PRIME-MOVER

SERVICE BULLETIN

SERVICE BULLETIN NO: TSB010716

MODEL (S): RRX35/45, RDX30, and RSX40/50
Date: November 16, 2001
SUBJECT: A5 logic cards in above trucks with Drive Controller (part number 305803000).
DESCRIPTION: Due to a vendor component modification the logic chip currently
installed in the A5 logic card becomes obsolete when the Traction Transistor Controller
is replaced.
REMEDY: When replacing the Traction Transistor Controller the logic chip in the A5
logic card needs to be updated.
PROCEDURES: See pages 2 through 11.
PARTS AVAILABILITY: The kit (part number: 311783-000) includes;
traction transistor controller
logic chip containing P5-07 software
static dissipation strap
logic chip/IC extraction tool
installation instruction sheets, parameter and error code tables
handling guidelines for electrostatic-discharge-sensitive devices/assemblies
Order additional parts as needed through your parts department.
WARRANTY: Not applicable.
FILING INSTRUCTIONS: Place a copy of this in the appropriate trucks service file and
Service Manual.

SERVICE BULLETIN NO: 010716

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Installation Procedures for Logic Chip

Record all current parameter settings of the A5 logic card.

Turn truck off and disconnect battery.
Remove the drivers compartment right side panel (exposing the A5 logic card) by
loosening the lower two allen bolts (5mm) and removing the upper two allen bolts
(5mm). Carefully pull the panel towards the centerline of the truck and lift. Set the
panel aside.
Remove the two lower torx screws (T20) holding the aluminum cover on the A5 card.
Remove the two allen bolts (5mm) holding the A5 card to the frame at the top of A5
card.
Carefully tip the card towards the centerline of the truck far enough to allow access
to the two top torx screws (T20) holding the aluminum cover on the A5 card and
remove.
Cut the Warranty Seals and remove the aluminum cover.
NOTE: Cutting the warranty seals will not affect applicable product warranty.
Two allen
bolts holding
A5 logic card
to the frame.

Four screws
holding cover
on A5 logic
card.

Cut warranty seals

to gain internal
access to the A5
logic card.

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Install one of the top allen bolts (5mm) to hold the A5 card in place while changing
the logic chip.
Static Strap and Logic Chip Extractor

Alligator clip on
the end of the
static strap.

Logic chip
extractor tool.

Wrist strap on
the end of the
static strap.

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A5 Logic Card Component Location

A5 logic chip
to be removed
and replaced.

When installing the cover on

the A5 logic card be careful
not to damage or bend these
three components.

Attach alligator clip from static

strap to A5 logic card here.

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 Attach static strap to the wrist of the working hand and then to the A5 card frame.
Using chip removal tool carefully remove the chip and set aside.
NOTE: When removing the logic chip, be careful to grasp the only the logic chip
and not the chip socket with the extraction tool.
Carefully remove the new logic chip from its container.
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.

The new logic

chip properly
installed in the
A5 logic card.
Notch in logic
card to the top.
Carefully align
logic chip pins
with socket
holes.
Note the four
empty socket
holes located at
the top of the
logic chip.
The logic chip
label shows the
software version
number. Version
P5-07 contains
18 parameters.

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Remove the static strap from the A5 card. Install the aluminum cover on the A5
logic card.
NOTE! When installing the cover on the A5 logic card be careful not to damage or
bend components on the A5 logic board.
Install lower two torx screws (T20) into the cover of the A5 card.
Remove the top allen bolt (5mm) from the A5 card; tip the A5 card outward far
enough to allow the two torx screws (T20) to be installed.
Install top two allen bolts (5mm) to hold the A5 card in place.
NOTE! Make sure the wiring harness is not caught behind the A5 card before
tightening.
Install the drivers compartment right side panel and tighten.
Plug battery in and power truck up.
Using the values recorded at the beginning of this procedure set the trucks
parameters.
Ensure proper operation of the truck before returning the truck to service.

Software Changes for P5-07

The new logic chip has a label that identifies it as P5-07. The new logic chip contains
software version P5-07. Software version P5-05 or earlier contained only 17
parameters. A new parameter has been inserted shifting the year parameter to 16, the
day parameter to 17 and the month parameter to 18.
See attached Parameters Tables for options made available by parameter 15. Some
options can not be used due to lack of truck wiring (options not installed when truck was
ordered and built). Set parameter 15 to the desired value.
If the logic chip is replacing a logic chip containing software P5-04 or earlier the
installation of the thermostat simulator kit (part number 307965-000) is required.
See Product Improvement Notice 000214, A5 Control Module Update for details on the
requirements and specifications for this update.

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Parameter Values by Truck Type

Software Version; P5-07
Software Release Date; 07/12/01
Applicable Software Versions; P5-07
Parameter
Table One
Parameter Parameter Name Default
Number
Value
1
2
3
4
5
6

Steer Prog Par

Steer Wheel Par
Top Speed Par
Red Speed Par
Accel Par
Reach Scale Par

1
0
100
40
50
80

RRX35
RSX40
24V
1
0
100
40
50
80

RRX35
RSX40
36V
1
0
100
40
50
80

RRX45
RDX30
RSX50
1
0
100
40
50
80

7
8
9
10
11
12
13
14
15
16
17
18
N/A

Not Used
Not Used
Spec Height Par
Fork Ref Par
Steer Dir Par
Timer Sel Par
Battery Par
Pump Type Par
Option Par
Clock Year
Clock Day
Clock Month
Clock Hour

0
0
0
90
1
2
15
2
1
0
0
0
0

0
0
See Table # 2
See Table # 3
See Table # 4
2
15
1
See Table # 5
Year
Day
Month
Hour

0
0
See Table # 2
See Table # 3
See Table # 4
2
15
0
See Table # 5
Year
Day
Month
Hour

0
0
See Table # 2
See Table # 3
See Table # 4
2
15
2
See Table # 5
Year
Day
Month
Hour

N/A

Clock Minute

Minute

Minute

Minute

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Additional Notes

New Parameter
Current Year
Current Day
Current Month
Set in Normal
Operating Mode
Set in Normal
Operating Mode

Parameter Table Two

Parameter Parameter Name Default
Number
Value
9

Spec Height Req

RRX35
RRX35
RRX45
Additional
RSX40
RSX40
RDX30
Notes
24V
36V
RSX50
0
0
0
0
Without U10 Pulse Counter
Customer Value, Range; 0 - 531 inches With U10 Pulse Counter and
Customer Specified Value
Mast Height in inches, see table 2A
With U10 Pulse Counter
Without
Customer Specified Value

Parameter Table 2A
Parameter Parameter Name Mast
Number
Height
9

Spec Height Req

192
198
210
240
258
270
285
300
321
330
360
390
402

Parameter Table 3
Parameter Parameter Name Mast
Number
Height
10

Fork Ref Par

192
198
210
240
258
270
285
300
321
330
360
390
402

RRX35
RSX40
24V
192
198
210
240
258
270
X
X
X
X
X
X
X

RRX35
RSX40
36V
192
198
210
240
258
270
X
X
X
X
X
X
X

RRX45
RDX30
RSX50
X
X
210
240
258
270
285
300
321
330
360
390
402

RRX35
RSX40
24V

RRX35
RSX40
36V
72
74
78
90
98
102
X
X
X
X
X
X
X

RRX45
RDX30
RSX50
X
X
75
87
95
99
105
111
119
123
135
147
151

X
X
X
X
X
X
X

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Parameter Table Four

Parameter Parameter Name Default
Number
Value
11

Steer Dir Par

Parameter Table Five

Parameter Parameter Name Default
Number
Value
15

Option Par

RRX35
RSX40
24V
1

RRX35
RSX40
36V
1

RRX45
RDX30
RSX50
1

RRX35
RSX40
24V
0
1
2
3

RRX35
RSX40
36V
0
1
2
3

RRX45
RDX30
RSX50
0
1
2
3

4
5

4
5

4
5

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Additional

Notes

Standard
Forward or U.S. Style
Customer Specified
Backward or European Style

Additional
Notes
None
Direction Change Beep
Travel Alarm
Direction Change Beep
with Travel Alarm
Backup Alarm
Direction Change Beep
with Backup Alarm

Parameter Values Defined

Parameter
Number

Parameter Name

Value
Range

Default
Value

Increm.
of

Values

Comments

Steer Prog Par

1-6

1 - Least Sensitivity
5 - Most Sensitivity
6 - Test Curve

Speed curve selection. Speed

curve has greater affect at
higher speeds.

Steer Wheel Par

0-3

0 - Least Sensitivity 3 Most Sensitivity

Steer tacho sensitivity.

Top Speed Par

10 - 100%

100

% of maximum speed

Drive speed reduction.

Red Speed Par

10 - 100%

40

% of maximum speed

Limited speed reduction.

Accel Par

10 - 100%

50

% of maximum accel.

Acceleration reduction.

Reach Scale Par

10 - 100%

80

% of max. reach speed

Reach movement speed.

Not Used

Spare parameter, not used.

Not Used

Spare parameter, not used.

Spec Height Par

0 - 531 in.

max. allowed lift height

Special height.

10

Fork Ref Par

60 - 177 in.

90

mast free height

Mast reference height.

11

Steer Dir Par

0-1

0 - backward (Euro)
1 - forward (U.S.)

Steer direction.

12

Timer Sel Par

1-4

1 - key (total) time

2 - lift/lowering time
3 - drive time
4 - pump time

Displayed timer.

13

Battery Par

1 - 30

15

1 - shallow discharge 29
- deep discharge 30 force BDI to full charge
indication

Battery type.

14

Pump Type Par

0-2

0 - 36V standard
1
- 24V standard
236V heavy duty

Hydraulic pump type.

15

Option Par

0-5

value determines
option(s) available

New Parameter, options.

16

Clock Year

0 - 99

17

Clock Day

0 - 31

Clock Day

18

Clock Month

0 - 12

Clock Month

N/A

Clock Hour

0 - 23

Hour - directly accessed.

N/A

Clock Minute

0 - 59

Minute - directly accessed.

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Clock Year

Guidelines for Handling

Electrostatic-Discharge-Sensitive
Devices and Assemblies

Static-sensitive items are to remain in their protective containers except when

actually in use at the static-free station.
Before removing the item(s) from their protective container, the operator should
place the container on the conductive grounded bench top and make sure the wrist
strap fits snugly around the wrist and is properly plugged into/attached to the ground
receptacle or truck. The operator should then touch their hands to the conductive
bench top, work station, or truck.
All operations on the items should be performed with the items in contact with the
grounded bench top as much as possible.
Do not allow conductive magazine to touch hard-grounded test gear on bench top.
Ordinary plastic solder-suckers and other plastic assembly aids shall not be used.
In cases where it is impossible or impractical to ground the operator with a wrist
strap, a conductive shoe strap may be used along with conductive tile/mats.
When the operator moves from any other place to the static-free station, the start-up
procedure shall be the same as in Preparation for Working at Static-Free
Workstation.
Plastic snow polystyrene foam, peanuts, or other high-dielectric materials shall
never come in contact with or be used around electrostatic sensitive items, unless
they have been treated with an antistat (as evidenced by pink color and generation
of less than 100volts).
Static-sensitive items shall not be transported or stored in trays, tote boxes, vials, or
similar containers made of untreated plastic material unless items are protectively
packaged in conductive material.

SERVICE BULLETIN NO: 010716

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