clamp, poly
29
Set, bearing
45
Cap, bearing
14
Cover
30
Screw
46
Bearing
15
Screw
31
Cap
47
Nut
16
Manifold
32
Bearing
48
Washer
Return
2001-09-10
F-code
PS
Section
C-code
S7.4
7241
Single Reach, RRX35
Version no
002
T-code
395
1. Maintenance
1.1. Inspection
It is critical that proper inspection, adjustment and
maintenance be performed at the normal Planned
Maintenance per the schedule (page 71) to ensure maximum
performance and reliability and eliminate costly premature
failures. The reach bumpers are critical to the proper
operation of the reach assembly and must be inspected at
every Planned Maintenance visit. The carriage/reach
bumpers assure that carriage remains square with the truck
in its nested position. The reach uses rectangular bumpers
attached to each side and at the bottom of carriage/reach
rear frame. The bumpers are attached with screws.
1. Inspect the reach for damage.
2. Inspect the rear frame for cracks.
3. Inspect the upper rear pin holes to ensure that they
have not wallowed out.
4. Inspect cylinders for cracks in the cylinder tube or
bent cylinder rods.
5. Check to make sure that the correct cylinders are
installed on the truck.
6. Verify that reach bumpers are in good condition.
Bumpers that show signs of wear, cracking,
splitting, or deformation must be replaced.
BT Prime-Mover, Inc.
Return
2001-09-10
547
F-code
Section
PS
S7.4
Single Reach, RRX35
Version no
T-code
002
395
C-code
7241
1.2. Adjustment
1. As a starting point, install one 0.1196 inch 3.03
mm) shim behind each reach bumper.
548
Return
2001-09-10
F-code
PS
Version no
002
Section
C-code
S7.4
7241
Single Reach, RRX35
T-code
395
BT Prime-Mover, Inc.
Return
2001-09-10
549
F-code
Section
PS
S7.4
Single Reach, RRX35
Version no
T-code
002
395
C-code
7241
550
Return
2001-09-10
F-code
PS
Version no
002
Section
C-code
S7.4
7241
Single Reach, RRX35
T-code
395
BT Prime-Mover, Inc.
Return
2001-09-10
551
F-code
Section
PS
S7.4
Single Reach, RRX35
Version no
T-code
002
395
C-code
7241
2. Reach Repair
2.1. Removal
NOTE!
1. Remove forks.
2. Remove load backrest (see page 604).
3. Jack truck up (see page 66).
4. Extend reach approximately half way. Securely
block reach so it will not retract.
WARNING Block all wheels to prevent truck from
rolling. Park the truck on a level surface and
make sure all wheels are blocked to
prevent accidental movement.
5. Park truck on a level surface. Turn key switch OFF
and disconnect battery connector from the truck.
Remove battery from truck.
2.1. Disassembly
2.1.1. Front Frame Removal
1. Disconnect hydraulic hoses from tilt and sideshift
cylinders from the input side of junction block. Cap
hoses with plugs to prevent contamination.
NOTE!
552
Return
2001-09-10
F-code
PS
Section
C-code
S7.4
7241
Single Reach, RRX35
Version no
002
T-code
395
Return
2001-09-10
553
F-code
Section
PS
S7.4
Single Reach, RRX35
Version no
T-code
002
395
C-code
7241
2.2. Assembly
Install new bearing, rollers, and pins as needed.
2.2.1. Reach Cylinder Installation
1. Install rear frame pins.
2. Install locking pins.
3. Connect hydraulic hoses.
2.2.2. Rear Frame Installation
NOTE!
Return
2001-09-10
F-code
PS
Version no
002
Section
C-code
S7.4
7241
Single Reach, RRX35
T-code
395
BT Prime-Mover, Inc.
Return
2001-09-10
555
F-code
Section
PS
S7.4
Single Reach, RRX35
Version no
T-code
002
395
C-code
7241
3. Carriage Bumpers
The carriage/reach retract bumpers assure that the carriage
remains square with the truck in its nested position. The
RRX35 reach uses rectangular bumpers (35) attached to
each side and at the bottom of the carriage/reach rear frame.
These bumpers are attached with socket head screws (34).
Verify that the three reach retract bumpers (35) are in good
condition. There should be no splitting, cracking, or
deformation on the bumpers. The reach retract bumpers are
critical to the proper operation of the reach assembly and
must be inspected at every Planned Maintenance visit.
Bumpers that show signs of wear, cracking, splitting, or
deformation must be replaced.
Return
2001-09-10
F-code
PS
Version no
002
Section
C-code
S7.4
7241
Single Reach, RRX35
T-code
395
Return
2001-09-10
557
F-code
Section
PS
S7.4
Single Reach, RRX35
Version no
T-code
002
395
C-code
7241
5.1. Removal
1. Remove carriage/reach.
2. The carriage bearing should slide off the shaft with
hand pressure. If necessary, a suitable bearing
puller may be required for removal.
3. Repeat step 2 for the other three bearings.
5.2. Installation
1. Install new bearing on shaft.
2. Repeat step 1 for the other three bearings.
3. Reinstall carriage/reach (see page 507).
4. Test lift/lower functions of the carriage.
5. Return truck to service.
558
Return
2001-09-10
F-code
Section
PS
C-code
S7.5
7242
Single Reach, RRX45
Version no
T-code
001
396
3
1
10
9
12
35
12
34
37
33
23
12
36
13
38
22
14
15
32
16
24
23
15
31
30
26
29 27
28
17
16
22
25 21
15
11
18
20
31
30
22
12
15
19
21
17
20
19
Return
2001-10-03
559
F-code
Section
PS
S7.5
Single Reach, RRX45
Version no
T-code
001
396
Item
No.
560
C-code
7242
Description
Item
No.
Description
Item
No.
Description
Spacer
14
Screw
27
Reach cylinder
assembly
Tilt cylinder
assembly
15
Shim
28
Screw
Frame, forward
16
Bearing
29
Cap, bearing
Screw
17
Fitting, grease
30
Bearing
Pin
18
31
Shim
Frame, fork
19
Screw
32
Frame, rear
Screw
20
Cap
33
Screw
Bar, wear
21
Bearing, roller
34
Pin
Shim
22
Bearing, thrust
35
10
Bumper
23
Bearing
36
Screw
11
Pin, roll
24
Arm, inner
37
Cover, valve
12
Pin, roll
25
Shim
38
Valve, control
13
Pin
26
Nut
Return
2001-10-03
F-code
Section
PS
Version no
T-code
001
4
39
C-code
S7.5
7242
Single Reach, RRX45
396
38
37
1
36 10
9
47 46
35
12
34
43
33
23
12
12
45
44 42
22
40
13
41
14
48 46 45
15
32
16
24
15
31
30
26
29
27
28
22
11
30
25
44
12
15
17
16
22
21
20
31
43
23
15
18
19
21
20
17
19
Return
2001-10-03
561
F-code
Section
PS
S7.5
Single Reach, RRX45
Version no
T-code
001
396
Item
No.
562
C-code
7242
Description
Item
No.
Description
Item
No.
Description
Spacer
17
Fitting, grease
33
Screw
Tilt cylinder
assembly
18
34
Pin
Frame, forward
19
Screw
35
Screw
20
Cap
36
Screw
Pin
21
Bearing, roller
37
Nut
Frame, fork
22
Bearing, thrust
38
Bracket, hose
Screw
23
Bearing
39
Screw, cap
Bar, wear
24
Arm, inner
40
Control valve
Shim
25
Shim
41
Cover, valve
10
Bumper
26
Nut
42
Screw, cap
11
Pin, roll
27
Reach cylinder
assembly
43
Clamp, poly
12
Pin, roll
28
Screw
44
Cover
13
Pin
29
Cap, bearing
45
Screw
14
Screw
30
Bearing
46
Screw, cap
15
Shim
31
Shim
47
16
Bearing
32
Frame, rear
48
Return
2001-10-03
F-code
Section
PS
Version no
T-code
001
37
39
38
C-code
S7.5
7242
Single Reach, RRX45
396
17
49
49
36 10
9
47 46
35
12
34
33
43
23
12
12
45
44 42
22
40
13
41
14
48 46 45
15
32
16
24
15
31
30
26
29
27
28
22
11
30
25
12
15
17
16
22
21
20
31
43
23
44
15
18
19
21
20
17
19
Return
2001-10-03
563
F-code
Section
PS
S7.5
Single Reach, RRX45
Version no
T-code
001
396
Item
No.
564
C-code
7242
Description
Item
No.
Description
Item
No.
Description
Spacer
18
34
Pin
Tilt cylinder
assembly
19
Screw
35
Frame, forward
20
Cap
36
Screw
Screw
21
Bearing, roller
37
Nut
Pin
22
Bearing, thrust
38
Bracket, hose
Frame, fork
23
Bearing
39
Screw, cap
Screw
24
Arm, inner
40
Control valve
Bar, wear
25
Shim
41
Cover, valve
Shim
26
Nut
42
Screw, cap
10
Bumper
27
Reach cylinder
assembly
43
Clamp, poly
11
Pin, roll
28
Screw
44
Cover
12
Pin, roll
29
Cap, bearing
45
Screw
13
Pin
30
Bearing
46
Screw, cap
14
Screw
31
Shim
47
15
Shim
32
Frame, rear
48
16
Bearing
33
Screw
49
Washer
17
Fitting, grease
Return
2001-10-03
F-code
Section
PS
Version no
T-code
001
4
3
37
396
17
39
C-code
S7.5
7242
Single Reach, RRX45
38
49
50
51
51
36 10
8
9
47 46
35
12
34
33
43
23
12
12
45
44 42
22
40
13
41
14
48 46 45
15
32
16
24
15
31
30
26
29
27
28
22
11
30
25
12
15
17
16
22
21
20
31
43
23
44
15
18
19
21
20
17
19
Return
2001-10-03
565
F-code
Section
PS
S7.5
Single Reach, RRX45
Version no
T-code
001
396
Item
No.
566
C-code
7242
Description
Item
No.
Description
Item
No.
Description
Spacer
18
35
Tilt cylinder
assembly
19
Screw
36
Screw
Frame, forward
20
Cap
37
Clamp
Screw
21
Bearing, roller
38
Bracket, hose
Pin
22
Bearing, thrust
39
Screw, cap
Frame, fork
23
Bearing
40
Control valve
Screw
24
Arm, inner
41
Cover, valve
Bar, wear
25
Shim
42
Screw, cap
Shim
26
Nut
43
Clamp, poly
10
Bumper
27
Reach cylinder
assembly
44
Cover
11
Pin, roll
28
Screw
45
Screw
12
Pin, roll
29
Cap, bearing
46
Screw, cap
13
Pin
30
Bearing
47
14
Screw
31
Shim
48
15
Shim
32
Frame, rear
49
Lockwasher
16
Bearing
33
Screw
50
Nut
17
Fitting, grease
34
Pin
51
Washer
Return
2001-10-03
F-code
PS
Version no
001
Section
C-code
S7.5
7242
Single Reach, RRX45
T-code
396
2. Reach Repair
NOTE!
without
1. Remove forks.
2. Remove load backrest.
3. Raise and block reach at a height for easy repair.
4. Extend reach approximately half way and block so
it will not retract.
5. Turn key switch to OFF and disconnect battery
connector from the truck.
2.1. Disassembly
NOTE!
BT Prime-Mover, Inc.
Return
2001-10-03
567
F-code
Section
PS
S7.5
Single Reach, RRX45
Version no
T-code
001
396
C-code
7242
Return
2001-10-03
F-code
PS
Version no
001
Section
C-code
S7.5
7242
Single Reach, RRX45
T-code
396
2.2. Assembly
1. Install new bearing, rollers, pins and wear strips as
needed.
2.2.1. Reach Cylinder Installation
1. Install cylinder tube mounting pins.
2. Install roll pins.
3. Connect hydraulic hoses.
2.2.2. Rear Frame Installation
NOTE!
Adjust frame rollers so there is 0.000 0.030 inch (0-0.762 mm) side movement of
rear frame at tight part of the inner mast
channel.
BT Prime-Mover, Inc.
Return
2001-10-03
569
F-code
Section
PS
S7.5
Single Reach, RRX45
Version no
T-code
001
396
C-code
7242
570
Return
2001-10-03
F-code
PS
Version no
Section
C-code
S7.5
7242
Single Reach, RRX45
T-code
001
396
BT Prime-Mover, Inc.
Return
2001-10-03
571
F-code
Section
PS
S7.5
Single Reach, RRX45
Version no
T-code
001
396
C-code
7242
4.1. Removal
1. Remove carriage reach.
2. A suitable bearing puller will be required if bearings
are removed.
3. Repeat step 2 for remaining three bearings.
4.2. Installation
1. On shaft install new bearing with same thickness of
shims as removed.
2. Install remaining bearings.
3. Reinstall carriage/reach.
NOTE!
Adjust carriage rollers so there is 0.000 0.030 inch (0.762 mm) side movement of
the carriage at the tight part of the inner
mast channel.
572
Return
2001-10-03
F-code
Section
C-code
PS
S7.6
7243
Double Reach Mechanism, RDX30
Version no
T-code
000
397
7
39
6
24
37
6
61
59
33
28
67
25
41
27
45
67
26
60
34
40
58
50
63
32
64
47
38
17
19
18
19
57
48
56
26
55
17
18
22
62
46
65
43
49
22
45
11
51
45
54
BT Prime-Mover, Inc.
Return
52
24
2001-12-07
42
20
21
23
53
44
12
13
14
21
20
19
20
25
31
18
20
17
16
19
46
29
30
66
4
45
36
10
35
18
17
15
16
15
573
F-code
Section
C-code
PS
S7.6
7243
Double Reach Mechanism, RDX30
Version no
T-code
000
397
574
Return
Item
No.
Description
Item
No.
Description
Item
No.
Description
Rod
24
Bearing
46
Bearing, 3 stage
Arm
25
Ring, Nilos
47
Cap, bearing
Bearing, thrust
26
Set, bearing
48
Screw
Bearing
27
Spacer
49
Bearing
Arm
28
50
Cap
Pin, roll
29
Screw
51
Screw
Pin
30
Pin
52
Block, bumper
Frame, fork
31
Screw, set
53
Bumper
Screw
32
Arm
54
10
Frame, forward
33
Nut, lock
55
11
Bearing
34
Arm
56
Lockwasher
12
Shim
35
Arm
57
Bushing
13
Arm
36
Pin
58
Bracket
14
Nut
37
Screw
59
Shield
15
Pin, cotter
38
60
Screw, cap
16
Nut, slotted
39
Fitting, grease
61
Manifold
17
Washer
40
Frame, rear
62
Control valve
18
Ring, Nilos
41
Washer, shim
63
Cover
19
Cone, bearing
42
Screw
64
Screw, cap
20
Race, bearing
43
Bar, wear
65
Nut, flanged
21
Ring, retainer
44
Shim
66
Washer
22
Shim
45
Shim
67
Shim
23
Arm
2001-12-07
F-code
Section
C-code
PS
S7.6
7243
Double Reach Mechanism, RDX30
Version no
000
T-code
397
1. Theory of Operation
The reach mechanism extends the forks away from the mast
assembly by pushing the potentiometer forward. With the key
switch ON and the brake pedal and/or right foot pedal
depressed, pushing on the lever causes voltage to be sensed
at the main electronic card. Oil is fed through the reach valve
to the rear ports on the reach cylinders and drives pistons
outward. The oil flows from the front ports of the cylinders
through the reach valve and back to the hydraulic tank. (See
Hydraulic System on page 421.)
2. Maintenance
The only maintenance required on the reach mechanism is
the normal Planned Maintenance per the schedule (page 71).
3. Troubleshooting
CAUTION After elevating or reaching the carriage for
troubleshooting, be sure to use blocks to
secure the carriage.
Use extreme care when blocking the mast
for any reason. Never remove a block when
it is supporting the mast.
Lower the carriage fully and retract the reach mechanism
fully. If the truck is equipped with tilt, set the forks level. If the
truck is equipped with sideshift, center the forks horizontally.
When checking the voltage at the solenoids, make sure the
hydraulic lines and components are fully installed. When
possible, keep the key switch OFF and the battery connector
disconnected.
4. Repair
Minor repair of the reach mechanism include replacement of
the grease fittings on the frames, arms and arm assembly.
5. Rebuild
When it is becomes necessary to rebuild the reach
mechanism, replacement of the fork frame, forward frame,
arms and/or rear frame may be required.
BT Prime-Mover, Inc.
Return
2001-12-07
575
F-code
Section
C-code
PS
S7.6
7243
Double Reach Mechanism, RDX30
Version no
T-code
000
397
576
Return
2001-12-07
F-code
Section
PS
S7.7
Version no
C-code
7410
Forks
T-code
000
395/396/397/398/399
Forks
Lo
ng
er
Av
ai
la
bl
e
NO
BT Prime-Mover, Inc.
Return
Item No.
Description
Pin, roll
Handle
Spring
Pin
Fork
2000-08-04
577
F-code
Section
C-code
PS
Forks
S7.7
7410
Version no
T-code
000
395/396/397/398/399
1
2
3
4
Item No.
578
Return
Description
Knob
Wedge
Washer
Spring
Pin
Fork
2000-08-04
F-code
Section
PS
S7.7
Version no
000
C-code
7410
Forks
T-code
395/396/397/398/399
1. Removal
1. Turn key switch OFF and disconnect battery
connector from the truck.
2. Release fork locking mechanism by lifting up latch
on top of fork.
3. Slide fork toward cutout on bottom of carriage.
Once fork is aligned with cutout, pull up on tip of
fork and move fork away from lower cross member.
Cutout
2. Inspection
Visually inspect all fork surfaces for signs of damage,
including, but not limited to: bending, cracking, and
unauthorized modifications.
Unworn thickness
Minimum
worn thickness
Shank
(unworn portion)
Untapered portion
BT Prime-Mover, Inc.
Return
2000-08-04
579
F-code
Section
C-code
PS
Forks
S7.7
7410
Version no
T-code
000
395/396/397/398/399
3. Installation
1. Place top of fork onto upper cross member, over
cutout in lower cross member.
2. Carefully lower bend in fork toward cutout until fork
is in position at carriage lower cross member.
3. Slide fork to desired location on carriage and
secure in position by pushing fork latch down to
lock it. Latch will engage if fork is over one of the
slots on upper carriage cross member.
Cutout
580
Return
2000-08-04
F-code
Section
PS
S9.0
9310
Load Indicator
Version no
C-code
T-code
001
395/398
RRX35/RSX40
Load Indicator
On Mast
Column
11
10
12
5
6
2
1
13
14
15
19
18
Wiring
Harness
16
17
On Mast
Column
BT Prime-Mover, Inc.
Return
2001-11-07
581
F-code
Section
C-code
PS
S9.0
Load Indicator
9310
Version no
T-code
001
395/398
Item
No.
1
2
3
4
5
6
7
582
Return
Description
Screw
Cover
Arm
Screw
Roller
Ring, locking
Bearing
Item
No.
8
9
10
11
12
13
14
Description
Ring, snap
Hub
Screw
Nut
Washer
Screw
Support
Item
No.
15
16
17
18
19
Description
Cable
Spring
Anchor, bottom
Set screw
Device, sensing
2001-11-07
F-code
Section
PS
S9.0
9310
Load Indicator
Version no
001
C-code
T-code
395/398
Load Indicator
RRX45/RDX30/RSX50
On Mast
Column
10
11
13
12
5
2
1
3
6 7 8
4
14
15
20
19
Wiring
Harness
16
18
17
BT Prime-Mover, Inc.
Return
2001-11-07
583
F-code
Section
C-code
PS
S9.0
Load Indicator
9310
Version no
T-code
001
395/398
Item
No.
1
2
3
4
5
6
7
584
Return
Description
Screw
Cover
Arm
Screw
Roller
Ring, locking
Bearing
Item
No.
8
9
10
11
12
13
14
Description
Ring, retainer
Hub
Screw
Nut
Washer
Screw
Support
Item
No.
15
16
17
18
19
20
Description
Cable
Spring
Anchor, bottom
Screw
Screw, set
Sensing device
2001-11-07
F-code
Section
PS
S9.0
9310
Load Indicator
Version no
001
C-code
T-code
395/398
1. Pulse Sensor
1.1. Repair
1. Unplug wiring connector from assembly.
2. Remove screws (1) and remove cover (2).
3. To replace pulse sensor (19) or (20), loosen
setscrew (18) or (19) and remove pulse sensor.
4. Remove screws (4) and remove arm (3). Reverse
procedure to reinstall.
1.2. Cable
1.2.1. Removal
1. To replace cable (15), remove bolt from bottom
anchor (17) relieving spring tension.
2. Remove spring (16) and anchor (17) from cable
(15).
3. Remove cable (15) from top anchor, and remove
from pulley.
1.2.2. Installation
1. Install new cable (15) on top anchor. Wrap cable
once around pulley wheel.
2. Attach spring (16) and bottom anchor (17) to cable
(15).
3. Stretch cable (15) tight and reinstall bottom anchor
bolt.
BT Prime-Mover, Inc.
Return
2001-11-07
585
F-code
Section
C-code
PS
S9.0
Load Indicator
9310
Version no
T-code
001
395/398
1.3. Pulley
1.3.1. Removal
1. To replace roller (5), remove cover (2), pulse
sensor (19) or (20), and cable (15).
2. Remove screw (11) and nut (10). Remove pulley
wheel.
3. Remove hub (9), retaining ring (8), bearing (7) and
locking ring (6).
4. Reverse procedure to reinstall.
586
Return
2001-11-07
F-code
Section
C-code
PS
S9.1
9390
Height Indicator and Preset Selector
Version no
001
T-code
395/396/397/398/399
Item No
BT Prime-Mover, Inc.
Return
Description
2000-08-04
587
F-code
Section
C-code
PS
S9.1
9390
Height Indicator and Preset Selector
Version no
T-code
001
395/396/397/398/399
1. General
A height indicator is fit to trucks with high lifting heights which
show the current position of forks within the staging zone.
The character window shows the fork height, based on
information from the sensing device (pulse sensor) (U10)
mounted on mast. For electrical component symbols and
component locations see page 269 and page 273.
2. Operation
The measurement in the staging zone starts when reference
switch (S45) is activated and sends a signal to electronic card
(A5). The pulse sensor (U10) send pulses to (A5) which starts
by indicating preprogrammed free lift height on the display
(2). The pulse sensor has two channels, A and B, which give
signals at 90 degree to each other. This gives information to
(A5) on whether forks are moved up or down.
588
Return
2000-08-04
F-code
Section
C-code
PS
S9.1
9390
Height Indicator and Preset Selector
Version no
001
T-code
395/396/397/398/399
3. Preset Height
By using the preset height, the operator can lift and lower the
forks to a maximum of 99 different programmable levels,
within the main lift zone.
Based on height information obtained from the pulse sensor,
the lift and lowering mechanism is controlled to stop at the
required level. Depositing or collecting of the load takes place
manually.
The correct height for depositing or collecting the pallet is
requested/programmed via the keyboard. The selected level
can be read on the display, which also indicates any error
codes.
4
1 2 3
7 8
5 6
9 0
BT Prime-Mover, Inc.
Return
2000-08-04
589
F-code
Section
C-code
PS
S9.1
9390
Height Indicator and Preset Selector
Version no
T-code
001
395/396/397/398/399
4. Display
The diagram shows the rear of the display for preset height.
The table describes the contactors terminal number where I
stands for input and O stands for output.
Connection
Function
+48V
Minus
590
Return
2000-08-04
F-code
Section
C-code
PS
S9.1
9390
Height Indicator and Preset Selector
Version no
001
T-code
395/396/397/398/399
Function
Numerical push-buttons for
setting height levels.
BT Prime-Mover, Inc.
Return
2000-08-04
591
F-code
Section
C-code
PS
S9.1
9390
Height Indicator and Preset Selector
Version no
T-code
001
395/396/397/398/399
6. Programming
Press the button PROG briefly to enter programming mode.
The LED in the button comes on and display shows PL00
when programming routines have been started. Program new
lifting heights, modify programmed values, or remove
programmed values as necessary.
592
Return
2000-08-04
F-code
Section
C-code
PS
S9.1
9390
Height Indicator and Preset Selector
Version no
001
T-code
395/396/397/398/399
BT Prime-Mover, Inc.
Return
2000-08-04
593
F-code
Section
C-code
PS
S9.1
9390
Height Indicator and Preset Selector
Version no
T-code
001
395/396/397/398/399
594
Return
2000-08-04
F-code
Section
C-code
PS
S9.1
9390
Height Indicator and Preset Selector
Version no
001
T-code
395/396/397/398/399
6.3. Parameters
There are a number of parameters that can be modified in the
preset height program.
1. Press the button PROG for three seconds to start
programming routines. The LED comes on and the
display show P_ _ _.
2. Use numerical keys to enter code 852. The display
will now show P_.
3. State the required parameter 1 - 9 and then press
the LOAD button. The display shows factory
settings. These can be changed to any of the
minimum/maximum values shown in the,
Parameters table.
NOTE!
P1
Select the measurement unit (meters or inches) to be used.
Press the PROG button to save the unit selected. The display
shows P_.
P2
If distance between lifting heights is equal on all levels, make
a common program:
1. State parameter 2 and press the LOAD button.
The display shows P 00 and enter the number of
levels. Press the LOAD button and the display
shows P000.
2. Enter the "collect height" for the first level, in steps
of 10 mm. Press the LOAD button and the display
shows P000.
3. The next value to enter is the distance between the
collect and leave level, in steps of 10 mm. Press
the LOAD button and the display shows P000.
BT Prime-Mover, Inc.
Return
2000-08-04
595
F-code
Section
C-code
PS
S9.1
9390
Height Indicator and Preset Selector
Version no
T-code
001
395/396/397/398/399
P3
Programming the crawling speed for braking distances:
1. State parameter 3 and press the LOAD button.
The display shows the previously programmed
value for the crawling speed lower. Enter the new
value using numerical keys. The permitted
maximum/minimum values are shown in the
Parameters table.
2. Press the LOAD button to change the crawling
speed lift. The display shows the value for the
crawling speed. Enter the new value using
numerical keys.
3. Press the PROG button to save the new values.
The display shows P_.
P5
Programming the tolerance for the "stop levels":
1. State parameter 5 and press the LOAD button.
The display shows the previously programmed
value for the tolerance. Enter the new value using
the numerical keys. The permitted maximum/
minimum values are shown in the Parameters
table.
2. Press the PROG button to save the new values.
The display shows P_.
P7
Programming of the largest and smallest permitted
programming distance between the levels collect and leave:
1. State parameter 7. The display shows the
previously programmed value for the minimum.
distance. Enter the new value using numerical
keys, (e.g., 030=30 mm). The permitted maximum/
minimum values are shown in the Parameters
table.
596
Return
2000-08-04
F-code
Section
C-code
PS
S9.1
9390
Height Indicator and Preset Selector
Version no
001
T-code
395/396/397/398/399
P8
Reset all parameters to the factory settings.
NOTE!
P9
Programming the braking distance for leave/collect levels.
1. State parameter 9 and press the LOAD button.
The display shows the braking distance for lower.
Enter the new value using the numerical keys,
(e.g., 050=500 mm).
2. Press the LOAD button. The display shows the
braking distance for lift.
3. Enter the new value using the numerical keys,
(e.g., 030=300 mm).
4. Press the PROG button to save. The display
shows P_.
BT Prime-Mover, Inc.
Return
2000-08-04
597
F-code
Section
C-code
PS
S9.1
9390
Height Indicator and Preset Selector
Version no
T-code
001
395/396/397/398/399
Parameter Table
Parameter
number
P1
Maximum/
minimum
value
Factory
setting
001
002
Unit
m-10 mm
inch-10ths of
an inch
P2
P3
10s of mm
10 mm
10 mm
% of maximum
speed
Number of levels.
Distance first collect height.
Distance collect-leave.
Distance between leave levels.
Crawling speed before stop:
Lower
Lift
0-127
0-127
015
020
P5
0-255
010
mm
P7
0-255
0-255
030
150
mm
P8
P9
0-255
0-255
598
Measurement unit
Return
Function
050
030
10 mm
10 mm
2000-08-04
F-code
Section
C-code
PS
S9.1
9390
Height Indicator and Preset Selector
Version no
001
Position
T-code
395/396/397/398/399
Function
Leave level
Collect level
Staging zone
H2
P3
P9
A
P7
P5
B
P3
P9
P5
BT Prime-Mover, Inc.
Return
H2
2000-08-04
599
F-code
Section
C-code
PS
S9.1
9390
Height Indicator and Preset Selector
Version no
T-code
001
395/396/397/398/399
Error Codes
Error
Code
Remark
Err 1
Err 2
Err 9
Err flashes
Four points are lit in the display when forks are in the free
lift zone.
600
Return
2000-08-04
F-code
Section
PS
s9.2
9501
Load Backrest
Version no
000
C-code
T-code
395/396/397/398/399
Load Backrest
3
2
RRX35/RSX40
Item No
BT Prime-Mover, Inc.
Return
Description
Backrest
Screw, cap
Washer, flat
2000-08-04
601
F-code
Section
C-code
PS
s9.2
Load Backrest
9501
Version noT-code
000
395/396/397/398/399
3
4
2
RRX45/RDX30
Item No
602
Return
Description
Backrest
Screw, cap
Washer, flat
2000-08-04
F-code
Section
PS
s9.2
9501
Load Backrest
Version no
000
C-code
T-code
395/396/397/398/399
3
2
RSX50
Item No
BT Prime-Mover, Inc.
Return
Description
Backrest
Screw, cap
Washer, flat
2000-08-04
603
F-code
Section
C-code
PS
s9.2
Load Backrest
9501
Version noT-code
000
395/396/397/398/399
1. Removal
1. Park truck on a level surface.
2. Turn the key switch OFF and disconnect battery
connector from the truck.
3. Use a 3/4 (19 mm) socket to remove four screws
(2), two on each side.
4. Lift backrest off the front fork frame.
5. On RRX45 and RDX30, be sure to retrieve two
shims (4) that go between the backrest and the
front fork frame.
2. Installation
1. Place load backrest on the front fork frame.
2. On RRX45 and RDX30, slide shims (4) between
the frame and backrest, aligning the mounting
holes.
3. Insert mounting screws (2) and tighten.
4. Repeat steps 2 and 3 for the opposite side.
5. Connect battery connector to the truck.
6. Return truck to service.
604
Return
2000-08-04
Index
A
Alarm
Travel/Back-up . . . . . . . . . . . . . . 332
Application
Intended . . . . . . . . . . . . . . . . . . . . 34
Prohibited . . . . . . . . . . . . . . . . . . . 35
B
Battery
Charging . . . . . . . . . . . . . . . . . . . 327
Cleaning Exterior . . . . . . . . . . . . . 327
History Record . . . . . . . . . . . . . . 328
Inspection and Care . . . . . . . . . . 326
Installation . . . . . . . . . . . . . . . . . . 325
Maintenance . . . . . . . . . . . . . . . . 326
Removal . . . . . . . . . . . . . . . . . . . 325
Retainer Plates . . . . . . . . . . . . . . 106
Rollers . . . . . . . . . . . . . . . . . . . . . 106
Storage . . . . . . . . . . . . . . . . . . . . 328
Battery Connector
Inspection . . . . . . . . . . . . . . . . . . 341
Installation . . . . . . . . . . . . . . . . . . 342
Location . . . . . . . . . . . . . . . . . . . . 341
Battery Safety . . . . . . . . . . . . . . . . . . . 21
Brake
Electromagnetic . . . . . . . . . . . . . 179
Friction Plate . . . . . . . . . . . . . . . . 184
Pedal Adjustment . . . . . . . . 111, 114
Pedal Bearing Replacement 111, 114
Pedal Removal . . . . . . . . . . 110, 113
Braking Caster Assembly
Installation . . . . . . . . . . . . . . . . . . 208
Removal . . . . . . . . . . . . . . . . . . . 207
Braking Caster Wheel
Removal . . . . . . . . . . . . . . . . . . . 203
Bumpers, Retract
Carriage/Reach . . . . . . . . . . . . . . 556
C
Carriage
Roller Bearings . . . . . . . . . . . . . . 558
Installation . . . . . . . . . . . . . . . 558
BT Prime-Mover, Inc.
Return
Removal . . . . . . . . . . . . . . . . .558
Carriage, Reach
Adjustment . . . . . . . . . . . . . . . . . 556
Assembly . . . . . . . . . . . . . . . . . . 554
Disassembly . . . . . . . . . . . . . . . . 552
Repair . . . . . . . . . . . . . . . . . . . . . 552
Carriage/Reach
Bumpers, Retract . . . . . . . . . . . . 556
Chassis
Dash . . . . . . . . . . . . . . . . . . . . . . 100
Left-Hand Side Panel . . . . . . . . . 102
Main Card Access Panel . . . . . . 103
Motor Compartment Door . . . . . . 101
Operator Compartment Panel . . 103
Contactor
Battery Cut-out . . . . . . . . . . . . . . 356
Directional . . . . . . . . . . . . . . . . . . 352
Lift Bypass . . . . . . . . . . . . . . . . . 354
Resistance Testing . . . . . . . . . . . 351
Tip Inspection . . . . . . . . . . . . . . . 351
Control Pod . . . . . . . . . . . . . . . . . . . 217
Control Valve . . . . . . . . . . . . . . . . . . 461
Control Valve Assembly
Hydraulic Lowering . . . . . . . . . . . 470
Recondition Seal Kit . . . . . . . . . . 471
Conversion Formulas . . . . . . . . . . . . . 55
Cylinder
Freelift
Assembly . . . . . . . . . . . . . . . . .480
Disassembly . . . . . . . . . . . . . .480
Installation . . . . . . . . . . . . . . . .480
Removal . . . . . . . . . . . . . . . . .479
Reach Assembly
Assembly . . . . . . . . . . . . . . . . .486
Disassembly . . . . . . . . . . . . . .484
Inspection . . . . . . . . . . . . . . . .485
Installation . . . . . . . . . . . . . . . .487
Removal . . . . . . . . . . . . . . . . .483
Tilt Assembly
Assembly . . . . . . . . . . . . .493, 500
Disassembly . . . . . . . . . .491, 498
Inspection . . . . . . . . . . . .492, 499
Installation . . . . . . . . . . . .494, 501
Removal . . . . . . . . . . . . .489, 497
2001-08-21
605
Index
D
Data Plate . . . . . . . . . . . . . . . . . . . . . . 41
Decals . . . . . . . . . . . . . . . . . . . . . . . . 117
Definition
Caution . . . . . . . . . . . . . . . . . . . . . 15
Danger . . . . . . . . . . . . . . . . . . . . . 15
Note . . . . . . . . . . . . . . . . . . . . . . . . 15
Prohibitory . . . . . . . . . . . . . . . . . . . 16
Warning . . . . . . . . . . . . . . . . . . . . . 15
Definitions . . . . . . . . . . . . . . . . . . . . . . 97
Drive Wheel
Installation . . . . . . . . . . . . . . . . . . 186
Removal . . . . . . . . . . . . . . . . . . . 186
Tire Pressing . . . . . . . . . . . . . . . . 187
Driver Controls . . . . . . . . . . . . . . . . . 107
E
Electrical Compartment Fan . . . . . . . 123
Electrical Functions
12-Volt Power Supply . . . . . . . . . 255
Component Location . . . . . . . . . . 273
Direction Selection . . . . . . . . . . . 239
Forks First Direction . . . . . . . . . . 241
Forks Trailing Direction . . . . . . . . 245
Pump Motor Brush Indicator Switch 274
Electrical Schematics
Serial numbers 27163000 - 28105000
277
Serial numbers 28105001 - 28126000
289
Serial numbers 28126001 - 31285000
301
Serial numbers 31285001 - UP . . 313
Electrical Symbols . . . . . . . . . . . . . . 275
Electronic Card . . . . . . . . . . . . . . . . . 382
Main . . . . . . . . . . . . . . . . . . . . . . 369
F
Fan
Electrical Compartment . . . . . . . . 123
Operator . . . . . . . . . . . . . . . . . . . 333
Fasteners
606
Return
G
Grease Location Points . . . . . . . . . . . 85
Guard, Overhead . . . . . . . . . . . . . . . 115
H
Height Indicator
Display . . . . . . . . . . . . . . . . . . . . 590
Display Symbols Description . . . 591
Operation . . . . . . . . . . . . . . . . . . 588
Preset Height . . . . . . . . . . . . . . . 589
Programming . . . . . . . . . . . . . . . 592
Horn . . . . . . . . . . . . . . . . . . . . . . . . . 335
Installation . . . . . . . . . . . . . . . . . 335
Removal . . . . . . . . . . . . . . . . . . . 335
Hydraulic
Filter Adapter . . . . . . . . . . . . . . . 458
Troubleshooting . . . . . . . . . . . . . . 96
Hydraulic Filter . . . . . . . . . . . . . . . . . 457
Hydraulic Fluid
Refilling System . . . . . . . . . . . . . 449
Selection . . . . . . . . . . . . . . . . . . . 447
Hydraulic Pump . . . . . . . . . . . . . . . . 460
Hydraulic System . . . . . . . . . . . . . . . 421
Bleeding . . . . . . . . . . . . . . . . . . . 450
Changing Fluid . . . . . . . . . . . . . . 447
Schematic RRX30 . . . . . . . . . . . 444
Schematic RRX35 . . . . . . . . . . . 442
Schematic RRX45 . . . . . . . . . . . 443
Schematic RSX40 . . . . . . . . . . . 445
Schematic RSX50 . . . . . . . . . . . 446
Hydraulic Tank
Installation . . . . . . . . . . . . . . . . . 454
Removal . . . . . . . . . . . . . . . . . . . 453
2001-08-21
Index
I
Introduction . . . . . . . . . . . . . . . . . . . . . 65
J
Jacking Truck Off The Floor . . . . . . . . 66
K
Key Switch . . . . . . . . . . . . . . . . . . . . 337
L
Lift Chain, 3 Stage Mast . . . . . . . . . . 514
Lifting Gear
Assembly . . . . . . . . . . . . . . . . . . . 526
Disassembly . . . . . . . . . . . . . . . . 526
Installation . . . . . . . . . . . . . . . . . . 526
Removal . . . . . . . . . . . . . . . . . . . 525
Lights
Overhead Guard . . . . . . . . . . . . . 329
Warning . . . . . . . . . . . . . . . . . . . . 330
Working . . . . . . . . . . . . . . . . . . . . 331
Load Backrest
Installation . . . . . . . . . . . . . . . . . . 604
Removal . . . . . . . . . . . . . . . . . . . 604
Load Indicator
Pulse sensor . . . . . . . . . . . . . . . . 585
Load Wheels
Size 10.5 X 3.5 . . . . . . . . . . . . . . 213
Sizes 4 X 3, 5 X 4, and 5 X 3 . . . 209
Lubricants
Cold Storage . . . . . . . . . . . . . . . . . 68
Corrosion . . . . . . . . . . . . . . . . . . . . 68
Freezer Storage . . . . . . . . . . . . . . 70
Standard . . . . . . . . . . . . . . . . . . . . 68
Lubrication
Chart . . . . . . . . . . . . . . . . . . . . . . . 83
Points . . . . . . . . . . . . . . . . . . . . . . 83
BT Prime-Mover, Inc.
N
Non-Braking Caster Assembly
Installation . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . .
Non-Braking Caster Wheel
Caster Pivot . . . . . . . . . . . . . . . .
Thrust Bearing . . . . . . . . . . . . . .
200
200
191
193
O
Oils and Grease . . . . . . . . . . . . . . . . . 84
Overhead Guard . . . . . . . . . . . . . . . 115
Return
2001-08-21
607
Index
R
Reach Carriage
Adjustment . . . . . . . . . . . . . . . . . 556
Assembly . . . . . . . . . . . . . . . . . . . 554
Disassembly . . . . . . . . . . . . . . . . 552
Repair . . . . . . . . . . . . . . . . . . . . . 552
Reach, Double
Maintenance . . . . . . . . . . . . . . . . 575
Theory of Operation . . . . . . . . . . 575
Reach, Single
Carriage Roller Bearings . . . . . . . 572
Maintenance . . . . . . . . . . . . 547, 559
Repair . . . . . . . . . . . . . . . . . . . . . 567
Roller Bearings
Carriage . . . . . . . . . . . . . . . . . . . 558
Installation . . . . . . . . . . . . . . . 558
Removal . . . . . . . . . . . . . . . . . 558
RV2 Adjustment . . . . . . . . . . . . . . . . 382
S
Sensor
Drive Motor Speed . . . . . . . . . . . 419
Steer Stop Proximity . . . . . . . . . . 417
Wheel Direction . . . . . . . . . . . . . . 415
Sideshifter
Installation . . . . . . . . . . . . . . . . . . 535
Maintenance . . . . . . . . . . . . 530, 536
Mounting Instructions . . . . . 529, 535
Operation . . . . . . . . . . . . . . 530, 536
Troubleshooting . . . . . . . . . . . . . 540
Spare Parts, Ordering . . . . . . . . . . . . . 61
Static Safety . . . . . . . . . . . . . . . . . . . . 26
Steering Bearing
Installation . . . . . . . . . . . . . . . . . . 222
Removal . . . . . . . . . . . . . . . . . . . 222
Steering Motor
Installation . . . . . . . . . . . . . . . . . . 121
Steering Tach . . . . . . . . . . . . . . . . . . 219
Steering Wheel . . . . . . . . . . . . . . . . . 218
Switches
Emergency Disconnect . . . . . . . . 339
Key . . . . . . . . . . . . . . . . . . . . . . . 337
608
Return
T
Technical Service Data . . . . . . . . . . . 57
Three Stage Mast
Assembly . . . . . . . . . . . . . . . . . . 475
Disassembly . . . . . . . . . . . . . . . . 475
Installation . . . . . . . . . . . . . . . . . 475
Removal . . . . . . . . . . . . . . . . . . . 474
Transistor Regulator
Motor Connections . . . . . . . . . . . 360
Safety Control . . . . . . . . . . . . . . . 363
Transmission
Axle Sealing Ring . . . . . . . . . . . . 174
Fluid Changing . . . . . . . . . . . . . . 156
Repair
Leakage, Lower Cover . . . . . .177
Leakage, Top Cover . . . . . . . .176
Wheel Bolts . . . . . . . . . . . . . . .178
Troubleshooting
Hydraulic . . . . . . . . . . . . . . . . . . . . 96
Sideshifter . . . . . . . . . . . . . . . . . . 540
Troubleshooting Guidelines . . . . . . . . 89
Truck
Data . . . . . . . . . . . . . . . . . . . . . . . 35
Dimensions (RDX30) . . . . . . . . . . 38
Dimensions (RRX35) . . . . . . . . . . 36
Dimensions (RRX45) . . . . . . . . . . 37
Dimensions (RSX40) . . . . . . . . . . 39
Dimensions (RSX50) . . . . . . . . . . 40
Main Components . . . . . . . . . . . . 42
Truck Side Views . . . . . . . . . . . . . . . . 33
Truck Torque Specifications . . . . . . . 53
2001-08-21
Index
V
Valve
Control . . . . . . . . . . . . . . . . . . . . . 461
Pressure Setting . . . . . . . . . . . . . 469
415
415
416
416
348
349
Welding Safety . . . . . . . . . . . . . . . . . . 27
BT Prime-Mover, Inc.
Return
2001-08-21
609
Return
Return
Back Cover
Return