306756-000 2001 - November PDF
306756-000 2001 - November PDF
306756-000 2001 - November PDF
WARNING
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Return
F-code
Section
C-code
BT Standard Codes
Version no
T-code
000
BT 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
BT Standard Codes
Version no
T-code
000
Return
6000
7000
8000
Options / Attachments
9000
2000-08-04
Table of Contents
Table of Contents
BT 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 ............................................................ 74
Lubrication Chart ......................................................................................... 81
Oil and Grease Specifications ....................................................................
Approved Oils and Grease .......................................................................
Grease Location Points ............................................................................
Mast Adjustment Points ............................................................................
82
82
83
84
87
87
89
94
95
Chassis ......................................................................................................... 97
General ..................................................................................................... 97
Dash ......................................................................................................... 98
Motor Compartment Door ......................................................................... 99
Left-Hand Side Panel ............................................................................... 100
Operator Compartment Panel .................................................................. 101
Main Card Access Panel ......................................................................... 101
Battery Compartment ................................................................................. 103
Battery Retainer Plates ............................................................................ 104
Battery Rollers ......................................................................................... 104
Mounting Points ..........................................................................................
Drive Motor ..............................................................................................
Pump Motor .............................................................................................
Transmission ...........................................................................................
105
105
108
112
119
120
121
121
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2001-10-12
Table of Contents
Pedal Adjustment ..................................................................................... 124
Overhead Guard .......................................................................................... 125
Decals ........................................................................................................... 127
Decal with Protective Sheet ..................................................................... 127
Decal without Protective Sheet ................................................................ 127
Steering Motor .............................................................................................
Removal ...................................................................................................
Installation ................................................................................................
Steering Motor Gear Replacement ..........................................................
131
131
131
132
135
135
135
136
163
165
166
171
172
Transmission ...............................................................................................
Disassemble ............................................................................................
Assembly .................................................................................................
Axle Sealing Ring ....................................................................................
Leakage ...................................................................................................
Wheel Bolt ...............................................................................................
173
175
179
188
190
192
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2001-10-12
Table of Contents
Removal ...................................................................................................
Installation ................................................................................................
Adjustments .............................................................................................
Coil Check On Brake ...............................................................................
Electromagnetic Brake, Armature and Magnetic Coil ..............................
Brake Friction Plate .................................................................................
193
195
196
197
197
198
199
200
200
201
203
205
207
209
211
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229
231
232
233
2001-10-12
Table of Contents
Steering Bearing ......................................................................................... 235
Removal ................................................................................................... 236
Installation ................................................................................................ 236
Electrical Functions ....................................................................................
General ....................................................................................................
Start Up ....................................................................................................
Steering Components ..............................................................................
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
237
241
245
251
253
255
259
263
267
268
271
275
277
278
279
281
291
291
292
293
294
295
296
297
298
299
300
301
303
303
304
305
306
307
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2001-10-12
Table of Contents
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) .............................................................................
308
309
310
311
312
313
314
315
315
316
317
318
319
320
321
322
323
324
325
326
Battery ..........................................................................................................
Removal ...................................................................................................
Installation ................................................................................................
Battery Maintenance ................................................................................
Storage ....................................................................................................
Battery History Record .............................................................................
327
327
327
328
330
330
331
331
332
333
334
335
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339
339
339
340
2001-10-12
Table of Contents
Start/Stop Switches ....................................................................................
General ....................................................................................................
Key Switch (S17) .....................................................................................
Emergency Disconnect Switch (S21) ......................................................
341
341
341
343
353
353
354
356
358
365
365
366
367
369
369
370
374
374
380
381
381
382
382
383
384
390
393
395
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2001-10-12
Table of Contents
Programming Parameter ......................................................................... 400
Switches and Sensors ................................................................................
General ....................................................................................................
Platform (Right Foot) Switch (S108) ........................................................
Staging Switch (S45) ...............................................................................
Wheel Direction Sensor ...........................................................................
Steer Proximity Sensors A and B (S66 and S67) ....................................
Drive Motor Speed(S64)/Direction Sensors (S125) .................................
411
411
411
413
415
417
419
421
421
446
447
448
449
450
451
451
451
452
453
454
10
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2001-10-12
Table of Contents
Removal ...................................................................................................
Disassembly ............................................................................................
Assembly .................................................................................................
Installation ................................................................................................
478
479
479
479
481
483
484
484
484
485
487
488
488
488
489
491
492
493
494
495
497
499
500
501
502
503
505
507
508
509
510
511
513
515
516
517
518
519
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2001-10-12
11
Table of Contents
Tilt Cylinder Assembly, RSX50 ..................................................................
Removal ...................................................................................................
Disassembly ............................................................................................
Inspection ................................................................................................
Assembly .................................................................................................
Installation ................................................................................................
521
523
524
525
526
527
529
531
532
533
534
535
546
548
550
555
12
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577
579
580
580
585
587
593
598
604
608
2001-10-12
Table of Contents
Single Reach, RRX45 ..................................................................................
Maintenance ............................................................................................
Reach Repair ...........................................................................................
Fork Carriage Pivot Pins ..........................................................................
Carriage Roller Bearings .........................................................................
609
609
617
621
622
653
655
655
656
663
664
664
665
666
667
668
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2001-10-12
13
Table of Contents
14
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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 Instruction 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.
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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.
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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
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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
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.
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
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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 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
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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
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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
Forward
Right SIde
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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)
192-270
(4876-6858)
24 Volt
6.0 mph
36 Volt
6.5 mph
24 Volt
5.5 mph
36 Volt
6.0 mph
4500
(2041)
210-402
(5334-10210)
24 Volt
6.0 mph
36 Volt
6.5 mph
24 Volt
5.5 mph
36 Volt
6.0 mph
3000
(1360)
210-402
(5334-10210)
36 Volt
6.0 mph
4000
(1814)
192-270
(4876-6858)
24 Volt
6.0 mph
36 Volt
6.5 mph
24 Volt
5.5 mph
36 Volt
6.0 mph
5000(
2267)
210-402
(5334-10210)
24 Volt
6.0 mph
36 Volt
6.5 mph
24 Volt
5.5 mph
36 Volt
6.0 mph
Service weight
without battery,
lb (kg)
240 Mast
5595
(2537)
210 Mast
5915
(2682)
330 Mast
6945
(3150)
210 Mast
4645
(2106)
210 Mast
5530
(2508)
Service weight
including
battery, lb (kg)
Above +
battery
weight
Above +
battery weight
Above +
battery weight
(2600 min)
Above +
battery weight
(2400 min)
Above +
battery weight
(2400 min)
Lifting capacity
rated load
lb (kg)
Lift height,
inches (mm)
Operating
speed without
load, mph
Operating
speed with
load, mph
36 Volt
6.5 mph
The lifting capacity, lifting height, and weight of the truck can
be found on the truck data plate.
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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
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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
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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. There are several standards used by the
countries in the manufacture of threaded fasteners. 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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2001-09-18
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
2001-09-18
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! Identification marks are according to bolt
strength. The higher the number, or the
increase in the number of marks, indicates
increased bolt strength.
BT Prime-Mover, Inc.
Return
2001-09-18
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
2001-09-18
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
2001-09-18
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
2001-09-18
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
2001-09-18
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
N m
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
N m
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
2001-09-18
F-code
Section
C-code
M1.1
Inch (SAE) and Metric Fasteners
Version no
T-code
002
Torque Specification
BT Prime-Mover, Inc.
Return
2001-09-18
53
F-code
Section
C-code
M1.1
Inch (SAE) and Metric Fasteners
Version no
T-code
002
Torque Specification
54
Return
2001-09-18
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
2001-09-18
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)
By
To Get
TORQUE
Multiply
By
To Get
Multiply
inch pound
0.113
8.851
inch pounds
in-lb
feet pound
1.356
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
2001-09-18
F-code
PS
Section
C-code
M2.0
Technical Service Data
Version no
T-code
003
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
Minimum brush
length
Minimum
commutator
diameter
Minimum brush
spring
tension
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)
Normal temperature
Above 23F (-5C)
Below 23F (-5C)
Below 5F (-15C)
SAE 80W90
SAE 80W/90
ATF
SAE 80W90
SAE 80W/90
ATF
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
Minimum brush
length
Minimum brush
spring tension
6.4 oz (180 g)
40 oz (1120 g)
40 oz (1120 g)
Pressure at rated
load
2450 psi
2400 psi
2450 psi
24 V - 13 cc
36 V - 19 cc
36 V - 27 cc
36 V - 27 cc
Minimum
commutator
diameter
Pump displacement
Tank volume
58
Return
2001-09-18
F-code
PS
Version no
003
Section
C-code
M2.0
Technical Service Data
T-code
395/396/397/398/399
MODEL
Normal temperature
Above 23F (-5C)
Below 23F (-5C)
Below 5F (-15C)
RRX35 - RSX40
RDX30
RRX45 - RSX50
Sunoco TH
ATF
Texaco 15
Sunoco TH
ATF
Texaco 15
Sunoco TH
ATF
Texaco 15
FUSES
Drive motor circuit
250A fuses,
part number 305656-000
250A fuses,
part number 305656-000
250A fuses,
part number 305656-000
425A, 24V
part number 305656-002
355A, 36V
part number 305656-001
Control circuit
Steering circuit
15A (RRX35)
part number 122308-150
(S/N 27091000-27135000)
10A
part number 25275-12
(S/N 27135001 - UP)
30A (S/N 27135001 - UP)
part number 25275-13
30A (S/N 27091000 27135000)
part number 122308-300
10A
part number 25275-12
15A (RRX45)
part number 122308-150
(S/N 27091000-27135000)
10A
part number 25275-12
(S/N 27135001 - UP)
30A (S/N 27135001 - UP)
part number 25275-13
30A (S/N 27091000 27135000)
part number 122308-3003
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
Weight Minimum
(Maximum)
14.5 inch
1600 lb (726mm)
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)
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
DRIVING SPEEDS
Without load
With rated 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
LIFTING/LOWERING TIME
Lift without load
Lift with rated load
Lower without load,
electrical valve
Lower with rated
load,
electrical valve
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
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
Return
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.
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. Cold Storage Conditioning
The reach trucks are recommended to operate in
temperatures between 32 F (0 C) and 115 F (46 C) in
their standard design. Cold storage conditioning is available
for continuous operation in -5 F (-15 C) temperatures or for
in and out applications to -13 F (-25 C). A freezer
conditioning package is available for applications with
continuous operation to -31 F (-35 C).
If the truck is to be used in a cold storage application, it will be
equipped with cold storage components and cold storage
fluids in the hydraulic tank and the drive unit when delivered
from the factory.
68
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
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
Drive Motor
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 159)
Check brushes (see page 148 or
page 157, and page 167)
Drive Gear
Check for oil leakage
Brake
Clean dust and debris
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
2000-08-04
69
F-code
Section
C-code
PS
P2.0
Service Schedule
Version no
T-code
002
395/396/397/398/399
Item
3300.2
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
70
Return
Work Required
Interval in Hours
Interval in Days/Weeks/Months
Check brake shoes for wear
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
All connections: battery, battery
and charger plugs
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
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 364).
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
71
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
72
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
73
F-code
Section
C-code
PS
P2.0
Service Schedule
Version no
T-code
002
395/396/397/398/399
1/2
Discharged battery
74
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
75
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.
76
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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
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Section
C-code
PS
P2.0
Service Schedule
Version no
T-code
002
395/396/397/398/399
3. Sudden temperature changes (continuous in-dooroutdoor movement) that is refrigeration plant, etc.
Routine inspection every 480 hours (4 months).
78
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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
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 82)
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.
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2000-08-04
81
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
82
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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.
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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
84
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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.
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OPTIONS / ATTACHMENTS
2000-08-04
9000
85
F-code
Section
C-code
PS
S
Contents, Section S
Version no
T-code
000
86
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 on the negative side of a
component.
Rear 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.
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2000-08-04
87
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PS
S0.0
Troubleshooting Guidelines
Version no
T-code
000
395/396/397/398/399
Operating symptoms
88
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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 (S1) 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 400. Visually inspect all
wiring and electrical components for the following:
BT Prime-Mover, Inc.
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2000-08-04
89
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PS
S0.0
Troubleshooting Guidelines
Version no
T-code
000
395/396/397/398/399
Accumulation of dirt
Breakdown in insulation
Bare wires
90
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.
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2000-08-04
91
F-code
Section
C-code
PS
S0.0
Troubleshooting Guidelines
Version no
T-code
000
395/396/397/398/399
92
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F-code
Section
C-code
PS
S0.0
Troubleshooting Guidelines
Version no
000
T-code
395/396/397/398/399
BT Prime-Mover, Inc.
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2000-08-04
93
F-code
Section
C-code
PS
S0.0
Troubleshooting Guidelines
Version no
T-code
000
395/396/397/398/399
3. Hydraulic
NOTE! Proper care and cleanliness should be
observed when servicing a lift truck to
ensure that the oil does not become
contaminated with dirt or other foreign
material. Contaminants drawn into the
pump may cause the pump to stick,
For error code listings see pages 393, 394, and 396. For
programming parameters see page 400. If the hydraulic
pump assembly does not operate properly, the following
preliminary checks should be made:
94
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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
closed 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 safety 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 is actuated when the
carriage is above a certain height on the mast. It is used to
activate the speed limit feature to limit travel speed when the
carriage is elevated.
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
the motor power amplifier is from 185o F (85o 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.
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2000-08-04
95
F-code
Section
C-code
PS
S0.0
Troubleshooting Guidelines
Version no
T-code
000
395/396/397/398/399
96
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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.
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15
2001-09-20
97
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 and emergency stop switch
are mounted on the dash. The key switch, travel speed/
directional selector, lift and lower switch, horn switch, tilt
switch and sideshifter switch are in the pod (see page 117).
2.1. Removal
1. Park truck on a level surface and block.
2. Turn keys witch OFF and disconnect the battery at
the battery connector.
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.
98
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PS
S0.1
Version no
002
C-code
0000
Chassis
T-code
395/396/397/398/399
2.1. 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. Reconnect battery at the battery connector.
6. Return truck to service.
3.2. Installation
1. Set door (10) in place so hinge pins are securely
mounted in panel hinge.
CAUTION
BT Prime-Mover, Inc.
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2001-09-20
99
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C-code
PS
Chassis
S0.1
0000
Version no
T-code
002
395/396/397/398/399
Control
Pod
100
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.
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2001-09-20
101
F-code
Section
C-code
PS
Chassis
S0.1
0000
Version no
T-code
002
395/396/397/398/399
102
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.
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2000-08-04
103
F-code
Section
PS
S0.2
Battery Compartment
C-code
0391
Version no
T-code
000
365/396/397/398/399
f
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.
104
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F-code
Section
PS
S0.3
0451
Mounting Points
Version no
000
C-code
T-code
395/396/397/398/399
Mounting Points
1. Drive Motor
23
22
21
20
19
18
17
16
14
15
Item
No.
BT Prime-Mover, Inc.
Return
Description
Item
No.
Description
14
15
16
Ring, retainer
Ring, retainer
Bearing
19
20
21
O-ring
Screw, cap
Drive Motor Assembly
17
18
Ring, seal
Sleeve
22
23
Brake Assembly
Sensor Assembly
2000-08-04
105
F-code
Section
C-code
PS
S0.3
Mounting Points
0451
Version no
T-code
000
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 at the
battery connector.
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.
106
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to
prevent
2000-08-04
F-code
Section
PS
S0.3
0451
Mounting Points
Version no
000
C-code
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.
4. Apply Loctite 243 to drive motor mounting bolts.
A magnet may be handy to help start the back bolt
or to retrieve a bolt if dropped behind the drive
motor.
5. Using a 9/16 inch (13 mm) socket torque drive
motor mounting bolts (25) to 20-25 ft-lb (30-35
Nm).
6. Be sure to draw motor down evenly to allow the
gear on the motor shaft to properly mesh with the
transmission.
7. Attach brake electrical connection (R3).
8. Attach brush wear indicator connections.
9. Install drive motor power cables to terminal posts.
10. Add washers and nuts to terminal posts. Be sure
nuts are tight using an 11/16 inch (17 mm) wrench
for the armature and field connections.
11. Reconnect brush wear sensor, temperature
sensor, and two speed/directional sensor
connections.
12. Reinstall side panel, left side panel and motor
compartment door.
13. Reconnect battery at the battery connector.
Remove blocks from truck.
BT Prime-Mover, Inc.
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2000-08-04
107
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C-code
PS
S0.3
Mounting Points
0451
Version no
T-code
000
395/396/397/398/399
2. Pump Motor
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
108
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S0.3
0451
Mounting Points
Version no
000
C-code
T-code
395/396/397/398/399
2.1. 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
BT Prime-Mover, Inc.
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2000-08-04
109
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C-code
PS
S0.3
Mounting Points
0451
Version no
T-code
000
395/396/397/398/399
2.2. 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. Apply Loctite 243 to the four
mounting bolts. Insert bolts through the large
washer (5), then through the bracket mounting
plate into truck frame. Torque bolts to 14-18 ft-lb
(20-25 N) 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.
110
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F-code
Section
PS
S0.3
0451
Mounting Points
Version no
000
C-code
T-code
395/396/397/398/399
BT Prime-Mover, Inc.
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2000-08-04
111
F-code
Section
C-code
PS
S0.3
Mounting Points
0451
Version no
T-code
000
395/396/397/398/399
3. Transmission
13
12
11
8
10
9
112
Return
Item
No.
Description
Item
No.
Transmission assembly
11
Plate, EE
8
9
12
13
Screw, EE
Screw, cap
10
Gasket, EE
Description
2000-08-04
F-code
Section
PS
S0.3
0451
Mounting Points
Version no
000
C-code
T-code
395/396/397/398/399
3.2. Removal
1. Park truck on a level surface.
2. Turn key switch OFF and disconnect battery at the
battery connector.
CAUTION Use extreme care whenever truck is
jacked up for any reason. Never block
truck between mast columns and the
floor. Use a suitable hoist to stabilize the
mast. Keep hands and feet clear from
beneath the vehicle while jacking. Use
jack stands or solid blocks to support the
truck. Do not rely on jacks.
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. See paragraph 3.1 above.
5. Remove drive tire (see page 199).
BT Prime-Mover, Inc.
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2000-08-04
113
F-code
Section
C-code
PS
S0.3
Mounting Points
0451
Version no
T-code
000
395/396/397/398/399
3.3. 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.
5. Clean and apply Loctite 242 to the transmission
mounting bolts (18). Using an 3/4 inch (19 mm)
wrench to help get the bolts started straight.
6. The transmission will draw tight to the truck frame
mounting surface as the bolts are tightened.
Transmission mounting bolts (13) should be
torqued to 50-59 ft-lbs (70-80 Nm).
7. Add transmission fluid (see page 113.)
114
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F-code
Section
PS
S0.3
0451
Mounting Points
Version no
000
C-code
T-code
395/396/397/398/399
BT Prime-Mover, Inc.
Return
2000-08-04
115
F-code
Section
C-code
PS
S0.3
Mounting Points
0451
Version no
T-code
000
395/396/397/398/399
116
Return
2000-08-04
F-code
Section
PS
S0.4
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 229.
Dash
Pod
Steering
wheel
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
117
F-code
Section
C-code
PS
S0.4
Driver Controls
0640
Version no
T-code
000
395/396/397/398/399
118
Return
2000-08-04
F-code
Section
C-code
PS
S0.5
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
119
F-code
Section
C-code
PS
S0.5
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
120
Return
2000-08-04
F-code
Section
C-code
PS
S0.5
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
121
F-code
Section
C-code
PS
S0.5
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
122
Return
2000-08-04
F-code
Section
C-code
PS
S0.5
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
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
123
F-code
Section
C-code
PS
S0.5
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).
124
Return
2000-08-04
F-code
Section
PS
S0.6
0811
Overhead Guard
Version no
000
C-code
T-code
395/396/397/398/399
Overhead Guard
1
4
2
3
5
Item No.
BT Prime-Mover, Inc.
Return
Description
Overhead guard
2
3
4
Bolt
Screw, cap
Nut
2000-08-04
125
F-code
Section
C-code
PS
S0.6
Overhead Guard
0811
Version no
T-code
000
395/396/397/398/399
126
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.
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
127
F-code
Section
C-code
PS
Decals
S0.6
0851
Version no
T-code
000
365/396/397/398/399
14
12
13
Inches
Cap. (Lbs.)
Serial Number
Model
Truck Wt.
Less Batt. (Lbs.)
DC Voltage
Use UL Class
Battery Type
Type
Attachment
Max.
Back Tilt
B
A
BT Prime-Mover, Inc.
Muscatine, IA 52761
10
5
11
128
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
129
F-code
Section
C-code
PS
Decals
S0.6
0851
Version no
T-code
000
365/396/397/398/399
130
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 the
battery at the battery connector.
3. Remove motor compartment door (see page 99) to
access steering motor.
4. Disconnect steering motor from main electrical
harness.
5. Use a 0.20 inch (5 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
131
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. 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 131.
132
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 at the
battery connector.
1.2. Removal
1. Turn the key switch OFF and disconnect the
battery connector.
2. Remove dash.
3. Disconnect electrical connections from fan to main
wiring harness.
4. Remove four nuts (1) from upper electrical
compartment side.
BT Prime-Mover, Inc.
Return
2001-03-15
133
F-code
Section
C-code
PS
Fan Motor
S1.1
1740
Version no
T-code
001
395/396/397/398/399
1.3. Installation
1
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.
134
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
135
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.
136
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
137
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
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
138
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
139
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.
140
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
141
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
142
Return
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
2000-08-04
F-code
Section
C-code
PS
S1.3
1750
Pump Motor, RRX35/RSX40
Version no
T-code
001
395/398
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
2000-08-04
143
F-code
Section
C-code
PS
S1.3
1750
Pump Motor, RRX35/RSX40
Version no
T-code
001
395/398
Item
No.
144
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
2000-08-04
F-code
Section
C-code
PS
S1.3
1750
Pump Motor, RRX35/RSX40
Version no
001
T-code
395/398
1. Component Repair
1.1. Disassembly
1. Remove pump motor from truck (see page 108).
2. Remove band (14) from end head commutator (13)
of motor.
3. Use a brush hook to reach into the motor and lift
brush springs (8). Pull brushes (7) out of brush
holders. Either position brushes outside the motor
or remove brush retaining screws and remove
brushes (7) 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 (5) and head assembly (3)
as an assembly from the frame and field coil
assembly.
7. Separate the armature (5) from the head assembly
(3). This operation is usually done 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. When a puller is
used, protect the end of the armature shaft with a
nut or a thick flat washer.
BT Prime-Mover, Inc.
Return
2000-08-04
145
F-code
Section
C-code
PS
S1.3
1750
Pump Motor, RRX35/RSX40
Version no
T-code
001
395/398
CAUTION
Propane torch
Use Loctite on
this area of shaft
146
Return
2000-08-04
F-code
Section
C-code
PS
S1.3
1750
Pump Motor, RRX35/RSX40
Version no
001
T-code
395/398
2.3. Bearings
1. Check bearings by turning them with your fingers.
Feel for binding or gritty effects and excessive
looseness or wobble. A good bearing should also
have a small amount of drag or stiffness caused by
lubrication but should turn smoothly. If bearing
turns very freely, it should be replaced. Bearings
should also be changed if worn out, damaged, or
removed from armature shaft.
2. Ball bearings that have been pulled off shafts,
pressed out of end heads, or side loaded in such a
way as to apply pressure on the balls and races
must be replaced. Although the bearing may
appear or feel good, the bearing races have been
brinelled and will fail within a relatively short period
of service.
BT Prime-Mover, Inc.
Return
2000-08-04
147
F-code
Section
C-code
PS
S1.3
1750
Pump Motor, RRX35/RSX40
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
148
Return
2000-08-04
F-code
Section
C-code
PS
S1.3
1750
Pump Motor, RRX35/RSX40
Version no
001
T-code
395/398
page 137. 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. See drawing
below:
BT Prime-Mover, Inc.
Return
2000-08-04
149
F-code
Section
C-code
PS
S1.3
1750
Pump Motor, RRX35/RSX40
Version no
T-code
001
395/398
2.5. Armature
1. Check security fan.
2. Check for loose commutator bars. Loose
commutator bars will usually be indicated by
excessive wear or burning on one bar. The
commutator can be checked for loose bars by
lightly tapping all of the bars with the handle of a
plastic or wooden handled screwdriver. A
contrasting dull thud or vibration will indicate a
loose bar. Replace the armature if the commutator
bars are loose.
NOTE! If the armature has been turned and
undercut prior to testing, check for and
remove any copper buildup or filings
between commutator bars and at the
commutator riser. This condition will
cause an armature to check shorted and
usually results from a dull undercutting
tool.
3. Check for grounded circuits using a test light.
4. Check armature for grounded circuits by placing
one test lead of the test lamp on the commutator
150
Return
2000-08-04
F-code
Section
C-code
PS
S1.3
1750
Pump Motor, RRX35/RSX40
Version no
001
T-code
395/398
Grounded Circuit
Touch one test lead to a clean bare metal spot on
the frame and check all terminals with the other
lead. If a grounded condition exists, the test light
will light.
BT Prime-Mover, Inc.
Return
2000-08-04
151
F-code
Section
C-code
PS
S1.3
1750
Pump Motor, RRX35/RSX40
Version no
T-code
001
395/398
Open Circuit
Check between all connecting terminals with test
leads. If the bulb fails to light, an open circuit is
indicated.
Shorted Circuit
Shorted windings in series coils are very difficult to
detect. Generally, if the coil insulation is sound and
these are no signs of overheating, the coil can be
presumed good.
2.7. Assembly
2.7.1. Bearing Installation
1. Whenever ball bearings are pressed into an end
head or onto a shaft, always press against the race
that is absorbing the pressure.
2. Press on the outer race when installing into end
heads.
3. Press against the inner race when installing onto a
shaft.
4. End heads having slip-fit bearings are normally
retained by a retaining ring. Always install new
retaining ring(s).
2.7.2. Testing
1. The motor should be connected as specified in
troubleshooting and tested to the specifications.
2. When testing motors, the voltmeter connections
must be made at the motor terminals.
152
Return
2000-08-04
F-code
Section
C-code
PS
S1.4
1750
Pump Motor, RRX45/RDX30/RSX50
Version no
T-code
001
396/397/399
15
12
14
11
10
13
Item
No.
Description
Item
No.
Description
Retaining ring
Bearing
10
ROTATION
11
Bearing
C.C.W.C.E.
Fan
12
Washer, wave
Counterclockwise
when viewed from
commutator end.
13
14
Band
Brush
15
Spring, brush
BT Prime-Mover, Inc.
Return
2000-08-04
153
F-code
Section
C-code
PS
S1.4
1750
Pump Motor, RRX45/RDX30/RSX50
Version no
T-code
001
396/397/399
1. Component Repair
1.1. Disassembly
1. Remove pump motor from truck (see page 108).
2. Remove cover band (14)
commutator (13) of motor.
from
end
head
Return
2000-08-04
F-code
Section
C-code
PS
S1.4
1750
Pump Motor, RRX45/RDX30/RSX50
Version no
001
T-code
396/397/399
Propane torch
Use Loctite on
this area of shaft
BT Prime-Mover, Inc.
Return
2000-08-04
155
F-code
Section
C-code
PS
S1.4
1750
Pump Motor, RRX45/RDX30/RSX50
Version no
T-code
001
396/397/399
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.
156
Return
2000-08-04
F-code
Section
C-code
PS
S1.4
1750
Pump Motor, RRX45/RDX30/RSX50
Version no
T-code
001
396/397/399
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
BT Prime-Mover, Inc.
Return
2000-08-04
157
F-code
Section
C-code
PS
S1.4
1750
Pump Motor, RRX45/RDX30/RSX50
Version no
T-code
001
396/397/399
page 137. 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. See drawing
below:
158
Return
2000-08-04
F-code
Section
C-code
PS
S1.4
1750
Pump Motor, RRX45/RDX30/RSX50
Version no
001
T-code
396/397/399
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.
BT Prime-Mover, Inc.
Return
2000-08-04
159
F-code
Section
C-code
PS
S1.4
1750
Pump Motor, RRX45/RDX30/RSX50
Version no
T-code
001
396/397/399
160
Return
2000-08-04
F-code
Section
C-code
PS
S1.4
1750
Pump Motor, RRX45/RDX30/RSX50
Version no
001
T-code
396/397/399
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
BT Prime-Mover, Inc.
Return
2000-08-04
161
F-code
Section
C-code
PS
S1.4
1750
Pump Motor, RRX45/RDX30/RSX50
Version no
T-code
001
396/397/399
162
Return
2000-08-04
F-code
Section
PS
S1.5
Version no
001
C-code
1760
Drive Motor
T-code
395/396/397/398/399
Drive Motor
1
3
2
4
13
7
14
10
15
16
11
12
25
16
26
27
17
28
29
30
BT Prime-Mover, Inc.
Return
18
2000-08-04
163
F-code
Section
C-code
PS
S1.5
Drive Motor
1760
Version no
T-code
001
395/396/397/398/399
Item No.
164
Return
Description
Item No.
Description
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
2000-08-04
F-code
Section
PS
S1.5
Version no
001
C-code
1760
Drive Motor
T-code
395/396/397/398/399
1. Disassembly
1. Remove head band (2) from commutator (7) end of
motor.
2. Use a brush hook to reach into motor and lift brush
springs (10). Pull brushes (9) out of brush holders.
Either position brushes outside motor or remove
brush retaining screws and remove brushes from
motor.
3. Scribe or center punch locating marks in the end
head and frame. Although locating marks are not
always necessary because of locating pins in some
motors, time can be saved when the motor does
not have locating pins.
4. Remove commutator end head retaining screws
(1). Most motors have a slip fit bearing (11) at the
commutator end and the end head can be removed
with very little trouble.
5. Remove drive end head retaining screws (18), if
necessary. Separate armature (15) and drive end
head (17) as an assembly from 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 driver end head, the
armature or the drive spline usually has to
be replaced.
6. Separate armature (15) from drive end head (17),
by pressing armature out of drive end bearing.
Remove bearing (11) with a puller, protecting the
end of the armature shaft with a nut or a thick flat
washer.
7. Remove retainer (12) from drive end head (17)
Press bearing (11) out of drive end head.
8. After motor has been separated into all its major
subassemblies, components should be cleaned
and inspected for wear or damage.
BT Prime-Mover, Inc.
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2000-08-04
165
F-code
Section
C-code
PS
S1.5
Drive Motor
1760
Version no
T-code
001
395/396/397/398/399
2. Inspection
After motor components have been thoroughly cleaned and
dried, they should be inspected for the following:
2.3. Bearings
1. Check bearings by turning them with your fingers.
Feel for binding or gritty effects and excessive
looseness or wobble. A good bearing should also
have a small amount of drag or stiffness caused by
lubrication but should turn smoothly. If bearing
turns very freely, it should be replaced. Bearings
should also be changed if worn out, damaged, or
removed from armature shaft.
2. Ball bearings that have been pulled off shafts,
pressed out of end head or side loaded in such a
way as to apply pressure on the balls and races
must be replaced.
166
Return
2000-08-04
F-code
Section
PS
S1.5
Version no
C-code
1760
Drive Motor
T-code
001
395/396/397/398/399
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
BT Prime-Mover, Inc.
Return
2000-08-04
167
F-code
Section
C-code
PS
S1.5
Drive Motor
1760
Version no
T-code
001
395/396/397/398/399
page 137. 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. See drawing
below:
168
Return
2000-08-04
F-code
Section
PS
S1.5
Version no
001
C-code
1760
Drive Motor
T-code
395/396/397/398/399
2.5. Armature
1. Check for loose commutator bars. Loose
commutator bars will usually be indicated by
excessive wear or burning on one bar. The
commutator can be checked for loose bars by
lightly tapping all of the bars with the handle of a
plastic or wooden handled screwdriver. A
contrasting dull thud or vibration will indicate a
loose bar. Replace armature if commutator bars
are loose.
2. Check for grounded circuits using a test light.
NOTE! If the armature has been turned and
undercut prior to testing, check for and
remove any copper buildup or filings
between commutator bars and at the
commutator riser. This condition will
cause an armature to check shorted and
usually results from a dull undercutting
tool.
3. Check armature for grounded circuits by placing
one test lead of the test lamp on commutator and
the other test lead on armature shaft. If it lights,
armature is grounded.
BT Prime-Mover, Inc.
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2000-08-04
169
F-code
Section
C-code
PS
S1.5
Drive Motor
1760
Version no
T-code
001
395/396/397/398/399
Grounded Circuit
Open Circuit
Shorted Circuit
2.7. Assembly
2.7.1. Bearing Installation
1. Whenever ball bearings are pressed into an end
head or onto a shaft, always press against the race
that is absorbing the pressure.
170
Return
2000-08-04
F-code
Section
PS
S1.5
Version no
001
C-code
1760
Drive Motor
T-code
395/396/397/398/399
3. Temperature Sensors
Temperature sensors are located on the drive motor. If the
sensor detects an over temperature, the command signal to
the transistor regulator will be reduced to limit performance.
3.1. Removal
1. Turn the key switch OFF and disconnect the
battery at the battery connector.
2. Disconnect
harness.
sensor
cable
from
main
tractor
3.2. Installation
1. Screw thermistor (temperature sensor) into motor
casing.
BT Prime-Mover, Inc.
Return
2000-08-04
171
F-code
Section
C-code
PS
S1.5
Drive Motor
1760
Version no
T-code
001
395/396/397/398/399
The brush wear sensors are built into the motors. The brush
wear sensors are not replaceable.
172
Return
2000-08-04
F-code
Section
PS
S2.0
2550
Transmission
Version no
C-code
T-code
000
395/396/397/398/399
Transmission
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
22
21
26
15
27
37
18
23
25
BT Prime-Mover, Inc.
Return
34
2001-11-14
28
173
F-code
Section
C-code
PS
S2.0
Transmission
2550
Version no
T-code
000
395/396/397/398/399
Item
No.
174
Return
Item
No.
Description
Description
Transmission assembly
22
Screw
Gear, ring
23
Bearing
24
Washer
25
Spacer
26
Ring, sealing
27
Ring, locking
28
Plug, drain
Gear, wheel
29
Gear, wheel
30
10
Nut
31
11
Bearing
32
Screw
12
Kit, shim
33
Gear, bevel
13
Kit, shim
34
Screw
14
Bearing
35
Plug, fill
15
O-ring
36
Keeper
16
Screw
37
Cover
17
Axle
38
Case
18
Washer, copper
39
Bearing
19
Bearing
40
Screw
20
Kit, shim
41
O-ring
21
Cover ring
42
Breather
2001-11-14
F-code
Section
PS
S2.0
2550
Transmission
Version no
000
C-code
T-code
395/396/397/398/399
1. Disassemble
1. Remove transmission for the truck (see page 113).
2. When disassembling the transmission also use
page 188 of this manual for reference.
BT Prime-Mover, Inc.
Return
2001-11-14
175
F-code
Section
C-code
PS
S2.0
Transmission
2550
Version no
T-code
000
395/396/397/398/399
176
Return
2001-11-14
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
2001-11-14
177
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.
178
Return
2001-11-14
F-code
Section
PS
S2.0
2550
Transmission
Version no
000
C-code
T-code
395/396/397/398/399
2. Assembly
1. Position the transmission case with the axle output
side up.
BT Prime-Mover, Inc.
Return
2001-11-14
179
F-code
Section
C-code
PS
S2.0
Transmission
2550
Version no
T-code
000
395/396/397/398/399
180
Return
2001-11-14
F-code
Section
PS
S2.0
2550
Transmission
Version no
000
C-code
T-code
395/396/397/398/399
Check axle shaft bearing preload, rolling torque of 9-14 inlb (12-18 Nm). If not correct adjust by adding or
subtracting shims as required. Rolling torque is the amount
of torque needed to rotate the axle after it has started
turning. A spring scale can also be used to get this
BT Prime-Mover, Inc.
Return
2001-11-14
181
F-code
Section
C-code
PS
S2.0
Transmission
2550
Version no
T-code
000
395/396/397/398/399
182
Return
2001-11-14
F-code
Section
PS
S2.0
2550
Transmission
Version no
000
C-code
T-code
395/396/397/398/399
Check pinion preload. Rounding torque of 5-8 in-lb (0.560.90 Nm). If not, correct by adding or subtract shims under
top pinion bearing race. Rolling torque is the amount of
torque needed to rotate the axle after it has started turning.
A spring scale can also be used to get this measurement.
BT Prime-Mover, Inc.
Return
2001-11-14
183
F-code
Section
C-code
PS
S2.0
Transmission
2550
Version no
T-code
000
395/396/397/398/399
184
Return
2001-11-14
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
2001-11-14
185
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.
186
Return
2001-11-14
F-code
Section
PS
S2.0
2550
Transmission
Version no
000
C-code
T-code
395/396/397/398/399
3.
BT Prime-Mover, Inc.
Return
2001-11-14
187
F-code
Section
C-code
PS
S2.0
Transmission
2550
Version no
T-code
000
395/396/397/398/399
3.1. Disassembly
1. Drain transmission oil by removing drain plug (28).
Remove copper washer (18) from drain plug.
2. Remove transmission
page 113).
from
the
truck
(see
188
Return
from
axle
(17)
or
2001-11-14
F-code
Section
PS
S2.0
2550
Transmission
Version no
000
C-code
T-code
395/396/397/398/399
3.2. Assembly
1. Place drive axle outer bearing (23) in the
transmission case (38).
NOTE! Use care when pressing the new seal ring into
place so the seal is seated correctly in the
gear housing.
2. Press new seal ring (26) into transmission case
(38).
3. Press drive axle (17) into the transmission case.
Be sure the spacer (25) and washer (24) are
aligned with the axle (17) and that the splines on
the drive axle (17) are aligned with the splines in
the bevel gear (33).
4. Place keeper washer (36) onto the drive axle end
and install new bolts (16). Use Loctite 242 on
bolts (16). Torque axle bolts (16) to 81 ft-lb (109
Nm).
5. Install a new O-ring (15) on the lower cover (37).
Install lower cover (37). Lubricate new bolts (34).
Secure lower cover (37) with new bolts (34).
Torque bolts (34) to 18 ft-lb (25 Nm). Make sure
O-ring (15) is not damaged during installation.
6. Install a new copper washer (18) on drain plug
(28). Install drain plug (28) in the transmission. Fill
transmission with oil (see Approved Oils and
Grease on page 82). Install fill level plug (35) in
the transmission case.
7. Install transmission on truck (see page 114).
BT Prime-Mover, Inc.
Return
2001-11-14
189
F-code
Section
C-code
PS
S2.0
Transmission
2550
Version no
T-code
000
395/396/397/398/399
4. Leakage
When there is leakage from the transmission top cover,
proceed as follows:
190
Return
2001-11-14
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
2001-11-14
191
F-code
Section
C-code
PS
S2.0
Transmission
2550
Version no
T-code
000
395/396/397/398/399
5. 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 knock out the damaged bolt from the drive
axle rim.
NOTE! Always install a new drive axle seal during
assembly.
5. Smooth away any burring around the bolt hole.
Press or knock new bolt into place.
6. Install drive axle into the transmission case.
7. Install transmission on truck.
192
Return
2001-11-14
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
193
F-code
Section
C-code
PS
S3.0
3370
Electromagnetic Brake
Version no
T-code
001
395/396/397/398/399
194
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
195
F-code
Section
C-code
PS
S3.0
3370
Electromagnetic Brake
Version no
T-code
001
395/396/397/398/399
3. Adjustments
NOTE! Do Not remove retaining screws (9).
Adjustment is carried out by using a 9/16
inch (14 mm) open end wrench and a 1/4
(6 mm) socket key).
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! Be sure to tighten Allen head retaining
screw (9) before checking air gap. The
gap should be checked on each side of
the brass nut to assure consistency in
the setting.
3. The air gap should be set to 0.008 inch to 0.014
inch (0.20 mm to 0.36 mm) and be within 0.003
inch (0.08 mm) throughout entire circumference.
196
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
197
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! Make certain brake friction plate (5) and
armature (3) are clean and free of fluid.
1. Set armature (3) and magnetic coil (2) on base
plate (6).
2. Align and tighten three brake retaining screws (9).
3. Remove two manual release screws (11) and
washers (10) and electrically connect brake.
4. Set the air gap to 0.008 inch to 0.014 inch (0.20
mm to 0.36 mm) and be within 0.003 inch (0.08
mm) throughout entire circumference.
5. To test operation of brake, connect the battery at
the battery connector, turn key switch ON, and
depress brake pedal. This will allow truck to
operate.
6.2. Replacement
If brake friction plate needs replacement, remove and install
new plate.
198
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
199
F-code
Section
C-code
PS
S3.1
Drive Wheel
3530
Version no
T-code
001
395/396/397/398/399
1. Removal
NOTE! Replace drive wheel
problems develop.
when
traction
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 retaining nuts should be
torqued to 95 ft-lb (130 Nm).
200
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
New
Tire
Worn
Tire
Press
Table
BT Prime-Mover, Inc.
Return
2000-08-04
201
F-code
Section
C-code
PS
S3.1
Drive Wheel
3530
Version no
T-code
001
395/396/397/398/399
202
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
203
F-code
Section
C-code
PS
S3.2
3540
Non-Braking Caster Wheel, RRX35/RSX40
Version no
T-code
002
395/398
Item No.
204
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
002
T-code
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 101).
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!
BT Prime-Mover, Inc.
Return
2000-08-04
205
F-code
Section
C-code
PS
S3.2
3540
Non-Braking Caster Wheel, RRX35/RSX40
Version no
T-code
002
395/398
1.2. Installation
1. Install pivot block
compartment first.
(16)
closest
to
battery
206
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
207
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 inch (6.35
mm) turn.
6. Bend lockwasher tab (2) up to secure locknut (1).
NOTE!
208
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
209
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
210
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 at
battery connector 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
211
F-code
Section
C-code
PS
S3.2
3540
Non-Braking Caster Wheel, RRX35/RSX40
Version no
T-code
002
395/398
212
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
213
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! Replace caster wheel when caster spring can
no longer be adjusted. (See Caster Springs
on page 209.)
1. Park the truck on a flat surface.
2. Turn key switch to OFF and disconnect battery at
battery connector. Check to make sure the battery
retainer plates are in place.
3. Jack the rear of the truck (see page 66).
4. Remove wheel cap (8).
5. Bend lockwasher (5) tab down and remove locknut
(6).
6. Remove caster wheel assembly.
7. Inspect and replace race and bearing (4) as
needed.
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).
214
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
215
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.
216
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 at
battery connector. 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 101).
CAUTION
Adjusting
Nut
BT Prime-Mover, Inc.
Return
2000-08-04
217
F-code
Section
C-code
PS
S3.4
3540
Braking Caster Wheel, RRX45/RDX30/RSX50
Version no
T-code
002
396/397/399
218
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
3
4
BT Prime-Mover, Inc.
Return
2000-08-04
219
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.
220
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! Replace caster wheel when caster spring can
no longer be adjusted (see page 215.)
1. Park the truck on a flat surface.
2. Turn key switch to OFF and disconnect battery at
battery connector. Check to make sure the battery
retainer plates are in place.
3. Jack the rear of the truck (see page 66).
4. Remove wheel cap (8).
5. Bend lockwasher (5) tab down and remove locknut
(6).
6. Remove caster wheel assembly.
7. Inspect and replace race and bearing (4) as
needed.
8. Remove E ring (9) and remove cap screws (11) if
brake assembly is to be replaced otherwise
replace brake shoes.
9. Remove nuts (12) and washer (13). Slide brake
plunger (16) up to remove brake pivot (14) and
other washer (13).
10. Remove brake plunger (16) and spring (15).
BT Prime-Mover, Inc.
Return
2000-08-04
221
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
222
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
1
2
3
Axle
Toe box
Plate, rocker
7
8
9
Washer, 18 gauge
Bearing
Wheel, load
4
5
Ring, retainer
Fitting, grease
10
11
Nut
Bolt, shoulder
Washer, 10 gauge
2000-08-04
223
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.
224
Return
Description
Item No.
Description
1
2
3
Axle
Toe box
Plate rocker
7
8
9
Washer, 18 gauge
Bearing
Wheel, load
4
5
6
Ring, retainer
Fitting, grease
Washer, 10 gauge
10
11
Nut
Bolt, shoulder
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
NOTE! Replace load wheels when traction problems
develop.
1. Park the truck on a flat surface.
2. Lower carriage fully.
3. Turn key switch to OFF and disconnect battery at
battery connector. Check to make sure the battery
retainer plates are in place.
WARNING Block all wheels to prevent ruck 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. Use a piece of rod or a punch to tap 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
225
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.
WARNING Install bearing shield and 10 gauge
spacer properly.
3. Install load wheel assembly in toe box (2).
NOTE! Place a block behind the axle to hold it in
place while assembling the rocker plate and
snap rings.
4. Install axle (1), washers (6 and 7) and rocker plate
(3).
5. Install retainer rings (4) to axle (1).
6. Remove the blocking. Lower truck to the floor.
7. Reconnect battery at the battery connector.
8. Test operate truck.
9. Return truck to service.
226
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.
BT Prime-Mover, Inc.
Return
Description
Item No.
Description
1
2
7
8
3
4
Washer, 18 gauge
Bearing
9
10
Nut
Bolt, shoulder
5
6
Tire, load
Wheel
11
2001-09-21
227
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
NOTE! Replace load wheels when traction problems
develop.
1. Park the truck on a flat surface.
2. Lower carriage fully.
3. Turn key switch to OFF and disconnect battery at
battery connector. Check to make sure the battery
retainer plates are in place.
WARNING Block all wheels to prevent ruck 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 (10) and bolts (11).
6. Remove right toe box (2) and load wheel (9).
7. Grease as needed.
WARNING Install bearing shield and 10 gauge
spacer properly.
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 #242 to nuts (10) and bolts (11).
5. Remove blocking and lower truck to the floor.
6. Reconnect battery at battery connector.
7. Test operation of load wheel and truck.
8. Return truck to service.
228
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
229
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.
230
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 at
battery connector. Block truck.
3. Remove adjusting lever (23) and washer (27).
4. Lift pod assembly.
5. Lift dash approximately 6 inch (152.4 mm) to
access controls pod's wiring harness connectors.
6. 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 (see page 98).
BT Prime-Mover, Inc.
Return
2000-08-04
231
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. Test operation of steering wheel (10) and truck.
232
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. Remove four screws (31) holding tach motor (17).
Electrically disconnect steering tach motor (17)
wires from wiring harness.
3.2. Installation
1. Connect steering tach motor (17) wires from wiring
harness.
2. Install steering tach motor (17) and secure with
four screws (31).
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
233
F-code
Section
C-code
PS
S4.0
4110
Steering Arm / Wheel / Lever
Version no
T-code
001
395/396/397/398/399
234
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
235
F-code
Section
C-code
PS
S4.1
Steering Bearing
4180
Version no
T-code
001
395/396/397/398/399
1. Removal
NOTE! Transmission and drive motor must be
removed from truck to access steering
bearing. (To remove drive motor see
page 106 and page 113 for removal of
transmission.
1. Park the truck on a flat surface.
Mounting
Screws
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). Install screws (3).
3. Install
transmission
mounting
plate
and
transmission in truck and torque six mounting
screws to 50-59 ft-lb (70-80 Nm).
4. Install drive motor.
O ring Location
NOTE: Photo is a representation
of transmission assembly.
236
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 291, page 303, or page 315 and Hydraulic Schematics
page 446.
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 400. For information on the fuses and their location see
page 349.
R11
R12 R13
R14
3 4
1 2
8
5 6 7
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
hydraulic lever (R12) is used for reach extend and retract.
BT Prime-Mover, Inc.
Return
2001-11-12
237
F-code
Section
PS
S5.0
Electrical Functions
C-code
5000
Version no
T-code
002
395/396/397/398/399
238
Return
2001-11-12
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
2001-11-12
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
A2
M1
F55
ARMATURE
A1
K11
K11
M1
B-
A5
S21
34
7
2
15
ACC
RELAY 1
B+
44
101
K13
K13
8
805
64
Y1
803
51
K11
802
808
36V only
501
S48
43 111
52
K13
22
25
F50
S108
21
S21
24
40
M
1
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)
240
Return
2001-11-12
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
2001-11-12
241
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)
242
Return
2001-11-12
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
2001-11-12
243
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)
244
Return
2001-11-12
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 (forks trailing or forks first).
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
2001-11-12
245
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.
246
Return
2001-11-12
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
2001-11-12
247
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
40
40
LEGEND
Pressure Oil
203
STEERING ANGLE B
202
STEER WHEEL POSITION
902 (OV)
Return Oil
Electric Positive
Electric Negative
LED Off (Not Lit)
LED Input (Lit)
LED Output (Lit)
248
Return
2001-11-12
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
2001-11-12
249
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
30
65
M
1
902
504 +7.35V
510 OV
511
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)
250
Return
2001-11-12
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 increase 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). 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
2001-11-12
251
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+
M1
44
B-
2
K11
K11
M1
29
R1
K13
K13
8
50
30
M
1
101
34
A1
A5
S21
29
22
R3
F50
65
902
504 +7.35V
505 +3.65V
510 OV
805
64
Y1
803
51
K11
802
52
K13
511
30
36V only
S48
21
S108
S21
24
S17
43
49
22
A6
123
Rx +
Rx -
LEGEND
Pressure Oil
124
40
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)
252
Return
2001-11-12
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
2001-11-12
253
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
B+
ARMATURE
2
A1
FIELD
K11
M1
K11
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)
254
Return
2001-11-12
F-code
PS
Version no
002
Section
C-code
S5.0
5000
Electrical Functions
T-code
395/396/397/398/399
Return
2001-11-12
255
F-code
Section
PS
S5.0
Electrical Functions
C-code
5000
Version no
T-code
002
395/396/397/398/399
256
Return
2001-11-12
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
2001-11-12
257
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
M1
K11
A5
B7
10 36
44
101
34 S21
11
A
6 35
R1
902
40
29 504 +7.35V
K13
K13
8
610
611
609 -
37
50
30
M
1
22
R3
F50
505 +3.65V
510 OV
64
Y1
803
51
K11
802
808
501
43
111
49
102
22
809
52
K13
65 511
805
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)
258
Return
2001-11-12
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
2001-11-12
259
F-code
Section
PS
S5.0
Electrical Functions
C-code
5000
Version no
T-code
002
395/396/397/398/399
responds
by
reducing
the
260
Return
2001-11-12
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
2001-11-12
261
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 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
21
S21
24
S17
65
40
504 +7.35V
50 505 +3.65V
30
22
F50
101
103
610
902
609 611
805
510 OV
803
511
64
Y1
51
K11
52
K13
802
810 +
22
808 811 36V only
501
S48
43
111
S125
S125
102
S108
23
49
105
56
22
201
809
LEGEND
Plug Braking
Pressure Oil
Return Oil
Electric Positive
Electric Negative
LED Off (Not Lit)
LED Input (Lit)
LED Output (Lit)
262
Return
2001-11-12
F-code
PS
Version no
002
Section
C-code
S5.0
5000
Electrical Functions
T-code
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 one is using the directional/speed control lever and
is detailed first. The second method is accomplished through
raising the brake pedal and is detailed second.
Return
2001-11-12
263
F-code
Section
PS
S5.0
Electrical Functions
C-code
5000
Version no
T-code
002
395/396/397/398/399
264
Return
2001-11-12
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
2001-11-12
265
F-code
Section
PS
S5.0
Electrical Functions
C-code
5000
Version no
T-code
002
395/396/397/398/399
266
Return
2001-11-12
F-code
PS
Version no
002
Section
C-code
S5.0
5000
Electrical Functions
T-code
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)
BT Prime-Mover, Inc.
Return
2001-11-12
267
F-code
Section
PS
S5.0
Electrical Functions
C-code
5000
Version no
T-code
002
395/396/397/398/399
29
R1
50
30
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
268
Return
2001-11-12
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
2001-11-12
269
F-code
Section
PS
S5.0
Electrical Functions
C-code
5000
Version no
T-code
002
395/396/397/398/399
S45
22 40
A5
106
S31
207
79
107
22 40
29
504 7.35 V
505 6.35V
50
R1
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)
270
Return
2001-11-12
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
2001-11-12
271
F-code
Section
PS
S5.0
Electrical Functions
C-code
5000
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)
272
Return
2001-11-12
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
2001-11-12
273
F-code
Section
C-code
PS
S5.0
Electrical Functions
5000
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
98
205A
99
206B
32
811
LEGEND
Pressure Oil
Return Oil
Electric Positive
Electric Negative
LED Off (Not Lit)
LED Input (Lit)
LED Output (Lit)
274
Return
2001-11-12
F-code
PS
Version no
002
Section
C-code
S5.0
5000
Electrical Functions
T-code
395/396/397/398/399
Return
2001-11-12
275
F-code
Section
PS
S5.0
Electrical Functions
C-code
5000
Version no
T-code
002
395/396/397/398/399
276
Return
2001-11-12
F-code
Section
PS
C-code
S5.0
5000
Electrical Functions
Version no
T-code
002
395/396/397/398/399
K10
K10
A1
F1
SA2
M1
B+
ARMATURE
2
FIELD
SA1
K11
K13
M1
K13
K11
44
B7
34
S21
A5
101
902
40
803 51
K11
802 52 K13
41
LEGEND
208
Pressure Oil
42
Return Oil
209
Electric Positive
Electric Negative
LED Off (Not Lit)
LED Input (Lit)
LED Output (Lit)
BT Prime-Mover, Inc.
Return
2001-11-12
277
F-code
Section
PS
S5.0
Electrical Functions
C-code
5000
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)
LED Input (Lit)
278
Return
2001-11-12
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 A
Return Oil
Electric Positive
Electric Negative
LED Off (Not Lit)
LED Input (Lit)
LED Output (Lit)
BT Prime-Mover, Inc.
Return
2001-11-12
279
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 B
Electric Positive
Electric Negative
LED Off (Not Lit)
LED Input (Lit)
LED Output (Lit)
280
Return
2001-11-12
F-code
Section
PS
C-code
S5.0
5000
Electrical Functions
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)
BT Prime-Mover, Inc.
Return
2001-11-12
281
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
282
Designation
Function
Remark
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
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
F1
Fuse
Drive Motor
250 Amp
F3
Fuse
Pump Motor
RRX35/RSX40
425A 24V/355A 36V
RRX45/RDX30/RSX50
250A 36V
F4
Fuse
Pump Motor
RRX45/RDX30/RSX50
250A 36V
Return
24/36 Volt
2001-11-12
F-code
PS
Section
C-code
S5.0
5000
Electrical Functions
Version no
T-code
002
395/396/397/398/399
List of Symbols
Symbol
Designation
Function
Remark
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
M12
Fan
Electronics
R1
Potentiometer
Travel
R3
Potentiometer
Brake
BT Prime-Mover, Inc.
Return
RRX45 only
2001-11-12
283
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
284
Designation
Function
Remark
R11
Potentiometer
R12
Potentiometer
R13
Potentiometer
R14
Potentiometer
R20
Resistor
Plug-in Module
R21
Resistor
Output Load
Not used
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 Stop A
S67
Inductive sensor
Steer Stop B
S96
Switch
Fan
Push Button
S97
Switch
Work Light
Push Button
S99
Switch
Light
Push Button
S108
Switch
Right Foot
S111
Switch
A1 & A2 Thermostat
S112
Switch
S113
Switch
A5 Thermostat
Return
Push Button
2001-11-12
F-code
Section
PS
C-code
S5.0
5000
Electrical Functions
Version no
T-code
002
395/396/397/398/399
List of Symbols
Symbol
Designation
Function
Remark
S125
Inductive sensor
Drive Direction
S211
Switch
Tilt Up
S212
Switch
Tilt Down
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
BT Prime-Mover, Inc.
Return
2001-11-12
285
F-code
Section
C-code
PS
S5.0
Electrical Functions
5000
Version no
T-code
002
395/396/397/398/399
A2
R11
U1
R14
K10
4
1 2 3
7 8
5 6
9 0
1
2
3
4
S17
R12 R13
A1
K13
R1
K34
1
2
3
4
A1
1
2
3
4
F1
F3
A2
K10
K11
K13
Y14
Y15
Y17
Y16
286
Return
2001-11-12
F-code
PS
Version no
002
Section
C-code
S5.0
5000
Electrical Functions
T-code
395/396/397/398/399
Y12
S125
S64
Y13
A5
S18
Y1
M11
S65
M1
S60
M6
CONTROL
FUSES
S48
BT Prime-Mover, Inc.
Return
R3
2001-11-12
287
F-code
Section
PS
S5.0
Electrical Functions
C-code
5000
Version no
T-code
002
395/396/397/398/399
288
Return
2001-11-12
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
289
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
290
Return
Service Manual
2001-03-15
F-code
Section
C-code
PS
5.2
5000
Electrical Schematics (P5-04 Serial numbers 27163000-28105000)
Version no
002
T-code
395/396/397/398/399
Legend
BT Prime-Mover, Inc.
Return
2000-08-04
291
F-code
Section
C-code
PS
5.2
5000
Electrical Schematics (P5-04 Serial numbers 27163000-28105000)
Version no
T-code
002
395/396/397/398/399
292
Legend
Return
2000-08-04
F-code
Section
C-code
PS
5.2
5000
Electrical Schematics (P5-04 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
293
F-code
Section
C-code
PS
5.2
5000
Electrical Schematics (P5-04 Serial numbers 27163000-28105000)
Version no
T-code
002
395/396/397/398/399
294
Return
Legend
2000-08-04
F-code
Section
C-code
PS
5.2
5000
Electrical Schematics (P5-04 Serial numbers 27163000-28105000)
Version no
002
T-code
395/396/397/398/399
Legend
BT Prime-Mover, Inc.
Return
2000-08-04
295
F-code
Section
C-code
PS
5.2
5000
Electrical Schematics (P5-04 Serial numbers 27163000-28105000)
Version no
T-code
002
395/396/397/398/399
296
Legend
Return
2000-08-04
F-code
Section
C-code
PS
5.2
5000
Electrical Schematics (P5-04 Serial numbers 27163000-28105000)
Version no
002
T-code
395/396/397/398/399
Legend
BT Prime-Mover, Inc.
Return
2000-08-04
297
F-code
Section
C-code
PS
5.2
5000
Electrical Schematics (P5-04 Serial numbers 27163000-28105000)
Version no
T-code
002
395/396/397/398/399
298
Legend
Return
2000-08-04
F-code
Section
C-code
PS
5.2
5000
Electrical Schematics (P5-04 Serial numbers 27163000-28105000)
Version no
002
T-code
395/396/397/398/399
Legend
BT Prime-Mover, Inc.
Return
2000-08-04
299
F-code
Section
C-code
PS
5.2
5000
Electrical Schematics (P5-04 Serial numbers 27163000-28105000)
Version no
T-code
002
395/396/397/398/399
300
Legend
Return
2000-08-04
F-code
Section
C-code
PS
5.2
5000
Electrical Schematics (P5-04 Serial numbers 27163000-28105000)
Version no
002
T-code
395/396/397/398/399
Legend
BT Prime-Mover, Inc.
Return
2000-08-04
301
F-code
Section
C-code
PS
5.2
5000
Electrical Schematics (P5-04 Serial numbers 27163000-28105000)
Version no
T-code
002
395/396/397/398/399
302
Return
2000-08-04
F-code
Section
C-code
PS
5.3
5000
Electrical Schematics (P5-04 Serial numbers 2810500-28126000)
Version no
000
T-code
395/396/397/398/399
Legend
BT Prime-Mover, Inc.
Return
2000-08-04
303
F-code
Section
C-code
PS
5.3
5000
Electrical Schematics (P5-04 Serial numbers 2810500-28126000)
Version no
T-code
000
395/396/397/398/399
304
Legend
Return
2000-08-04
F-code
Section
C-code
PS
5.3
5000
Electrical Schematics (P5-04 Serial numbers 2810500-28126000)
Version no
000
T-code
395/396/397/398/399
Legend
Input
BT Prime-Mover, Inc.
Return
2000-08-04
305
F-code
Section
C-code
PS
5.3
5000
Electrical Schematics (P5-04 Serial numbers 2810500-28126000)
Version no
T-code
000
395/396/397/398/399
306
Return
Legend
2000-08-04
F-code
Section
C-code
PS
5.3
5000
Electrical Schematics (P5-04 Serial numbers 2810500-28126000)
Version no
000
T-code
395/396/397/398/399
Legend
BT Prime-Mover, Inc.
Return
2000-08-04
307
F-code
Section
C-code
PS
5.3
5000
Electrical Schematics (P5-04 Serial numbers 2810500-28126000)
Version no
T-code
000
395/396/397/398/399
308
Legend
Return
2000-08-04
F-code
Section
C-code
PS
5.3
5000
Electrical Schematics (P5-04 Serial numbers 2810500-28126000)
Version no
000
T-code
395/396/397/398/399
Legend
BT Prime-Mover, Inc.
Return
2000-08-04
309
F-code
Section
C-code
PS
5.3
5000
Electrical Schematics (P5-04 Serial numbers 2810500-28126000)
Version no
T-code
000
395/396/397/398/399
310
Legend
Return
2000-08-04
F-code
Section
C-code
PS
5.3
5000
Electrical Schematics (P5-04 Serial numbers 2810500-28126000)
Version no
000
T-code
395/396/397/398/399
Legend
BT Prime-Mover, Inc.
Return
2000-08-04
311
F-code
Section
C-code
PS
5.3
5000
Electrical Schematics (P5-04 Serial numbers 2810500-28126000)
Version no
T-code
000
395/396/397/398/399
312
Legend
Return
2000-08-04
F-code
Section
C-code
PS
5.3
5000
Electrical Schematics (P5-04 Serial numbers 2810500-28126000)
Version no
000
T-code
395/396/397/398/399
Legend
BT Prime-Mover, Inc.
Return
2000-08-04
313
F-code
Section
C-code
PS
5.3
5000
Electrical Schematics (P5-04 Serial numbers 2810500-28126000)
Version no
T-code
000
395/396/397/398/399
Legend
314
Return
2000-08-04
F-code
Section
C-code
PS
5.4
5000
Electrical Schematics (P5-05/06/07 Serial number 28126001-UP)
Version no
000
T-code
395/396/397/398/399
Legend
BT Prime-Mover, Inc.
Return
2000-08-04
315
F-code
Section
C-code
PS
5.4
5000
Electrical Schematics (P5-05/06/07 Serial number 28126001-UP)
Version no
T-code
000
395/396/397/398/399
316
Legend
Return
2000-08-04
F-code
Section
C-code
PS
5.4
5000
Electrical Schematics (P5-05/06/07 Serial number 28126001-UP)
Version no
000
T-code
395/396/397/398/399
Legend
BT Prime-Mover, Inc.
Return
2000-08-04
317
F-code
Section
C-code
PS
5.4
5000
Electrical Schematics (P5-05/06/07 Serial number 28126001-UP)
Version no
T-code
000
395/396/397/398/399
318
Return
Legend
2000-08-04
F-code
Section
C-code
PS
5.4
5000
Electrical Schematics (P5-05/06/07 Serial number 28126001-UP)
Version no
000
T-code
395/396/397/398/399
Legend
BT Prime-Mover, Inc.
Return
2000-08-04
319
F-code
Section
C-code
PS
5.4
5000
Electrical Schematics (P5-05/06/07 Serial number 28126001-UP)
Version no
T-code
000
395/396/397/398/399
320
Legend
Return
2000-08-04
F-code
Section
C-code
PS
5.4
5000
Electrical Schematics (P5-05/06/07 Serial number 28126001-UP)
Version no
000
T-code
395/396/397/398/399
Legend
BT Prime-Mover, Inc.
Return
2000-08-04
321
F-code
Section
C-code
PS
5.4
5000
Electrical Schematics (P5-05/06/07 Serial number 28126001-UP)
Version no
T-code
000
395/396/397/398/399
322
Legend
Return
2000-08-04
F-code
Section
C-code
PS
5.4
5000
Electrical Schematics (P5-05/06/07 Serial number 28126001-UP)
Version no
000
T-code
395/396/397/398/399
Legend
BT Prime-Mover, Inc.
Return
2000-08-04
323
F-code
Section
C-code
PS
5.4
5000
Electrical Schematics (P5-05/06/07 Serial number 28126001-UP)
Version no
T-code
000
395/396/397/398/399
324
Legend
Return
2000-08-04
F-code
Section
C-code
PS
5.4
5000
Electrical Schematics (P5-05/06/07 Serial number 28126001-UP)
Version no
000
T-code
395/396/397/398/399
BT Prime-Mover, Inc.
Return
Legend
2000-08-04
325
F-code
Section
C-code
PS
5.4
5000
Electrical Schematics (P5-05/06/07 Serial number 28126001-UP)
Version no
T-code
000
395/396/397/398/399
Legend
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
Battery
CAUTION Before working on the battery, review
Battery Safety, beginning on page 21.
Batteries may weigh more than 2,900
pounds. 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
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 104).
4. Move lifting device from the area.
5. Reconnect battery at the battery connector, turn
key switch ON, and test operation of truck.
BT Prime-Mover, Inc.
Return
2000-08-04
327
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.
328
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.
CAUTION
BT Prime-Mover, Inc.
Return
2000-08-04
329
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.
330
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 at
the battery connector.
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.
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. Reconnect battery at the battery connector.
BT Prime-Mover, Inc.
Return
2000-08-04
331
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 at
the battery connector.
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 2
6
5
Description
Screw
Light
Bulb
Bracket, mounting
Alarm, travel
Screw
Fitting
332
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. Reconnect battery at the battery connector.
4. Test operation of warning lights, then return truck
to service.
3.1. Removal
1. Turn the key switch OFF and disconnect battery at
the battery connector.
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. Reconnect battery at the battery connector.
4. Test operation of working lights, then return truck
to service.
BT Prime-Mover, Inc.
Return
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
4.1. Removal
1. Turn the key switch OFF and disconnect battery at
the battery connector.
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. Reconnect battery at the battery connector.
4. Test operation of alarm, then return truck to
service.
334
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
335
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 at
the battery connector.
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. Reconnect battery at the battery connector.
5. Test operation of light assembly, then return truck
to service.
336
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
NOTE! The horn can only be sounded with the
key switch in the ON position.
3
1. Removal
1. Turn the key switch OFF and disconnect battery at
the battery connector.
2. Open motor compartment door to access the horn.
3. Disconnect wires from the horn.
2
Item No.
Description
Horn
Screw
Capacitor
Clamp
2. Installation
1. Attach horn to truck frame and tighten mounting
bolt (2).
2. Attach three wires.
3. Reconnect battery at the battery connector and
test operation.
4. Close motor compartment door.
BT Prime-Mover, Inc.
Return
2000-08-04
337
F-code
Section
C-code
PS
Horn
S5.7
5160
Version no
T-code
000
395/396/397/398/399
338
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 at
the battery connector.
2. Check battery connector for damaged cables.
BT Prime-Mover, Inc.
Return
2000-08-04
339
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! Battery charger unintentionally connected
to battery connector at truck chassis would
result in premature, unwarrantable, logic
card failure. Installation of spacer block
onto battery connector would prevent a
battery charger to truck connection.
1. Disconnect power supply to battery charger.
2. Attach spacer block to the topside of the battery
connector from the battery charger using two cap
screws and two hex nuts.
NOTE! Verify spacer block is installed correctly
by attempting to connect the battery
charger connector to truck battery
connector. If properly installed, the
spacer block will not allow the battery
charger connector to slide against truck
chassis and will prevent a connection of
battery charger and truck battery
connector.
3. Reconnect supply to battery charger.
340
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 291, page 303, or page 315).
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
1 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.
Return
2000-08-04
341
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 at
the battery connector.
2. Remove pod. Remove bottom half of pod see
page 229).
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. Reconnect battery at the battery connector and
check operation.
4. Turn the key switch OFF and disconnect battery at
the battery connector.
5. Install bottom half of pod. Install pod.
6. Reconnect battery at the battery connector.
342
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 when the key switch is
ON. 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 the
battery at the battery connector.
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
343
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. Reconnect battery at the battery connector.
8. Test truck operation, then return to service.
344
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
schematics page 291, page 303, or page 315).
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.
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
Item No.
346
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). 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
347
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 even with the bottom of 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 at
the battery connector.
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. Reconnect battery at the battery connector.
5. Adjust switch following the procedure on page 347.
6. Return truck to service.
348
Return
2001-08-20
F-code
PS
Section
C-code
S5.11
5391
Control Cable and Harness
Version no
000
T-code
395/396/397/398/399
1. Fuses
Examine the fuse for signs of overheating, discoloration,
cracking, or other physical damage. Replace fuse if
damaged.
AF2
AF1
F55
F54
Fuse
No.
Amp
AF1
10
AF2
10
F53
F52
F50
F1
250
F3
425
355
250
F51
F4
Located under Dash
F1
F3 or F4
BT Prime-Mover, Inc.
Return
Function
F50
15/
10
F51
30
Steering Circuit
F52
1/4
F53
1/4
F54
1/4
F55
10
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
2. Wiring
2.1. Harness
When working on the truck, use care around the wiring
harnesses.
350
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
351
F-code
Section
C-code
PS
S5.11
5391
Control Cable and Harness
Version no
T-code
000
395/396/397/398/399
352
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 trucks key switch OFF and disconnect
battery at the battery connector.
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
353
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.
354
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 at
the battery connector.
2. Remove dash (see page 98).
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. Reconnect battery at the battery connector.
5. Turn key switch ON and test truck operation.
6. Turn the key switch OFF, disconnect battery at the
battery connector, and install dash.
7. Reconnect battery at the battery connector.
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
(RRX45/RSX50/RDX30)
Item No.
356
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 at
the battery connector.
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. Reconnect battery at the battery connector.
5. Turn key switch ON and test truck operation.
6. Turn key switch OFF, disconnect battery at the
battery connector, and install dash.
7. Reconnect battery at the battery connector.
BT Prime-Mover, Inc.
Return
2000-08-04
357
F-code
Section
C-code
PS
S5.12
Contactors
5441
Version no
T-code
000
395/396/397/398/399
2
3
Item No.
358
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 the
battery at the battery connector.
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. Reconnect battery at the battery connector.
5. Turn the key switch ON and test truck operation.
6. Turn the key switch OFF, disconnect battery at the
battery connector, and install dash.
BT Prime-Mover, Inc.
Return
2000-08-04
359
F-code
Section
PS
S5.12
Contactors
C-code
5441
Version no
T-code
000
395/396/397/398/399
360
Return
2000-08-04
F-code
Section
PS
C-code
S5.13
5460
Transistor Panel (Drive)
Version no
T-code
000
395/396/397/398/399
3
4
Item No.
Description
Screw
Lockwasher
Nut
Screw
Screw
BT Prime-Mover, Inc.
Return
2000-08-04
361
F-code
Section
C-code
PS
S5.13
Transistor Panel (Lift)
5460
Version no
T-code
000
395/396/397/398/399
3
4
Item No.
362
Return
Description
Screw
Lockwasher
Nut
Screw
Screw
2000-08-04
F-code
PS
Section
C-code
S5.13
5460
Transistor Panel (Lift)
Version no
T-code
000
395/396/397/398/399
1. Motor Connections
The transistor regulator 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
BT Prime-Mover, Inc.
Return
Function
Not used
Common connection B -
Common connection B -
Plug braking
10
11
LED No.
Color
Green
Supply voltage
Yellow
Upper/lower temperature
Red
Red
2000-08-04
Function
363
F-code
Section
PS
S5.13
Transistor Panel (Lift)
C-code
5460
Version no
T-code
000
395/396/397/398/399
2. Circuit Check
This check applies to all BT Prime-Mover trucks equipped
with a transistor regulator type.
1. Jack up the truck (see page 66).
2. Block truck securely.
3. Remove control pod and dash (see page 231 and
page 98).
4. Reinstall control pod.
5. Turn the key switch so that the electronic card is
on.
6. Connect jumper wire between the battery negative
(B-) and the contact for the control current (pin
number 2) on the transistor regulator. The main
contactor, K10, should now open to indicate that
the transistor regulators safety system is
functioning. If K10 does not open, replace the
entire transistor regulator. See Power Circuit
Checks on page 397.
7. Reset the safety circuits by turning the ignition key
to the OFF position.
8. Return the truck to its original condition after the
check.
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 291,
page 303, or page 315. 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.
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 at
the battery connector.
2. Loosen pod 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. Reconnect battery at the battery connector.
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 at
the battery connector.
2. Loosen the pod 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. Reconnect battery at the battery connector.
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.
372
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
12. Install the new chip with the notch in the chip
located toward the top of the A5 card in the lower
socket holes (at the top of the new chip there
should be four socket holes visible on each side).
NOTE! Be sure to carefully align the logic chip pins
with the socket holes to ensure no logic chip
pins are bent during installation.
NOTE! When installing the cover on the A5 logic card
be carefully no to damage or bend
components on the A5 logic board.
13. Remove the static strap from the A5 card. Install
the aluminum cover on the A5 logic card.
14. Install lower two screws into the cover of the A5
card.
15. Remove the top allen 0.19 inch (5 mm) bolt from
the A5 card. Tip the A5 card outward far enough to
allow the two screws to be installed.
NOTE! Make sure the wiring harness is not caught
behind the A5 card before tightening.
16. Install top two allen (5 mm) bolts to hold the A5
card in place.
17. Install the drivers compartment right side panel
and tighten.
18. Plug battery in and power truck up.
19. Using the values recorded at the beginning of this
procedure set the trucks parameters as noted.
20. Ensure proper operation of the truck before
returning the truck to service.
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 at the
battery connector.
2. Remove main
page 101).
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. Reconnect battery at the battery connector.
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.
Color
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
Terminal Number
Return
Function
Connection
Function
301
Display power +
302
Display power -
303
TX positive display
304
TX negative display
Terminal Number
376
Function
Connection
Function
402
403
404
405
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
Function
806
807
378
Return
810
Sensor feed +
811
Sensor feed -
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
J
380
Return
I H G FE
Parameters
Running time
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
Set parameter 12 at 4
BT Prime-Mover, Inc.
Return
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
6. Press brake pedal all the way down and the display
should read 247.
7. To adjust with the pedal all the way down loosen
the bolts on the brake transducer and adjust until
247 appears on the display.
8. The brake switch should be adjusted so it actuates
between 45 and 52 on the display when
depressing the pedal.
9. After making adjustments, go back into the
programming mode.
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
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
386
Return
RRX35/45/RSX40/50/RDX30
1.94
RRX45/RDX30/RSX50
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
BATTERY EXCEEDS
FULL DISCHARGE
1.74
1.59
1.52
NOT VALID
1.67
Force Reset
1.53
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
BAR LEVEL
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
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
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
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)
A5 Logic Box
308035-000
Jumper Harness
A5 Control Module
Connector 800
(Connector Plug-in # 8)
Input 809
Wire 22
Wire 22
Key Lock
Wire 22
Wire 22
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
11
12
Not used
13
16
17
18
19
Default Par
20
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
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 needs 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
C-code
PS
S5.15
Main Electronic Card
5710
Version no
T-code
001
395/396/397/398/399
SW1
SW2
SW3
400
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
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.
BT Prime-Mover, Inc.
Return
Values
2001-10-31
Comment
401
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
0-36V Std (RRX35/RSX40)
1-24V Std (RRX35/RSX40)
2-36V HD (RRX45/RDX30/
RSX50)
Comment
Hydraulic pump type.
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.
402
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
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.
BT Prime-Mover, Inc.
Return
Values
2001-10-31
Comment
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
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.
404
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
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
72
210
78
76
240
90
88
270
102
100
300
111
330
123
360
135
402
152
BT Prime-Mover, Inc.
Return
Standard - Forward
(U.S. style)
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
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
406
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
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
BT Prime-Mover, Inc.
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
407
F-code
Section
PS
S5.15
Main Electronic Card
C-code
5710
Version no
T-code
001
395/396/397/398/399
408
Return
Mast Height
(inch)
RRX35/RSX40
RRX45/RDX30/RSX50
192
198
198
210
240
258
258
270
285
285
300
321
321
330
360
390
390
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
72
210
78
75
240
90
87
258
95
270
102
99
300
111
330
123
360
135
390
147
402
151
BT Prime-Mover, Inc.
Return
Mast Height
(inch)
RRX35/RSX40
RRX45/RDX30/RSX50
192
198
74
210
240
258
98
95
270
285
105
300
321
119
330
360
390
402
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
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.
To test a 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 switch. In a closed position, switch should
be less than 1 ohm. In an open position, switch should show
a resistance greater than 10 megohms.
+
1
1/2
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 the
battery at battery connector.
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 at
battery connector.
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. Reconnect battery at battery connector.
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 at
battery connector.
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. Reconnect battery at battery connector.
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 behind the drive motor and. Sensors can be
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! Do
not
overtighten
jam
nut.
Overtightening can cause sensor
damage.
BT Prime-Mover, Inc.
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 the
battery at battery connector.
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! Do not overtighten jam nut. Overtightening can
cause sensor damage.
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 the
battery at battery connector.
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. Reconnect battery at battery connector.
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 serious 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 446, RRX45
Hydraulic Schematic on page 447, RDX30 Hydraulic
Schematic on page 448, RSX40 Hydraulic Schematic on
page 449, or RSX50 Hydraulic Schematic on page 450. For
a listing of error codes see page 393 and page 394. For a
listing of parameters see page 401, page 403, or page 406.
For a listing on the fuses and their location see page 349.
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.
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
LEGEND
R14
Pressure Oil
Return Oil
506
507
508 509
Electric Positive
A5
Electric Negative
701
702
703
75
76
10
11
40
10
B-
A2
B+
M3
(+)
Supply
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
1.2. Lifting
With the key switch ON and brake pedal and/or right foot
switch depressed, by pushing potentiometer (R11) forward
causes potentiometer (R11) to output a voltage less than
when in the neutral position. The main electronic card (A5)
senses this decrease 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
BT Prime-Mover, Inc.
Return
2001-11-08
423
F-code
Section
C-code
PS
S6.0
Hydraulic System
6000
Version no
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 pulling back potentiometer (R11)
causes output voltage greater than when in the neutral
position. The main electronic card (A5) senses this increase
in voltage at input 506 (wire #82). The main electronic (A5)
card enables voltage to the proportional lower solenoid coil
(Y10/3) 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
804
88
506
704
89
2
3
Y10/3
(-)
40
Y10/2
Lowering
424
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
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
507
(-)
40
Y15
Y14
R12
A5
707
708
706
705
92
93
91
90
Y12
Y13
Reach (RRX35)
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 (RRX45/RDX30)
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 by
pushing potentiometer (R12) forward. With the key switch ON
and the brake pedal and/or right foot pedal depressed,
pushing the lever causes voltage to be sensed at the main
electronic (A5) card input 507 (wire #83). 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). Reach solenoids Y14 and Y15 are combined into
one solenoid on some reach models.
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
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
Y14
30
83
507
(-)
Y15
R12
40
A5
707
708
706
705
92
93
91
90
Y13
Y12
Retract (RRX35)
428
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)
29
R12
83
A5
707
507 708
706
705
(-)
Y15
Y14
30
40
92
93
91
90
Y13
Y12
Retract (RRX45/RDX30)
BT Prime-Mover, Inc.
Return
2001-11-08
429
F-code
Section
PS
S6.0
Hydraulic System
C-code
6000
Version no
T-code
000
395/396/397/398/399
1.5. Retract
Retract withdraws the forks toward the mast assembly by
pulling back potentiometer (R12). With the key switch ON and
the brake pedal and/or the right foot pedal depressed, pulling
potentiometer (R12) rearward causes voltage to be sensed at
A5 input 507 (wire #83). 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). Reach solenoids Y14 and Y15 are combined into
one solenoid on some reach models.
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.
430
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
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
BT Prime-Mover, Inc.
Return
2001-11-08
431
F-code
Section
PS
S6.0
Hydraulic System
C-code
6000
Version no
T-code
000
395/396/397/398/399
1800 PSI
0.020
300 PSI
29
Y14
30 R12
(-)
83
A5
507
707
708
706
705
40
Y15
92
93
91
90
Y13
Y12
Impact (RRX35)
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
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 (RRX35/RSX40/50)
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
Y17
30
R13
84
A5
710
508
706
705
(-)
40
94
91
90
Y13
Y12
Tilt Up (RRX45/RDX30)
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
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 sensed 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 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, 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
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
Y17
R13
84
A5
94
710
508
706
705
(-)
40
91
90
Y13
Y12
436
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)
29
Y17
30
R13
84
A5
710
508
706
705
(-)
40
94
91
90
Y12
Y13
BT Prime-Mover, Inc.
Return
2001-11-08
437
F-code
Section
PS
S6.0
Hydraulic System
C-code
6000
Version no
T-code
000
395/396/397/398/399
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
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
440
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
441
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
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
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
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
Y10/2
Valve
Lift/lower
Y10/3
Valve
Lift of Forks
Y13
Valve
Direction B
444
Return
Function
Remarks
2001-11-08
F-code
Section
PS
S6.0
6000
Hydraulic System
Version no
000
Symbol
Designation
Y14
Valve
Reach out
Y15
Valve
Reach in
Y16
Valve
Sideshifter
Y17
Valve
Tilt
Y12
Valve
Direction A
BT Prime-Mover, Inc.
Return
Function
2001-11-08
C-code
T-code
395/396/397/398/399
Remarks
445
F-code
Section
PS
S6.0
Hydraulic System
C-code
6000
Version no
T-code
000
395/396/397/398/399
446
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
447
F-code
Section
C-code
PS
S6.0
Hydraulic System
6000
Version no
T-code
000
395/396/397/398/399
448
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
449
F-code
Section
C-code
PS
S6.0
Hydraulic System
6000
Version no
T-code
000
395/396/397/398/399
450
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 82.
BT Prime-Mover, Inc.
Return
2000-08-04
451
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 at the
battery connector.
3. Remove dash and open motor compartment door
(see page 98).
4. Remove diagnostic fitting near control valve. Be
sure not to let fluid get into drive motor.
5. Place a piece of tubing or rubber hose over fitting
and direct into a waste container with a capacity
greater than 5 gallons (19 liters).
6. Reconnect battery at the battery connector and
turn key switch ON.
7. Operate lift until you hear air in system.
8. Turn the key switch OFF and disconnect the
battery at the battery connector.
9. Remove drainage tube and replace diagnostic
fitting.
10. Remove filter.
11. If it is necessary to flush reservoir, remove
reservoir.
12. Dispose of old hydraulic fluid according to local
regulations for hazardous materials.
452
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. Reconnect battery at the battery connector and
turn key switch ON.
5. Bleed hydraulic system.
6. Install dash and secure motor compartment door.
BT Prime-Mover, Inc.
Return
2000-08-04
453
F-code
Section
C-code
PS
S6.1
Hydraulic Fluid
6112
Version no
T-code
000
395/396/397/398/399
454
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
455
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.
456
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 98).
3. Drain hydraulic system (see page 451).
4. Remove left side panel (see page 100).
5. Turn the key switch OFF and disconnect the
battery at the battery connector.
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
457
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. Reconnect battery at the battery connector.
10. Bleed hydraulic system.
11. Test operate truck.
12. Turn key switch OFF and disconnect battery at the
battery connector. Install dash. Reconnect battery
at the battery connector.
458
Return
2000-08-04
F-code
PS
Section
C-code
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.
BT Prime-Mover, Inc.
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
459
F-code
Section
C-code
PS
S6.2
6131
Hydraulic Filter Assembly
Version no
T-code
000
395/396/397/398/399
1. Hydraulic Filter
1.1. Removal
NOTE! It is recommended that hydraulic fluid be
drained from hydraulic tank prior to
replacing filter.
1. Lower carriage fully to ensure all hydraulic
pressure is relieved.
2. Turn key switch OFF, and disconnect battery at the
battery connector.
3. Remove dash (see page 98).
4. Remove blue cover on filter adapter collar. Filter is
attached to the bottom of the blue cover.
5. Remove filter by pulling straight down to snap it out
of latch.
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. Reconnect battery at the battery connector.
7. Return to service.
460
Return
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
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 inch-lb
(50 Nm).
3. Install cap and filter.
4. Check fill level fluid in the hydraulic tank.
5. Reconnect battery at the battery connector.
6. Bleed hydraulic system.
7. Test operate truck.
8. Turn key switch OFF and disconnect battery
connector.
9. Install dash.
BT Prime-Mover, Inc.
Return
2000-08-04
461
F-code
Section
C-code
PS
S6.2
6131
Hydraulic Filter Assembly
Version no
T-code
000
395/396/397/398/399
462
Return
2000-08-04
F-code
Section
PS
S6.3
6141
Hydraulic Pump
Version no
000
C-code
T-code
395/396/397/398/399
Hydraulic Pump
1. Removal
Remove pump motor (see page 108). 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
BT Prime-Mover, Inc.
Return
2000-08-04
463
F-code
Section
C-code
PS
S6.3
Hydraulic Pump
6141
Version no
T-code
000
395/396/397/398/399
464
Return
2000-08-04
F-code
Section
PS
S6.4
6211
Control Valve
Version no
000
Y10 Lift and
Prop. Lower
C-code
T-code
395/396/397/398/399
Control Valve
To
Mast
1. Removal
1. Turn key switch OFF and disconnect battery at the
battery connector.
To
Reservoir
2. Remove dash.
Y12 DIRA
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
465
F-code
Section
C-code
PS
S6.4
Control Valve
6211
Version no
T-code
000
395/396/397/398/399
466
Return
F-code
Section
PS
S6.4
6211
Control Valve
Version no
000
C-code
T-code
395/396/397/398/399
MALFUNCTION
Lifting Function
POSSIBLE CAUSE
1. 2/2-way seated valve does
not open (only if forks do not
raise).
POSSIBLE REPAIR
Check electrical connection of the
pins at the plug connection Y10.
Check the voltage supply.
Replace the Y10 solenoid.
Check the valve insert under the
on/off section of the twin solenoid:
Is the valve operation smooth? Is
there any contamination? Check
seals for damage at valve insert
(O rings). Replace main control
block.
Unintentionally lift
during the actuation
of auxiliary
functions.
BT Prime-Mover, Inc.
Return
467
F-code
Section
C-code
PS
S6.4
Control Valve
6211
Version no
T-code
000
395/396/397/398/399
MALFUNCTION
Forks do not drop
or drop too slow.
POSSIBLE CAUSE
1.Electrical actuation (see
LIFTING/LOWERING TIME
on page 60).
POSSIBLE REPAIR
Check the electrical connection of
the pins at plug Y10.
Check the voltage supply to the
proportional lowering solenoid.
Replace the Y10 solenoid valve.
Forks lower
unintentionally.
2.Proportional pre-pressure
reducing valve sticks or does
not operate smoothly.
468
Return
F-code
Section
PS
S6.4
6211
Control Valve
Version no
000
C-code
T-code
395/396/397/398/399
Main control
valve (general)
BT Prime-Mover, Inc.
Return
MALFUNCTION
POSSIBLE CAUSE
Auxiliary functions
(reach, tilt,
sideshift) do not
operate or operate
too slowly.
POSSIBLE REPAIR
469
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
470
Return
41
50
51
F-code
PS
Section
Version no
T-code
000
Item
No.
Description
C-code
S6.4
6211
Control Valve Assembly
Item
No.
395/396/397/398/399
Description
24
Piston
Plug
25
Spring
O ring
26
Spring
Insert
27
Sleeve
4a
O ring
28*
Ball
4b
Seal ring
29*
Screw
5*
Rod
29A*
Screw
6*
30*
7*
Pin
31
Seal
8*
Valve core
32*
Spring
9*
Seal
33*
Guide, ball
10*
Return Spring
36
Locknut
11*
Spring
37
Screw
12*
Seal
40
Seal
13*
41*
Plug
14
Seal
43*
Screw
15*
Spring
46*
16*
Damping insert
47
O ring
17
Screw
48
Valve, assembly
18
Nut
49
Plate, end
19
Screw
50
Washer
20
Ring, seal
51
21
Disc
52
Solenoid, double
22
Spring
53
Valve assembly
23
Guide spring
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
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).
472
Return
F-code
PS
Version no
000
Section
C-code
S6.4
6211
Control Valve Assembly
T-code
395/396/397/398/399
Relief
Valve
Adjusting
Screw
Relief Pressure
Test Port
(beneath
reservoir hose)
BT Prime-Mover, Inc.
Return
473
F-code
Section
C-code
PS
S6.4
6211
Control Valve Assembly
Version no
T-code
000
395/396/397/398/399
474
Return
F-code
PS
Version no
000
Section
C-code
S6.4
6211
Control Valve Assembly
T-code
395/396/397/398/399
BT Prime-Mover, Inc.
Return
475
F-code
Section
C-code
PS
S6.4
6211
Control Valve Assembly
Version no
T-code
000
395/396/397/398/399
476
Return
F-code
Section
C-code
PS
S6.5
6610
Staging Cylinder, Three Stage Mast, RRX35/RSX40
Version no
T-code
001
395/398
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
2000-08-04
477
F-code
Section
C-code
PS
S6.5
6610
Staging Cylinder, Three Stage Mast, RRX35/RSX40
Version no
T-code
001
395/398
1. Removal
1. Park the truck on a level surface and apply the
brake.
2. Fully extend the cylinders to inspect the rod (12) for
gouges or pits. If gouges or pits are detected,
remove cylinder for repair.
WARNING When blocking mast columns to prevent
lowering, always block both sides of
column. If both sides are not blocked, the
truck could tip over on its side.
3. Lift mast so inner column is raised approximately
12 inches (305 mm). Securely block mast, using 4
inch x 4 inch (102 mm x 102 mm) blocks under
each side of the inner columns.
4. Remove bolts from top end of staging cylinder
rods. Lower cylinder rods hydraulically.
5. Turn key switch to OFF and disconnect battery at
the battery connector.
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.
478
Return
2000-08-04
F-code
Section
C-code
PS
S6.5
6610
Staging Cylinder, Three Stage Mast, RRX35/RSX40
Version no
001
T-code
395/398
2. Disassembly
1. Remove bearing (14) from the cylinder tube.
2. Remove rod wiper (16), seal (15), wear ring (9) and
O ring (13) from 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 crosshead, chains, hoses, and electric
cables.
2. Connect battery at the battery connector.
3. Test for proper operation.
BT Prime-Mover, Inc.
Return
2000-08-04
479
F-code
Section
C-code
PS
S6.5
6610
Staging Cylinder, Three Stage Mast, RRX35/RSX40
Version no
T-code
001
395/398
480
Return
2000-08-04
F-code
Section
C-code
PS
S6.6
6610
Staging Cylinder, Three Stage Mast, RRX45/RDX30/RSX50
Version no
001
T-code
396/397/399
11
16
10
9
15
14
13
12
8
7
6
BT Prime-Mover, Inc.
Return
2000-08-04
481
F-code
Section
C-code
PS
S6.6
6610
Staging Cylinder, Three Stage Mast, RRX45/RDX30/RSX50
Version no
T-code
001
396/397/399
Item
No.
Description
Screw
10
Ring, stop
Washer, seal
11
Rod cylinder
12K
13
Ring retainer
14K
Seal
Plunger assembly
15K
Seal
Spring
16K
Wiper
482
Item
No.
8K
Return
Description
Ring, guide
O ring
Bearing
Piston
2000-08-04
F-code
Section
C-code
PS
S6.6
6610
Staging Cylinder, Three Stage Mast, RRX45/RDX30/RSX50
Version no
001
T-code
396/397/399
1. Removal
1. Park the truck on a level surface and apply the
brake.
2. Fully extend the cylinders to inspect the rod (11) for
gouges or pits. If gouges or pits are detected,
remove cylinder for repair.
WARNING When blocking mast columns to prevent
lowering, always block both sides of
column. If both sides are not blocked, the
truck could tip over on its side.
3. Lift mast so inner column is raised approximately
12 inches (305 mm). Securely block mast, using 4
inch x 4 inch (102 mm x 102 mm) blocks under
each side of the inner columns.
4. Remove bolts from top end of staging cylinder
rods. Lower cylinder rods hydraulically.
5. Turn key switch to OFF and disconnect battery at
the battery connector.
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.
6. Clean the exterior of the lift cylinder.
BT Prime-Mover, Inc.
Return
2000-08-04
483
F-code
Section
C-code
PS
S6.6
6610
Staging Cylinder, Three Stage Mast, RRX45/RDX30/RSX50
Version no
T-code
001
396/397/399
2. Disassembly
1. Remove bearing (13) from the cylinder tube.
2. Remove and discard rod wiper (16), seal (15),
wear ring (14) and O ring (12) from bearing (13).
Use care NOT to damage the inside of the bearing.
3. Assembly
1. Install new seal (15), wear ring (14), O ring (12)
and rod wiper (16).
2. The lip of the wiper must face outward.
4. Installation
1. Install crosshead, chains, hoses, and electric
cables.
2. Connect battery at the battery connector.
3. Test for proper operation.
484
Return
2000-08-04
F-code
Section
C-code
PS
S6.7
6620
Freelift Cylinder, Three Stage Mast
Version no
001
T-code
395/396/397/398/399
K
2
3
15
14
13
7
12
6
11
5
10
BT Prime-Mover, Inc.
Return
2000-08-04
485
F-code
Section
C-code
PS
S6.7
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
Piston
Description
Rod cylinder
486
Return
2000-08-04
F-code
Section
C-code
PS
S6.7
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.
WARNING When blocking mast columns to prevent
lowering, always block both sides of
column. Otherwise truck could tip over on
its side.
3. Lift carriage/reach approximately 6 inches (152
mm). Block carriage/reach to prevent lowering.
4. Lower cylinder so chains, hoses, and electric
cables are loose.
5. Turn key switch to OFF and disconnect battery at
the battery connector.
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 (206 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
487
F-code
Section
C-code
PS
S6.7
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 at the battery connector.
3. Test for proper operation.
488
Return
2000-08-04
F-code
Section
C-code
PS
S6.8
6650
Reach Cylinder Assembly, RRX35
Version no
T-code
002
395
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
489
F-code
Section
C-code
PS
S6.8
6650
Reach Cylinder Assembly, RRX35
Version no
T-code
002
395
Item
No.
Description
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
490
Return
2000-08-04
F-code
Section
C-code
PS
S6.8
6650
Reach Cylinder Assembly, RRX35
Version no
002
T-code
395
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 at the
battery connector.
BT Prime-Mover, Inc.
Return
2000-08-04
491
F-code
Section
C-code
PS
S6.8
6650
Reach Cylinder Assembly, RRX35
Version no
T-code
002
395
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! CLEANLINESS! Perform procedures in
a clean environment. Make sure all parts
are cleaned before disassembly and kept
clean during assembly.
1. Before disassembly, clean exterior of the reach
cylinder in a cleaning solution to remove all
contamination.
2. Be sure all hydraulic fluid has been removed from
the cylinder. Stroking the piston rod will help force
fluid out.
3. Put base end of cylinder in a vise equipped with
soft jaws.
4. Remove bearing retainer (22) and bearing (9) by
rotating bearing with a spanner wrench from
cylinder tube (23 or 24).
5. Remove bearing assembly, seal (11), rings (8 and
17), and cylinder assembly consisting of the rod
(13), piston (19) and lock nut (21). Discard seal
(11).
6. Remove and discard rod wiper (12).
7. Inspect mounting bearing (25) located at base end
of the cylinders. Do not remove bearing unless
found to be unfit for further service.
492
Return
2000-08-04
F-code
Section
C-code
PS
S6.8
6650
Reach Cylinder Assembly, RRX35
Version no
002
T-code
395
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
493
F-code
Section
C-code
PS
S6.8
6650
Reach Cylinder Assembly, RRX35
Version no
T-code
002
395
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
(18) 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).
494
Return
2000-08-04
F-code
Section
C-code
PS
S6.8
6650
Reach Cylinder Assembly, RRX35
Version no
002
T-code
395
5. Installation
1. Reconnect battery at the battery connector. 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 serious 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
495
F-code
Section
C-code
PS
S6.8
6650
Reach Cylinder Assembly, RRX35
Version no
T-code
002
395
496
Return
2000-08-04
F-code
Section
C-code
PS
S6.9
6650
Reach Cylinder Assembly, RRX45
Version no
T-code
001
396
18
19
20 22
17
23
25
21
24
26
7
12
13
15
16
9
11
10
14
BT Prime-Mover, Inc.
Return
2000-08-04
497
F-code
Section
C-code
PS
S6.9
6650
Reach Cylinder Assembly, RRX45
Version no
T-code
001
396
Item
No.
498
Description
Item
No.
Description
Item
No.
Description
Pin
10
Retainer
19
Ring, back-up
Pin, roll
11
Lock Nut
20
Bearing
Pin
12
Ring, guide
21
Ring, guide
Pin, roll
13
Piston
22
Seal
Cylinder assembly,
right hand
14
O ring
23
Wiper
Cylinder assembly,
left hand
15
Ring, back-up
24
Rod, cylinder
Bushing
16
O ring
25
Nut
17
Bushing
26
Yoke, rod
18
O ring
Return
2000-08-04
F-code
Section
C-code
PS
S6.9
6650
Reach Cylinder Assembly, RRX45
Version no
001
T-code
396
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 reach cylinders.
5. Remove hoses from reach cylinder.
6. Remove roll pins (4). Remove front mounting pins
(3). Remove reach cylinder from truck.
7. Raise reach assembly above full freelift. Remove
roll pins (2). Remove rear mounting pins (1).
8. Remove reach cylinder from truck.
9. Turn key switch to OFF. Disconnect battery at the
battery connector.
BT Prime-Mover, Inc.
Return
2000-08-04
499
F-code
Section
C-code
PS
S6.9
6650
Reach Cylinder Assembly, RRX45
Version no
T-code
001
396
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! CLEANLINESS! Perform procedures in
a clean environment. Make sure all parts
are cleaned before disassembly and kept
clean during assembly.
1. Before disassembly, clean exterior of the reach
cylinder in a cleaning solution to remove all
contamination.
2. Be sure all hydraulic fluid has been removed from
cylinder. Stroking the piston rod will help force fluid
out.
3. Put base end of cylinder in a vise equipped with
soft jaws.
4. Remove bearing retainer (10) and bearing (20) by
rotating bearing with a spanner wrench from
cylinder tube (8 or 9).
5. Remove bearing assembly, seal (22), back-up
rings (15) and (19), and rod (24) with spacer and
piston seals.
6. Remove and discard seal (22), rod wiper (23), seal
(18), back up ring (19), ring guide (21), O rings (14)
and (16), back up ring (15), and ring guide (12).
7. Inspect mounting bushing (7) located at base end
of the cylinders. Do not remove bearing unless
found to be unfit for further service.
500
Return
2000-08-04
F-code
Section
C-code
PS
S6.9
6650
Reach Cylinder Assembly, RRX45
Version no
001
T-code
396
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
501
F-code
Section
C-code
PS
S6.9
6650
Reach Cylinder Assembly, RRX45
Version no
T-code
001
396
4. Assembly
1. Install new O rings (18), back up ring (19), seal
(22), ring guide (21), and rod wiper (23) in bearing
assembly (20). The lip of the wiper must face
outward.
2. Install new O rings (14) and (16), back up ring (15),
and ring guide (12) on piston (13). Torque cylinder
piston lock nut (11) to 60-65 ft-lb (81-88 Nm)
3. Apply clean hydraulic fluid to rod cylinder (24).
Coat the inside of cylinder tube and bearing
assembly with clean fluid.
4. Carefully slide bearing assembly (20) onto the
cylinder rod (24). Be sure rod end does not cut or
nick wiper (23) and seal (22) upon installation.
5. Install cylinder rod (24) into cylinder tube (8 or 9).
Be careful not to nick or cut piston seals on the
edge of cylinder tube or when sliding over groove
within tube.
6. Install bearing assembly into cylinder tube. Use
care not to nick or cut seals upon installation.
7. Install retainer (10).
8. Check installation by making sure piston rod
assembly moves smoothly within tube assembly
without binding.
9. Install bearing (20).
502
Return
2000-08-04
F-code
Section
C-code
PS
S6.9
6650
Reach Cylinder Assembly, RRX45
Version no
001
T-code
396
5. Installation
1. Reconnect battery at the battery connector. Turn
key switch to ON.
2. Raise reach to full freelift height. Install reach
cylinder rear mounting pins (1). Secure mounting
pins with roll pins (2).
3. Lower reach assembly. Install reach cylinder front
mounting pins (3). Secure mounting pins with roll
pins (4).
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 serious 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
503
F-code
Section
C-code
PS
S6.9
6650
Reach Cylinder Assembly, RRX45
Version no
T-code
001
396
504
Return
2000-08-04
F-code
Section
C-code
PS
S6.10
6650
Reach Cylinder Assembly, RDX30
Version no
T-code
001
397
22
18
25
21
23
19
20
24
26
12
13
15
17
9
11
16
14
10
BT Prime-Mover, Inc.
Return
2000-08-04
505
F-code
Section
C-code
PS
S6.10
6650
Reach Cylinder Assembly, RDX30
Version no
T-code
001
397
Item
No.
506
Description
Item
No.
Description
Item
No.
Description
Pin
10
Retainer
19
Ring, guide
Pin, roll
11
Nut
20
Bearing
Pin
12
Ring, guide
21
Ring, guide
Pin, roll
13
Piston
22
Seal
Cylinder assembly,
right hand
14
O ring
23
Wiper
Cylinder assembly,
left hand
15
Ring, back-up
24
Rod, cylinder
Bushing
16
O ring
25
Nut
17
Spacer (Sideshifter)
26
Yoke, rod
18
O ring
Return
2000-08-04
F-code
Section
C-code
PS
S6.10
6650
Reach Cylinder Assembly, RDX30
Version no
001
T-code
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 reach cylinders.
5. Remove hoses from reach cylinder.
6. Remove roll pins (4). Remove front mounting pins.
Remove reach cylinder from truck.
7. Raise reach assembly above full freelift. Remove
roll pins (2). Remove rear mounting pins.
8. Turn key switch to OFF. Disconnect battery at the
battery connector.
BT Prime-Mover, Inc.
Return
2000-08-04
507
F-code
Section
C-code
PS
S6.10
6650
Reach Cylinder Assembly, RDX30
Version no
T-code
001
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! CLEANLINESS! Perform procedures in
a clean environment. Make sure all parts
are cleaned before disassembly and kept
clean during assembly.
1. Before disassembly, clean exterior of the reach
cylinder in a cleaning solution to remove all
contamination.
2. Be sure all hydraulic fluid has been removed from
cylinder. Stroking the piston rod will help force fluid
out.
3. Put base end of cylinder in a vise equipped with
soft jaws.
4. Remove bearing retainer (10) and bearing (7) by
rotating bearing with a spanner wrench from
cylinder tube (8 or 9).
5. Remove bearing assembly, seal (22), back-up
rings (15 and 19), and rod (24) with spacer and
piston seals.
6. Remove and discard seal (22) and rod wiper (23).
7. Inspect mounting bearing (20) located at base end
of the cylinders. Do not remove bearing unless
found to be unfit for further service.
508
Return
2000-08-04
F-code
Section
C-code
PS
S6.10
6650
Reach Cylinder Assembly, RDX30
Version no
001
T-code
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
509
F-code
Section
C-code
PS
S6.10
6650
Reach Cylinder Assembly, RDX30
Version no
T-code
001
397
4. Assembly
1. Install new O rings (18), ring guide (19), seal (22),
ring guide (21), and rod wiper (23) in bearing
assembly (20). The lip of the wiper must face
outward.
2. Install new O rings (14) and (16), back-up ring (15),
and ring guide (12) on piston (13). Install nut (11)
and torque to 150-170 ft-lb (203-230 Nm).
3. Apply clean hydraulic fluid to rod cylinder (24).
Coat the inside of cylinder tube and bearing
assembly with clean fluid.
4. Carefully slide spacer (if used) and bearing
assembly onto the cylinder rod (24). Be sure rod
end does not cut or nick wiper (23) upon
installation.
5. Install cylinder rod (24) into cylinder tube (8) or (9).
Be careful not to nick or cut piston seals on the
edge of cylinder tube or when sliding over groove
within tube.
6. Install bearing assembly into cylinder tube. Use
care not to nick or cut seals upon installation.
7. Install retainer (10).
8. Check installation by making sure piston rod
assembly moves smoothly within tube assembly
without binding.
9. Install bearing (7).
510
Return
2000-08-04
F-code
Section
C-code
PS
S6.10
6650
Reach Cylinder Assembly, RDX30
Version no
001
T-code
397
5. Installation
1. Reconnect battery at the battery connector. Turn
key switch to ON.
2. Raise reach to full freelift height. Install reach
cylinder rear mounting pins (1). Secure mounting
pins with roll pins (2).
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 serious 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
511
F-code
Section
C-code
PS
S6.10
6650
Reach Cylinder Assembly, RDX30
Version no
T-code
001
397
512
Return
2000-08-04
F-code
Section
C-code
PS
S6.11
6660
Tilt Cylinder Assembly, RRX35/RSX40
Version no
T-code
002
395/398/399
13
14
11
7
5
12
10
1
2
3
4
BT Prime-Mover, Inc.
Return
2000-08-04
513
F-code
Section
C-code
PS
S6.11
6660
Tilt Cylinder Assembly, RRX35/RSX40
Version no
T-code
002
395/398/399
Item No.
514
Return
Description
Item No.
Description
Ring, back-up
Bushing
O Ring
Retainer, cylinder
10
Rod, cylinder
Screw, cap
11
O Ring
Wiper
12
Ring, back-up
Seal
13
Retainer
Bearing, cylinder
14
Tube, cylinder
2000-08-04
F-code
Section
C-code
PS
S6.11
6660
Tilt Cylinder Assembly, RRX35/RSX40
Version no
002
T-code
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 at the
battery connector.
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
BT Prime-Mover, Inc.
Return
2000-08-04
515
F-code
Section
C-code
PS
S6.11
6660
Tilt Cylinder Assembly, RRX35/RSX40
Version no
T-code
002
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.
1. Before disassembly, clean exterior of tilt cylinder
(1) in a cleaning solution to remove all
contamination.
2. Be sure all hydraulic fluid has been removed from
cylinder. Stroking piston rod will help force fluid out.
3. Put base end of cylinder in a vise equipped with
soft jaws.
4. Remove bearing retainer (13) and back-up ring
(12) from cylinder tube.
5. Remove bearing assembly, seal (6), back-up ring
(8), cylinder rod (10) and piston seals.
6. Remove and discard all seals (6), O rings (9 and
11), back-up rings (8 and 12) and rod wiper (5).
7. Inspect mounting bushings (2) located at both ends
of cylinder. Do not remove bushings unless found
to be unfit for further service.
516
Return
2000-08-04
F-code
Section
C-code
PS
S6.11
6660
Tilt Cylinder Assembly, RRX35/RSX40
Version no
002
T-code
395/398/399
3. Inspection
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.
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.
BT Prime-Mover, Inc.
Return
2000-08-04
517
F-code
Section
C-code
PS
S6.11
6660
Tilt Cylinder Assembly, RRX35/RSX40
Version no
T-code
002
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.
518
Return
2000-08-04
F-code
Section
C-code
PS
S6.11
6660
Tilt Cylinder Assembly, RRX35/RSX40
Version no
002
T-code
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 at the battery connector.
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 serious 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.
BT Prime-Mover, Inc.
Return
2000-08-04
519
F-code
Section
C-code
PS
S6.11
6660
Tilt Cylinder Assembly, RRX35/RSX40
Version no
T-code
002
395/398/399
520
Return
2000-08-04
F-code
Section
C-code
PS
S6.12
6660
Tilt Cylinder Assembly, RSX50
Version no
002
T-code
395/398/399
13
12
11
7
5
14
10
15
1
2
3
4
BT Prime-Mover, Inc.
Return
2000-08-04
521
F-code
Section
C-code
PS
S6.12
6660
Tilt Cylinder Assembly, RSX50
Version no
T-code
002
395/398/399
Item No.
522
Return
Description
Item No.
Description
O ring
Bushing
10
Rod, cylinder
Retainer, cylinder
11
O ring
Screw, cap
12
Ring, back-up
Wiper
13
Retainer
Seal
14
Tube, cylinder
Bearing, cylinder
15
Spacer
Ring, back-up
2000-08-04
F-code
Section
C-code
PS
S6.12
6660
Tilt Cylinder Assembly, RSX50
Version no
002
T-code
395/398/399
1. Removal
1. Park the truck on a level surface and apply the
brake.
2. Raise carriage approximately 12 inches (304 mm)
and block so reach will not lower.
3. Pivot carriage/reach upward and block to prevent
carriage/reach from lowering.
4. Turn key switch to OFF. Disconnect battery at the
battery connector.
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
BT Prime-Mover, Inc.
Return
2000-08-04
523
F-code
Section
C-code
PS
S6.12
6660
Tilt Cylinder Assembly, RSX50
Version no
T-code
002
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.
1. Before disassembly, clean exterior of tilt cylinder
(1) in a cleaning solution to remove all
contamination.
2. Be sure all hydraulic fluid has been removed from
cylinder. Stroking piston rod will help force fluid out.
3. Put base end of cylinder in a vise equipped with
soft jaws.
4. Remove bearing retainer (13) and back-up ring
(12) from cylinder tube.
5. Remove bearing assembly, seal (6), back-up ring
(8), cylinder rod (10) and piston seals.
6. Remove and discard all seals (6), O rings (9) and
(11), back-up rings (8) and (12) and rod wiper (5).
7. Inspect mounting bushings (2) located at both ends
of cylinder. Do not remove bushings unless found
to be unfit for further service.
524
Return
2000-08-04
F-code
Section
C-code
PS
S6.12
6660
Tilt Cylinder Assembly, RSX50
Version no
002
T-code
395/398/399
3. Inspection
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.
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.
BT Prime-Mover, Inc.
Return
2000-08-04
525
F-code
Section
C-code
PS
S6.12
6660
Tilt Cylinder Assembly, RSX50
Version no
T-code
002
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.
526
Return
2000-08-04
F-code
Section
C-code
PS
S6.12
6660
Tilt Cylinder Assembly, RSX50
Version no
002
T-code
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 at the battery connector.
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 serious 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.
BT Prime-Mover, Inc.
Return
2000-08-04
527
F-code
Section
C-code
PS
S6.12
6660
Tilt Cylinder Assembly, RSX50
Version no
T-code
002
395/398/399
528
Return
2000-08-04
F-code
Section
C-code
PS
S6.13
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
529
F-code
Section
C-code
PS
S6.13
6660
Tilt Cylinder Assembly, RRX45/RDX30
Version no
T-code
001
396/397
Item
No.
530
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
S6.13
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 at
the battery connector.
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
531
F-code
Section
C-code
PS
S6.13
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 (205 kPa)
and then only with effective chip guarding
and personal protective equipment.
NOTE! CLEANLINESS! Perform procedures in
a clean environment. Make sure all parts
are cleaned before disassembly and kept
clean during assembly.
1. Before disassembly, clean exterior of tilt cylinder in
a cleaning solution to remove all contamination.
2. Be sure all hydraulic fluid has been removed from
cylinder. Stroking the piston rod will help force fluid
out.
3. Put base end of cylinder in a vise equipped with
soft jaws.
4. If necessary, remove roller bearing (3) at base of
cylinder rod (24). Remove roll pin (1) and slide
mounting pin (4) from clevis (26).
5. Remove retainer (10) and ring guide (21) by
rotating gland with a spanner wrench from cylinder
tube (9).
6. Remove gland assembly, seals, rings, rod and
piston, and piston seals.
7. Remove and discard all seals and rod wiper (23).
8. Inspect mounting bearing (8) located at base end
of cylinder tube (9). Do not remove bearing unless
found to be unfit for further service.
532
Return
2000-08-04
F-code
Section
C-code
PS
S6.13
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 (205 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
533
F-code
Section
C-code
PS
S6.13
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 gland bearing (20).
12. If removed, install roller bearing and clevis
assembly.
534
Return
2000-08-04
F-code
Section
C-code
PS
S6.13
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 top
and bottom of tilt cylinder.
3. Remove blocking and chains.
4. Fill hydraulic reservoir with new clean oil.
5. Connect battery at the battery connector.
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 serious 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
535
F-code
Section
C-code
PS
S6.13
6660
Tilt Cylinder Assembly, RRX45/RDX30
Version no
T-code
001
396/397
536
Return
2000-08-04
F-code
Section
C-code
PS
S7.0
7110
Mast, 3 Stage, RRX35/RSX40
Version no
T-code
001
395/398
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
537
F-code
Section
C-code
PS
S7.0
7110
Mast, 3 Stage, RRX35/RSX40
Version no
T-code
001
395/398
Item
No.
538
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
C-code
PS
S7.0
7110
Mast, 3 Stage, RRX35/RSX40
Version no
001
T-code
395/398
Return
2000-08-04
539
F-code
Section
C-code
PS
S7.0
7110
Mast, 3 Stage, RRX35/RSX40
Version no
T-code
001
395/398
540
Return
2000-08-04
F-code
Section
C-code
PS
S7.0
7110
Mast, 3 Stage, RRX35/RSX40
Version no
001
T-code
395/398
Plate
BT Prime-Mover, Inc.
Return
2000-08-04
541
F-code
Section
C-code
PS
S7.0
7110
Mast, 3 Stage, RRX35/RSX40
Version no
T-code
001
395/398
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! Lift cylinder can be repaired at this time, if
needed.
4. Remove chain sheaves and cable sheaves from all
columns.
5. Pull inner column straight forward until it stops (hits
bearings) and then 90 degrees straight up from
intermediate column.
6. Remove cap screws from the top of intermediate
column. Remove staging cylinder assemblies by
pushing intermediate column forward.
NOTE! Lift cylinder can be repaired at this time, if
needed.
7. Pull intermediate column straight forward until it
stops (hits bearings) and then pull 90 degrees
straight up from the outer column.
8. Remove mast bearings and shim washers from all
columns.
9. Thoroughly clean all parts.
542
Return
2000-08-04
F-code
Section
C-code
PS
S7.0
7110
Mast, 3 Stage, RRX35/RSX40
Version no
001
T-code
395/398
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 clearance with columns in
fully closed 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).
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.
BT Prime-Mover, Inc.
Return
2000-08-04
543
F-code
Section
C-code
PS
S7.0
7110
Mast, 3 Stage, RRX35/RSX40
Version no
T-code
001
395/398
Return
2000-08-04
F-code
Section
C-code
PS
S7.0
7110
Mast, 3 Stage, RRX35/RSX40
Version no
001
T-code
395/398
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 at the battery connector. Test
operations of mast and unit.
BT Prime-Mover, Inc.
Return
2000-08-04
545
F-code
Section
C-code
PS
S7.0
7110
Mast, 3 Stage, RRX45/RSX50/RDX30
Version no
T-code
001
395/398
29
30
8
31
5
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
546
Return
36
2000-08-04
F-code
Section
C-code
PS
S7.0
7110
Mast, 3 Stage, RRX45/RSX50/RDX30
Version no
001
Item
No.
Description
Item
No.
Description
Item
No.
T-code
395/398
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
BT Prime-Mover, Inc.
Return
2000-08-04
547
F-code
Section
C-code
PS
S7.0
7110
Mast, 3 Stage, RRX45/RSX50/RDX30
Version no
T-code
001
395/398
Return
2000-08-04
F-code
Section
C-code
PS
S7.0
7110
Mast, 3 Stage, RRX45/RSX50/RDX30
Version no
001
T-code
395/398
BT Prime-Mover, Inc.
Return
2000-08-04
549
F-code
Section
C-code
PS
S7.0
7110
Mast, 3 Stage, RRX45/RSX50/RDX30
Version no
T-code
001
395/398
Plate
Bolts
550
Return
2000-08-04
F-code
Section
C-code
PS
S7.0
7110
Mast, 3 Stage, RRX45/RSX50/RDX30
Version no
001
T-code
395/398
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 mast.
3. Remove freelift chain anchor, two cotter pins, and
two cylinder anchor pins from inner column.
Remove freelift cylinder assembly by pulling
straight up.
NOTE! Lift cylinder can be repaired at this time, if
needed.
4. Remove chain sheaves and cable sheaves from all
columns.
5. Pull inner column straight forward until it stops (hits
bearings) and then 90 degrees straight up from
intermediate column.
6. Remove cap screws from the top of intermediate
column. Remove staging cylinder assemblies by
pushing the intermediate column forward.
NOTE! Lift cylinder can be repaired at this time, if
needed.
7. Pull intermediate column straight forward until it
stops (hits bearings) and then pull 90 degrees
straight up from the outer column.
8. Remove mast bearings and shim washers from all
columns.
9.
BT Prime-Mover, Inc.
Return
2000-08-04
551
F-code
Section
C-code
PS
S7.0
7110
Mast, 3 Stage, RRX45/RSX50/RDX30
Version no
T-code
001
395/398
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 the intermediate
and outer columns.
3. Assemble intermediate column in the outer
column. Slide columns together.
4. Determine the amount of shims required. Pry the
inner column to one side and slip shims between
the bearing and web on the mast. Add shims by
hand until no more can be added.
5. Divide shims as equally as possible between two
bearings. Install shims under 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 clearance with the columns in
the fully closed 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).
Check for excessive bearing clearance with the
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 the intermediate column.
Slide columns together.
8. Determine the amount of shims required. Pry inner
column to one side and slip shims between bearing
552
Return
2000-08-04
F-code
Section
C-code
PS
S7.0
7110
Mast, 3 Stage, RRX45/RSX50/RDX30
Version no
001
T-code
395/398
Return
2000-08-04
553
F-code
Section
C-code
PS
S7.0
7110
Mast, 3 Stage, RRX45/RSX50/RDX30
Version no
T-code
001
395/398
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 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 chains equally until top
of rails are level in the fully lowered position.
Retighten jam nut and torque to 200 ft-lb (271
Nm).
Carriage chains should be adjusted in the fully
lowered position. Adjust chains until the top of forks
are 2.0 inch (50 mm) off the floor.
9. Grease all chain sheaves.
10. Bleed any air from the cylinders.
554
Return
2000-08-04
F-code
Section
C-code
PS
S7.0
7110
Mast, 3 Stage, RRX45/RSX50/RDX30
Version no
001
T-code
395/398
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.
BT Prime-Mover, Inc.
Return
2000-08-04
555
F-code
Section
C-code
PS
S7.0
7110
Mast, 3 Stage, RRX45/RSX50/RDX30
Version no
T-code
001
395/398
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
Stress-corrosion Cracking
556
Return
2000-08-04
F-code
Section
C-code
PS
S7.0
7110
Mast, 3 Stage, RRX45/RSX50/RDX30
Version no
001
T-code
395/398
BT Prime-Mover, Inc.
Return
2000-08-04
557
F-code
Section
C-code
PS
S7.0
7110
Mast, 3 Stage, RRX45/RSX50/RDX30
Version no
T-code
001
395/398
Rusty joints
Return
2000-08-04
F-code
Section
C-code
PS
S7.0
7110
Mast, 3 Stage, RRX45/RSX50/RDX30
Version no
001
T-code
395/398
Protruding Pins
MA0633.ill
MA0000.ill
Turned Pins
BT Prime-Mover, Inc.
Return
2000-08-04
559
F-code
Section
C-code
PS
S7.0
7110
Mast, 3 Stage, RRX45/RSX50/RDX30
Version no
T-code
001
395/398
Prevent corrosion
560
Return
2000-08-04
F-code
Section
C-code
PS
S7.0
7110
Mast, 3 Stage, RRX45/RSX50/RDX30
Version no
001
T-code
395/398
Lubricate
BT Prime-Mover, Inc.
Return
2000-08-04
561
F-code
Section
C-code
PS
S7.0
7110
Mast, 3 Stage, RRX45/RSX50/RDX30
Version no
T-code
001
395/398
562
Return
2000-08-04
F-code
Section
C-code
PS
7.1
7170
Lifting Gear (Crosshead), RRX35/RSX40
Version no
T-code
000
395/396/397/398/399
3
7
9
3
10
6
5
4
3
2
1
Freelift Cylinder
Item
No.
BT Prime-Mover, Inc.
Return
Description
Item
No.
Description
1
2
Fitting, grease
Ring, retainer
6
7
Sheave, chain
Head, sheave
3
4
5
Shim
Race
Bearing, roller
8
9
10
2000-08-04
563
F-code
Section
C-code
PS
7.1
7170
Lifting Gear (Crosshead), RRX35/RSX40
Version no
T-code
000
395/396/397/398/399
564
Return
2000-08-04
F-code
Section
C-code
PS
7.1
7170
Lifting Gear (Crosshead), RRX35/RSX40
Version no
000
T-code
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 at the battery connector.
5. Remove blocking and test for proper operation.
BT Prime-Mover, Inc.
Return
2000-08-04
565
F-code
Section
C-code
PS
7.1
7170
Lifting Gear (Crosshead), RRX45/RSX50/RDX30
Version no
T-code
000
395/396/397/398/399
2
3
4
5
6
3
8
7
9
3
10
6
5
4
3
2
1
Item
No.
566
Return
Description
Item No.
Description
Fitting, grease
Sheave, chain
2
3
Ring, retainer
Shim
7
8
Head, sheave
Sheave, hydraulic and electrical
4
5
Race
Bearing, roller
9
10
Shaft
Screw, set
2000-08-04
F-code
Section
C-code
PS
7.1
7170
Lifting Gear (Crosshead), RRX45/RSX50/RDX30
Version no
000
T-code
395/396/397/398/399
BT Prime-Mover, Inc.
Return
2000-08-04
567
F-code
Section
C-code
PS
7.1
7170
Lifting Gear (Crosshead), RRX45/RSX50/RDX30
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 shaft
(9).
3. Repeat steps 1 and 2 for the opposite side.
4. Loosen set screw (10) in the side of 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 the 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 the shaft (9).
5. Repeat step 4 for the opposite side.
6. Install a grease fitting (1) in each end of the shaft
(9).
568
Return
2000-08-04
F-code
Section
C-code
PS
7.1
7170
Lifting Gear (Crosshead), RRX45/RSX50/RDX30
Version no
000
T-code
395/396/397/398/399
1.4. Installation
1. Place lifting gear assembly on the top of the freelift
cylinder.
2. Tighten set screw (10) in the base of the sheave
head (7) to secure the lifting gear to the cylinder.
3. Grease chain sheaves. Install chains, hoses, and
electric cables.
4. Connect battery at the battery connector.
5. Remove blocking and test for proper operation.
BT Prime-Mover, Inc.
Return
2000-08-04
569
F-code
Section
C-code
PS
7.1
7170
Lifting Gear (Crosshead), RRX45/RSX50/RDX30
Version no
T-code
000
395/396/397/398/399
570
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
571
F-code
Section
C-code
PS
7.2
7210
Sideshifter, RRX35/45/RDX30
Version no
T-code
000
395/396/397
Item
No.
572
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
NOTE! 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
573
F-code
Section
C-code
PS
7.2
7210
Sideshifter, RRX35/45/RDX30
Version no
T-code
000
395/396/397
574
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
575
F-code
Section
C-code
PS
7.2
7210
Sideshifter, RRX35/45/RDX30
Version no
T-code
000
395/396/397
576
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
577
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
578
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! Clean fork carriage and inspect to be
sure it is free of damage or grooves
before installing sideshifter carriage.
Apply grease to fork carriage frame
where lower pads slide.
1. Remove lower pads (12) from sideshifter
assembly. Grease lower pads and return to
sideshifter unit.
2. Lift sideshifter unit onto trucks carriage using a
lifting device with a minimum capacity of 1000 lbs.
(454 kg).
3. Make sure centering lug (X) on cylinder support (3)
fits completely in center notch of truck carriage.
4. Remove cylinder retaining caps.
5. Loosen two lower hook securing bolts (6). Lift lower
hook (11), bringing plastic pad (12) in contact with
the underside of lift truck carriage. Secure bolts (6)
and torque to 65 ft-lb (88 Nm).
6. Remove safety screw (28) located between lower
hook mounting bolts (6).
7. Torque set screw (8) to 21 ft-lb (28 Nm).
8. Install safety screw (28) into the hole with screw
(8). Torque safety screw to 70 ft-lb. (95 Nm).
9. Connect hydraulic fittings to sideshifter cylinder.
Torque fittings to 56 ft-lb (76 Nm).
10. Mount forks in notches on upper bar of sideshifter
carriage.
11. Install fork stop bolt (7) with washer (9 and 10) into
lower bar of sideshifter carriage.
12. Sideshift unit several times to insure there are no
leaks. Check sideshifter unit for smooth operation
with no interference.
BT Prime-Mover, Inc.
Return
2000-08-04
579
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
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 69.)
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.
580
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
581
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
582
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
13. Install safety screw (28) into the hole with screw
(8). Torque safety screw to 70 ft-lb. (95 Nm).
14. Connect hydraulic fittings to sideshifter cylinder.
Torque fittings to 56 ft-lb (76 Nm).
15. Mount forks in notches on upper bar of sideshifter
carriage.
16. Install fork stop bolt (7) with washer (9 and 10) into
lower bar of sideshifter carriage.
17. Sideshift unit several times to insure there are no
leaks. Check sideshifter unit for smooth operation
with no interference.
NOTE! Following assembly, check operation of
sideshifter unit by sideshifting first
without a load, then with a load.
3.4. Cylinder
1. Remove sideshifter carriage from truck. See
Carriage Removal on page 581.
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! When replacing seals, follow the correct
mounting sequence.
5. Reassemble cylinder.
6. Secure cylinder in cylinder support (3) using
brackets (2) and screws (1).
BT Prime-Mover, Inc.
Return
2000-08-04
583
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
584
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
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.
BT Prime-Mover, Inc.
Return
2000-08-04
585
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
586
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
587
F-code
Section
PS
S7.4
Single Reach, RRX35
Version no
T-code
002
395
Item
No.
588
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
14 15
21
22
16
9
45 46
Reach
Cylinders
24
44
42
Tilt
Cylinder
7
23
26
36
35
39
36
38
23
25
34
41
40
11
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
589
F-code
Section
PS
S7.4
Single Reach, RRX35
Version no
T-code
002
395
Item
No.
590
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
591
F-code
Section
PS
S7.4
Single Reach, RRX35
Version no
T-code
002
395
Item
No.
592
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 69) 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
593
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 0.125 inch (3.18
mm) shim behind each reach bumper.
594
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
595
F-code
Section
PS
S7.4
Single Reach, RRX35
Version no
T-code
002
395
C-code
7241
596
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
597
F-code
Section
PS
S7.4
Single Reach, RRX35
Version no
T-code
002
395
C-code
7241
2. Repair
NOTE! The reach can be repaired without being
removed from the mast.
1. Remove forks.
2. Remove load backrest.
3. Fully extend the reach assembly.
4. Turn key switch to OFF and disconnect battery at
battery connector.
5. Block both side of the reach columns to prevent the
reach assembly from accidentally retracting.
Close-up view of
blocking procedure.
NOTE: Remember to
block both sides.
598
Return
2001-09-10
F-code
PS
Version no
002
Section
C-code
S7.4
7241
Single Reach, RRX35
T-code
395
2.1. Disassembly
1. Remove the reach cylinder mounting roll pins at
the clevis end of the reach cylinders.
CAUTION The roll pins must be replaced once
removed. The roll pins must never be
reused.
BT Prime-Mover, Inc.
Return
2001-09-10
599
F-code
Section
PS
S7.4
Single Reach, RRX35
Version no
T-code
002
395
C-code
7241
Reach cylinder
mounting pin
600
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
601
F-code
Section
PS
S7.4
Single Reach, RRX35
Version no
T-code
002
395
C-code
7241
602
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
603
F-code
Section
PS
S7.4
Single Reach, RRX35
Version no
T-code
002
395
C-code
7241
3. Rear Frame
3.1. Inspection and Maintenance
Trucks with serial number RRX3528163001 and above will
use a rear pin that has a tear drop shaped retaining tab
welded to the pin with a bolt used to secure the rear pin to the
rear frame. This pin secures the inner arm assemblies to the
rear frame. During Planned Maintenance visits, the retaining
bolt should be inspected and tightened if necessary. Torque
to 34.36 ft-lb (47 Nm) with Loctite 242 .
Rear mounting pin
604
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
605
F-code
Section
PS
S7.4
Single Reach, RRX35
Version no
T-code
002
395
C-code
7241
Rear pin
retaining nut
606
Return
2001-09-10
F-code
PS
Version no
002
Section
C-code
S7.4
7241
Single Reach, RRX35
T-code
395
as
BT Prime-Mover, Inc.
Return
2001-09-10
607
F-code
Section
PS
S7.4
Single Reach, RRX35
Version no
T-code
002
395
C-code
7241
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 side movement of the
carriage at the tight part of the inner
mast channel.
4. Test lift/lower functions of carriage.
5. Return truck to service.
608
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
609
F-code
Section
PS
S7.5
Single Reach, RRX45
Version no
T-code
001
396
Item
No.
610
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
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
44
12
15
17
16
22
21
20
31
43
23
15
18
19
21
20
17
19
Return
2001-10-03
611
F-code
Section
PS
S7.5
Single Reach, RRX45
Version no
T-code
001
396
Item
No.
612
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
25
30
12
15
17
16
22
21
20
31
43
23
44
15
18
19
21
20
17
19
Return
2001-10-03
613
F-code
Section
PS
S7.5
Single Reach, RRX45
Version no
T-code
001
396
Item
No.
614
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
25
30
12
15
17
16
22
21
20
31
43
23
44
15
18
19
21
20
17
19
Return
2001-10-03
615
F-code
Section
PS
S7.5
Single Reach, RRX45
Version no
T-code
001
396
Item
No.
616
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! The reach can be repaired without
removing from the mast.
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 at
battery connector.
Return
2001-10-03
617
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! Install same number of shims
removed for initial adjustment.
as
Return
2001-10-03
619
F-code
Section
PS
S7.5
Single Reach, RRX45
Version no
T-code
001
396
C-code
7242
620
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
621
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 side movement of the
carriage at the tight part of the inner
mast channel.
4. Test lift/lower functions of carriage.
5. Return truck to service.
622
Return
2001-10-03
F-code
Section
PS
C-code
S7.6
7243
Double Reach, RDX30
Version no
T-code
000
397
2
7
39
3
35
6
10
24
36
61
37
6
59
40
58
33
45
28
25
41
27
45
26
43
60
34
49
50
22
32
63 64
47
19
18
57
48
56
26
55
11
18
17
38
17
22
45 62
46
65
29
30
51
20
21
25
21
20
19
20
14
31
18
17
16
19
45
18
54
23
53
46
52
24
42
12
13
19
20
44
17
15
16
15
Return
2001-11-13
623
F-code
Section
PS
S7.6
Double Reach, RDX30
Version no
T-code
000
397
Item
No.
624
Return
C-code
7243
Description
Item
No.
Description
Item
No.
Description
Rod
23
Arm
45
Shim
Arm
24
Bearing
46
Bearing, 3 stage
Bearing, thrust
25
Ring, Nilos
47
Cap, bearing
Bearing
26
Set, bearing
48
Screw
Arm
27
Spacer
49
Bearing
Pin, roll
28
50
Cap
Pin
29
Screw
51
Screw
Frame, fork
30
Pin
52
Block, bumper
Screw
31
Screw, set
53
Bumper
10
Frame, forward
32
Arm
54
11
Bearing
33
Nut
55
12
Shim
34
Arm
56
Lockwasher
13
Pin
35
Arm
57
Bushing
14
Arm
36
Pin
58
Bracket
15
Pin, cotter
37
Screw
59
Shield
16
Nut
38
60
Screw, cap
17
Washer
39
Fitting, grease
61
Manifold
18
Ring, Nilos
40
Frame, rear
62
Control valve
19
Cone, bearing
41
Washer
63
Cover
20
Race, bearing
42
Screw
64
Screw, cap
21
Ring, retainer
43
Bar, wear
65
Nut
22
Shim
44
Shim
2001-11-13
F-code
Section
PS
Version no
T-code
000
7
6
24
36
9
6
10
35
397
2
39
37
6
61
59
33
28
25
41
27
45
26
43
60
34
40
58
49
50
22
63
45
32
64
62
47
38
17
19
18
19
57
48
56
26
55
17
18
22
46
65
11
51
45
54
52
24
42
20
21
21
23
53
44
12
13
20
25
20
19
20
14
31
18
17
16
19
46
29
30
66
45
C-code
S7.6
7243
Double Reach, RDX30
18
17
15
16
15
Return
2001-11-13
625
F-code
Section
PS
S7.6
Double Reach, RDX30
Version no
T-code
000
397
Item
No.
626
Return
C-code
7243
Description
Item
No.
Description
Item
No.
Description
Rod
23
Arm
45
Shim
Arm
24
Bearing
46
Bearing, 3 stage
Bearing, thrust
25
Ring, Nilos
47
Cap, bearing
Bearing
26
Set, bearing
48
Screw
Arm
27
Spacer
49
Bearing
Pin, roll
28
50
Cap
Pin
29
Screw
51
Screw
Frame, fork
30
Pin
52
Block, bumper
Screw
31
Screw, set
53
Bumper
10
Frame, front
32
Arm
54
11
Bearing
33
Nut
55
12
Shim
34
Arm
56
Lockwasher
13
Pin
35
Arm
57
Bushing
14
Arm
36
Pin
58
Bracket
15
Pin, cotter
37
Screw
59
Shield
16
Nut
38
60
Screw, cap
17
Washer
39
Fitting, grease
61
Manifold
18
Ring, Nilos
40
Frame, rear
62
Control valve
19
Cone, bearing
41
Washer, shim
63
Cover
20
Race, bearing
42
Screw
64
Screw, cap
21
Ring, retainer
43
Bar, wear
65
Nut
22
Shim
44
Shim
66
Washer
2001-11-13
F-code
Section
PS
Version no
T-code
000
7
39
37
6
61
59
33
28
67
25
41
27
45
67
26
60
34
40
58
50
63
32
64
62
47
38
17
19
18
19
57
48
56
26
55
17
18
22
46
65
43
49
22
45
11
51
45
54
52
42
20
21
21
20
19
20
14
31
18
17
23
53
44
12
13
20
25
16
19
46
29
30
66
4
45
36
9
10
35
397
24
C-code
S7.6
7243
Double Reach, RDX30
24
18
17
15
16
15
Return
2001-11-13
627
F-code
Section
PS
S7.6
Double Reach, RDX30
Version no
T-code
000
397
Item
No.
628
Return
C-code
7243
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
2001-11-13
F-code
PS
Section
C-code
S7.6
7243
Double Reach, RDX30
Version no
000
T-code
397
Sideshifter
Fork Frame
6. Knock pins (30) out. Shims (41) will fall out when
fork frame (8) is removed.
7. Remove fork frame (8).
8. Remove grease fittings in fork bar.
BT Prime-Mover, Inc.
Return
2001-11-13
629
F-code
Section
PS
S7.6
Double Reach, RDX30
Version no
T-code
000
397
C-code
7243
Fork Frame
630
Return
2001-11-13
F-code
PS
Version no
000
Section
C-code
S7.6
7243
Double Reach, RDX30
T-code
397
Forward Frame
BT Prime-Mover, Inc.
Return
2001-11-13
631
F-code
Section
PS
S7.6
Double Reach, RDX30
Version no
T-code
000
397
C-code
7243
632
Return
2001-11-13
F-code
PS
Version no
000
Section
C-code
S7.6
7243
Double Reach, RDX30
T-code
397
BT Prime-Mover, Inc.
Return
2001-11-13
633
F-code
Section
PS
S7.6
Double Reach, RDX30
Version no
T-code
000
397
C-code
7243
634
Return
2001-11-13
F-code
PS
Section
C-code
S7.6
7243
Double Reach, RDX30
Version no
000
T-code
397
BT Prime-Mover, Inc.
Return
2001-11-13
635
F-code
Section
PS
S7.6
Double Reach, RDX30
Version no
T-code
000
397
C-code
7243
636
Return
2001-11-13
F-code
PS
Version no
000
Section
C-code
S7.6
7243
Double Reach, RDX30
T-code
397
BT Prime-Mover, Inc.
Return
2001-11-13
637
F-code
Section
PS
S7.6
Double Reach, RDX30
Version no
T-code
000
397
638
Return
C-code
7243
2001-11-13
F-code
Section
C-code
PS
S7.7
7243
Double Reach Arm Assembly, RDX30
Version no
T-code
000
397
7
39
24
37
6
61
59
33
28
67
25
41
27
45
67
26
60
34
40
58
50
63
32
64
62
47
38
17
19
18
19
57
48
56
26
55
17
18
22
46
65
43
49
22
45
11
51
45
54
BT Prime-Mover, Inc.
Return
52
24
2001-11-13
42
20
21
21
23
53
44
12
13
20
25
20
19
20
14
31
18
17
16
19
46
29
30
66
4
45
36
10
35
18
17
15
16
15
639
F-code
Section
C-code
PS
S7.7
7243
Double Reach Arm Assembly, RDX30
Version no
T-code
000
397
Item
No.
640
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
(Torque 6 ft-lb (9 Nm)
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
32
Arm
54
10
Frame, forward
33
55
11
Bearing
34
Arm
56
Lockwasher
12
Shim
35
Arm
57
Bushing
13
Arm
36
Pin
58
Bracket
14
37
Screw
59
Shield
15
Pin, cotter
38
60
Screw, cap
16
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
(Torque 13 ft-lb (18 Nm)
21
Ring, retainer
44
Shim
66
Washer
22
Shim
45
Shim
67
Shim
23
Arm
Return
2001-11-13
F-code
Section
C-code
PS
S7.7
7243
Double Reach Arm Assembly, RDX30
Version no
000
T-code
397
Inner Arms
BT Prime-Mover, Inc.
Return
2001-11-13
641
F-code
Section
C-code
PS
S7.7
7243
Double Reach Arm Assembly, RDX30
Version no
T-code
000
397
Rear Frame
642
Return
2001-11-13
F-code
Section
C-code
PS
S7.7
7243
Double Reach Arm Assembly, RDX30
Version no
000
T-code
397
Return
2001-11-13
643
F-code
Section
C-code
PS
S7.7
7243
Double Reach Arm Assembly, RDX30
Version no
T-code
000
397
Retaining
Ring
Bearing Cup
Bearing Cone
Spacer
644
Return
2001-11-13
F-code
Section
C-code
PS
S7.7
7243
Double Reach Arm Assembly, RDX30
Version no
000
T-code
397
BT Prime-Mover, Inc.
Return
2001-11-13
645
F-code
Section
C-code
PS
S7.7
7243
Double Reach Arm Assembly, RDX30
Version no
T-code
000
397
Nilos Ring
Bearing Cup
Lock nut
Bearing
Cone
Spacer
Bearing Cup
Retaining
Ring
Nilos Ring
Arm (32)
Retaining
Ring
Bearing
Cone
Arm (23)
Bearing
646
Return
2001-11-13
F-code
Section
C-code
PS
S7.7
7243
Double Reach Arm Assembly, RDX30
Version no
000
T-code
397
Control Valve
Pipe Clamp
BT Prime-Mover, Inc.
Return
2001-11-13
647
F-code
Section
C-code
PS
S7.7
7243
Double Reach Arm Assembly, RDX30
Version no
T-code
000
397
Rear Frame
17. Drive pin (36) into rear frame on both sides. On the
inside of frame install screws (37) to drive pins
(36). Secure pins (36) and (37) with roll pins (6).
18. Extend arm assembly and block with wooden 8
inch blocks.
648
Return
2001-11-13
F-code
Section
C-code
PS
S7.7
7243
Double Reach Arm Assembly, RDX30
Version no
000
T-code
397
BT Prime-Mover, Inc.
Return
2001-11-13
649
F-code
Section
C-code
PS
S7.7
7243
Double Reach Arm Assembly, RDX30
Version no
T-code
000
397
650
Return
2001-11-13
F-code
Section
C-code
PS
S7.7
7243
Double Reach Arm Assembly, RDX30
Version no
000
T-code
397
BT Prime-Mover, Inc.
Return
2001-11-13
651
F-code
Section
C-code
PS
S7.7
7243
Double Reach Arm Assembly, RDX30
Version no
T-code
000
397
652
Return
2001-11-13
F-code
Section
PS
S7.8
Version no
C-code
7410
Forks
T-code
000
395/396/397/398/399
Forks
ab
le
ge
rA
va
il
Lo
n
NO
Item No.
BT Prime-Mover, Inc.
Return
Description
Pin, roll
Handle
Spring
Pin
Fork
2000-08-04
653
F-code
Section
C-code
PS
Forks
S7.8
7410
Version no
T-code
000
395/396/397/398/399
1
2
3
4
Item No.
654
Return
Description
Knob
Wedge
Washer
Spring
Pin
Fork
2000-08-04
F-code
Section
PS
S7.8
Version no
000
C-code
7410
Forks
T-code
395/396/397/398/399
1. Removal
1. Turn key switch OFF and disconnect battery at the
battery connector.
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
655
F-code
Section
C-code
PS
Forks
S7.8
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
656
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
1
13
14
15
19
18
Wiring
Harness
16
17
On Mast
Column
BT Prime-Mover, Inc.
Return
2001-11-07
657
F-code
Section
C-code
PS
S9.0
Load Indicator
9310
Version no
T-code
001
395/398
Item
No.
658
Return
Description
Item
No.
Description
Item
No.
Description
Screw
Ring, snap
15
Cable
2
3
4
Cover
Arm
Screw
9
10
11
Hub
Screw
Nut
16
17
18
Spring
Anchor, bottom
Set screw
5
6
7
Roller
Ring, locking
Bearing
12
13
14
Washer
Screw
Support
19
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
659
F-code
Section
C-code
PS
S9.0
Load Indicator
9310
Version no
T-code
001
395/398
Item
No.
660
Return
Description
Item
No.
Description
Item
No.
Description
Screw
Ring, retainer
15
Cable
2
3
4
Cover
Arm
Screw
9
10
11
Hub
Screw
Nut
16
17
18
Spring
Anchor, bottom
Screw
5
6
Roller
Ring, locking
12
13
Washer
Screw
19
20
Screw, set
Sensing device
Bearing
14
Support
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.
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).
BT Prime-Mover, Inc.
Return
2001-11-07
661
F-code
Section
C-code
PS
S9.0
Load Indicator
9310
Version no
T-code
001
395/398
662
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
663
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 282 and page 286.
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.
664
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
665
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
O
+48V
Minus
666
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
667
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.
668
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
669
F-code
Section
C-code
PS
S9.1
9390
Height Indicator and Preset Selector
Version no
T-code
001
395/396/397/398/399
670
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: If a value outside the minimum/maximum
range is programmed in, this will be
replaced by the maximum/minimum
factory setting.
4. Press the STOP button to complete programming.
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
671
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.
672
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: Reset all factory parameters after
upgrading to a new program version.
1. State parameter 8 and press the LOAD button.
The display shows no value.
2. Press the PROG button until the display stops
showing PP.
3. Turn the key switch on and off to start the new
Program.
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
673
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
674
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
675
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.
676
Return
2000-08-04
F-code
Section
PS
s9.2
9501
Load Backrest
Version no
C-code
T-code
000
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
677
F-code
Section
C-code
PS
s9.2
Load Backrest
9501
Version no
T-code
000
395/396/397/398/399
3
4
2
RRX45/RDX30
Item No
678
Return
Description
Backrest
Screw, cap
Washer, flat
2000-08-04
F-code
Section
PS
s9.2
9501
Load Backrest
Version no
C-code
T-code
000
395/396/397/398/399
3
2
RSX50
Item No
BT Prime-Mover, Inc.
Return
Description
Backrest
Screw, cap
Washer, flat
2000-08-04
679
F-code
Section
C-code
PS
s9.2
Load Backrest
9501
Version no
T-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 at
the battery connector.
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. Reconnect battery at the battery connector.
6. Return truck to service.
680
Return
2000-08-04
Index
A
Alarm
Travel/Back-up . . . . . . . . . . . . . . 334
Application
Intended . . . . . . . . . . . . . . . . . . . . 34
Prohibited . . . . . . . . . . . . . . . . . . . 35
B
Battery
Charging . . . . . . . . . . . . . . . . . . . 329
Cleaning Exterior . . . . . . . . . . . . . 329
History Record . . . . . . . . . . . . . . 330
Inspection and Care . . . . . . . . . . 328
Installation . . . . . . . . . . . . . . . . . . 327
Maintenance . . . . . . . . . . . . . . . . 328
Removal . . . . . . . . . . . . . . . . . . . 327
Retainer Plates . . . . . . . . . . . . . . 104
Rollers . . . . . . . . . . . . . . . . . . . . . 104
Storage . . . . . . . . . . . . . . . . . . . . 330
Battery Connector
Inspection . . . . . . . . . . . . . . . . . . 339
Installation . . . . . . . . . . . . . . . . . . 340
Location . . . . . . . . . . . . . . . . . . . . 339
Battery Safety . . . . . . . . . . . . . . . . . . . 21
Brake
Electromagnetic . . . . . . . . . . . . . 193
Friction Plate . . . . . . . . . . . . . . . . 198
Pedal Adjustment . . . . . . . . 121, 124
Pedal Bearing Replacement 121, 124
Pedal Removal . . . . . . . . . . 120, 123
Braking Caster Assembly
Installation . . . . . . . . . . . . . . . . . . 222
Removal . . . . . . . . . . . . . . . . . . . 221
Braking Caster Wheel
Removal . . . . . . . . . . . . . . . . . . . 217
C
Chassis
Dash . . . . . . . . . . . . . . . . . . . . . . . 98
Left-Hand Side Panel . . . . . . . . . 100
Main Card Access Panel . . . . . . . 101
Motor Compartment Door . . . . . . . 99
BT Prime-Mover, Inc.
Return
2001-08-21
681
Index
D
Data Plate . . . . . . . . . . . . . . . . . . . . . . 41
Decals . . . . . . . . . . . . . . . . . . . . . . . . 127
Definition
Caution . . . . . . . . . . . . . . . . . . . . . 15
Danger . . . . . . . . . . . . . . . . . . . . . 15
Note . . . . . . . . . . . . . . . . . . . . . . . . 15
Prohibitory . . . . . . . . . . . . . . . . . . . 16
Warning . . . . . . . . . . . . . . . . . . . . . 15
Definitions . . . . . . . . . . . . . . . . . . . . . . 95
Double Reach
Arm (2) and (13) Removal . . . . . . 641
Arm Assembly Installation . . . . . . 643
Fork Frame Removal . . . . . . . . . 629
Forward Frame Removal . . . . . . 630
Inner Arm (5) Removal . . . . . . . . 642
Rear Frame Removal . . . . . . . . . 635
Drive Motor
Brush Wear Sensors . . . . . . . . . . 172
Disassembly . . . . . . . . . . . . . . . . 165
Inspection . . . . . . . . . . . . . . . . . . 166
Temperature Sensors . . . . . . . . . 171
Drive Wheel
Installation . . . . . . . . . . . . . . . . . . 200
Removal . . . . . . . . . . . . . . . . . . . 200
Tire Pressing . . . . . . . . . . . . . . . . 201
Driver Controls . . . . . . . . . . . . . . . . . 117
E
Electrical Compartment Fan . . . . . . . 133
Electrical Functions
12-Volt Power Supply . . . . . . . . . 268
Component Location . . . . . . . . . . 286
Direction Selection . . . . . . . . . . . 253
Forks First Direction . . . . . . . . . . 255
Forks Trailing Direction . . . . . . . . 259
Pump Motor Brush . . . . . . . . . . . 288
Electrical Schematics
P5-04 - Serial numbers 28105001 28126000 . . . . . . . . . . . . . 303
P5-04 Serial numbers 27163000 28105000 . . . . . . . . . . . . . 291
P5-05/06 Serial number 28126001 - UP
682
Return
315
Electrical Symbols . . . . . . . . . . . . . . 289
Electronic Card . . . . . . . . . . . . . . . . 382
Main . . . . . . . . . . . . . . . . . . . . . . 369
F
Fan
Electrical Compartment . . . . . . . 133
Operator . . . . . . . . . . . . . . . . . . . 335
Fasteners
Bolt and Screw Designations . . . . 48
Strength Identification . . . . . . . . . . 47
Torque Nut Designations . . . . . . . 50
Truck Torque Specifications . . . . . 53
Forks
Inspection . . . . . . . . . . . . . . . . . . 655
Installation . . . . . . . . . . . . . . . . . 656
Removal . . . . . . . . . . . . . . . . . . . 655
Fuses . . . . . . . . . . . . . . . . . . . . . . . . 349
G
Grease Location Points . . . . . . . . . . . 83
Guard, Overhead . . . . . . . . . . . . . . . 125
H
Height Indicator
Display . . . . . . . . . . . . . . . . . . . . 666
Display Symbols Description . . . 667
Operation . . . . . . . . . . . . . . . . . . 664
Preset Height . . . . . . . . . . . . . . . 665
Programming . . . . . . . . . . . . . . . 668
Horn . . . . . . . . . . . . . . . . . . . . . . . . . 337
Installation . . . . . . . . . . . . . . . . . 337
Removal . . . . . . . . . . . . . . . . . . . 337
Hydraulic
Filter Adapter . . . . . . . . . . . . . . . 461
Troubleshooting . . . . . . . . . . . . . . 94
Hydraulic Filter . . . . . . . . . . . . . . . . . 460
Hydraulic Fluid
Refilling System . . . . . . . . . . . . . 453
Selection . . . . . . . . . . . . . . . . . . . 451
Hydraulic Pump . . . . . . . . . . . . . . . . 463
2001-08-21
Index
Hydraulic System . . . . . . . . . . . . . . .
Bleeding . . . . . . . . . . . . . . . . . . .
Changing Fluid . . . . . . . . . . . . . .
Schematic RRX30 . . . . . . . . . . . .
Schematic RRX35 . . . . . . . . . . . .
Schematic RRX45 . . . . . . . . . . . .
Schematic RSX40 . . . . . . . . . . . .
Schematic RSX50 . . . . . . . . . . . .
Hydraulic Tank
Installation . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . .
421
454
451
448
446
447
449
450
458
457
I
Introduction . . . . . . . . . . . . . . . . . . . . . 65
K
Key Switch . . . . . . . . . . . . . . . . . . . . 341
L
Lift Chain, 3 Stage Mast . . . . . . . . . .
Lifting Gear
Assembly
RRX35/RSX40 . . . . . . . . . . . .
RRX45/RSX50/RDX30 . . . . .
Disassembly
RRX35/RSX40 . . . . . . . . . . . .
RX45/RSX50/RDX30 . . . . . . .
Installation
RRX35/RSX40 . . . . . . . . . . . .
RRX45/RSX50/RDX30 . . . . .
Removal
RRX35/RSX40 . . . . . . . . . . . .
RRX45/RSX50RDX30 . . . . . .
Lights
Overhead Guard . . . . . . . . . . . . .
Warning . . . . . . . . . . . . . . . . . . . .
Working . . . . . . . . . . . . . . . . . . . .
Load Backrest
Installation . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . .
Load Indicator
Pulse sensor . . . . . . . . . . . . . . . .
BT Prime-Mover, Inc.
Return
Load Wheels
Size 10.5 X 3.5 . . . . . . . . . . . . . . 227
Sizes 4 X 3, 5 X 4, and 5 X 3 . . . 223
Lubricants
Cold Storage . . . . . . . . . . . . . . . . . 68
Lubrication
Chart . . . . . . . . . . . . . . . . . . . . . . . 81
Points . . . . . . . . . . . . . . . . . . . . . . 81
555
565
568
565
568
565
569
564
567
331
332
333
680
680
661
M
Main Electronic Card . . . . . . . . . . . . 369
Battery Discharge Indicator . . . . 384
Brake Switch and Transducer . . 383
Display . . . . . . . . . . . . . . . . . . . . 380
Error Codes . . . . . . . . . . . . . . . . 395
Programming Parameters . . . . . 400
Running time . . . . . . . . . . . . . . . 382
Time Setting . . . . . . . . . . . . . . . . 381
Warning Codes . . . . . . . . . . . . . . 393
Maintenance . . . . . . . . . . . . . . . . . . . 65
Mast Adjustment Points . . . . . . . . . . . 84
Mast, 3 Stage
Lift Chain . . . . . . . . . . . . . . . . . . 555
Motor
Brush Performance . . . . . . . . . . . 137
Drive . . . . . . . . . . . . . . . . . . . . . . 163
General . . . . . . . . . . . . . . . . . .135
Operating Environment . . . . . .135
Troubleshooting . . . . . . . . . . .136
Pump
Component Repair . . . . . . . . .145
Steering . . . . . . . . . . . . . . . . . . . 131
Mounting Points
Drive Motor . . . . . . . . . . . . . . . . . 105
Pump Motor . . . . . . . . . . . . . . . . 108
Transmission . . . . . . . . . . . . . . . 112
N
Non-Braking Caster Assembly
Installation . . . . . . . . . . . . . . . . . 214
Removal . . . . . . . . . . . . . . . . . . . 214
Non-Braking Caster Wheel
Caster Pivot . . . . . . . . . . . . . . . . 205
2001-08-21
683
Index
Thrust Bearing . . . . . . . . . . . . . . . 207
O
Oils and Grease . . . . . . . . . . . . . . . . . 82
Overhead Guard . . . . . . . . . . . . . . . . 125
P
Programming Parameters . . . . . . . . 400
Pump Motor
Component Repair . . . . . . . . . . . 154
Inspection and Troubleshooting . 147
R
Reach, Double
Maintenance . . . . . . . . . . . . . . . . 623
Reach, Single
Carriage Roller Bearings . . . 608, 622
Maintenance . . . . . . . . . . . . 593, 609
Repair . . . . . . . . . . . . . . . . . 598, 617
RV2 Adjustment . . . . . . . . . . . . . . . . 382
S
Safe Jacking Procedure . . . . . . . . . . . 66
Sensor
Brush Wear . . . . . . . . . . . . . . . . . 172
Drive Motor Speed . . . . . . . . . . . 419
Steer Stop Proximity . . . . . . . . . . 417
Wheel Direction . . . . . . . . . . . . . . 415
Sideshifter
Installation . . . . . . . . . . . . . . . . . . 579
Maintenance . . . . . . . . . . . . 574, 580
Mounting Instructions . . . . . 573, 579
Operation . . . . . . . . . . . . . . 574, 580
Troubleshooting . . . . . . . . . . . . . 585
Spare Parts, Ordering . . . . . . . . . . . . . 61
Static Safety . . . . . . . . . . . . . . . . . . . . 26
Steering Bearing
Installation . . . . . . . . . . . . . . . . . . 236
Removal . . . . . . . . . . . . . . . . . . . 236
Steering Motor
Installation . . . . . . . . . . . . . . . . . . 131
684
Return
T
Technical Service Data . . . . . . . . . . . 57
Three Stage Mast, RRX35/RSX40
Assembly . . . . . . . . . . . . . . . . . . 479
Disassembly . . . . . . . . . . . . . . . . 479
Installation . . . . . . . . . . . . . . . . . 479
Removal . . . . . . . . . . . . . . . . . . . 478
Three Stage Mast, RRX45/RDX30/RSX50
Assembly . . . . . . . . . . . . . . . . . . 484
Disassembly . . . . . . . . . . . . . . . . 484
Installation . . . . . . . . . . . . . . . . . 484
Removal . . . . . . . . . . . . . . . . . . . 483
Transistor Regulator
Motor Connections . . . . . . . . . . . 363
Safety Control . . . . . . . . . . . . . . . 364
Transmission
Axle Sealing Ring . . . . . . . . . . . . 188
Fluid Changing . . . . . . . . . . . . . . 113
Repair
Leakage, Lower Cover . . . . . .191
Leakage, Top Cover . . . . . . . .190
Wheel Bolts . . . . . . . . . . . . . . .192
Troubleshooting
Control Valve . . . . . . . . . . . . . . . 467
Hydraulic . . . . . . . . . . . . . . . . . . . . 94
Sideshifter . . . . . . . . . . . . . . . . . . 585
Troubleshooting Guidelines . . . . . . . . 87
2001-08-21
Index
Truck
Data . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions (RDX30) . . . . . . . . . .
Dimensions (RRX35) . . . . . . . . . .
Dimensions (RRX45) . . . . . . . . . .
Dimensions (RSX40) . . . . . . . . . . .
Dimensions (RSX50) . . . . . . . . . . .
Main Components . . . . . . . . . . . . .
Truck Installation
Cold Storage Conditioning . . . . . .
Truck Side Views . . . . . . . . . . . . . . . .
Truck Torque Specifications . . . . . . . .
35
38
36
37
39
40
42
68
33
53
Control . . . . . . . . . . . . . . . . . . . . 465
Pressure Setting . . . . . . . . . . . . . 473
W
Welding Safety . . . . . . . . . . . . . . . . . . 27
Wheel Direction Sensor . . . . . . . . . . 415
Adjustment . . . . . . . . . . . . . . . . . 415
Installation . . . . . . . . . . . . . . . . . 416
Removal . . . . . . . . . . . . . . . . . . . 416
Wiring
Harness . . . . . . . . . . . . . . . . . . . 350
Power Cables . . . . . . . . . . . . . . . 351
V
Valve
BT Prime-Mover, Inc.
Return
2001-08-21
685
Return
Return
Back Cover
Return