306756-000 2002 - February PDF

Fron
Master Service Manual

RRX35/45, RDX30, RSX40/50
Electric Electrical Stand-Up Rider Truck
Effective Serial Number 27258000- UP
WARNING Read and observe all warnings on this unit

before operating it.
WARNING DO NOT operate this equipment unless all
factory installed guards and shields are
properly secured in place.
Part no: 306756-000
Return
Date: February 07, 2002
Prime-Mover is a trademark of BT Prime-Mover Inc.,

2002 BT Prime-Mover Inc., Muscatine, Iowa.
All Rights Reserved.
Return
F-code
Section
C-code
Standard Codes
Version no
T-code
000
Standard Codes
B-Code
= Business area
F-Code
= Product family
T-Code
= Product type
C-Code
= Component function
Worksheet standard
W-Code = Working code
R-Code
= Reason code
SO-Code = Assortment
F-Code List
PS - Powered Pallet Stacker
T-Code List
Code
Model
395
RRX35
396
RRX45
397
RDX30
398
RSX40
399
RSX50
C-Code List
No Function Group
BT Prime-Mover, Inc.
Return
C-Code
Chassis
0000
Motors
1000
Drive Gear / Transmission
2000
Brake / Wheel System
3000
Steering System
4000
Electrical System
5000
2000-08-04
F-code
Section
C-code
Standard Codes
Version no
T-code
000
Return
Hydraulic / Pneumatic System
6000
Operating Function-lifting Mast / Cylinders
7000
Peripheral / Installation Equipment
8000
Options / Attachments
9000
2000-08-04
Table of Contents
Table of Contents
Standard Codes ............................................................................................. 1
Warning Symbols ......................................................................................... 15
Warning Levels ......................................................................................... 15
Prohibitory Symbols .................................................................................... 16
Ordinance Symbols .................................................................................. 16
Safety ............................................................................................................ 17
General Safety .......................................................................................... 17
Battery Safety ............................................................................................... 21
Static Safety .................................................................................................. 26
Welding Safety ............................................................................................. 27
Introduction, Service Manual ...................................................................... 29
Contents, Section M ..................................................................................... 31
Machine Information ................................................................................. 31
General Product Information ...................................................................... 33
Presentation of the Rider Trucks. ............................................................. 33
Main Components ..................................................................................... 42
Inch (SAE) and Metric Fasteners ...............................................................
Introduction ...............................................................................................
Nomenclature, Threads ............................................................................
Strength Identification ...............................................................................
Conversion of Metric and English Units ....................................................
45
45
46
47
55
Technical Service Data ................................................................................ 57

Ordering Spare Parts ................................................................................... 61
Contents, Section P ..................................................................................... 63
Planned Maintenance ............................................................................... 63
Introduction, Maintenance .......................................................................... 65
Jacking Truck Off The Floor ..................................................................... 66
Lubricants ................................................................................................. 68
Service Schedule ......................................................................................... 71
Planned Maintenance Schedule ............................................................... 71
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2001-10-12
Table of Contents
Planned Maintenance Procedures ............................................................ 76
Lubrication Chart ......................................................................................... 83
Oil and Grease Specifications ....................................................................
Approved Oils and Grease .......................................................................
Grease Location Points ............................................................................
Mast Adjustment Points ............................................................................
84
84
85
86
Contents, Section S ..................................................................................... 87

Service Instructions .................................................................................. 87
Troubleshooting Guidelines .......................................................................
General .....................................................................................................
Electrical ...................................................................................................
Hydraulic ...................................................................................................
Definitions .................................................................................................
89
89
91
96
97
Chassis ......................................................................................................... 99
General ..................................................................................................... 99
Dash ........................................................................................................ 100
Motor Compartment Door ........................................................................ 101
Left-Hand Side Panel ............................................................................... 102
Operator Compartment Panel .................................................................. 103
Main Card Access Panel ......................................................................... 103
Battery Compartment ................................................................................. 105
Battery Retainer Plates ............................................................................ 106
Battery Rollers ......................................................................................... 106
Driver Controls ............................................................................................ 107
Brake Pedal, RSX40/RRX35 ........................................................................
Pedal Removal ........................................................................................
Pedal Bearing Replacement ....................................................................
Pedal Adjustment .....................................................................................
109
110
111
111
Brake Pedal, RSX50/RRX45/RDX30 ...........................................................

Pedal Removal ........................................................................................
Pedal Bearing Replacement ....................................................................
Pedal Adjustment .....................................................................................
112
113
114
114
Overhead Guard .......................................................................................... 115

Decals ........................................................................................................... 117
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2001-10-12
Table of Contents
Decal with Protective Sheet ..................................................................... 117
Decal without Protective Sheet ................................................................ 117
Steering Motor .............................................................................................
Removal ...................................................................................................
Installation ................................................................................................
Steering Motor Gear Replacement ..........................................................
121
121
121
122
Fan Motor ..................................................................................................... 123

Upper Electrical Compartment Fan ......................................................... 123
Operator Fan ........................................................................................... 124
Motor Maintenance
Schedule/Troubleshooting .........................................................................
General Information .................................................................................
Operating Conditions ...............................................................................
Troubleshooting .......................................................................................
125
125
125
126
Motor Repair ................................................................................................ 133

Disassembly ............................................................................................ 133
Motor Inspection ...................................................................................... 135
Pump Motor ................................................................................................. 141
Mounting Points ....................................................................................... 141
Repair ...................................................................................................... 145
Drive Motor .................................................................................................. 149
Mounting Points ....................................................................................... 149
Repair ...................................................................................................... 152
Transmission ...............................................................................................
Mounting Points .......................................................................................
Repair ......................................................................................................
Disassemble ............................................................................................
Assembly .................................................................................................
Axle Sealing Ring ....................................................................................
Leakage ...................................................................................................
Wheel Bolt ...............................................................................................
155
155
159
161
165
174
176
178
Electromagnetic Brake ...............................................................................

Removal ...................................................................................................
Installation ................................................................................................
Adjustments .............................................................................................
Coil Check On Brake ...............................................................................
Electromagnetic Brake, Armature and Magnetic Coil ..............................
179
179
181
182
183
183
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2001-10-12
Table of Contents
Brake Friction Plate ................................................................................. 184
Drive Wheel ..................................................................................................
Removal ...................................................................................................
Installation ................................................................................................
Tire Pressing Procedure ..........................................................................
185
186
186
187
Non-Braking Caster Wheel, RRX35/RSX40 ...............................................

Caster Pivot .............................................................................................
Thrust Bearing .........................................................................................
Caster Springs .........................................................................................
Caster Stops ............................................................................................
189
191
193
195
197
Non-Braking Caster Assembly, RRX35/RSX40 ........................................ 199

Removal ................................................................................................... 200
Installation ................................................................................................ 200
Braking Caster Wheel, RRX45/RDX30/RSX50 .......................................... 201
Removal ................................................................................................... 203
Braking Caster Assembly, RRX45/RDX30/RSX50 .................................... 205
Removal ................................................................................................... 207
Installation ................................................................................................ 208
Load Wheels, Sizes 4 X 3, 5 X 4, and 5 X 3 .............................................. 209
Removal ................................................................................................... 211
Installation ................................................................................................ 212
Load Wheels, Size 10.5 X 3.5 ..................................................................... 213
Removal ................................................................................................... 214
Installation ................................................................................................ 214
Steering Arm / Wheel / Lever .....................................................................
Control Pod ..............................................................................................
Steering Wheel ........................................................................................
Steering Tach ..........................................................................................
215
217
218
219
Steering Bearing ......................................................................................... 221

Removal ................................................................................................... 222
Installation ................................................................................................ 222
Electrical Functions ....................................................................................
General ....................................................................................................
Start Up ....................................................................................................
Steering Components ..............................................................................
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223
223
227
231
2001-10-12
Table of Contents
Brake Release .........................................................................................
Direction Selection ...................................................................................
Travel Request, Forks First .....................................................................
Travel Request, Forks Trailing .................................................................
Plug Braking ............................................................................................
12-Volt Power Supply ..............................................................................
7.35-Volt Power Supplies ........................................................................
Limit Switches ..........................................................................................
Height Indicator ........................................................................................
Drive Motor Brush Wear Indicator Switches ............................................
Pump Motor Brush Indicator Switch ........................................................
Safety Check ...........................................................................................
Shunt Power Cable ..................................................................................
237
239
241
245
250
254
255
258
262
264
265
266
268
Electrical Symbols ...................................................................................... 275

Electrical Schematics (Serial numbers 27163000-28105000) ..................
Circuit Diagram 1(11) ...............................................................................
Circuit Diagram 2(11) ...............................................................................
Circuit Diagram 3(11) ...............................................................................
Circuit Diagram 4(11) ...............................................................................
Circuit Diagram 5(11) ...............................................................................
Circuit Diagram 6(11) ...............................................................................
Circuit Diagram 7(11) ...............................................................................
Circuit Diagram 8(11) ...............................................................................
Circuit Diagram 9(11) ...............................................................................
Circuit Diagram 10(11) .............................................................................
Circuit Diagram 11(11) .............................................................................
277
277
278
279
280
281
282
283
284
285
286
287
Electrical Schematics (Serial numbers 28105001-28126000) ..................

Circuit Diagram 1(12) ...............................................................................
Circuit Diagram 2(12) ...............................................................................
Circuit Diagram 3(12) ...............................................................................
Circuit Diagram 4(12) ...............................................................................
Circuit Diagram 5(12) ...............................................................................
Circuit Diagram 6(12) ...............................................................................
Circuit Diagram 7(12) ...............................................................................
Circuit Diagram 8(12) ...............................................................................
Circuit Diagram 9(12) ...............................................................................
Circuit Diagram 10(12) .............................................................................
Circuit Diagram 11(12) .............................................................................
Circuit Diagram 12(12) .............................................................................
289
289
290
291
292
293
294
295
296
297
298
299
300
Electrical Schematics (Serial numbers 28126001-31285000) .................. 301

Circuit Diagram 1(12) ............................................................................... 301
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2001-10-12
Table of Contents
Circuit Diagram 2(12) ...............................................................................
Circuit Diagram 3(12) ...............................................................................
Circuit Diagram 4(12) ...............................................................................
Circuit Diagram 5(12) ...............................................................................
Circuit Diagram 6(12) ...............................................................................
Circuit Diagram 7(12) ...............................................................................
Circuit Diagram 8(12) ...............................................................................
Circuit Diagram 9(12) ...............................................................................
Circuit Diagram 10(12) .............................................................................
Circuit Diagram 11(12) .............................................................................
Circuit Diagram 12(12) .............................................................................
302
303
304
305
306
307
308
309
310
311
312
Electrical Schematics (Serial numbers 31285001-UP) .............................

Circuit Diagram 1(12) ...............................................................................
Circuit Diagram 2(12) ...............................................................................
Circuit Diagram 3(12) ...............................................................................
Circuit Diagram 4(12) ...............................................................................
Circuit Diagram 5(12) ...............................................................................
Circuit Diagram 6(12) ...............................................................................
Circuit Diagram 7(12) ...............................................................................
Circuit Diagram 8(12) ...............................................................................
Circuit Diagram 9(12) ...............................................................................
Circuit Diagram 10(12) .............................................................................
Circuit Diagram 11(12) .............................................................................
Circuit Diagram 12(12) .............................................................................
313
313
314
315
316
317
318
319
320
321
322
323
324
Battery ..........................................................................................................
Removal ...................................................................................................
Installation ................................................................................................
Battery Maintenance ................................................................................
Storage ....................................................................................................
Battery History Record .............................................................................
325
325
325
326
328
328
Light Assemblies ........................................................................................

Overhead Guard Lights (Option) .............................................................
Warning Lights (Option) ...........................................................................
Working Lights (Option) ...........................................................................
Travel Alarm (Option) ..............................................................................
Operator Fan (Option) .............................................................................
329
329
330
331
332
333
Horn .............................................................................................................. 335

Removal ................................................................................................... 335
Installation ................................................................................................ 335
Start/Stop Switches .................................................................................... 337
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2001-10-12
Table of Contents
General .................................................................................................... 337
Key Switch (S17) ..................................................................................... 337
Emergency Disconnect Switch (S21) ...................................................... 339
Battery Connector .......................................................................................
Location ...................................................................................................
Inspection ................................................................................................
Installation ................................................................................................
341
341
341
342
Mast Switch (S31) ........................................................................................ 343

General .................................................................................................... 343
Control Cable and Harness ........................................................................ 347
Fuses ....................................................................................................... 347
Wiring ....................................................................................................... 348
Contactors ...................................................................................................
General ....................................................................................................
Direction Contactors ................................................................................
Lift Bypass Contactor
(RRX45/RSX50/RDX30) ..........................................................................
Main Contactor ........................................................................................
351
351
352
354
356
Transistor Panel (Drive) .............................................................................. 359

Motor Connections ................................................................................... 360
Transistor Panel (Lift) ................................................................................. 361
Circuit Check, Drive Only ......................................................................... 363
Micro Switches ............................................................................................
General ....................................................................................................
Lift Limit Override Switch (S33) Optional .................................................
Optional Light and Fan Switches (S96, S97 and S99) ............................
365
365
366
367
Main Electronic Card ..................................................................................

Connectivity to Truck ...............................................................................
Transistor Controller Replacement ..........................................................
Removal ...................................................................................................
Installation ................................................................................................
Display .....................................................................................................
Time .........................................................................................................
Effect on Truck .........................................................................................
Running time ............................................................................................
RV2 Adjustment Procedure .....................................................................
Adjustment Procedures for Setting Brake Switch and Brake Transducer
369
369
370
374
374
380
381
381
382
382
383
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2001-10-12
Table of Contents
Battery Discharge Indicator Parameter Adjustment .................................
A5 Jumper Harness Kit Installation (Serial numbers 28126000 - below)
Warning\Caution Codes ...........................................................................
Error Codes .............................................................................................
Programming Parameter .........................................................................
384
390
393
395
401
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
Hydraulic System ........................................................................................

Operation .................................................................................................
RRX35 Hydraulic Schematic ...................................................................
RRX45 Hydraulic Schematic ...................................................................
RDX30 Hydraulic Schematic ...................................................................
RSX40 Hydraulic Schematic ....................................................................
RSX50 Hydraulic Schematic ....................................................................
421
421
442
443
444
445
446
Hydraulic Fluid ............................................................................................

Hydraulic Fluid Selection .........................................................................
Changing Hydraulic System Fluid ............................................................
System Draining ......................................................................................
Refilling System .......................................................................................
Bleeding Hydraulic System ......................................................................
447
447
447
448
449
450
Hydraulic Tank ............................................................................................ 452

Removal ................................................................................................... 453
Installation ................................................................................................ 454
Hydraulic Filter Assembly .......................................................................... 456
Hydraulic Filter ......................................................................................... 457
Hydraulic Filter Adapter ........................................................................... 458
Hydraulic Pump .......................................................................................... 460
Removal ................................................................................................... 460
Repair ...................................................................................................... 460
Control Valve ............................................................................................... 461
Removal .................................................................................................. 461
Installation ................................................................................................ 461
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Table of Contents
Control Valve Assembly ............................................................................. 466
Repair ...................................................................................................... 468
Staging Cylinder, Three Stage Mast ..........................................................
Bearing Removal .....................................................................................
Disassembly ............................................................................................
Assembly .................................................................................................
Installation ................................................................................................
473
474
475
475
475
Freelift Cylinder, Three Stage Mast ...........................................................

Removal ...................................................................................................
Disassembly ............................................................................................
Assembly .................................................................................................
Installation ................................................................................................
477
479
480
480
480
Reach Cylinder Assembly ..........................................................................

Removal ...................................................................................................
Disassembly ............................................................................................
Inspection ................................................................................................
Assembly .................................................................................................
Installation ................................................................................................
481
483
484
485
486
487
Tilt Cylinder Assembly, RRX35/RSX40/RSX50 .........................................

Removal ...................................................................................................
Disassembly ............................................................................................
Inspection ................................................................................................
Assembly .................................................................................................
Installation ................................................................................................
489
490
491
492
493
494
Tilt Cylinder Assembly, RRX45/RDX30 .....................................................

Removal ...................................................................................................
Disassembly ............................................................................................
Inspection ................................................................................................
Assembly .................................................................................................
Installation ................................................................................................
495
497
498
499
500
501
Mast, 3 Stage ...............................................................................................

Shimming Carriage with Mast on Truck ...................................................
Three Stage Mast ....................................................................................
Lift Chain ..................................................................................................
503
507
509
514
Lifting Gear (Crosshead) ............................................................................ 523

Lifting Gear Repair ................................................................................... 525
Sideshifter, RRX35/45/RDX30 .................................................................... 527
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2001-10-12
11
Table of Contents
Mounting Instructions ............................................................................... 529
Operation and Maintenance .................................................................... 530
Sideshifter, RRX35/45/RSX40/50/RDX30 ...................................................
Mounting Instructions ...............................................................................
Operation .................................................................................................
Maintenance ............................................................................................
533
535
536
536
540
Single Reach, RRX35 ..................................................................................

Maintenance ............................................................................................
Reach Repair ...........................................................................................
Carriage Bumpers ....................................................................................
Fork Carriage Pivot Pins ..........................................................................
Carriage Roller Bearings .........................................................................
541
547
552
556
558
558
Single Reach, RRX45 ..................................................................................

Maintenance ............................................................................................
Reach Repair ...........................................................................................
Fork Carriage Pivot Pins ..........................................................................
Carriage Roller Bearings .........................................................................
559
559
567
571
572
Double Reach Mechanism, RDX30 ............................................................

Theory of Operation .................................................................................
Maintenance ............................................................................................
Repair ......................................................................................................
Rebuild .....................................................................................................
573
575
575
575
575
575
Forks ............................................................................................................
Removal ...................................................................................................
Inspection ................................................................................................
Installation ................................................................................................
577
579
579
580
Load Indicator ............................................................................................. 581

Load Indicator ............................................................................................. 583
Pulse Sensor ........................................................................................... 585
Height Indicator and Preset Selector .......................................................
General ....................................................................................................
Operation .................................................................................................
Preset Height ...........................................................................................
Display .....................................................................................................
Display Symbols Description ...................................................................
12
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587
588
588
589
590
591
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Table of Contents
Programming ........................................................................................... 592
Load Backrest ............................................................................................. 601
Removal ................................................................................................... 604
Installation ................................................................................................ 604
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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 Service Manual
and on the truck to avoid accidents and incidents from
occurring.
1. Warning Levels
Warning levels
Warning texts are given in four levels and provide information
on the risks, describe the consequences, and instruct how to
avoid accidents.
DANGER
Warns that an accident will occur if the instructions are
not followed.
The consequences are serious personal injury or
possibly death, and/or extremely large material damage.
WARNING
Warns that an accident can occur if the instructions are
not followed.
The consequences are serious personal injury or
possibly death, and/or large material damage.
CAUTION
Warns that an accident can occur if the instructions are
not followed.
The consequences are personal injury and/or material
damage.
NOTE!
Marks the risk of an accident or breakdown if the
instructions are not followed.
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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.
OPEN FLAMES PROHIBITED

If open flames are used in situations where open flames are
prohibited, 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.
Know the controls on the truck and what they do.
Do NOT operate truck if it needs repair or if it is in any way

unsafe.
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2000-08-04
17
F-code
Section
C-code
PS
Safety
Version no
T-code
001
Operate truck only from the position of the Operator.
Before working on this truck always turn key switch to OFF

and disconnect battery connector on truck (unless this
manual states otherwise).
Do NOT wear watches, rings, or jewelry when working on

truck.
Follow the scheduled

inspection steps.
18
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lubrication,
maintenance,
and
2000-08-04
F-code
Section
PS
Version no
C-code
Safety
T-code
001
Follow exactly the safety and repair instructions in this

manual. Do NOT take shortcuts.
Do NOT Use an open flame near the truck.
Do NOT use gasoline or other flammable liquids for cleaning

parts.
Clean up any hydraulic fluid, oil, or grease that has leaked or

spilled on the floor.
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2000-08-04
19
F-code
Section
C-code
PS
Safety
Version no
T-code
001
Always operate and park truck indoors.
Do NOT wash truck with a hose.
Do NOT add to or modify truck without written approval from

20
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2000-08-04
F-code
Section
PS
Version no
C-code
Battery Safety
T-code
001
Battery Safety
WARNING As a battery is being charged, an explosive
gas mixture forms within and around each
cell. If the area is not properly ventilated,
this explosive gas can remain in or around
the battery for several hours after charging.
Be sure there are no open flames or sparks
in the charging area. An open flame or
spark can ignite this gas, resulting in
serious damage or injury.
WARNING Battery electrolyte is a solution of sulfuric
acid and water. Battery acid causes burns.
Should any electrolyte come in contact with
clothing or skin, flush the area immediately
with cold water. Should the solution get on
the face or in the eyes, flush the area with
cold water and receive medical attention
immediately.
Read, understand and follow procedures, recommendations
and specifications in the battery and battery charger manuals
from the manufacturer.
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2000-08-04
21
F-code
Section
C-code
PS
Battery Safety
Version no
T-code
001
Wear personal protective equipment to protect eyes, face,

and skin when checking, handling, or filling batteries. This
equipment includes goggles or face shield, rubber gloves
(with or without arm shields) and a rubber apron.
Make sure a shower and eyewash station are nearby in case

there is an accident.
A battery gives off explosive gases. Never smoke, use an

open flame, or use anything that gives off sparks near a
battery.
Keep the charger area well-ventilated to avoid hydrogen gas

concentration.
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.
Do NOT lay tools or metal objects on top of battery. A short

circuit or explosion could result.
Keep batteries clean. Corrosion causes shorts and possibly

sparks to the frame.
Keep plugs, terminals, cables, and receptacles in good
condition to avoid shorts and sparks.
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2000-08-04
23
F-code
Section
C-code
PS
Battery Safety
Version no
T-code
001
Keep filler plugs firmly in place at all times except when the
electrolyte level is checked, when water is added to the cells
or when the specific gravity is checked.
Make sure vent holes in filler plugs are open to allow gas to
escape from the cells.
Vent Plug
Do NOT allow cleaning solution, dirt, or any foreign matter to

enter the cell.
Make sure to install the correct size battery. A smaller or
lighter weight battery could seriously affect truck stability. See
the trucks specification (data) plate for more information.
Never plug a battery charger into the truck battery connector.

Plug battery charger ONLY into battery connector from
battery.
24
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2000-08-04
F-code
Section
PS
Version no
C-code
Battery Safety
T-code
001
Follow the charging procedures in the Battery Instruction

Manual and in the Battery Charger Instruction Manual.
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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.
CAUTION Disconnect battery before attempting to

inspect, service or repair truck.
Check for shorts to frame. If any shorts are detected,
remove before proceeding with the welding operation.
Clean the area to be welded.
Protect all truck components from heat, weld spatter and
debris.
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2000-08-04
27
F-code
Section
C-code
PS
Welding Safety
Version no
T-code
001
Attach the ground cable as close to the weld area as

possible.
Disconnect all electrical cards before any type of electric

resistance welding is done.
Do not perform any welding operations near the electrical
components.
If welding must be done near the battery compartment,
remove the battery from truck.
When welding is completed, perform all ground tests and
electrical inspections before the vehicle is operated.
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

The information in this Service Manual covers models
RRX35, RRX45, RDX30, RSX40, and RSX50.
Federal and State laws require that operators be completely
trained in the safe operation of trucks in accordance with
OSHA regulation 1910.178.
An Operators Manual is sent with every BT Prime-Mover lift
truck when it is manufactured. If the Operators Manual is
missing from the truck, a new manual may be obtained by
contacting:
3305 N Highway 38
Muscatine, Iowa
52761-8800
(563) 262-7700
This Service Manual is not a training manual. The information
contained in this service manual is intended as a guide to
help trained, qualified, and authorized technicians safely
service the truck.
The Service Manual is divided into four separate sections,
which cover needed information for servicing the truck types.
The main subject for each of the sections are as described
below.
SECTION
Return
SUBJECT
MACHINE INFORMATION
PLANNED MAINTENANCE
SERVICE INSTRUCTIONS
OPTIONS
2000-08-04
29
F-code
Section
C-code
M
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
Return
M1.0
GENERAL PRODUCT INFORMATION
M2.0
TECHNICAL SERVICE DATA
M3.0
ORDERING SPARE PARTS
2000-08-04
31
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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

1. Presentation of the Rider Trucks.
The RRX35/45 are battery powered reach trucks. The RDX30
is a battery powered deep reach truck. The RSX40/50 are
battery powered straddle arm trucks.
These trucks are intended solely to be operated handling
pallets or similar load carriers indoors. The trucks are
equipped with a steering wheel with all the controls for
operating within easy access.
The trucks have various maximum lifting capacities (review
data plate on the truck to note the maximum lifting capacity)
and are equipped with a 24V or 36V electrical system. Speed
of the truck is regulated by means of a transistor controller to
provide infinite control of acceleration and speed while
driving.
The forks and auxiliary functions are controlled by means of a
transistor controller. Control of the lift and auxiliary functions
are done electrically with the levers on the control pod.
Control of the speed and positioning of the forks when
stacking is done by the position of the levers.
The trucks can be fitted with different accessories including
sideshifter, warning light, lights/fan package, travel alarm,
and adjustable driving lights. The trucks can be specially
equipped to work in cold conditions.
1.1. Truck Side Views

The terms rearward and forward used indicate the front and
back side of the truck as viewed from the operators line of
sight for proper operation of truck. The terms right-hand and
left-hand used indicate the right and left side of the truck as
viewed from the operators line of sight for proper operation of
truck.
Left Side
Rearward
Forward
Right SIde
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2000-08-04
33
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M1.0
Version no
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001
395/396/397/398/399
1.2. Open Back Compartment

The truck compartment has an open back design. The United
States Department of Labor Occupational Safety and Health
Administration (OSHA) has determined that when a stand up
narrow aisle lift truck tips over the operator should be trained
to step off the truck. The open back design allows the
operator to make the quickest exit from the truck should the
truck begin to tip over or fall from an elevated height such as
a loading dock or ramp. The ease of entering and exiting the
open back design also minimizes operator fatigue.
Open
back
compartment
1.3. Intended Truck Application

The trucks are solely designed and manufactured to handle
goods. The trucks should be fitted with the appropriate
accessories relevant to the application.
34
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Version no
001
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395/396/397/398/399
1.4. Prohibited Truck Application

The trucks are designed for handling goods indoors. It is not
permitted to use the trucks for other purposes including the
following:
As a towing tractor for trailers.
To tow other trucks.
To transport/lift passengers.
To drive on gravel or grass.
1.5. Truck Data

The following table provides information regarding some
technical data which is of value with daily use of the trucks.
Truck
data
Lifting capacity
rated load
lb (kg)
Lift height,
inches (mm)
RRX35
RRX45
RDX30
RSX40
RSX50
3500
(1587)
4500
(2041)
3000
(1360)
4000
(1814)
5000(
2267)
192-270
(4876-6858)
210-402
(5334-10210)
210-402
(5334-10210)
192-270
(4876-6858)
210-402
(5334-10210)
Operating
speed without
load, mph
24 Volt
6.0 mph
36 Volt
6.5 mph
Operating
speed with
load, mph
24 Volt
5.5 mph
36 Volt
6.0 mph
Service weight
without battery,
lb (kg)
Service weight
including
battery, lb (kg)
36 Volt
6.5 mph
36 Volt
6.5 mph
24 Volt
6.0 mph
36 Volt
6.5 mph
24 Volt
5.5 mph
36 Volt
6.0 mph
36 Volt
6.5 mph
36 Volt
6.0 mph
36 Volt
6.0 mph
36 Volt
6.0 mph
240 Mast
5595
(2537)
210 Mast
5915
(2682)
330 Mast
6945
(3150)
210 Mast
4645
(2106)
210 Mast
5530
(2508)
Above +
battery
weight
Above +
battery weight
Above +
battery weight
(2600 min)
Above +
battery weight
(2400 min)
Above +
battery weight
(2400 min)
The lifting capacity, lifting height, and weight of the truck can
be found on the truck data plate.
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2000-08-04
35
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C-code
M1.0
Version no
T-code
001
395/396/397/398/399
1.6. RRX35 Dimensions

The following diagram shows external dimensions for the
RRX35 truck in its standard design.
(17 67.0
03 5
mm
)
5.5 (139 mm)

16.0
32.0 (812 mm)
(406 mm)
to
1.75 (44 mm)
to
x 4.0(101 mm)
50.0 (1270 mm)
Forks 30, 36, 42, 44, 48 29.5
(749 mm)
40.5
(1028 mm) 31.0
(787 mm)
5.5 (139 mm)

72.2
(1833 mm)
B
5.7 (144 mm)
A
45.5
(1155 mm)
23.0 (584 mm)
48.0 (1219 mm)

+4
95.0 (2413 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)
5.0 (127 mm)
10% Gradient Performance-Loaded
36
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Version no
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001
395/396/397/398/399
1.7. RRX45 Dimensions

RRX45 truck in its standard design.
(17 69.5
65
mm
)
5.5 (139 mm)

32.0
8.0
(812
mm)
(203
mm)
1.75 (44 mm)
to
to
x 4.0 (101 mm)
50.0
Forks 30, 36, 42, 44, 48 29.5
(749 mm) (1270 mm)
40.5
(1028 mm)
31.0
(787 mm)
5.5 (139 mm)

72.2
(1833 mm)
7.6 (193 mm)

A
45.5
1155 mm)
22.0 (558 mm)
48.0 (1219 mm)

+4
95.0 (2413 mm)
OALH
11.5
(292 mm)
Step
Height
3.0
(76 mm)
-3
2.0
(50 mm)
Battery
Free Lift
Roller 7.0 (177 mm)

Height
16.4
(416 mm)
9.1
231 mm)
5.0
(127 mm)
60.0
(1524mm)
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37
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Version no
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001
395/396/397/398/399
1.8. RDX30 Dimensions

RDX30 truck in its standard design.
8.5 (215 mm)
to
29.5 (749 mm)
(17 69.5
65
mm
)
5.5 (139 mm)
40.5
(1028 mm) 31.0
(787 mm)
1.75 (44 mm)

x 4.0 (101 mm)
Forks 30, 36, 42, 44, 48
32.0 (812 mm)

to
50.0 (1270 mm)
5.5 (139 mm)

74.6
(1894 mm)
53.4 (1356 mm) Max. Reach
46.0
(1168 mm)
A
13.3 337 mm)

B
39.7 (1008 mm)
Max. Stroke
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)
2.0 (50 mm)
60.0
(1524 mm)
5.0 (127 mm)
38
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Version no
001
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395/396/397/398/399
1.9. RSX40 Dimensions

RSX40 truck in its standard design.
Fork length
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2000-08-04
39
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Version no
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001
395/396/397/398/399
1.10. RSX50 Dimensions

RSX50 truck in its standard design.
Fork length
40
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Version no
001
T-code
395/396/397/398/399
1.11. Data Plate

The illustration below shows the data plate used on the truck.
Legend
1
2
3
4
5
6
7
8
9
10
11
12
13
Return
Truck model number

Truck serial number
Weight less battery
Maximum battery weight
Minimum battery weight
Truck voltage DC
Battery type UL class
Battery maximum AMP hours
Truck type
Mast serial number
Attachment
Maximum degree rear tilt
Truck capacity
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41
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C-code
M1.0
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.
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Version no
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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.
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2000-08-04
43
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C-code
M1.0
Version no
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001
395/396/397/398/399
12
11
10
19
16
17
8
5
4
6
7
9
18
13
14
15
Main Components of Truck
44
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2000-08-04
F-code
Section
C-code
M1.1
Inch (SAE) and Metric Fasteners
Version no
T-code
002
10
10
1. Introduction
Threaded fasteners such as bolts, nuts, cap screws, and
studs are made to specifications that describe the mechanical
strength and hardness of the fastener. A fastener used in a
design application is selected in accordance with its
specifications. Parts used on this truck are purchased from
many countries. Many of these fasteners are similar but
cannot be used as direct replacements.
Service persons must use replacement fasteners that have
the same specifications. Fasteners made to each
specification have identification marks for that specification.
This specification is commonly called grade for SAE
standards and property for metric standards. This section
describes the identification of some common fasteners.
The metric system used is described as SI (International
System of Units, also called SI in all languages). The SI
system of measurement is described in ISO Standard 1000,
1973.
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2002-01-16
45
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Section
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M1.1
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
1/2 x 13 UNC x 1-1/2

A
B
C
D
M12 x 1.75 x 50
A
B
C
Shank diameter
Number of threads per unit of length
Type of thread
Shank length
A = Thread size
B = Pitch
C = Length
2002-01-16
F-code
Section
C-code
M1.1
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!
Return
Identification marks are according to bolt

strength. The higher the number, or the
increase in the number of marks, indicates
increased bolt strength.
2002-01-16
47
F-code
Section
C-code
M1.1
Version no
T-code
002
Table 1. Bolt and Screw Designations
Types of
Fasteners
Metric Fasteners
Inch Fasteners
Strength Levels: SAE Grades
5.2
Hex Head Bolts

& Cap Screws
5
Strength Levels: Property Classes
* Markings Not Required
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
Hex Socket Head

Cap Screws
Markings Not Required
5.1
8.8
12.9
8.8
12.9
4.8*
9.8
4.8
9.8
SEMS
48
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2002-01-16
F-code
Section
C-code
M1.1
Version no
T-code
002
Table 2. Stud and Nut Designations
Types of
Fasteners
Inch Fasteners
Metric Fasteners
4.6*
4.6
5.2*
5*
9.8
9.8
8*
Hex Nuts
Hex Slotted Nuts
Hex Flange Nuts
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*
Optional Geometric Symbols for

Size M5 through M11 ONLY.
10
12
10
12
10
12
or
or
10
12
10
12
10
12
10
12
2002-01-16
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M1.1
Version no
T-code
002
Table 3. Torque Nut Designations
Types of
Fasteners
Inch Fasteners
Metric Fasteners
10
10
or
All Metal Prevailing
Torque Nuts
G
9
10
or
9
All Metal Prevailing Torque

Flange Nuts
10
or
50
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Section
C-code
M1.1
Version no
T-code
002
Table 4. Torque Nut with Nylon Insert Designations
Types of
Fasteners
Metric Fasteners
Inch Fasteners
10
10
or
Nylon Insert Prevailing Torque
Nuts
or
or
10
10
or
Nylon Insert Prevailing Torque

Flange Nuts
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2002-01-16
51
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M1.1
Version no
T-code
002
Table 5. Fastener Torque Values
Size and Pitch
Property, Class
8.8*
Property, Class
10.9**
Property, Class
12.9***
Nm
in-lb
Nm
in-lb
Nm
in-lb
5-6
8-10
20-25
44-53
71-88
177-221
7-8
12-14
30-35
62-71
106-124
------------
8-10
14-16
------------
71-88
124-142
------------
Nm
ft-lb
Nm
ft-lb
Nm
ft-lb
M8 x 1.25
M10 x 1.5
-----------40-45
-----------30-33
-----------60-65
22-26
44-48
34-40
70-75
26-30
52-55
M12 x 1.75
M14 x 2
70-80
110-125
30-33
52-59
100-110
155-180
74-81
114-133
115-130
180-210
85-96
133-155
M16 x 2
M20 x 2.5
170-190
340-380
125-140
251-280
240-270
450-500
177-199
332-369
280-320
550-600
207-236
406-443
M24 x 3
580-650
428-479
800-900
590-664
900-1050
664-774
M30 x 3.5
1150-1300
848-959
1600-1800
1180-1328
1850-2100
1364-1549
M36 x 4
2000-2250
1479-1660
2800-3150
2065-2323
3250-3700
2397-2729
M5 x 0.8
M6 x 1
M8 x 1.25
Property class 8.8, Protective Treatment CMHC

Specification H (zinc phosphate), applies also to
internally threaded fasteners made of property
class 8 material.
** Property class 10.9, Protective Treatment CMHC

internally threaded fasteners made of property
class 10 material.
*** Property class 12.9, Protective Treatment CMHC
internally threaded fasteners of property class 12
material.
52
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Section
C-code
M1.1
Version no
T-code
002
Truck Torque Specifications

Description
Torque Specification
Steering motor gear mounting bolt
88 in-lb (10 Nm)
Motor terminals
140 in-lb (15.82 Nm)
Motor pole piece screws
250-300 in-lb (28-33 Nm)
Pump motor mounting bolts
14-18 ft-lb (19-24 Nm)
Pump motor electrical power cable nuts
100-120 in-lb (11.3-13.6 Nm)
Drive motor mounting bolts
20-25 ft-lb (30-35 Nm)
Transmission mounting bolts
50-59 ft-lb (68-80 Nm)
Drive wheel nuts
65 ft-lb (88 Nm)
Overhead guard mounting bolts
200 ft-lb (271 Nm)
Drive axle retaining bolts
81 ft-lb (109 Nm)
Steering gear ring bolts
50-59 ft-lb (68-80 Nm)
Steer motor shaft
Loctite 243
Drive tire lug nut
95 ft-lb (129 Nm)
Transmission axle bearing preload
9-14 in-lb (1.01-1.58 Nm)
Transmission bevel gear nut
90 ft-lb (122 Nm)
Transmission pinion nut
110-120 ft-lb (149-162 Nm)
Transmission pinion bearing preload
5-8 in-lb (0.56-0.90 Nm)
Transmission cover bolts
18 ft-lb (24 Nm)
Transmission case
Loctite 515
Hydraulic collar mounting bolts
44.4 in-lb (5.01 Nm)
Tilt cylinder piston nut (RRX45/RDX30)
60-65 ft-lb (81-88 Nm)
Lift chain adjusting nuts and locknuts
200 ft-lb (271 Nm)
Control valve assembly hose fastener nut

Control valve double solenoid screw and mounting screw
Control vale plug
Control valve block screw
Control valve spring ball screw
480 + 25 in lb (54 Nm)

14.75 ft-lb (20 Nm)
11.06 ft-lb (15 Nm)
5.9 ft-lb (8 Nm)
8.85 ft-lb (12 Nm)
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53
F-code
Section
C-code
M1.1
Version no
T-code
002
Truck Torque Specifications

Description
Torque Specification
Lower mast mounting bolts
400 ft-lb (543 Nm)
Overhead guard post base bolts
25 ft-lb (34 Nm)
Reach cylinder piston locknut (RRX35/RRX45/RDX30)
47.94 ft-lb (65 Nm)
Mast mounting plate bolts
85 ft-lb (115 Nm)
Sideshifter lower hook bolts

Sideshifter lower hook set screw
(RRX35 S/N 27091-000-28075000; RRX45 S/N 2709100028266000; RDX30 S/N 27091000-28266000)
55 ft-lb (74 Nm)

42 ft-lb (57 Nm)
Sideshifter lower hook bolts

Sideshifter lower hook set screw
Sideshifter safety screw
Sideshifter cylinder hydraulic fittings
(RRX35 S/N 28075001 - UP; RRX45 S/N 28266001 - UP;
RDX30 S/N 28266001 - UP; RSX40 S/N 2830800 - UP;
RSX50 S/N 28308000 - UP)
65 ft-lb
21 ft-lb
70 ft-lb
56 ft-lb
Reach outer arm jam nut (RRX35)
34.36 ft-lb (47 Nm) Loctite 243
Reach outer arm jam nut (RRX35/45/RDX30)
Loctite 243
54
Return
(88 Nm)
(28 Nm)
(95 Nm)
(76 Nm)
2002-01-16
F-code
Section
C-code
M1.1
Version no
T-code
002
4. Conversion of Metric and English

Units
AREA
Multiply
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)
tons (2000 lb)
907.18
kilograms (kg)
kilograms
0.001
tons (2000 lb)
tons (2000 lb)
0.907
metric ton (t)
metric ton
1.102
tons (2000 lb)
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)
Return
2002-01-16
55
F-code
Section
C-code
M1.1
Version no
T-code
002
TEMPERATURE
Multiply
By
To Get
Multiply
By
To Get
(Fahrenheit
-32)
0.56
Celsius (C)
(Celsius x
1.8)
+32
Fahrenheit
(F)
TORQUE
Multiply
By
To Get
Multiply
By
To Get
inch pound
0.113
Newton meter
(Nm)
Newton
meter
8.851
inch pounds
in-lb
feet pound
1.356
Newton meter
(Nm)
Newton
meter
0.738
foot pounds
ft-lb
VELOCITY
Multiply
By
To Get
Multiply
By
To Get
miles/hour
1.609
kilometer/hour
(km/h)
kilometer/
hour
0.621
miles/hour
(mph)
VOLUME
56
Multiply
By
To Get
Multiply
By
To Get
inches
16.387
centimeters (cm)
centimeters
0.061
inches (in)
inches
0.016
liters
liters
61.024
inches (in)
quarts, U.S.
0.946
liters
liters
1.057
quarts, U.S.
(qt)
quarts, U.S.
0.83
quarts, Imp. (qt)
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. (gal)
gallons, Imp.
1.205
gallons, U.S.
(gal)
ounces
29.57
milliliters (ml)
milliliters
0.034
ounces (oz)
Return
2002-01-16
F-code
PS
Section
C-code
M2.0
Technical Service Data
Version no
003
T-code
395/396/397/398/399

WARNING When the battery is fully charged,
performance may vary due to motor and
system efficiency tolerance. Technical
service data represents nominal values
obtained under typical operating conditions.
Specifications are subject to change
without notice.
MODEL
RRX35 - RSX40
RDX30
RRX45 - RSX50
Series - DC
Series - DC
Series - DC
Duty factor
1 Hour Continuous
1 Hour Continuous
1 Hour Continuous
Minimum brush length
0.8 inch (20 mm)
0.8 inch (20 mm)
0.8 inch (20 mm)
Minimum commutator diameter
2.90 inches (74 mm)
2.90 inches (74 mm)
2.90 inches (74 mm)
Minimum brush spring tension
6.4 oz (180 grams)
6.4 oz (180 grams)
6.4 oz (180 grams)
DRIVE MOTOR
Type
Power
TRANSMISSION/GEAR
Type
Vertical motor spiralbevel output
Gear ratio
17.57
17.57
17.57
Oil volume
1 gal (4 liters)
1 gal (4 liters)
1 gal (4 liters)
TRANSMISSION/GEAR AMBIENT TEMPERATURES

Standard and corrosion continuous
operation (see page 68)
above 23F (-5C)
SAE 80W90
Cold Storage (see page 68)

Continuous operation 5F (-15C)
Intermittent operation -13F (-25C)
SAE 80W/90
Freezer continuous operation

To -31F (-35C) (see page 70)
ATF
Return
2001-09-18
57
F-code
Section
C-code
PS
M2.0
Version no
T-code
003
395/396/397/398/399
MODEL
RRX35 - RSX40
RDX30
RRX45 - RSX50
WHEELS
Drive wheel
inch (mm)
13.5 x 5.5 x 10.0

(342.9 x 139.7x 254)
13.5 x 5.5 x 10.0

(342.9 x 139.7x 254)
13.5 x 5.5 x 10.0

(342.9 x 139.7x 254)
Drive wheel weight without

load with battery
240 Mast
3175 lb (1440 kg)
330 Mast
3595 lb (1630 kg)
402 Mast
3875 (1757 mm)
Drive wheel weight with rated load

and battery
240 Mast
2385 lb (1081 mm)
330 Mast
2670 lb (1211 mm)
402 Mast
3184 lb(1444 mm)
Torque drive tire lug nut
95 ft-lb (129 Nm)
Load wheel
5.0 x 3.6 inches

(127 x 91 mm)
Load wheel weight

with rated load
6975 lbs
(3163807 g)
5.0 x 3.6 inches

(127 x 91 mm)
5.0 x 3.6 inches

(127 x 91 mm)
HYDRAULIC UNIT
Power
24 V 36 V - 9.8 Kw
13.1 hp
36 V -
36 V -
Revolutions/minute
at work pressure
2200 rpm
2550 rpm
2550 rpm
Duty factor
20% on 5 min. cycles
20% on 5 min.
cycles
20% on 5 min. cycles
Minimum brush
length
0.8 inch (20 mm)
0.62 inch (16 mm)
0.62 inch (16 mm)
Minimum commutator
diameter
2.90 inches (74 mm)
2.80 inches (71 mm)
2.80 inches (71 mm)
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
Pump displacement
24 V - 13 cc
36 V - 19 cc
36 V - 27 cc
36 V - 27 cc
Tank volume
5 gal (19 liters)
5 gal (19 liters)
5 gal (19 liters)
HYDRAULIC UNIT AMBIENT TEMPERATURES

Standard and corrosion continuous
operation (see page 68)
above 23F (-5C)
58
Return
Sunoco TH
2001-09-18
F-code
PS
Section
C-code
M2.0
Version no
003
T-code
395/396/397/398/399
MODEL
RRX35 - RSX40
RDX30
Cold Storage (see page 68)

Continuous operation 5F (-15C)
Intermittent operation -13F (-25C)
ATF
Freezer continuous operation

To -31F (-35C) (see page 70)
Texaco 15
RRX45 - RSX50
FUSES
Drive motor circuit
250A fuses, part number 305656-000
Pump motor circuit
425A, 24V part number

305656-002
355A, 36V part number
305656-001
Control circuit
15A (RRX35) part

number 122308-150
(S/N 2709100027135000)
10A
part number 25275-12
(S/N 27135001 - UP)
Steering circuit
2 - 250A fuses F3 &

F4 part number
305656-000
2 - 250A fuses (F3 &

F4) part number
305656-000
10A
15A (RRX45) part

number 122308-150
(S/N 2709100027135000)
10A
(S/N 27135001 - UP)
30A (S/N 27135001 - UP) part number 25275-13

30A (S/N 27091000 - 27135000) part number 122308-300
BATTERIES
Dimension W x L x H
inches (mm)
14.4 x 38.8 x 32.0

(355 x 985 x 812)
16.4 x 38.8 x 32.0
(416 x 985 x 812)
16.4 x 38.8 x 32.0

(416 x 985 x 812)
21.0 x 38.8 x 32.0
(533 x 985 x 812)
16.4 x 38.8 x 32.0

(416 x 985 x 812)
21.0 x 38.8 x 32.0
(533 x 985 x 812)
Capacity (Max.
Amp-hrs.)
24 V - 1395
36 V - 1240
36 V - 1240
36 V - 1240
14.5 inch
1600 lb (726 mm)
2300 lb (1043 mm)
16.5 inch
2000 lb (907 mm)
2300 lb (1043 mm))
16.5 inch
2000 lb (907 mm)
2300 lb (1043 mm)
21.0 inch
2600 lb (1179 mm)
2900 lb (1315 mm)
16.5 inch
2000 lb (907 mm)
2300 lb (1043 mm)
21.0 inch
2400 lb (1089 mm)
2900 lb (1315 mm)
Weight Minimum
(Maximum)
DRIVING SPEEDS
Without load
24 V - 6.0 mph
36 V - 6.5 mph
36 V - 6.5 mph
36 V - 6.5 mph
With rated load
24 V - 5.5 mph
36 V - 6.0 mph
36 V - 6.0 mph
36 V - 6.0 mph
Return
2001-09-18
59
F-code
Section
C-code
PS
M2.0
Version no
T-code
003
395/396/397/398/399
MODEL
RRX35 - RSX40
RDX30
RRX45 - RSX50
LIFTING/LOWERING TIME
Lift without load
24 V - 60 fpm
36 V - 80 fpm
36 V - 94 fpm
36 V - 94 fpm
Lift with rated load
24 V - 40 fpm
36 V - 60 fpm
36 V - 60 fpm
36 V - 60 fpm
Lower without load,

electrical valve
75 fpm
90 fpm
90 fpm
Lower with rated load,

electrical valve
80 fpm
95 fpm
95 fpm
CURRENT READINGS
60
Return
Driving without
load
24 V - 140 amp
36 V - 140 amp
36 V - 150 amp
36 V - 150 amp
Driving with rated

load
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
Lifting with rated

load
24 V 36 V - 415 amp
36 V - 570 amp
36 V - 570 amp
2001-09-18
F-code
PS
Version no
Section
C-code
M3.0
Ordering Spare Parts
T-code
001

1. Locate fault on truck.
2. Identify truck model, serial number, and battery voltage.
3. Locate page with the exploded diagram and find the
item number for the part required.
4. Locate item number in table. Select the column for
actual truck model and serial number. The following is
an explanation of a serial number:
R_X 00 3 1 265 001

Number of unit
for that day
Day of year (365)
Year (2001)
Decade (2000)
Capacity * (lb)
Model **
* 3500, 4500, 3000, 4000, 5000
** RRX, RDX, RSX
CAUTION Although some trucks appear to be similar,

component
parts
may
not
be
interchangeable. If an incorrect part is
used, the truck may malfunction.
5. Note part number.
6. Call your local BT Prime-Mover Dealer and state the
part number.
7. If truck model, serial number, or article number cannot
be found, call your local BT Prime-Mover Dealer for
assistance.
Return
2000-08-04
61
F-code
Section
C-code
PS
M3.0
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
Return
P1.0
INTRODUCTION, MAINTENANCE
P2.0
SERVICE SCHEDULE
P3.0
LUBRICATION CHART
P4.0
OIL AND GREASE SPECIFICATIONS
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
The schedules of maintenance and lubrication given in this
section of the Service Manual cover up to one years
operation of a truck. These schedules are based on hourly
usage and can be adapted to suit most normal one shift
patterns. The following hourly usage figures have been used
when calculating the schedule:
Single shift, 30 hours per week usage
Double shift, 60 hours per week usage
Triple shift, 90 hours per week usage
The schedules are intended only as a guide, not as a rigid
structure. Operators of trucks may wish to adapt them to local
requirements; but it is emphasized that the schedules
represent minimum manufacturer requirements, and all items
should be included in a service program to ensure minimum
downtime and a high safety status of the equipment.
Use only spare parts approved by BT PrimeMover.
Always clean the equipment and carry out a full
safety check after service.
Return
2000-08-04
65
F-code
Section
C-code
PS
P1.0
Version no
T-code
000
1. Jacking Truck Off The Floor

To perform maintenance that requires the truck to be lifted
from the floor, observe the proper safety precautions as
follows:
Adjustment bolt
Pivot plate
1. Lower the forks completely. Remove any load.

2. Turn key switch OFF and disconnect battery
connector from the truck.
3. If possible, stabilize the top of the mast with an
overhead chain hoist.
4. Before jacking the truck, check the stop block and
adjustment bolt on the pivot plate to make sure
they are in good condition. If the block or
adjustment bolt are excessively worn or missing,
take the truck out of service and contact your local
BT Prime-Mover Product Support Representative.
WARNING Use extreme care whenever the truck is
jacked up for any reason. Never block the
truck between the mast column and floor.
Use a suitable hoist to stabilize the mast.
Keep hands and feet clear from beneath
truck while jacking. Use jack stands or solid
blocks to support the truck, do not rely on
jacks.
5. Place the jack under the designated jacking points.
Jack only in these areas
1.1. Elevate Rear of Truck

1. Place the jack in the designated jacking position.
2. Jack the rear of the truck so the drive tire is off the
floor no more than 3 inches (76 mm).
3. Block truck in place.
66
Return
2000-08-04
F-code
PS
Section
C-code
P1.0
Version no
T-code
000
1.2. Elevate Either Side of Truck

1. Place the jack in the designated jacking position.
2. Jack the side of the truck so that the load wheel is
off the floor no more than 0.50 inch (12.7 mm).
3. Block truck in place.
Return
2000-08-04
67
F-code
Section
C-code
PS
P1.0
Version no
T-code
000
2. Lubricants
2.1. Standard
For reach trucks in their standard design under continuous
operation, the recommended ambient temperature is 23 F (5 C). These trucks should apply to the following guidelines:
Parked outside storage when not in use
Charging and maintenance work to be done
outside storage
2.2. Corrosion
In an environment where a damp, wet, or corrosive condition
exits, these trucks apply to the following guidelines:
All hardware coated with LPS Rust Inhibitor
during and/or after assembly
Sealed components (switches, push/pull
cables, sensors, etc.) where appropriate
Grease fittings provided on axle and other pivot
points
Plated pins, shafts and linkage where required
All electrical connections coated with Dow
Corning No. 4 compound during assembly
Lift chains coated with Libriplate chain
protectant
Components coated with LPS Cold Galvanize
where appropriate
Components (adjustable features, bearing
races, etc.) coated with Antisieze where
appropriate
2.3. Cold Storage

To prevent moisture contamination in the electrical system,
trucks equipped with cold storage conditioning packages
have electrical compound applied to all electrical connections
during assembly. For cold storage reach trucks with
continuous
operation,
the
recommended
ambient
temperature is 5 F (-15 C). Cold storage trucks should apply
to the following guidelines:
68
Return
2000-08-04
F-code
PS
Section
C-code
P1.0
Version no
T-code
000
Trucks completely dry prior to commencing the

continuous stay in the cold storage
Parked inside the cold storage for operator
breaks
Charging and maintenance work done outside
the cold storage
Trucks completely dry before returning to
continuous cold storage operation
For cold storage reach trucks with intermittent operation, the

recommended ambient temperature is -13 F (-25 C). Trucks
apply to the following guidelines:
Surface condensation occurs, wet trucks
should neither remain idle in the cold storage
for no longer than 10 minutes nor operate inside
the cold storage for extended periods
Condensation must not be allowed to freeze on
the truck at any time
Park outside the cold storage for operator
breaks
Charging and maintenance work to be done
outside the cold storage
Items included in the cold storage package are as follows:
All corrosion conditioning items
Sealed components used in all non-heated
locations
Heavy-duty mechanical switches used where
appropriate
Thermostat controlled heaters used to prevent
moisture buildup in electrical component areas
Heaters located around the electronic card, the
drive and lift power controllers, the steering
tachometer, and hydraulic control
potentiometers
Windshield replaced with a screen
Hydraulic fluid in lift/auxiliary system changed to
ATF
Anti-seize compound used on the control
console, vertical adjustment bar
Standard grease replaced with Mobiltemp SHC
32 lubricating grease
Return
2000-08-04
69
F-code
Section
C-code
PS
P1.0
Version no
T-code
000
2.4. Freezer Storage

To prevent moisture contamination in the electrical system,
trucks equipped with freezer storage conditioning packages
have electrical compound applied to all electrical connections
during assembly. For freezer storage reach trucks with
continuous
operation,
the
recommended
ambient
temperature is -31 F (-35 C). Trucks should apply to the
following guidelines:
Trucks must be parked inside the freezer for
operator breaks
Trucks stay in the freezer during battery
charging or change-out (If truck is removed
from freezer for maintenance work or battery
charging, it must be completely dry before
reentering the continuous shift in the freezer)
Items included in the freezer storage package are as follows:
All cold storage items contained
Transmission fluid in the lift/auxiliary system will
be changed to Texaco 15
Cooling fan in the component compartment will
be disconnected.
70
Return
2000-08-04
F-code
Section
PS
P2.0
Service Schedule
Version no
C-code
T-code
002
395/396/397/398/399
Service Schedule
1. Planned Maintenance Schedule
Item
0000
0000.1
0000.2
0000.3
0000.4
0640
0640.1
0640.2
0640.3
1700
1700.1
1700.2
1700.3
1700.4
1700.5
1700.6
1700.7
1700.8
2550
2550.1
3300
3300.1
3300.2
Work Required
Interval in Hours
Interval in Days/Weeks/Months
Chassis
Check truck identification plate for
legibility
Check for damage and cracks
Retighten truck body bolts (to
chassis)
Check cover screws
Operator Controls
Check travel direction/speed
selectors for operation
Check horn button for operation
Check hydraulic levers for
operation
Motors
Check for arcing due to poor
connections
Check tightness on all
connections
Clean motor of dirt and dust
Check torque of motor bolts
Check for abnormal noise in
motor bearings
Blow carbon, copper, and plastic
particle accumulations from the
motor using compressed air
Check electrical armature (see
page 138)
Check brushes (see page 135)
Drive Gear
Check for oil leakage
Brake
Clean dust and debris
Check brake shoes for wear
Return
30
120
240
360
720
1440
4320
1d
1w
1m
2m
3m
6m
12 m
36 m
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
2000-08-04
71
F-code
Section
C-code
PS
P2.0
Service Schedule
Version no
T-code
002
395/396/397/398/399
Item
3300.3
3300.4
3500
3500.1
3500.2
3500.3
3500.4
4100
4100.1
4100.2
5110
5110.1
5110.2
5110.3
5110.4
5200
5200.1
5300
5300.1
5300.2
5300.3
5300.4
5300.5
5400
5400.1
5400.2
72
Return
Work Required
Interval in Hours
Check correct clearance of
electrical brake and brake shoes
Check brake operation
Wheels
Remove all string, wrapping and
debris
Check all wheels for wear
Grease load wheel bearings
Grease caster and caster wheels
Steering Wheel
Check fasteners
Check ease of steering
Battery
Electrolyte level, 0.50-0.625 inch
(12-15 mm) above cell plates
Check all connections: battery,
battery and charger plugs
Check all cell and link covers
intact
Check battery specific gravity
Instrument Panel
Check battery indicator and hour
meter for correct operation
Electrical Control System
Check key switch
Check brake micro switch
Check control wiring harness for
proper routing
Examine negative cable and
wires from the battery to the main
electronic card (A5)
Check red emergency stop switch
for operation
Electrical Panel
Cleaning and mounting to
chassis
Check tightness on all
connections
30
120
240
360
720
1440
4320
1d
1w
1m
2m
3m
6m
12 m
36 m
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
2000-08-04
F-code
Section
PS
P2.0
Service Schedule
Version no
T-code
002
Item
5400.3
5400.4
5400.5
5400.6
5710
5710.1
6000
6000.1
6000.2
6000.3
6000.4
6000.5
6000.6
7100
7100.1
7100.2
7100.3
7100.4
7100.5
7100.6
7100.7
7100.8
7100.9
7210
7210.1
7210.2
7210.3
395/396/397/398/399
Work Required
Interval in Hours
Check contactor tips
Check contactor tips for free
movements
Check all cable insulation for
damage
Check power safety control
system on the transistor regulator
(see page 363).
Electronic Card
Check for connections in harness
connectors
Hydraulic System
Check hoses and connections for
leakage
Check hoses for wear and
damage
Check oil tank for cracks, leaks
and mounting
Check correct oil level
Change hydraulic oil
Change hydraulic filter element
Mast
Check for damage and cracks
Retighten mast mounting bolts
Check clearance of rollers
Check lateral play of inner section
Check for wear on lift chains and
chain rollers
Check adjustment of lift chains
Clean & lube lift chains
Clean & lube mast columns
Lube chain sheaves
Side Shifter
Check torque of lower hook
mounting bolts
Inspect hydraulic hoses
Inspect cylinder and fittings
Return
C-code
30
120
240
360
720
1440
4320
1d
1w
1m
2m
3m
6m
12 m
36 m
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
2000-08-04
73
F-code
Section
C-code
PS
P2.0
Service Schedule
Version no
T-code
002
395/396/397/398/399
Item
7210.4
7210.5
7210.6
7210.7
7310
7310.1
7310.2
7400.
7400.1
7400.2
7400.3
7400.4
7400.5
7400.6
7400.7
74
Return
Work Required
Interval in Hours
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
proper reach stroke and timing.
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
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Service Schedule
Version no
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T-code
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7310
7100
5400
5300
7200
6000
7400
4110
5110
1700
3300
2550
5710
0000
3500
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Service Schedule
Version no
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002
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2. Planned Maintenance Procedures

This section describes how to perform the services listed in
the Schedule of Planned Maintenance Operations. As with
the Schedule, this section is subdivided into service
intervals.
2.1. Services Performed Daily or Every 8

Operating Hours
The daily inspection is to be made by the operator prior to
each operating shift. It is the operator's responsibility to report
any defects to the proper authorities. The truck should not be
operated until it has been inspected and repaired by a
trained, qualified, and authorized technician. The operator is
ultimately responsible for the safe operation of reach truck.
2.1.1. Battery Discharge Indicator with slow down
The battery discharge indicator indicates the current charge
status of trucks battery. (See Battery Discharge Indicator
Parameter Adjustment on page 384.)
1
Full charge battery
1/2
Half charged battery
Discharged battery
The battery discharge indicator has an integrated cut-out

function that slows down trucks lift function when a
predetermined charge level has been reached. This prevents
overloading the battery and increases the operating economy
of truck. When the battery has reached a charge level
equivalent to 70% discharge, a warning signal is given via
flashing lights. A further 10% of the batterys capacity can
then be used before the battery discharge indicator slows
down the lift function.
2.1.2. Hydraulic System
Inspect entire truck for leaks, especially around hydraulic
pump assembly and lift cylinders. Any sign of oil on the floor
under truck is an indication that truck may be leaking
hydraulic oil or transmission fluid. Report any problems to the
proper authorities, and DO NOT operate truck until it has
been inspected and repaired by a trained, qualified, and
authorized technician.
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2.1.3. Frame/Sheet Metal

Inspect truck for loose, damaged or missing parts. All shields
must be in place and functional. Report any problems to the
proper authorities. DO NOT operate truck until it has been
inspected and repaired by a trained, qualified, and authorized
technician.
2.1.4. Wheels/Tires
Inspect wheels and tires for wear and damage. Trash that is
wrapped around wheels and axles will cause premature tire
wear and bearing damage. The floors should be kept clear of
trash to prevent damage to wheels and tires.
2.1.5. Functions/Operations
Test truck for the proper operation of all functions including
the travel controls, lift and lower functions, brakes, and
emergency disconnect button. Safety devices must be
operational. Report any problems to the proper supervisors.
DO NOT operate truck until it has been inspected and
repaired by a trained, qualified, and authorized technician.
2.2. Services Performed Monthly or Every

120 Operating Hours
The monthly planned maintenance service should be
performed by a trained, qualified, and authorized technician.
2.2.1. Inspection
All services and inspections listed above for the daily
inspection should be performed at this time. The inspection
procedure should be more thorough, and minor deficiencies
should be corrected.
2.2.2. Transmission
Inspect for oil leakage.
2.2.3. Brakes
When the foot is lifted from the brake pedal it should stop a
fully loaded truck at full speed in approximately one truck
length.
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Service Schedule
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002
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2.2.4. Battery
Contact your battery dealer for specific instructions on care
and maintenance of the battery. An average battery will have
a specific gravity of 1.170 at the 80% discharged level.
However, there are many different batteries on the market.
Only the battery manufacturer can accurately determine the
fully charged and 80% charged levels. Contact the battery
manufacturer for this information.
2.2.5. Electrical Connections
Check that all electrical connections are clean and tight. Plugin connectors should be unplugged and plugged back in to
clean terminals. If the truck is equipped with any of the coldstorage, freezer use, or corrosive environment application
packages, the di-electric compound in the plug-in connectors
should be renewed.
2.2.6. Contactor Tips (NOT Sealed)
Inspect contactor tips for arcing, pitting, or burning. Minor
pitting of the tips is not a problem. However, if tips are pitted
through the tip to the copper bar, tips should be replaced. DO
NOT file tips. Replace tips only in complete sets. Some
contactors have concealed tips or fully sealed so tips cannot
be replaced.
2.2.7. Motor Brushes
The drive motor and pump motor are equipped with a brush
wear sensor which will indicate when brushes need replacing.
For minimum brush length see page 57. As a rule of thumb,
brushes should be replaced if brush spring is within 0.0625
inch (1.59 mm) of touching brush holder.
2.2.8. Drive Motor
Blow out drive motor fan and vents. Check for any signs of oil
on drive motor fan and air vents. Check for any damage to
fan or air vents.
WARNING Compressed air used for cleaning MUST
be reduced to less than 30 psi (206 kPa)
and then only with effective chip-guarding
and personal protective equipment worn.
78
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Service Schedule
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T-code
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2.2.9. Hydraulic Reservoir

Check fluid level in the hydraulic reservoir.
2.2.10. Frame Lube
The pressure type grease fittings (zerk fittings) should be
lubricated with grease (see page 84). The total number of
grease fittings depends on truck options when built (see
page 83). A truck with a cold-storage, freezer use, or
corrosive environment application package will have more
grease fittings than a standard truck. Look for flush-type
grease fittings on the load wheel axles. Regular fittings may
be found on the transmission mounting bearing and mast
chain sheave shafts.
2.2.11. Pivot Points
There are pivot points and other items that need to be
lubricated but do not have grease fittings. Lubricate these
non-greasable wear points with a drip oil can using 10 weight
machine oil.
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79
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Service Schedule
Version no
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002
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2.3. Services Performed Every 480 or 960

Operating Hours
The planned maintenance service should be performed by a
trained, qualified, and authorized technician.
2.3.1. Drive Motor
Since the operating environment of material handling
equipment varies widely, the following recommendations are
suggested for periodic maintenance inspections for the drive
motor armature.
Normal Service 8 hours per day operation
Routine inspection every 960 hours (8 months).
Severe Service 24 hours of daily operation
1. Dusty or sandy locations; such as a cement plant,
lumber or flour mills, coal dust or stone-crushing
areas.
2. High temperature areas; such as steel mills,
foundries, etc.
3. Sudden temperature changes (continuous in-dooroutdoor movement) that is refrigeration plant, etc.
Routine inspection every 480 hours (4 months).
80
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Service Schedule
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002
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T-code
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2.4. Services Performed Annually or Every

1440 Operating Hours
The annual planned maintenance service will take a longer
period of time to complete than does the monthly service.
This would be a good time to arrange other repairs that have
been noted on the monthly service.
2.4.1. Inspection
All services and inspections listed for the daily and monthly
inspection should be performed at this time. The inspection
procedure should be more thorough, and minor deficiencies
should be corrected.
2.4.2. Transmission
The transmission fluid should be drained once a year. The
drain port is located on the lower portion of the side cover
opposite the drive tire. Remove bolt to drain transmission
fluid. Flush transmission case. Pour a clean solution into the
fill port accessed from the battery compartment. With the
drive tire off the floor, allow solution to run out of drain port
while transmission is running. Stop flushing when the solution
runs clean. Allow the solution to drain well before replacing
drain plug bolt. Replace drain plug bolt. Refill transmission
with proper clean oil before operating truck.
2.4.3. Battery
At approximately 1500 hours, contact an authorized battery
dealer to determine the overall condition of the battery.
Determine if the battery needs to be washed down. This can
only be done by properly trained, qualified, and authorized
technician.
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Service Schedule
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2.4.4. Hydraulic System

The hydraulic system should be drained, flushed and refilled,
and the pressure relief valve setting should be checked and
adjusted. This will maintain proper lubrication properties
within the system.
WARNING Before siphoning oil from reservoir, make
certain siphon is clean.
To drain reservoir, remove reservoir filter assembly. Siphon
oil from reservoir and purge oil out of hydraulic system. Fill
reservoir with proper clean oil. Operate the raise and lower
function several times to purge air from the system. Check oil
level. Put rated truck capacity load on forks and adjust
pressure relief valve, if necessary, so that truck will lift rated
load.
2.4.5. Brakes
Follow procedures for brake removal before inspecting.
Remove brake assembly and inspect friction disc for wear.
The friction disc should be replaced once thickness is 0.25
inch (6 mm) or less. The armature and magnetic coil should
be adjusted if machine will not meet stopping and holding
specifications. The air gap should not exceed 0.018 inch
(0.46 mm) and should remain within 0.003 inch (0.076 mm)
throughout the circumference.
2.4.6. Lift and Carriage Chains.
Lift and carriage chains should be checked every 720 hours.
A chain gauge should be used to check stretch of the links.
To adjust inner columns, loosen jam nut and tighten chains
equally until the top of the columns are level in the fully
lowered position. Retighten jam nut and torque. Carriage
chains should be adjusted in the fully lowered position. Adjust
chains until the top of forks are 2.0 inches (50.8 mm) off of the
floor.
82
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F-code
Section
PS
P3.0
Lubrication Chart
Version no
C-code
T-code
001
395/396/397/398/399
Lubrication Chart
Pos. No.
Service Point
Interval/Running Hours
360 h
1
2
3
4
5
6
Wheel bearings
Mast beam
Lifting chains
Hydraulic system
Steering bearings
Drive gear
720 h
Lubricant
(See Approved Oils and
Grease on page 84)
1440 h
L
L
L
C
O
L
O
C
L= Lubrication
A
E
D
B
C
C
C = Check
O = Oil change
2
3
6
5
1
1
Truck Lubrication Points
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83
F-code
Section
C-code
PS
P4.0
Oil and Grease Specifications
Version no
T-code
001
395/396/397/398/399

1. Approved Oils and Grease
Specification
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
* Refer to section 10000 of Parts Book for special lubricants.
84
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PS
P4.0
Version no
001
T-code
395/396/397/398/399
2. Grease Location Points
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85
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PS
P4.0
Version no
T-code
001
395/396/397/398/399
3. Mast Adjustment Points
86
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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
DRIVE GEAR / TRANSMISSION
2000
BRAKE / WHEEL SYSTEM
3000
STEERING SYSTEM
4000
ELECTRICAL / PNEUMATIC SYSTEM
5000
HYDRAULIC SYSTEM
6000
LIFTING MAST / CYLINDERS
7000
PERIPHERAL / INSTALLATION
8000
EQUIPMENT
9
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OPTIONS / ATTACHMENTS
2000-08-04
9000
87
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PS
S
Contents, Section S
Version no
T-code
000
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
1. General
Troubleshooting can be broken down into two sections: (1)
mechanical and (2) electrical circuits. Electrical circuits can
be further broken down into control circuit and power circuit.
Many hours of troubleshooting time can be saved by knowing
the exact operational symptoms. If the proper switch operates
for the chosen direction and speed, the problem can be found
in the controller or the power circuit of that function.
Voltage tests are made with the negative lead of the
voltmeter connected to battery negative if the negative lead is
connected to a negative terminal on the electrical panel. First,
verify the negative connection to the battery by touching the
positive meter lead to the positive battery post. The battery
voltage must be at least 25.2 volts for a 24 volt system. If the
battery voltage is below 22 volts (no load), the controller may
not operate properly. The battery voltage must be at least
37.8 volts for a 36 volt system. If the battery voltage is below
33 volts (no load), the controller may not operate properly.
Charge the battery before starting the troubleshooting
procedures.
When testing voltage, the positive side of any component
refers to the terminal on that component that is closest
electrically to the battery positive terminal. The negative
side of any component refers to the terminal on that
component that is farthest electrically from the battery
positive terminal. It is possible, and in many cases desirable,
to measure battery voltage at both the positive and negative
side of a component.
Rearward direction refers to travel in the direction of the
truck with the forks trailing. Forward direction refers to travel
with the forks first.
After the final test is completed, the truck should be repaired
and operating properly. If it is not, then verify test results and
possibly re-evaluate the failure symptoms. If truck is still not
repaired, then call your local authorized BT Prime-Mover
Dealer for assistance.
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PS
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Version no
T-code
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The following information is required when placing a service

call:
Truck model and serial number
Service hour meter
Actual battery voltage at open circuit
Actual battery voltage at open circuit at

hydraulic operation under full load
Operating symptoms
Exact results of the testing performed
Perform the following steps before starting all troubleshooting

procedures:
1. Inspect truck for physical damage or mechanical
malfunction. Contactors must be free to move and
tips must not be welded or burnt.
2. Check for ground faults from the electrical system
to the frame with an ohmmeter. A minimum of
20,000 ohms resistance from the frame to any and
all wiring is acceptable.
3. Check that the battery is fully charged and
connected.
4. Operate truck in all modes to determine the exact
symptoms. DO NOT forget that systems are
equipped with circuits that prevent operation in the
event of improper operating procedures.
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Version no
000
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2. Electrical
Many problems are caused by a faulty or dirty battery. Make
sure the battery is clean. Check the electrolyte level and state
of charge.
CAUTION Be sure to block truck whenever a
troubleshooting procedure requires turning
key switch (S17) ON. This will avoid
accidents caused by unexpected lift truck
travel.
CAUTION Unless otherwise directed, disconnect
battery connector when checking electrical
circuits or components with an ohmmeter.
Electrical current can damage the
ohmmeter.
For error code listings see pages 393, 394, 396. For
programming parameters see page 401. Visually inspect all
wiring and electrical components for the following:
Loose connections or connectors
Loose or broken terminals
Damaged terminals, blocks, or strips
Broken wiring and shorted conditions

(especially those that are close to metal edges
or surfaces)
Use an ohmmeter to check for wiring continuity.
2.1. Shorts to Frame Test

Shorts to frame is an industry term for unintentional current
leakage paths between normally isolated electrical circuits
and their metal enclosures.
Shorts to frame may be metallic connections, such as a wire
conductor contacting metal through worn insulation. More
often, shorts to frame are resistive leakage paths caused by
contamination and/or moisture.
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Version no
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These leakage paths can result in unwanted electrical noise

on the metallic truck structure, and may result in improper
operation.
Shorts to frame can be caused by the following:
Accumulation of dirt
Battery electrolyte leakage
Motor brush dust
Motor brush leads touching housing
Breakdown in insulation
Bare wires
Pinched wiring harness
Improper mounting of circuit cards
Shorts to frame can occur at numerous locations on truck

including the following:
92
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Batteries
Motors
Cables, wiring, and harnesses
Heat sinks
Bus bars
Solenoids
Contactors
Terminal strips
Switches
Power panel insulation
Circuit card mounts
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Section
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PS
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Version no
000
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395/396/397/398/399
To test for shorts to frame:

1. Turn the key switch OFF and disconnect battery
2. To test battery for shorts to case, connect a 12-volt
test light to battery case from battery B+, and then
to battery case from battery B-. If it lights at all,
even momentarily, there is a problem with the
battery, either external contamination or internal
damage. DO NOT continue until this condition
is corrected. Meter may be damaged if
proceeding before correcting condition. Install
another battery in truck and repeat procedure from
step 1. If the test light does not light, continue to
the next step.
3. With the battery disconnected from truck, use a
digital volt/ohm/ammeter on the ampere function to
measure the leakage current from the battery case
to battery B+ and from battery case to battery B-.
Begin measuring at the highest Ampere scale and
work toward the lowest. A reading of more than
0.001 ampere (1 mA) indicates a short. DO NOT
continue until this condition is corrected. The
meter may be damaged if proceeding before
correcting condition. Install another battery in truck
and repeat procedure from step 1. If current is less
than 0.0002 ampere (0.2 mA), go to step 4. If
current is greater than 0.0002 ampere (0.2 mA)
and less than 0.001 ampere (1 mA), remove
battery from truck, and continue with step 4.
Ensure battery case does not touch truck frame
during the remaining tests.
4. With battery disconnected (or removed and
disconnected) from truck, use a digital ohmmeter
to measure the resistance from truck frame to truck
B+, to truck B- (NOT battery B+ and B-), and to all
fuses and motors. A reading of less than 1000
ohms indicates a short. DO NOT continue until
this condition is corrected. Meter may be
damaged if proceeding before correcting condition.
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PS
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Version no
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a. To identify cause of short to frame, disconnect

circuit components until the low resistance
condition disappears. Do not reconnect
components one at a time, but leave
disconnected until the low resistance reading
disappears. Prevent disconnected terminals or
connectors from touching truck frame or other
conductive surfaces.
b. The most likely areas to check are as follows:
Motors
Heat sinks
Power cables
Power circuit components
Control circuit components
c. Repair or replace the component causing the
low resistance condition, then repeat Step 4.
d. Reconnect all other components previously
disconnected, one at a time, measuring
resistance between steps. If a reading is less
than 1000 ohms when reconnecting a
component, that component or its wiring is
defective; repair or replace as appropriate.
e. When all components are reconnected, and
readings are greater than 1000 ohms, continue
with the next step.
5. Connect battery connector to the truck and turn key
switch ON. If battery was previously removed,
ensure battery case does not touch truck frame.
6. Use a volt/ohm/ammeter on the current function
meter to measure leakage current to truck frame
from B+, B-, and all fuses and motor terminals.
Begin measuring at the highest ampere scale and
work toward the lowest. If current is less than 0.001
ampere (1 mA), go to step 7. If current is greater
than 0.001 ampere (1 mA), continue with the step
below.
94
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000
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a. To identify the cause of the short to frame,

disconnect circuit components until leakage
current reads less than 0.001 ampere (1 mA).
Do not reconnect components one at a time,
but leave disconnected until leakage current
reads less than 0.001 ampere (1 mA). Prevent
disconnected terminals or connectors from
touching truck frame or other conductive
surfaces.
b. The most likely areas to check are as follows:
Motors
Heat sinks
Power cables
Power circuit components
Control circuit components
c. Repair or replace the component(s) causing
the leakage current. Repeat step 6.
d. Reconnect all other components previously
disconnected, measuring current between
steps. If reading is greater than 0.001 ampere
(1MA) when reconnecting a component,
component or its wiring is defective. Repair/
replace as appropriate.
7. After all components are reconnected, reading is
less than 0.001 ampere (1 mA) there is no short to
frame condition with truck or battery. If the battery
was previously removed from truck, reinstall
battery.
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PS
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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, score,
or fail.
For error code listings see pages 393, 394, and 396. For
programming parameters see page 401. If the hydraulic
pump assembly does not operate properly, the following
preliminary checks should be made:
Proper oil level
All electrical connections tight
Battery fully charged
CAUTION After elevating or reaching the carriage for

troubleshooting, be sure to use blocks to
secure the carriage.
Use extreme care when blocking the mast
for any reason. Never remove a block when
it is supporting the mast.
96
Return
Lower the carriage fully and retract the reach

mechanism fully.
If truck is equipped with tilt, set the forks level,

not tilted either up or down.
If truck is equipped with sideshift, center the

forks horizontally.
When checking voltage at solenoids, make sure

hydraulic lines and components are fully
installed.
Whenever possible, keep the key switch OFF

and battery connector disconnected.
2000-08-04
F-code
Section
C-code
PS
S0.0
Version no
000
T-code
395/396/397/398/399
4. Definitions
Auxiliary Function. A hydraulic function other than lift/lower.
Included on the truck is reach/retract, tilt, and sideshift. Some
auxiliary functions, or aux functions, are options not present
on every truck.
Continuity. A continuous and uninterrupted path between
two or more locations in an electrical circuit, typically having a
resistance of less than 1 ohm.
Brake Pedal Switch. The switch in the truck that must be
opened to allow lift truck operation. It is activated by the
operator stepping on the foot pedal thus engaging the brake
pedal. Travel is prohibited when the brake is applied.
High Speed Travel Limit. A reduced speed initiated when
the truck is driven and carriage is elevated above a certain
mast height. This is a feature that limits the speed of travel
with an elevated mast and helps prevent unstable load
conditions.
Mast Assembly. The elevating section of truck, bolts to the
truck section adjacent to the battery. The mast assembly
consists of column sections, carriage assembly, lift cylinders,
lift chains, etc.
Mast Switch. A switch on the mast upper position switch is
actuated when the carriage is above a certain height on the
mast. This switch regulates mast transition speeds.
Open Circuit. A lack of a continuous path between two or
more electrical connections. Generally, when such a circuit is
tested, it will have a resistance greater than ten megohms.
Overtemperature (Power Amplifier). Overtemperature
of
o
o
the motor power amplifier is from 185 F (85 C) and above.
At overtemperature the drive current limit is linearly
decreased from full set current down to zero. Plug current is
not reduced to provide full vehicle braking under all thermal
conditions.
Pulse Width Modulation. Pulse Width Modulation (PWM),
also called chopping, controls the speed of the motor by
switching the battery voltage to the motor on and off very
quickly.
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PS
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Version no
T-code
000
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Short Circuit or Short. A short circuit is an unspecified

path in a circuit that provides unwanted full or partial
continuity between two or more locations in an electrical
circuit.
Example: Two insulated wires are physically next
to each other and the insulation has been worn off
each of the wires. Because the conductors inside
each wire are now touching each other, there is a
short circuit.
Example: A power cable from the battery to a
junction post in the truck has had the insulation
worn away. Because the wire conductors are
touching the truck frame, there is a short circuit of
the battery cable.
Chassis. The body section of the truck that contains the
battery, motors, drive unit, controls, and handle. The mast
assembly bolts to the chassis, which is adjacent to the
battery.
Undertemperature. When the power amplifier is operating at
less than 13o F (25o C), the current limit is cut back
resulting in reduced travel speed.
98
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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
Return
15
2001-09-20
99
F-code
Section
C-code
PS
Chassis
S0.1
0000
Version no
T-code
002
395/396/397/398/399
Item
No.
Description
Item
No.
Description
Item
No.
Description
Panel, left hand
Washer, flat
14
Screw
Panel, side
Nut
15
Panel, cover
Grill, fan
10
Door
16
Mount, console
Screw
11
Panel, right hand
17
Screw
Screw
12
Dash
18
Plate, heat sink
Washer
13
Plug, hole
19
Plate, contactor
Latch
2. Dash
The dash is a one piece unit. It covers the motor
compartment, the drive and pump transistor regulators, and
contactors. The operator display is mounted on the dash. The
emergency stop switch is mounted on the truck. The key
switch, travel speed/directional selector, lift and lower switch,
horn switch, tilt switch and sideshifter switch are in the pod
(see page 107).
2.1. Removal
1. Park truck on a level surface and block.
3. Remove the pod from the mount.
4. Remove hardware securing the dash to the frame.
5. Lift the cover up enough to disconnect the wiring
harness connections to the operator display.
6. Lift the dash off removing it from the truck.
100
Return
2001-09-20
F-code
Section
PS
S0.1
Version no
002
C-code
0000
Chassis
T-code
395/396/397/398/399
2.2. Removal
1. Install the dash on the truck.
2. Attach the harness connections to the operator
display.
3. Align the bolt holes in the cover with the ones in the
frame.
4. Secure dash to the frame.
5. Connect battery connector to the truck.
6. Return truck to service.
3. Motor Compartment Door

3.1. Removal
1. Turning screw (5) clockwise one quarter turn.
2. Open door (10) fully and lift door upward to release
hinge pins.
3.2. Installation
1. Set door (10) in place so hinge pins are securely
mounted in panel hinge.
CAUTION Do not force screw (5) past quarter turn or
latch can become loose.
2. Close door. Turn screw (5) counter clockwise one
quarter turn.
Return
2001-09-20
101
F-code
Section
C-code
PS
Chassis
S0.1
0000
Version no
T-code
002
395/396/397/398/399
4. Left-Hand Side Panel

4.1. Removal
Overhead
guard post
1. Park truck on level surface and block.

2. Turn key switch to OFF and disconnect battery
3. Turning screw (5) clockwise one quarter turn.
4. Open door (10) fully and lift door upward to release
hinge pins.
Control
Pod
5. Remove dash (12) by removing seven screws (14)

and control pod.
6. Remove three flanged nuts. Two nuts are located
under dash by reservoir and the third nut can be
accessed through battery box left hand side or by
removal of operators compartment side panel (2).
7. Remove bolt at rear of panel located by drive
motor.
NOTE!
Be sure the wire assemblies are pushed up

into the overhead guard post before the
bolts are removed to prevent damage to the
wires if the post shifts as the bolts are
removed.
8. Remove four bolts securing overhead guard post.

Disconnect harness at post if applicable.
CAUTION Side panel is heavy. Help may be required
to remove.
9. Pull left-hand panel (1) outward and set aside.
102
Return
2001-09-20
F-code
Section
PS
S0.1
Version no
002
C-code
0000
Chassis
T-code
395/396/397/398/399
5. Operator Compartment Panel

5.1. Removal
1. Remove top bolt securing panel (2).
2. Loosen bottom bolt (5) while holding panel (2) in
place.
3. Lift up and set aside.
6. Main Card Access Panel

6.1. Removal
1. Loosen two lower bolts.
2. Remove two top bolts and lift electrical cover panel
(15) up and set aside.
Return
2001-09-20
103
F-code
Section
C-code
PS
Chassis
S0.1
0000
Version no
T-code
002
395/396/397/398/399
104
Return
2001-09-20
F-code
PS
Section
C-code
S0.2
0391
Battery Compartment
Version no
000
T-code
365/396/397/398/399
Battery Compartment
1
1
Item No.
Description
Bearing
Roller, battery
Shaft, battery
Plate, battery retainer
CAUTION Before working on battery, review Battery

Safety, beginning on page 21. Batteries
may weigh more than 2900 pounds (1315
kg). Use extreme care during replacement.
Use a suitable battery replacement device
or hoist for lifting.
Truck is equipped with battery rollers and battery retainer
plates for ease of battery removal and replacement.
Return
2000-08-04
105
F-code
Section
PS
S0.2
Battery Compartment
C-code
0391
Version no
T-code
000
365/396/397/398/399
Battery
Rollers
1. Battery Retainer Plates

Battery
Retainer
Plate
1.1. Inspection
Inspect battery retainer plates for bending or cracks. Replace
if necessary.
1.2. Removal
1. While lifting battery retainer plate upward, tilt edge
toward mast slightly forward to disengage tongue
on operator compartment end of battery retainer
plate.
2. Continue lifting until battery retainer plate is clear of
truck, then set aside.
1.3. Installation
1. Position battery retainer plate with tongued edges
on bottom and facing operator compartment.
2. The edge toward operator compartment should be
tilted in so that tongue engages with slot in back of
battery compartment.
3. Carefully lower battery retainer plate into position.
Move plate forward and backward until proper
engagement is noted.
2. Battery Rollers
2.1. Inspection
Inspect battery rollers to ensure they can turn freely. Clean off
electrolyte using a solution of 1 pound (0.45 kg) of baking
soda added to 1/2 gallon (3.7 liters) of hot water.
2.2. Replacement
Lift damaged roller from its slot and replace with a new.
106
Return
2000-08-04
F-code
Section
PS
S0.3
0640
Driver Controls
Version no
C-code
T-code
000
395/396/397/398/399
Driver Controls
The control console can be adjusted to a suitable height and
angle to obtain a comfortable working position. The steering,
hydraulic functions, horn, parking brake, preset height, travel
direction, key switch, and any extra hydraulic functions are all
controlled from the console. The position of the console may
be set in 1 of 3 positions; forward facing, 45 degrees, or side
stance. To remove console and/or the pod see page 215.
Dash
Steering
wheel
Pod
Lift &
lower
Reach
Tilt
Sideshifter
Horn
switch
Key switch
4
1 2 3
7 8
5 6
9 0
Travel speed /
direction selector
Console
Return
Emergency
disconnect
switch
Spinner
Light & fan

switches
2000-08-04
107
F-code
Section
C-code
PS
S0.3
Driver Controls
0640
Version no
T-code
000
395/396/397/398/399
108
Return
2000-08-04
F-code
Section
C-code
PS
S0.4
0642
Brake Pedal, RSX40/RRX35
Version no
T-code
000
395/396/397/398/399

12
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
Return
Description
2000-08-04
Item
No.
Description
109
F-code
Section
C-code
PS
S0.4
0642
Version no
T-code
000
395/396/397/398/399
1. Pedal Removal
1. Park the truck on a flat surface.
2. Turn key switch to OFF and disconnect battery at
battery connector. Check to make sure battery
retainer plates are in place.
3. Jack the rear of the truck (see page 66).
4. Looking into the operator's compartment, remove
the four screws from the right panel covering the
logic card. Take panel out and set to the side.
CAUTION Pinch point. Keep fingers clear of floor
board cutout while holding down left foot
brake pedal.
5. Push down on left foot brake pedal (1) with one
hand and remove the floor board by pulling up and
pivoting plate (7) toward motor compartment.
Release left foot brake pedal as the floor board
pivots up.
CAUTION Disconnect wire connections to right foot
pedal switch prior to removal of floor board.
6. Remove floor board and set to the side.
7. Remove the screws (11) holding the potentiometer
(10) and remove wires from the brake switch (14).
8. Loosen four mounting bolts holding brake pedal
assembly to the frame. Remove brake pedal
assembly from truck to service.
110
Return
2000-08-04
F-code
Section
C-code
PS
S0.4
0642
Version no
000
T-code
395/396/397/398/399
2. Pedal Bearing Replacement

1. To replace bearing assemblies on brake pedal (1),
remove brake pedal return spring (5).
2. Remove flange bearing mounting screws (8) on
both bearings.
3. Loosen set screws on bearing collars and slide
bearing assemblies back.
4. Remove brake pedal assembly from bracket (4)
and remove bearings (2).
5. Install bearings (2) on brake pedal shaft (1).
6. Install brake pedal assembly into bracket (4).
7. Engage bearings in bracket by sliding bearings
forward. Install bearing mounting screws (8).
8. Install brake pedal return spring (5).
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).
Return
2000-08-04
111
F-code
Section
C-code
PS
S0.4
0642
Brake Pedal, RSX50/RRX45/RDX30
Version no
T-code
000
395/396/397/398/399
Brake Pedal, RSX50/RRX45/

RDX30
12
6
2
1
17
16
5
4
3
8
13
14
10
11
15
112
Return
2000-08-04
F-code
Section
C-code
PS
S0.4
0642
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
Pin with cotter pin
Bumper
12
Mat, pedal
Description
Item
No.
Description
1. Pedal Removal
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.
brake pedal.
5. Push down on the left foot brake pedal (1) with one
hand and remove the floor board by pulling up and
pivoting the plate (7) toward the motor
compartment. Release the left foot brake pedal as
the floor board pivots up.
6. Remove floor board and set to the side.
Return
2000-08-04
113
F-code
Section
C-code
PS
S0.4
0642
Version no
T-code
000
395/396/397/398/399
7. Remove screws (11) holding the potentiometer

brake (10) and remove wires from brake switch
(14). Remove brake cable pin with cotter pin (17).
8. Loosen four mounting bolts holding brake pedal
assembly to the frame. Remove brake pedal
assembly from truck to service.
2. Pedal Bearing Replacement

1. Remove brake pedal return spring (5) to replace
bearing assemblies on brake pedal (1).
2. Remove flange bearing mounting screws (8) on
both bearings.
3. Loosen set screws on bearing collars and slide
bearing assemblies back.
4. Remove brake pedal assembly from bracket (4)
and remove bearings (2).
5. Install bearings (2) on brake pedal (1) shaft.
6. Install brake pedal assembly in the bracket (4).
7. Engage bearings in bracket by sliding bearings
forward. Install bearing mounting screws (8).
8. Install brake cable pin with cotter pin (17) and
brake pedal return spring (5).
3. Pedal Adjustment
1. See Adjustment Procedures for Setting Brake
Switch and Brake Transducer on page 383.
2. When replacing the pedal stop bumper (6) it should
be threaded down until the stop makes contact with
the bracket (4).
114
Return
2000-08-04
F-code
Section
PS
S0.5
0811
Overhead Guard
Version no
000
C-code
T-code
395/396/397/398/399
Overhead Guard
1
4
2
3
5
Item No.
1
2
3
4
5
Return
2000-08-04
Description
Overhead guard
Bolt
Screw, cap
Nut
Post, overhead guard
115
F-code
Section
C-code
PS
S0.5
Overhead Guard
0811
Version no
T-code
000
395/396/397/398/399
Remove of the overhead guard is not recommended.

Checking tightness of the mounting bolts (2) is recommended
on a regular basis. Overhead guard mounting bolts should be
torqued to 200 ft-lb (271 Nm).
116
Return
2000-08-04
F-code
Section
PS
S0.6
Version no
000
C-code
0851
Decals
T-code
365/396/397/398/399
Decals
Remove and replace any decals that are damaged. Replace
any missing decals. Remove a damaged decal by using a
sharp edge to peel decal from the surface. Use caution not to
scratch or damage the paint on truck when removing the
decal. Replacement of warning decals are free from BT
Prime-Mover.
Using the required cleaning solution, thoroughly clean the
surface of truck before applying a new decal. Allow the
surface to completely dry, be sure that there is no residue.
Touch up paint in the area of the decal, as required.
1. Decal with Protective Sheet

To install this style, peel off backing, place decal into position,
and press decal into place. Do not wrinkle decal. Rub over
the protective over-sheet with a firm, straight, plastic edge to
remove air bubbles and any wrinkles. Peel off the over-sheet.
2. Decal without Protective Sheet

To install this style, peel off backing, place decal into position,
and press decal into place. Do not wrinkle decal. Smooth
decal into place using clean fingers. Be sure all the edges are
secured to the surface.
Return
2000-08-04
117
F-code
Section
C-code
PS
Decals
S0.6
0851
Version no
T-code
000
365/396/397/398/399
14
KEEP HANDS CLEAR
12
13
Inches
Serial Number
Model
Cap. (Lbs.)
Truck Wt.
Less Batt. (Lbs.)
Battery Wt., Max. (Lbs.)
Battery Wt., Min. (Lbs.)
DC Voltage
Use UL Class
Battery Type
Max. Amp. Hours
Type
Mast Serial Number
Attachment
Max.
Back Tilt
C
B
Truck as rated at factory conforms to requirements of Part III of ASME B561-1993
306040-000
Muscatine, IA 52761
10
5
11
118
Return
2000-08-04
F-code
Section
PS
S0.6
Version no
T-code
000
Item
No.
Description
Item
No.
C-code
0851
Decals
365/396/397/398/399
Description
Decal, BT
Decal, Warning
Decal, hydraulic function
Plate, Data
Decal, sideshifter
10
Plate, UL
Decal, left BT logo
11
Box, Manual
Decal, right BT logo
12
Decal, Warning
Decal, RRX35, RRX/45, RDX30,

RSX40, RSX50
13
Decal, special oil (Cold Storage)
Decal, Warning
14
Decal, reverse steering *
* On trucks with reverse steering (see parameter 11 page 402).
Return
2000-08-04
119
F-code
Section
C-code
PS
Decals
S0.6
0851
Version no
T-code
000
365/396/397/398/399
120
Return
2000-08-04
F-code
Section
PS
S1.0
1730
Steering Motor
Version no
000
C-code
T-code
395/396/397/398/399
Steering Motor
The steering motor is located in the lower right section of the
motor compartment, to the right of the drive motor and
beneath the control valve.
1. Removal
WARNING Block all wheels to prevent truck from
rolling.
1. Park truck on a level surface. Block truck to
prevent accidental movement.
3. Remove motor compartment door (see page 101)
to access steering motor.
4. Disconnect steering motor from main electrical
harness.
5. Use a 0.24 inch (6 mm) Allen wrench to remove
four bolts securing steering motor to truck frame.
The rubber gasket should remain on each bolt.
Spacer
6. Gently lift the motor upward. Rock it a little to

unseat it if necessary.
O rings
7. Be sure two O rings stay on the bottom of steering

motor. The black rubber spacer under steering
motor is to reduce noise. Be sure to keep spacer
with steering motor for reassembly.
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.
Return
2000-08-04
121
F-code
Section
C-code
PS
S1.0
Steering Motor
1730
Version no
T-code
000
395/396/397/398/399
3. Apply black graphite grease to gear to help prevent

excessive wear.
4. Place electrical connectors toward lift motor. Insert
steering motor into truck frame.
5. Apply thread locking compound to mounting bolt
threads. Install four bolts with rubber grommets.
Tighten using a 0.24 inch (6 mm) Allen wrench.
6. Reconnect electrical harness connections.
7. Install motor compartment door.
8. Remove blocks from truck. Connect battery
connector to the truck.
9. Test truck for proper operation.
3. Steering Motor Gear Replacement

3.1. Removal
1. Remove steering motor.
2. Loosen bolt attaching steering gear to steering
motor shaft.
3. Remove steering gear from motor shaft.
3.2. Installation
1. Apply Loctite 243 to steer motor shaft. Slide
steering gear onto steering motor shaft.
2. Install mounting bolt in steering gear.
3. Torque gear mounting bolt to 88 in-lb (10 Nm).
4. Return steering motor to lift truck following the
installation procedure on page 121.
122
Return
2000-08-04
F-code
Section
PS
S1.1
Version no
001
C-code
1740
Fan Motor
T-code
395/396/397/398/399
Fan Motor
The main fan motor in the truck cools the upper electrical
compartment. An optional operator cooling fan is also
available.
1. Upper Electrical Compartment Fan

The upper electrical compartment fan is located in the front of
the truck section. This fan vents heat out of the upper
electrical compartment toward the mast. It is standard
equipment on all reach trucks.
NOTE!
On the freezer storage trucks, the fan will

be covered and unplugged.
1.1. Removal
2. Remove dash (see page 100).

3. Disconnect electrical connections from the fan to
the main wiring harness.
3
4. Remove four nuts (3) from the upper electrical

compartment side.
5. Remove four screws (2) from the mast side of the
truck compartment.
6. Remove the fan assembly from truck.
1.2. Installation
1. Install fan assembly by inserting four screws (2)
through the truck frame from the mast side.
2. Install four nuts (3) from the electrical compartment
side.
3. Connect electrical connections to the main wiring
harness.
4. Install dash.
Return
2001-03-15
123
F-code
Section
C-code
PS
Fan Motor
S1.1
1740
Version no
T-code
001
395/396/397/398/399
5. Reconnect battery at the battery and return truck to

service.
2. Operator Fan
The operator fan is located in the compartment with the
overhead light on the left side of the overhead guard. The
operator fan/overhead light is an option, therefore, it may not
be on your particular truck.
124
Return
2001-03-15
F-code
Section
C-code
PS
S1.2
1750
Motor Maintenance Schedule/Troubleshooting
Version no
001
T-code
395/396/397/398/399
Motor Maintenance
Schedule/Troubleshooting
1. General Information
A routine maintenance schedule with recorded findings is the
best way to reduce costly shut-downs and repair of
equipment during operating hours. The goal of any
maintenance program, long-life and trouble-free operations is
related to the time spent making inspections and correcting
minor problems as they occur. The drive motor and pump
motor are both equipped with brush sensors. When brushes
are in need of replacement, a warning code C16 for the pump
motor and C-17 for the drive motor will show on the dash
display.
2. Operating Conditions
Operating environment of reach truck motors varies
widely: The following recommendations should be applied as
actual conditions dictate.
Normal Service:
Basically an eight hour day of indoor

material handling.
Severe Service:
Extended operating hours, or constant

usage.
Extreme Service:
yChemical Processing
yFreezer operation
yProcessing plants (poultry, meat)
Return
2000-08-04
125
F-code
Section
C-code
PS
S1.2
1750
Version no
T-code
001
395/396/397/398/399
3. Troubleshooting
When a motor has trouble in operation, a reasonable decision
has to be made as to the proper corrective course of action. A
review of the many troubleshooting guides has been
conducted and have been reduced to a few which seem to be
the most effective Symptom/Cause relationships and are
listed on tables 1 and 2.
126
Return
Table 1
Unsatisfactory brush performance.
Table 2
Primary sources of unsatisfactory brush

performance.
2000-08-04
F-code
Section
C-code
PS
S1.2
1750
Version no
001
T-code
395/396/397/398/399
Table 1. Unsatisfactory Brush Performance

Indications
Immediate Causes
Primary Faults
Sparking
Commutator surface condition

Overcommutation
Undercommutation
Too rapid reversal of current
Faulty machine adjustment
Mechanical fault in machine
Electrical fault in machine
Bad load condition
Poor equalized parallel operation
Vibration
Chattering of brushes
Wrong brush grade
Fluctuating contact drop
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
Etched or burned bands on

brush face
Overcommutation
Undercommutation
Too rapid reversal of current
7-12-31-33
7-12-30-32
7-12-30-32
Pitting of Brush Face
Glowing
Embedded copper
See Glowing at brush face

See Copper in brush face
Rapid Brush Wear
See specific surface fault in

evidence. Also see 50.
See Sparking
Severe sparking
Imperfect contact with
commutator
Wrong brush grade
11-14-15-16-51-52
54-58
Glowing at Brush Face
Embedded copper
Severe load condition
Bad service condition
Wrong brush grade
See Copper in brush face

7-12
38-39-41-42
46-47
57-61-62
Copper in Brush Face

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

Looseness in machine
Faulty machine adjust
High friction
Wrong brush grade
See specific surface in evidence

15-16-17
10-11
6-43-45-49-52-58-59
55-58-59
Return
2000-08-04
127
F-code
Section
C-code
PS
S1.2
1750
Version no
T-code
001
395/396/397/398/399

Indications
Immediate Causes
Primary Faults
Brush Chipping or Breakage

evidence
15-16-17
52
See Chattering or Noisy Brushes
14
Looseness in machine
Vibration
Chattering
Sluggish brush movement
Rough or Uneven Surface
1-2-3-4-17
Dull or Dirty Surface
5-44-60
Eccentric Surface
1-19-22-52
High Commutator Bar
Sparking
17
Low Commutator Bar

Streaking or Threading of
Surface
Sparking
Copper or foreign material in
brush face
Glowing
2-25
2-3-43-44-45-46-47-48-49-59-61
Bar Etching or Burning
Sparking
Flashover
2-3-7-12-30-31-32-33
5-11-14-35-38-39-41-53
Bar Marking at Pole

Pitch Spacing
Sparking
25-37
Bar Marking at Slot

Pitch Spacing
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
See Heating at Commutator

44-46
60
Raw Copper Surface
Embedded copper
Wrong brush grade
See Copper in Brush Face

43-45-47-49
59-61
Rapid Commutator
Wear with Blackened Surface
Burning
Severe sparking
2-3-11-14
See Sparking
Rapid Commutator
Wear with Bright Surface
Copper Dragging
Foreign material in brush face

Wrong brush grade
Brush vibration
43-45-47-49
61
39-52-58-59
128
Return
See Glowing at Brush Face
2000-08-04
F-code
Section
C-code
PS
S1.2
1750
Version no
001
T-code
395/396/397/398/399

Indications
Immediate Causes
Primary Faults
Heating in Windings

Unbalanced magnetic field
Unbalanced armature currents
Poorly equalized parallel
operation, lack of ventilation
38-41-42-53
18-19-20-21-27-28-29
8-19-22-25-27-28-29-37

Severe sparking
High friction
Poor commutator surface
Depreciation
High contact resistance
38-41-42
7-8-9-12-20-33-45-57
10-11-36-43-45-49-58-59
evidence
6-24
56

Severe sparking
Raw streaks on commutator
surface
Embedded copper
Wrong brush grade
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
Return
2000-08-04
7-13-23-24
129
F-code
Section
C-code
PS
S1.2
1750
Version no
T-code
001
395/396/397/398/399
Table 2. Primary Sources of Unsatisfactory Brush Performance

Preparation and Care of Machine
1.
Poor preparation of commutator surface
2.
High mica
3.
Feather-edge mica
4.
Bar edges not chamfered after undercutting
5.
Need for periodic cleaning
6.
Clogged ventilating ducts

Machine Adjustment
7.
Brushes in wrong position
8.
Unequal brush spacing
9.
Poor alignment of brush holders
10.
Incorrect brush angle
11.
Incorrect spring tension
12.
Interpoles improperly adjusted
13.
Series field improperly adjusted

Mechanical Fault in Machine
130
Return
14.
Brushes tight in holders
15.
Brushes too loose in holders
16.
Brush holders loose at mounting
17.
Commutator loose
18.
Loose pole pieces or pole-face shoes
19.
Loose or worn bearings
20.
Unequal air gaps
21.
Unequal pole spacing
22.
Dynamic unbalance
23.
Variable angular velocity

2000-08-04
F-code
Section
C-code
PS
S1.2
1750
Version no
001
T-code
395/396/397/398/399

24.
Commutator too small

Electrical Fault in Machine
25.
Open or high resistance connection at commutator
26.
Poor connection at shunt terminal
27.
Short circuit in field or armature winding
28.
Ground in field or armature winding
29.
Reversed polarity on main pole or interpole

Machine Design
30.
Commutating zone too narrow
31.
Commutating zone too wide
32.
Brushes too thin
33.
Brushes too thick
34.
Magnetic saturation of interpoles
35.
High bar-to-bar voltage
36.
High ratio of brush contact to commutator surface area
37.
Insufficient cross connection of armature coils

Load or Service Condition
Return
38.
Overload
39.
Rapid change of load
40.
Reversing operation of non-interpole machine
41.
Plugging
42.
Dynamic braking
43.
Low average current density in brushes
44.
Contaminated atmosphere
45.
Contact poisons
46.
Oil on commutator or oil mist in air
47.
Abrasive dust in air

2000-08-04
131
F-code
Section
C-code
PS
S1.2
1750
Version no
T-code
001
395/396/397/398/399

48.
Humidity too high
49.
Humidity too low
50.
Silicone contamination
Disturbing External Condition
132
Return
51.
Loose or unstable foundation
52.
External source of vibration
53.
External short circuit or very heavy load surge
54.
Commutation factor too high
55.
Commutation factor too low
56.
Contact drop of brushes too high
57.
Contact drop of brushes too low
58.
Coefficient of friction too high
59.
Lack of film forming properties in brush
60.
Lack of polishing action in brush
61.
Brushes too abrasive
62.
Lack of carrying capacity
2000-08-04
F-code
Section
PS
S1.3
Version no
001
C-code
1750
Motor Repair
T-code
395/398
Motor Repair
1. Disassembly
1. Remove motor from truck (for pump motor see
page 141 and for drive motor see page 149).
2. Remove band from end head commutator of
motor.
3. Use a brush hook to reach into the motor and lift
brush springs. Pull brushes out of brush holders.
Either position brushes outside the motor or
remove brush retaining screws and remove
brushes from motor.
4. Scribe or center punch locating marks in the end
head and frame. Although locating marks are not
always necessary, they can save time when the
motor does not have locating pins.
5. Remove commutator end head retaining screws.
Most motors have a slip fit bearing at the
commutator end allowing the end head to be
removed with very little trouble. On motors that
have a shaft extension on both ends of the
armature, the attachment on the commutator end
of the shaft must be removed before the end head
can be separated from the motor.
6. Remove drive end head retaining screws, if
necessary. Some smaller pump motors retain the
drive end head with the motor through bolts.
Separate the armature and head assembly as an
assembly from the frame and field coil assembly.
CAUTION Use caution and DO NOT damage the
armature during removal. If the shaft,
coupling or spline is damaged when
removing the end head, the armature or the
drive spline usually has to be replaced.
7. Separate the armature from the drive end head by
pressing the armature out of the drive end bearing.
On some of the larger motors, the end head and
bearing will have to be removed with a puller.
Return
2002-01-09
133
F-code
Section
C-code
PS
S1.3
Motor Repair
1750
Version no
T-code
001
395/398
Puller
When a puller is used, protect the end of the

armature shaft with a nut or a thick flat washer.
8. Separate bearing from the end head. On larger
motors, the bearing is retained with a snap ring.
Remove the snap ring. Then press the bearing out
of the end head.
Propane torch
9. The ventilation fan (if equipped) material is of cast

aluminum. Once fans have been pressed onto the
armature, they must be heated to be removed
without damage.
10. Install a puller and apply slight pressure against the
fan (if equipped). Use a small propane torch to
heat the area of the fan around the shaft. When the
fan becomes loose on the shaft, as evidenced by
the puller becoming loose, remove as quickly as
possible.
Use Loctite on
this area of shaft
11. When the fan (if equipped) is reassembled on the

shaft, make sure it is a tight fit. Use Loctite
Retaining Compound 40 or equivalent on the
inside of the fan hub when reassembling fan.
12. After the motor has been separated into all its
major subassemblies, the components should be
cleaned and inspected for wear or damage.
134
Return
2002-01-09
F-code
Section
PS
S1.3
Version no
001
C-code
1750
Motor Repair
T-code
395/398
2. Motor Inspection
A good planned maintenance program will save many hours
of future down time on a piece of equipment. Maintenance
schedules should consist of periodic routine inspections of
motors, battery and wiring circuitry.
2.1. External Motor

Routine motor inspection should include the following:
1. Check for clean, tight terminal studs and mounting
bolts.
2. Cooling holes must be kept free of any debris or
restriction, which would prevent proper airflow and
hamper cooling.
3. Internal and external spline drives must be
periodically lubricated in accordance with the
original manufacturers recommendation.
4. Check for any sign of oil leaks.
5. Make visual inspection of brush and commutation
area. Headband, if equipped, should be removed
for clear, proper viewing.
2.2. Brush and Commutator

The most important part of any planned maintenance
schedule is the brush and commutator inspection. By
recognizing undesirable commutator and/or brush conditions,
corrective action can be taken before a major component is
damaged beyond serviceability.
Brush and commutator inspection can usually be
accomplished by removing the cover band (if equipped) from
the commutator end of the motor. The brushes and
commutator should be inspected for even wear and good
commutation. Good commutation will be indicated by a dark
brownish, polished commutator and an evenly polished brush
wearing surface. If the commutator appears rough, pitted,
scored or has signs of burning or heavy arcing between the
commutator bars, the motor should be removed for servicing.
Return
2002-01-09
135
F-code
Section
C-code
PS
S1.3
Motor Repair
1750
Version no
T-code
001
395/398
For a detailed inspection of the commutator, the motor should

be disassembled. With the armature supported on both
bearing journals, check run-out of commutator with a dial
gauge. Total indicated run-out should not exceed 0.003 inch
(0.0762 mm) or 0.001 inch (0.0254 mm) bar to bar. If the
readings fall outside this limit, commutator must be turned
and reundercut. After the commutator has been undercut, the
armature should be placed in a lathe and the commutator
lightly sanded with No. 00 sandpaper. This will remove any
burrs left from the undercutting operation. Clean commutator
with dry compressed air and recheck commutator run-out.
mica
segments
GOOD UNDERCUT
0.04 inch deep
mica
segments mica
segments
BAD UNDERCUT
Brushes should be inspected for uneven wear and signs of
overheating such as discolored brush shunts and brush
springs. See Table 1. Unsatisfactory Brush Performance on
page 127. Check the brush holders for physical damage and
make sure they are not loose on the end head or the brush
holder plate. Check the brush springs for correct alignment on
the brush. A brush spring that does not apply equal pressure
on the center of the brush will cause the brush to wear
unevenly. Check for correct clearance and freedom of brush
movement in the holder. If any of the brushes are worn to the
point that replacement is necessary, the complete brush set
should be replaced. Do not replace just one or two brushes.
When brush service is required on the motor, lift brush spring
over holding bracket before removing brush.
136
Return
2002-01-09
F-code
Section
PS
S1.3
Version no
001
C-code
1750
Motor Repair
T-code
395/398
Put Spring In This

Position For Brush Removal
Do not substitute brushes. The brushes are matched to the

motor type and application to provide the best service.
Substituting brushes of the wrong grade can cause
commutator damage or excessive brush wear.
and personal protective equipment worn.
NOTE!
Blow stone dust out with dry compressed

air.
After the installation of new brushes, the motor should be

operated at 12 Volts, no load and brushes seated to the
commutator with a dressing stone. Remove stone dust.
Minimum commutator diameter before armature needs to be
replaced is specified on original manufacturers test
specification.
Return
2002-01-09
137
F-code
Section
C-code
PS
S1.3
Motor Repair
1750
Version no
T-code
001
395/398
2.3. Bearings
After the motor has been disassembled, it is recommended
that new bearings are installed. Bearings may have been
damaged during removal. Although the bearings may appear
and feel good, the bearing races could be brinelled and fail
within a relatively short period of service.
2.4. Armature Electrical Check

Before the armature is reassembled into the motor, the
following test should be performed.
1. Check armature for grounded circuits by placing
one test lead of a Dielectric Breakdown Tester on
the commutator and the other lead at the armature
shaft. If the test light comes on, the armature is
grounded.
2. For short circuit connection, one armature is tested
on a growler using a hacksaw plate to locate any
shorted windings.
3. All motor armatures are wave wound and can be
short circuit tested. For helpful maintenance guides
for proper servicing of motors, see page 71.
138
Return
2002-01-09
F-code
Section
PS
S1.3
Version no
001
C-code
1750
Motor Repair
T-code
395/398
2.5. Frame & Field Service

Recommendation
Motors disassembled for servicing should also include a
complete inspection of the frame and field assembly. It is not
uncommon that the frame and field of a motor becomes
exceptionally dirty after many hours of operation. This may
result in a grounding condition due to dirt, grease and other
foreign materials. In this case it is recommended to clean the
complete frame and field in a cleaning solution. After
cleaning, the frame and field must be oven-cured for one hour
at 300F (148C). Add a coat of WS-200 PT George Varnish
for proper insulation protection. This is a Class H water
soluble varnish. A similar air-dry varnish may also be used
providing it has a Class H thermal specification.
If new field coils are installed the cross-over connection
should be brazed for a good sound connection and to prevent
breakage due to vibration. It is not recommended that
connections be soldered. Motor terminals should be torqued
to 140 in-lbs (15.82 Nm). Pole piece screws should be
torqued to 250-300 in-lbs (28-33 Nm).
NOTE!
Do not use a torch for the crossover

connection. The insulation of the field coils
is easily damaged by this method.
A high capacity resistance power unit with a plier-type

handpiece may be used for brazing field connections.
Return
2002-01-09
139
F-code
Section
C-code
PS
S1.3
Motor Repair
1750
Version no
T-code
001
395/398
2.6. Assembly/Testing
Refer to the following drawing whenever a bearing is installed
into an end head or shaft.
Press Ram
Pipe Same Size

As Inner Race
Bearings
Inner Race
End Head
Armature
Shaft
Snap Ring
1. Press against the race that is absorbing the

pressure.
2. Use a new bearing when servicing a motor.
3. After assembly, the motor should be tested per the
original motor manufacturer.
WARNING Do not run motor NO LOAD at full motor
voltage.
4. In the event no dynamometer is available for
testing, the motor should be tested against a NO
LOAD POINT outlined on the specification.
5. Reinstall motor on truck (for pump motor see
page 141 and for drive motor see page 149).
140
Return
2002-01-09
F-code
Section
PS
S1.4
Version no
C-code
1750
Pump Motor
T-code
001
395/398
Pump Motor
1. Mounting Points
1
2
3
4
5
6
Item
No.
1
2
Description
Lift Pump Assembly
Screw
Item
No.
Description
Item
No.
3
4
Bracket, pump mounting

Screw
5
6
Description
Washer, flat
Shock, mount
The pump motor and lift pump should be removed and

installed as a single unit.
Return
2002-01-09
141
F-code
Section
C-code
PS
S1.4
Pump Motor
1750
Version no
T-code
001
395/398
1.1. Removal
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
2. Lower carriage completely.

3. Drain hydraulic fluid (see page 448).
5. Remove motor compartment door, and operator
compartment left side panel (see page 102).
Suction (Supply)
Hose To Pump
Lift
Pump
6. Disconnect hose from the pump to the control

valve at the control valve. Plug both the port and
hose to prevent contamination of the hydraulic
system.
7. Remove control valve from the bracket and lay
over the reservoir.
8. Remove pump motor electrical power cables. Use
a M10 wrench to remove the nuts on the motor
terminals. Note the proper location of each wire on
the motor. The terminal number should be marked
on the power cables. If the marking is worn or
missing, remark the cable.
9. Move all wires and cables up out of the way.
10. Remove four bolts (4) attaching bracket to the truck
frame using a 9/16 inch (13 mm) socket. If drive
motor has not been removed, a 24 inch (609 mm)
extension will be required to reach the back
mounting bolt.
11. Loosen screws in hose clamp for hose connecting
the pump to the reservoir. Slide hose clamp back.
Remove hydraulic line from pump to the reservoir.
Drain the line as required into a small container.
Plug port and hose to prevent contamination of the
hydraulic system.
142
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2002-01-09
F-code
Section
PS
S1.4
Version no
001
C-code
1750
Pump Motor
T-code
395/398
12. Disconnect brush wear indicator terminals at the

back of the motor.
13. Remove motor and pump assembly from truck. If a
hoist is available, attach a hoist to the bracket and
lift the assembly out. If a hoist is not available,
carefully lift the assembly out while standing in the
operator compartment. Use proper lifting practices
to avoid back injuries.
1.2. Installation
1. Place lift pump and motor assembly with bracket
onto truck frame. Make sure four rubber grommet
shock mounts (6) are in the bracket mounting
holes.
2. Align suction tube flange with reservoir hose. Slide
reservoir hose onto flange as the pump and motor
assembly is installed into the truck. Install hose
clamp at the flange. Be sure clamp is tightened to
prevent leakage. If a leak is found later, the drive
motor will have to be removed to access the
clamps.
3. Install mounting bolts (4) to secure the motor/pump
into position. Insert bolts through the large washer
(5), then through the bracket mounting plate into
truck frame. Torque bolts to 14-18 ft-lb (19-24 Nm)
using a 9/16 inch (13 mm) socket and extension if
needed.
4. Install control valve on the bracket.
5. Install hydraulic line from the pump to the control
valve.
6. Install pump motor electrical power cables to the
motor, following the markings on the cables.
Tighten terminal nuts using a M10 wrench. Torque
motor cable securing nuts to 100-120 in-lbs (11.213.6 Nm). Use a second wrench on the stud
terminal securing nut to avoid twisting the stud.
7. Attach brush wear indicator connections using
needle nosed pliers. Connectors are male and
female with one large and one small.
Return
2002-01-09
143
F-code
Section
C-code
PS
S1.4
Pump Motor
1750
Version no
T-code
001
395/398
8. Fill hydraulic reservoir with hydraulic fluid.

9. Reinstall left side panel and motor compartment
door.
10. Bleed hydraulic system.
11. Remove blocks from truck.
switch ON.
13. Test hydraulic operation of truck.
144
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2002-01-09
F-code
Section
PS
S1.4
Version no
C-code
1750
Pump Motor
T-code
001
395/398
2. Repair
See Motor Repair on page 133.
RRX35/RSX40
12 11
7
8
10
9
14
13
ROTATION
C.C.W.C.E.
Counterclockwise
when viewed from
commutator end.
Return
2002-01-09
145
F-code
Section
C-code
PS
S1.4
Pump Motor
1750
Version no
T-code
001
395/398
Item
No.
146
Description
Item
No.
Description
Retaining ring
Set, spring
Bearing
Plate assembly, brush
Head assembly, drive
10
Lead assembly
Fan
11
Bearing
Armature assembly
12
Spring Washer
Field coil assembly
13
Head assembly
Set, brush
14
Headband assembly
Return
2002-01-09
F-code
Section
PS
S1.4
Version no
C-code
1750
Pump Motor
T-code
001
395/398
RRX45/RDX30/RSX50
15
12
14
11
10
13
Item
No.
ROTATION
C.C.W.C.E.
Counterclockwise
when viewed from
commutator end.
Return
Description
Item
No.
Description
Retaining ring
Plate assembly, brush
Bearing
10
Kit, lead assembly
End head, drive
11
Bearing
Fan
12
Washer, wave
Armature & fan assembly
13
End head, commutator
Kit, field coil
14
Band
Brush
15
Indicator kit, brush wear
Spring, brush
2002-01-09
147
F-code
Section
C-code
PS
S1.4
Pump Motor
1750
Version no
T-code
001
395/398
148
Return
2002-01-09
F-code
Section
PS
S1.4
Version no
001
C-code
1760
Drive Motor
T-code
395/396/397/398/399
Drive Motor
1. Mounting Points
23
22
21
20
19
18
17
16
14
15
Item
No.
14
15
16
17
18
Return
Description
Item
No.
Ring, retainer
Ring, retainer
Bearing
Ring, seal
Sleeve
19
20
21
22
23
2002-01-09
Description
O-ring
Screw, cap
Drive Motor Assembly
Brake Assembly
Sensor Assembly
149
F-code
Section
C-code
PS
S1.4
Drive Motor
1760
Version no
T-code
001
395/396/397/398/399
1.1. Removal
WARNING There is no brake on the truck when drive
motor is removed from transmission
assembly. Block all wheels to prevent truck
from rolling.
1. Park the truck on a level surface and make sure all
wheels are blocked to prevent accidental
movement.
3. Remove motor compartment door, left side panel,
and side panel to allow access to drive motor.
4. Remove four power cables. An 11/16 inch (17 mm)
wrench is required to loosen terminal nuts for the
field and armature connections. Note cable
numbers and terminal locations for use in
reassembly.
5. Disconnect the drive motor brush sensor, two
speed/directional sensors, temperature sensor,
and brake assembly connectors.
6. Using a 9/16 inch (13 mm) socket, remove the six
drive motor mounting bolts (20). A 24 inch (609
mm) extension is helpful to access the two bolts
behind the drive motor.
7. Attach a lifting tool to lift the drive motor. (Using two
eye bolts screwed into the top of the brake
assembly (two empty holes used for the brake
manual release screws), attach a piece of chain
(about 20 inches (508 mm) long) with a S hook at
each end to each of the eye bolts.)
8. Attach a hoist to the lifting tool attached to the top
of the brake assembly.
9. Gently lift the drive motor out of the transmission.
(It may be necessary to rock the drive motor gently
to loosen it from the transmission.)
10. Cap top of the transmission
contamination of transmission fluid.
150
Return
to
prevent
2002-01-09
F-code
Section
PS
S1.4
Version no
001
C-code
1760
Drive Motor
T-code
395/396/397/398/399
1.2. Installation
1. Remove cap from the top of transmission.
2. Lower drive motor straight down onto transmission.
The drive motor terminals and brush motor sensor
should be facing out.
3. Remove chain, S hooks, and eye bolts from brake
assembly.
NOTE!
A magnet may be handy to help start the

back bolt or to retrieve a bolt if dropped
behind the drive motor.
4. Using a 9/16 inch (13 mm) socket torque drive

motor mounting bolts (20) to 20-25 ft-lb (30-35
Nm).
5. Be sure to draw motor down evenly to allow the
gear on the motor shaft to properly mesh with the
transmission.
6. Attach brake electrical connection (R3).
7. Attach brush wear indicator connections.
8. Install drive motor power cables to terminal posts.
9.
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.
10. Reconnect brush wear sensor, temperature

sensor, and two speed/directional sensor
connections.
11. Reinstall side panel, left side panel and motor
compartment door.
12. Connect battery connector to the truck. Remove
blocks from truck.
Return
2002-01-09
151
F-code
Section
C-code
PS
S1.4
Drive Motor
1760
Version no
T-code
001
395/396/397/398/399
2. Repair
See Motor Repair on page 133.
1
3
2
4
13
7
8
9
14
6
5
10
15
16
11
12
25
16
26
27
17
28
29
30
152
Return
18
2002-01-09
F-code
Section
PS
S1.4
Version no
T-code
001
Item No.
Item No.
Description
395/396/397/398/399
Item No.
Description
Screw
Set, brush
17
End head,
drive
Band, head
10
Set, spring
18
Screw
Fan unit
11
Bearing
25
Ring, seal
Guard, fan
12
Retainer
26
O ring
Field coil
13
Retainer and seal
27
Sleeve
Screw, pole shoe
14
Stud, terminal
28
Bearing
End head,
commutator
15
Armature
29
Ring, retainer
Plate, brush
16
Key, woodruff
30
Ring, retainer
Return
Description
C-code
1760
Drive Motor
2002-01-09
153
F-code
Section
C-code
PS
S1.4
Drive Motor
1760
Version no
T-code
001
395/396/397/398/399
154
Return
2002-01-09
F-code
Section
PS
S2.0
2550
Transmission
Version no
000
C-code
T-code
395/396/397/398/399
Transmission
1. Mounting Points
13
12
11
8
10
9
Item
No.
7
8
9
10
Return
Description
Transmission assembly
Drive wheel assembly
Screw, set
Gasket, EE
2002-01-09
Item
No.
Description
11
12
13
Plate, EE
Screw, EE
Screw, cap
155
F-code
Section
C-code
PS
S2.0
Transmission
2550
Version no
T-code
000
395/396/397/398/399
1.1. Fluid Changing Procedure

1. Remove drain plug (28, see page 159) from drive
unit and drain all the fluid.
2. Reinstall drain plug.
NOTE!
Level plug may be accessed through

3. Remove fill level plug (35, see page 159).

4. Refill using the proper grade fluid. The capacity of
the drive unit is 1 gallon (3.785 liters).
CAUTION Incorrect selection of fluid, for a particular
application, may cause damage. No
warranty will be considered on component
damage resulting from incorrect fluid
selection.
1.2. Removal
1. Park truck on a level surface.
CAUTION Any misalignment of tire and hub while tire
is being pressed onto hub can cause
damage to hub. For this reason, chamfers
have been provided on the outside edge of
hub and on the end of the inside diameter
of tires metal insert. The chamfers help to
center hub and tire during the pressing
operation and reduce the possibility of
misalignment. To prevent damage, hub
must be installed on circular ram with its
chamfered side up.
3. Jack the rear of truck so the drive and caster
wheels are approximately 1 inch (25.4 mm) off the
floor. Block truck in this position.
4. Drain transmission fluid.
156
Return
2002-01-09
F-code
Section
PS
S2.0
2550
Transmission
Version no
000
C-code
T-code
395/396/397/398/399
5. Remove drive tire (see page 185).

6. Place drive tire face down on the floor. Slide it
under the transmission to act as a cradle to keep
the transmission upright when it is unbolted from
truck frame. There should be an 1/2 inch (25.4
mm) gap between the tire and the transmission
before the transmission is unbolted.
7. Remove drive motor (see page 149).
8. Using an 3/4 inch (19 mm) socket remove six bolts
(13) that secure the transmission to truck frame.
9. Tap transmission with a rubber mallet to break it
loose from the frame. The transmission will drop
down, into the recess in the back of the drive tire.
10. Using a hoist, lift the truck high enough to slide the
transmission, in the tire cradle, out from
underneath the truck.
1.3. Installation
1. Place transmission in drive tire and slide
transmission, in the tire cradle, beneath the truck.
Using a hoist, lower the truck frame onto the
transmission. Be careful not to pinch hands
between the transmission and the truck frame.
2. Line grease fittings up with the indentations in the
frame.
3. The half-moon shaped piece mounted to the top
surface of the transmission should be toward the
left so that the sensors will read the wheel position
correctly.
4. Guide the transmission, with one hand through the
hole in the truck frame, while lowering the frame
onto the transmission.
NOTE!
Return
Use an 3/4 inch (19 mm) wrench to help get

the bolts started straight. The transmission
will draw tight to the truck frame mounting
surface as the bolts are tightened.
2002-01-09
157
F-code
Section
C-code
PS
S2.0
Transmission
2550
Version no
T-code
000
395/396/397/398/399
5. Transmission mounting bolts (13) should be

torqued to 50-59 ft-lbs (70-80 Nm).
6. Add transmission fluid (see page 156).
7. Install drive motor (see page 149).
8. Install drive wheel. Lubricate wheel nut. Secure
drive wheel with wheel nut. Torque wheel nut to 95
ft-lb (129 Nm).
9. Lower truck and remove blocks.
158
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2002-01-09
F-code
Section
PS
S2.0
2550
Transmission
Version no
C-code
T-code
000
395/396/397/398/399
2. Repair
Before disassembly of parts, thoroughly clean the outside of
the assembly with a cleaning solution or other non-corrosive
cleaning fluid and air dry parts. Refer to Parts Book for any
up-dates of transmission.
31
30
For steering bearing data

see page 221.
8
10
29
42
39
11
12
38
40
35
41
32
24
13
20
14
19
17
33
36
16
15
37
22
21
26
27
18
23
25
Return
34
2002-01-09
28
159
F-code
Section
C-code
PS
S2.0
Transmission
2550
Version no
T-code
000
395/396/397/398/399
160
Return
Item
No.
Description
Item
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Gear, ring
Kit, spare parts (Bearing)
Kit, spare parts (Sealing)
Kit, spare parts (Helical gear)
Kit, spare parts (Wheel shaft)
Kit, spare parts (Bevel gear)
Gear, wheel
Gear, wheel
Nut
Bearing
Kit, shim
Kit, shim
Bearing
O-ring
Screw
Axle
Washer, copper
Bearing
Kit, shim
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
Screw
Bearing
Washer
Spacer
Ring, sealing
Ring, locking
Plug, drain
Nut (not part of item #1)
Washer, locking (not part of item #1)
Washer (not part of item #1)
Screw
Gear, bevel
Screw
Plug, fill
Keeper
Cover
Case
Bearing
Screw
O-ring
21
Cover ring
42
Breather
Description
2002-01-09
F-code
Section
PS
S2.0
2550
Transmission
Version no
C-code
T-code
000
395/396/397/398/399
3. Disassemble
1. Remove transmission
page 155).
from
the
truck
(see
2. When disassembling the transmission also use

page 174 of this manual for reference.
Remove steer gear and

bearing from the top of the
transmission case.
Remove
eight
screws
retaining the cover and
remove cover.
Remove three bolts and

retainer plate from end of
axle shaft.
Drive out the axle shaft.
Remove the bevel gear and

bearing
from
the
transmission case.
Return
2002-01-09
161
F-code
Section
C-code
PS
S2.0
Transmission
2550
Version no
T-code
000
395/396/397/398/399
Remove the axle shaft,

seal, outer bearing cone,
spacer, and washer from
the transmission case.
Remove nut from the pinion

shaft.
Remove the input gear

from the pinion shaft.
Drive out pinion shaft.
Remove outer bearing cone

from pinion shaft.
Remove pinion shaft and

inner bearing from the
transmission case.
162
Return
2002-01-09
F-code
Section
PS
S2.0
2550
Transmission
Version no
000
C-code
T-code
395/396/397/398/399
Remove inner pinion shaft

bearing race from the
transmission case.
Remove inner pinion shaft

bearing race shims from the
transmission case. Be sure to
keep track of thickness of
shims removed. This is for
ease of assemble.
Remove outer pinion shaft

transmission case.
Remove outer pinion shaft

bearing race shims from the
transmission case. Be sure to
keep track of thickness of
shims removed. This is for
ease of assemble.
Remove inner axle shaft

transmission case.
Remove inner axle shaft bearing

race shims from the transmission
case. Be sure to keep track of
thickness of shims removed. This
is for ease of assemble.
Return
2002-01-09
163
F-code
Section
C-code
PS
S2.0
Transmission
2550
Version no
T-code
000
395/396/397/398/399
Remove snap ring from

transmission case.
Remove outer axle shaft

transmission case.
Remove
washer,
spacer, outer bearing
cone and seal from the
axle shaft.
164
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2002-01-09
F-code
Section
PS
S2.0
2550
Transmission
Version no
000
C-code
T-code
395/396/397/398/399
4. Assembly
1. Position the transmission case with the axle output
side up.
Install outer axle bearing into transmission caster
Install locking ring into groove outside of bearing race.

The seal stops against locking ring.
DO NOT INSTALL SEAL AT THIS TIME.
2. Position transmission case with bevel gear side up.
Install shims in inner axle bearing cone bore of the

transmission case. Install the same thickness of
shims as removed during disassembly.
Install inner axle bearing race in the transmission case.
Return
2002-01-09
165
F-code
Section
C-code
PS
S2.0
Transmission
2550
Version no
T-code
000
395/396/397/398/399
Tool for adjusting bevel gear bearing preload and

bevel gear to pinion gear backlash.
Install outer axle bearing cone, spacer and

washer onto the tool.
Install tool with bearing cone, spacer and

washer into transmission case.
Install bevel gear using tool shown above.

There are NO shims behind this bearing.
Install washer and nut on

the tool.
Torque nut to 81 ft-lb (109
Nm).
166
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2002-01-09
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 in-lb

(1.01-1.58 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 measurement.
Install shims in top pinion bearing bore.

Use same thickness of shims as was removed during
disassemble.
Install top pinion bearing race.
Install shims in bottom pinion bearing bore.

Use same thickness of shims as was removed during
disassemble.
Return
2002-01-09
167
F-code
Section
C-code
PS
S2.0
Transmission
2550
Version no
T-code
000
395/396/397/398/399
Install bottom pinion bearing race. Use same thickness

of shims as was removed during disassemble.
Install bottom pinion cone on the pinion shaft.
Install the pinion shaft with

bearing
cone
in
the
transmission case from the
bottom.
Install spacer on the pinion shaft from top side of

transmission.
Install top pinion bearing cone onto the pinion shaft.
168
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2002-01-09
F-code
Section
PS
S2.0
2550
Transmission
Version no
000
C-code
T-code
395/396/397/398/399
Install gear on the pinion shaft.
Install nut on pinion shaft (see page 159 and page 160).
Torque nut to 110-120 ft-lb (149-162 Nm).

DO NOT LOCK NUT AT THIS TIME
Check pinion preload. Rolling torque of 5-8 in-lb

(0.56-0.90 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. For transmission assembly
drawing and parts legend see page 159 and
page 160.
Return
2002-01-09
169
F-code
Section
C-code
PS
S2.0
Transmission
2550
Version no
T-code
000
395/396/397/398/399
Install outer bearing cone, spacers and washer on the tool.

Place bevel gear, washer, and nut on the tool. Torque nut
to 90 ft-lb (122 Nm).
Using a magnetic base and dial
indicator check the backlash.
Reading should be within 0.0020.006 inch (0.05-0.015 mm).
Backlash is adjusted by adding or
subtracting shims from under the
pinion shaft bearing races. Remove
the same shim thickness from 24
that is fitted under 20.
Check tooth pattern

with engineers blue.
Adjust shim 13 when needed. After adjusting 13, 12 will

need to be set. If 13 thickness is increased,12 needs to be
reduced. If the thickness of 13 is reduced, then 12 is
increased. It may be necessary to adjust shim 20. If 20 is
increased, 24 is reduced. If 20 is reduced, 24 is increased.
170
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2002-01-09
F-code
Section
PS
S2.0
2550
Transmission
Version no
000
C-code
T-code
395/396/397/398/399
Place outer axle shaft bearing into outer bearing in the

transmission case.
Install axle seal into the transmission case.
Start axle shaft into

outer bearing cone.
Washer
Spacer
Install spacer on
the axle shaft.
Return
2002-01-09
171
F-code
Section
C-code
PS
S2.0
Transmission
2550
Version no
T-code
000
395/396/397/398/399
Install washer
on axle shaft.
Install bevel gear with bearing on the axle shaft.
Install keeper and bolts.
Torque axle bolts to

81 ft-lb (109 Nm).
Lock pinion nut, using a

square end punch. Do not
bend nut enough to break
it.
172
Return
2002-01-09
F-code
Section
PS
S2.0
2550
Transmission
Version no
000
C-code
T-code
395/396/397/398/399
Install new o-ring on

the cover.
Install cover on the

transmission case.
Torque cover bolts
to 18 ft-lb (24 Nm).
If transmission to steer bearing

and steer gear were removed
from the truck, mount and torque
bolts to 18 ft-lb (24 Nm). Use
Loctite 515 for sealing the
transmission to the top housing.
3. Install transmission on truck (see page 155).
Return
2002-01-09
173
F-code
Section
C-code
PS
S2.0
Transmission
2550
Version no
T-code
000
395/396/397/398/399
5. Axle Sealing Ring

Replace the axle sealing ring when there is oil leakage from
the drive axle.
5.1. Disassembly
1. Drain transmission oil by removing drain plug (28).
Remove copper washer (18) from drain plug.
2. Remove transmission
page 155).
from
the
truck
(see
3. Remove bolts (34) from lower case cover (37).

Remove lower case cover (37). Remove O-ring
(15) from cover.
4. Loosen drive axle bolts (16). Remove bolts (16)
and keeper washer (36).
5. Drive out the drive axle (17).
NOTE!
To avoid bearing damaging during removal,

use a split bearing puller.
6. Using a puller, remove bearing (23) from drive axle

(17).
NOTE!
The seal ring (26) may remain in the

transmission case (38).
7. Remove seal ring (26)

174
Return
from
axle
(17)
or
2002-01-09
F-code
Section
PS
S2.0
2550
Transmission
Version no
000
C-code
T-code
395/396/397/398/399
5.2. Assembly
1. Place drive axle outer bearing (23) in the
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). 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 (24 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 84). Install fill level plug (35) in
7. Install transmission on truck (see page 155).
Return
2002-01-09
175
F-code
Section
C-code
PS
S2.0
Transmission
2550
Version no
T-code
000
395/396/397/398/399
6. Leakage
When there is leakage from the transmission top cover,
proceed as follows:
6.1. Top Cover

2. Remove transmission from truck.
3. Remove bolts (32) securing steering gear ring (2)
to the transmission case (38).
4. Remove steering gear ring (2) from the
transmission case (38). Carefully clean the sealing
surfaces of steering gear ring and transmission
case.
5. Apply sealant, type Loctite 515, to the
transmission case (38), following the instructions
given on the sealant container.
6. Install steering gear ring (2). Lubricate bolts (32)
and install on the steering gear ring. Torque bolts
(32) to 18 ft-lb (25 Nm).
(28). Install drain plug (28) in transmission. Fill
transmission with oil. Install fill level plug (35) in the
transmission case.
8. Install transmission on truck.
176
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2002-01-09
F-code
Section
PS
S2.0
2550
Transmission
Version no
000
C-code
T-code
395/396/397/398/399
6.2. Lower Cover

When there is leakage from the transmission lower cover,
proceed as follows:
Remove washer (18) from drain plug (28).
2. Remove bolts (34) from the cover (37). Remove
lower cover (37) from the transmission case (38).
Remove O-ring (15) from the cover (37).
3. Install a new O-ring (15) on the cover (37). Install
the cover (37). Lubricate the 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.
(28). Install drain plug (28) in the transmission. Fill
the transmission with oil. Install fill level plug (35) in
Return
2002-01-09
177
F-code
Section
C-code
PS
S2.0
Transmission
2550
Version no
T-code
000
395/396/397/398/399
7. Wheel Bolt
2. Remove transmission from truck.
3. Remove drive axle from the transmission case.
4. Press or drive out the damaged bolt from the drive
axle rim.
NOTE!
Always install a new drive axle seal during

assembly.
5. Smooth away any burring around the bolt hole.

Press or drive new bolt into place.
6. Install drive axle into the transmission case.
7. Install transmission on truck.
178
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2002-01-09
F-code
PS
Section
C-code
S3.0
3370
Electromagnetic Brake
Version no
T-code
001
395/396/397/398/399
13
Item No.
11
10
7
4
Description
Brake assembly
Coil
Armature
Hub
Plate, friction
Plate, mounting
Spacer, adjustable
Spring
Screw, socket head
10
Washer
11
Screw, socket head
12
Screw
13
Spacer
1. Removal
5
12

rolling.
1. Park the truck on a flat surface and block securely.

3. Remove dash, motor compartment door, and left
side panel to allow access to electromagnetic
brake.
Return
2000-08-04
179
F-code
Section
C-code
PS
S3.0
3370
Version no
T-code
001
395/396/397/398/399
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).
4. Fully tighten two manual release screws (11).
5. Remove three screws (9) which hold brake parts
and set aside. Avoid moving adjustable spacers (7)
if possible, thus maintaining correct axial air gap
when reassembled.
6. Electrically disconnect the brake assembly. Lift
upward to remove armature (3) and coil (2) from
the top of drive motor.
7. Slide friction plate (5) off hub spline and away from
mounting plate (6).
8. Remove brake hub (4) from motor shaft.
9. Remove mounting plate (6) from electric drive
motor if drive motor is to be replaced and check for
flatness. If only the brake is being changed, the
mounting plate may be reused for the new brake
assembly.
180
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2000-08-04
F-code
PS
Version no
001
Section
C-code
S3.0
3370
T-code
395/396/397/398/399
2. Installation
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).
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.
Return
2000-08-04
181
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Section
C-code
PS
S3.0
3370
Version no
T-code
001
395/396/397/398/399
8. Check air gap and adjust if necessary. (See the

following paragraph for adjustment instructions.)
9. After making adjustment, check that brake will
release when power is applied.
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.
182
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2000-08-04
F-code
PS
Section
C-code
S3.0
3370
Version no
001
T-code
395/396/397/398/399
4. Coil Check On Brake

Check the brake coil electrical resistance.
24V coil at 70F (20C) should be 9 ohms
36V coil at 70F (20C) should be 22 ohms
5. Electromagnetic Brake, Armature

and Magnetic Coil
5.1. Removal
rolling.
1. Park truck on a flat surface and block securely.
side panel to allow access to electromagnetic
brake.
WARNING The magnetic coil (2) and armature (3) are
under pressure. Do not remove retaining
screws (9) without manual release screws
(11) in place.
5. Remove three brake retaining screws (9).
6. Electrically disconnect brake assembly and lift
upwards to remove.
Return
2000-08-04
183
F-code
Section
C-code
PS
S3.0
3370
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. Brake Friction Plate

6.1. Inspection
The friction plate should be replaced when the thickness is
0.23 inch (6 mm) or less.
6.2. Replacement
If brake friction plate needs replacement, remove and install
new plate.
184
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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
Return
Item No.
Description
Item No.
Drive wheel assembly
Nut
Tire
Washer, spherical
Wheel, drive
2000-08-04
Description
185
F-code
Section
C-code
PS
S3.1
Drive Wheel
3530
Version no
T-code
001
395/396/397/398/399
1. Removal
1. Park the truck on a level surface.
3. Jack rear of truck so drive and caster wheels are
approximately 1 inch (25.4 mm) off the ground.
Block truck in this position.
4. Remove seven wheel retaining nuts (4) and
spherical washers (5). Pull tire (2) and drive wheel
(3) from transmission drive axle hub.
5. Press tire (1) from drive wheel (2).
2. Installation
1. Press drive tire on wheel hub. This is usually done
while pressing off old tire. Press hub to the center
of tire (2).
2. Install drive tire assembly on transmission axle
hub. The seven drive tire wheel nuts should be
torqued to 95 ft-lb (129 Nm).
186
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2000-08-04
F-code
Section
PS
S3.1
Version no
001
C-code
3530
Drive Wheel
T-code
395/396/397/398/399
3. Tire Pressing Procedure

1. Check the inside surface of metal insert on the new
tire. Remove any scaling or rust with sandpaper.
Clean the inside of metal insert and lubricate with a
soap solution.
Outside of Hub
and Tire Assembly
New
Tire
Worn
Tire
Circular
Ram
Press
Table
2. Place a circular ram on press table. The length of

ram must be longer than the width of old tire to
allow complete removal of old tire. The outside
diameter of ram must be small enough to fit loosely
in the insert of tire, but large enough to rest
squarely on the flat surface on the outer edge of
hub.
3. If the outside edge of hub is not flush with the edge
of the metal insert in old tire, measure how far hub
is recessed inside tire. The new tire must be placed
in the same position old tire was installed on hub. A
spacer (slightly smaller in diameter than the inside
diameter of tire insert and the same thickness as
the depth of the recess) can be used to obtain
proper amount of recession.
4. Position hub assembly with the old tire on the top
of circular ram so the outside of the wheel is
positioned upward. The outside edge of hub has a
chamfer to help guide new tire onto the wheel. The
chamfered edge must always be the leading edge
when a tire is pressed onto the hub.
5. Center hub assembly on top of the ram and make
sure they mate squarely.
6. Position new tire with its chamfered insert facing
hub. Align new tire and hub so they are concentric.
Return
2000-08-04
187
F-code
Section
C-code
PS
S3.1
Drive Wheel
3530
Version no
T-code
001
395/396/397/398/399
CAUTION Any misalignment of tire and hub while tire

is being pressed onto hub can cause
damage to hub. For this reason, chamfers
have been provided on the outside edge of
hub and on the end of the inside diameter
of tires metal insert. The chamfers help to
center hub and tire during the pressing
operation and reduce the possibility of
misalignment. To prevent damage, hub
must be installed on circular ram with its
chamfered side up.
NOTE!
If new tire does not press on with a

minimum of 5 tons (5080.235 kg) force,
replace hub.
7. Begin pressing new tire onto hub and old tire off
the hub. Run the press slowly for the first few
inches of travel, because this is the critical stage of
the operation. If tire begins to cock to one side,
stop press and realign the tire. A sharp jar with a
soft-headed mallet will usually realign tire on hub.
8. Release the press. Remove wheel, tire assembly,
and old tire from press table. Inspect wheel and tire
assembly.
9. Install wheel assembly following the procedure for
the specific type of wheel.
188
Return
2000-08-04
F-code
Section
C-code
PS
S3.2
3540
Non-Braking Caster Wheel, RRX35/RSX40
Version no
002
T-code
395/398
Non-Braking Caster Wheel, RRX35/

RSX40
1
2
3
6
4
7
8
9
17
10
11
12
19
20
18
13
14
17
15
16
Return
2000-08-04
189
F-code
Section
C-code
PS
S3.2
3540
Version no
T-code
002
395/398
Item No.
190
Return
Description
Item No.
Description
Locknut
11
Screw, cap
Lockwasher
12
Nut
Ring, Nilos
13
Pivot, caster
Bearing
14
Bearing, thrust
Screw, cap
15
Caster assembly
Nut
16
Block, pivot
Guide, spring
17
Fitting, grease
Spring
18
Bushing
Screw, set
19
Washer
10
Nut
20
Screw, cap
2000-08-04
F-code
Section
C-code
PS
S3.2
3540
Version no
T-code
002
395/398
1. Caster Pivot
1.1. Removal
3. Jack the rear of truck (see page 66).
4. Remove the main electronic card panel (see
page 103).
5. Remove floor board.
WARNING Secure caster pivot before removing
mounting bolts (20). Serious injury could
occur if failure to comply with this
requirement.
6. Turn and secure transmission to access mounting
bolts (20).
NOTE!
For models with a brake on caster wheels,

the cable linkage must be disconnected
before removal of foot pedal.
7. Bend lockwasher (2) tab down and remove locknut

(1).
8. Remove Nilos ring (3) and bearing (4).
9. Remove caster assembly.
10. Loosen screws (5) to release spring tension.
11. Remove mounting bolts (20).
12. Remove caster pivot (13). Inspect and replace
bushings and bearings as needed.
13. Installation
1. Install pivot block
compartment first.
(16)
closest
to
battery
2. Install rear pivot block (16) on caster pivot (13).

Return
2000-08-04
191
F-code
Section
C-code
PS
S3.2
3540
Version no
T-code
002
395/398
3. Maneuver caster pivot (13) in place between

frame.
4. Install caster assembly in caster pivot (13).
NOTE!
Make certain nilos ring and lockwasher are

in correct position.
5. Tighten locknut (1) while turning caster wheel

assembly until tight, then back off 1/4 turn.
6. Bend tab on lockwasher (2) up to secure locknut
(1).
7. Install brake pedal.
NOTE!
For models with brake on caster wheels,

the cable linkage must be installed.
8. Set spring tension and stops (see page 195).

9. Install floor board.
10. Install main electronic card panel.
11. Test truck operation, then return to service.
192
Return
2000-08-04
F-code
Section
C-code
PS
S3.2
3540
Version no
002
T-code
395/398
2. Thrust Bearing
2.1. Removal
3. Jack the rear of the truck.
4. Remove main electronic card panel.
NOTE!

remove brake arm.
6. Bend tab down on lockwasher (2).

7. Remove locknut (1), lockwasher (2) and Nilos ring
(3).
8. Inspect and replace bearings as needed.
Return
2000-08-04
193
F-code
Section
C-code
PS
S3.2
3540
Version no
T-code
002
395/398
2.2. Installation
1. The truck must be properly blocked at this time.
2. Install the race (4) in caster pivot (13) and thrust
bearing (14) on caster assembly.
3. Install caster assembly in caster pivot (13).
4. Install bearing (4), Nilos ring (3), lockwasher (2)
and locknut (1).
5. Tighten locknut (1) while turning caster wheel
assembly until tight, then back off 0.250 turn.
6. Bend lockwasher tab (2) up to secure locknut (1).
NOTE!

remove brake arm.
7. Test caster operation.
194
Return
2000-08-04
F-code
Section
C-code
PS
S3.2
3540
Version no
002
T-code
395/398
3. Caster Springs
3.1. Adjustment
5.375-5.50 inch
(136.5-139.7 mm)
1. Park truck on a flat surface.

battery connector and securely block truck.
3. Remove right-hand side electronics panel cover.
4. Measure from the top of spring spacer to the caster
pivot plate. The measurement should be within
5.375-5.50 inch (136.5-139.7 mm).
5. To change adjustment, loosen jam nuts (6) and
tighten or loosen bolts (5).
3.2. Removal
New Free Length
is 7 inch (178 mm)

6. Loosen jam nuts (6) and release all spring tension
with adjusting bolts (5). Remove bolts (5).
Worn Free Length

is 6.5 inch (165 mm)
or less
Return
7. Remove jam nut (10) and loosen stop bolt (9) to

allow caster pivot to rest on frame stop.
8. Remove springs from the side.
2000-08-04
195
F-code
Section
C-code
PS
S3.2
3540
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)
4. Tighten adjusting bolts (5) until the measurement is

within 5.375-5.50 inch (136.5-139.7 mm) from the
top of spring spacers to the caster pivot plate.
5. Adjust the bottom stop bolt (9) to 0.125 inch (3 mm)
clearance on the stop.
CAUTION Failure to determine battery compartment
size, battery weight, and mast height can
result in serious injury.
6. Adjust stops bolts (11). The recommended
dimension between the stop bolts and the stop
block is 0.25 (6.35 mm). See the table below to
determine if the maximum dimension for the truck
can be increased.
Mast Height
Battery
Compartment
192
210
240
270
14.5 inch (368 mm)

Minimum 1600 lb battery
0.375
inch
0.375
inch
0.375
inch
0.375
inch
16.5 inch (419 mm)

0.375
inch
0.375
inch
0.375
inch
21 inch (533 mm)

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
21 inch (533 mm)

0.250
inch
360
402
0.250
inch
0.250
inch
7. Install the floor board.

9. Test truck operation.
196
Return
2000-08-04
F-code
Section
C-code
PS
S3.2
3540
Version no
002
T-code
395/398
4. Caster Stops
4.1. Adjustment.
1. Park truck on a flat surface.
connector from the truck and securely block truck.
5.375-5.50 inch
(136.5-139.7 mm)

5. Measure from the top of the spring spacer to the
caster pivot plate. The measurement range should
be within 5.375-5.50 inches (136.5-139.7 mm).
Adjust the caster spring if necessary.
NOTE!
The stop bolts must NOT be touching stop

blocks when measuring the spring
compression.
6. Adjust the bottom stop bolt (9) to 0.125 inch (3 mm)

clearance on the stop.
CAUTION Failure to determine battery compartment
size, battery weight, and mast height can
result in serious injury.
7. Adjust the top stop bolts (11). The recommended
dimension between the stop bolts and the stop
block is 0.25 inch (6.35 mm). See Mast Height on
page 196 to determine if the maximum dimension
for the truck can be increased.
8. Secure the jam nuts (12).
11. Connect battery connector to the truck and test
truck operation.
Return
2000-08-04
197
F-code
Section
C-code
PS
S3.2
3540
Version no
T-code
002
395/398
198
Return
2000-08-04
F-code
Section
C-code
PS
S3.3
3540
Non-Braking Caster Assembly, RRX35/RSX40
Version no
T-code
002
395/398
Non-Braking Caster Assembly,

RRX35/RSX40
1
3
4
4
Item No.
Return
Description
Item No.
Wheel, caster
Lockwasher
Bracket, caster
Locknut
Ring, Nilos
Fitting, grease
Bearing
Cap, wheel
2000-08-04
Description
199
F-code
Section
C-code
PS
S3.3
3540
Non-Braking Caster Assembly, RRX35/RSX40
Version no
T-code
002
395/398
1. Removal
NOTE!
Replace caster wheel when caster spring

can no longer be adjusted. (See Caster
Springs on page 195.)

connector from the truck. Check to make sure the
battery retainer plates are in place.
4. Remove wheel cap (8).
(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).
200
Return
2000-08-04
F-code
Section
C-code
PS
S3.4
3540
Braking Caster Wheel, RRX45/RDX30/RSX50
Version no
002
T-code
396/397/399
Braking Caster Wheel, RRX45/RDX30/

RSX50
1
2
3
5
25
26
23
4
6
24
23
7
9
17
21
22
10
11
12
20
19
13
18
14
16
Return
15
17
2000-08-04
201
F-code
Section
C-code
PS
S3.4
3540
Version no
T-code
002
396/397/399
Item No.
202
Return
Description
Item No.
Description
Locknut
14
Bearing, thrust
Lockwasher
15
Caster assembly
Ring, Nilos
16
Block
Bearing
17
Fitting, grease
Screw, cap
18
Bushing
Nut
19
Washer
Guide, spring
20
Screw, cap
Spring
21
Shaft
Screw, set
22
Bracket
10
Nut
23
Bearing, flanged
11
Screw, cap
24
Pin, roll
12
Nut
25
Pivot
13
Pivot, caster
26
Screw, cap
2000-08-04
F-code
Section
C-code
PS
S3.4
3540
Version no
002
T-code
396/397/399
1. Removal
1.1. Caster Brake Adjustment
4. Remove main electronic card panel (page 103).
brake pedal.
6. Total travel of the left foot brake pedal from up to
down is 3.5 inch (89 mm). The pedal setpoint is 50
percent down or 1.8 inch (45.7 mm). This can be
felt by a change in force at the pedal by the spring
tension.
Spring
Rod
Adjusting
Nut
7. Loosen the adjuster nuts of the cable end at the

caster assembly bell crank. Adjust the cable
threaded end to allow for more engagement
required by a worn brake. At the 50 percent pedal
up position, the caster wheels should stop rotating
due to the brakes making contact with the caster
wheel drums.
8. When the cable can no longer be adjusted for
caster braking, the brake must be adjusted at the
caster wheels.
9. Run the cable adjustment back to the original
position. Full threads toward the caster assembly.
10. Remove only one caster wheel (see page 207).
11. Remove brake assembly for the caster wheel.
Return
2000-08-04
203
F-code
Section
C-code
PS
S3.4
3540
Version no
T-code
002
396/397/399
12. Adjust double nuts at the brake rod up or down by

tightening brake arm. Check brake at 50 percent
pedal up position. The caster wheel should stop
rotating due to the brake starting to make contact
with the drums.
13. Lock the double nuts together.
14. Reassemble and test truck for braking.
204
Return
2000-08-04
F-code
Section
C-code
PS
S3.5
3540
Braking Caster Assembly, RRX45/RDX30/RSX50
Version no
T-code
001
396/397/399
Braking Caster Assembly, RRX45/

RDX30/RSX50
16
15
13
9
14
2
11
10
13
12
9
10
11
1
4
4
Return
2000-08-04
205
F-code
Section
C-code
PS
S3.5
3540
Version no
T-code
001
396/397/399
Item No.
206
Return
Description
Item No.
Description
Wheel, caster
Ring, E
Bracket, caster
10
Brake assembly
Ring, Nilos
11
Screw, cap
Bearing
12
Nut
Lockwasher
13
Washer
Locknut
14
Pivot, brake
Fitting, grease
15
Spring
Cap, wheel
16
Plunger, brake
2000-08-04
F-code
Section
C-code
PS
S3.5
3540
Version no
001
T-code
396/397/399
1. Removal
NOTE!
Replace caster wheel when caster spring

can no longer be adjusted (see page 201.)

4. Remove wheel cap (8).
(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).
Return
2000-08-04
207
F-code
Section
C-code
PS
S3.5
3540
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).
13. Replace wheel cap (8).)
1
2
Brake Assembly Detail
3
4
208
Return
Item No.
Description
Cam
Plate
Lever
Clip
Spring
Shoe
2000-08-04
F-code
Section
C-code
PS
S3.6
3550
Load Wheels, Sizes 4 X 3, 5 X 4, and 5 X 3
Version no
T-code
000
398/399

1
2
11
3
10
6
7
8
9
8
7
6
RSX40/50
(Wheel Sizes 4 X 3 and 5 X 4)
Item No.
Return
Description
Item No.
Description
Axle
Washer, 18 gauge
Toe box
Bearing
Plate, rocker
Wheel, load
Ring, retainer
10
Nut
Fitting, grease
11
Bolt, shoulder
Washer, 10 gauge
2000-08-04
209
F-code
Section
C-code
PS
S3.6
3550
Version no
T-code
000
398/399
11
3
4
10
5
6
7
8
9
8
7
6
RRX35/45/RDX30
(Wheel Sizes 5 X 4 and 5 X 3)
Item No.
210
Return
Description
Item No.
Description
Axle
Washer, 18 gauge
Toe box
Bearing
Plate rocker
Wheel, load
Ring, retainer
10
Nut
Fitting, grease
11
Bolt, shoulder
Washer, 10 gauge
2000-08-04
F-code
Section
C-code
PS
S3.6
3550
Version no
000
T-code
398/399
1. Removal
2. Lower carriage fully.
rolling.
4. Hoist truck so load wheels are approximately 2
inches (50.8 mm) off the floor and securely block.
5. Remove retainer ring (4) from the axles.
6. Drive the axle back out through the wheels.
Remove rocker plate (3). Remove two washers (6
and 7) on each side of the wheel. Axle (1) is
welded into the rocker plate. Remove the load
wheel (9) from the toe box (2).
7. Inspect bearings (8).
Return
2000-08-04
211
F-code
Section
C-code
PS
S3.6
3550
Version no
T-code
000
398/399
2. Installation
1. Pack bearings with grease.
2. Install bearings in the load wheel.
3. Install load wheel assembly in toe box (2).
NOTE!
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.
8. Test operate truck.
212
Return
2000-08-04
F-code
Section
C-code
PS
S3.7
3550
Load Wheels, Size 10.5 X 3.5
Version no
T-code
000
398/399
1
10
2
3
4
11
RRX35/45/RDX30
(Wheel Size 10.5 X 3.5)
Item No.
1
2
3
4
5
6
Return
Description
Toe box, right hand
Washer, 10 gauge
Washer, 18 gauge
Bearing
Tire, load
Wheel
2001-09-21
Item No.
Description
7
8
9
10
11
Toe box, left hand

Fitting, grease
Nut
Bolt, shoulder
Load wheel assembly
213
F-code
Section
C-code
PS
S3.7
3550
Version no
T-code
000
398/399
1. Removal
2. Lower carriage fully.
rolling.
4. Hoist truck so load wheels are approximately 2
inches (50.8 mm) off the floor and securely block.
5. Remove toe box retaining nuts (9) and bolts (10).
6. Remove right toe box (2) and load wheel (9).
2. Installation
1. Inspect and replace bearings as needed.
2. Install load wheel assembly on toe box axle (1).
3. Install toe box (2).
4. Install toe box assembly on support arm. Apply
Loctite #243 to nuts (10) and bolts (11).
5. Remove blocking and lower truck to the floor.
7. Test operation of load wheel and truck.
214
Return
2001-09-21
F-code
Section
C-code
PS
S4.0
4110
Steering Arm / Wheel / Lever
Version no
001
T-code
395/396/397/398/399

6
7
30
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
Return
2000-08-04
215
F-code
Section
C-code
PS
S4.0
4110
Version no
T-code
001
395/396/397/398/399
Item
No.
216
Return
Description
Item
No.
Description
Item
No.
Description
Panel, lower pod
12
O ring
23
Lever
Panel, upper pod
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
Version no
001
T-code
395/396/397/398/399
1. Control Pod
1.1. Removal
1. Park truck on level surface.
connector from the truck. Block truck.
3. Remove dash retaining screws (see page 100).
4. Remove adjusting lever (23) and washer (27).
5. Lift pod assembly.
6. Lift dash approximately 6 inch (152.4 mm) to
access controls pod's wiring harness connectors.
7. Disconnect harness and remove control pod.
1.2. Installation
1. Route control pod wiring harness through dash.
2. Connect control pod harness to trucks main wiring
harness.
3. Install adjusting lever (23) and washer (27).
4. Install dash.
Return
2000-08-04
217
F-code
Section
C-code
PS
S4.0
4110
Version no
T-code
001
395/396/397/398/399
2. Steering Wheel
2.1. Removal
1. Park truck on level surface.
3. Remove control pod.
4. Remove screws (28) on lower control pod panel (1)
and remove panel.
5. Remove four screws (16).
6. Remove steering wheel (10). Inspect and replace
bearing as needed.
2.2. Installation
1. Install steering wheel (10) in upper control pod
panel (2).
2. Align holes on steering wheel mount and install
four screws (16). Check steering wheel for ease of
turning.
3. Install lower control pod panel (1) and install
screws (28).
4. Install control pod.
5. Connect battery connector to the truck. Turn key
switch to ON.
6. Test operation of steering wheel (10) and truck.
218
Return
2000-08-04
F-code
Section
C-code
PS
S4.0
4110
Version no
001
T-code
395/396/397/398/399
3. Steering Tach
3.1. Removal
1. Park truck on level surface
3. Remove control pod.
4. Remove screws (28) and remove lower control pod
panel (1).
5. Remove steering wheel (10).
6. Loose setscrew (25) and remove coupler (26).
7. Electrically disconnect steering tach motor (17)
wires from wiring harness. Remove four screws
(31) holding tach motor (17).
3.2. Installation
1. Install steering tach motor (17) and secure with
four screws (31).
2. Connect steering tach motor (17) wires from wiring
harness.
3. Install coupler (26) and tighten set screw (25).
4. Install steering wheel (10).
5. Install lower control pod panel (1) and tighten
screws (28).
6. Install control pod.
Return
2000-08-04
219
F-code
Section
C-code
PS
S4.0
4110
Version no
T-code
001
395/396/397/398/399
220
Return
2000-08-04
F-code
Section
PS
S4.1
4180
Steering Bearing
Version no
C-code
T-code
001
395/396/397/398/399
Steering Bearing
3
2
Item No.
Return
Description
Bearing
Breather
Screw
O ring
2000-08-04
221
F-code
Section
C-code
PS
S4.1
Steering Bearing
4180
Version no
T-code
001
395/396/397/398/399
1. Removal
NOTE!
Transmission and drive motor must be

removed from truck to access steering
bearing. (To remove drive motor see
page 149 and page 155 for removal of
transmission.)

Mounting
Screws

4. Remove door and left-side panel to access motor
compartment (see page 102).
5. Disconnect all electrical connections on drive
motor and brake assembly.
6. Remove drive motor.
7. Remove transmission.
8. Remove mounting ring.
9. Remove fifteen screws (3) from the retaining 360
degree bearing (1).
10. Remove breather (2). Remove O ring (4) from
breather.
2. Installation
1. Install new O ring (4), making sure it is positioned
before installing breather (2). Install breather (2).
2. Install new steer bearing (1).
3. Install
transmission
mounting
plate
and
transmission in truck and torque six mounting
screws to 50-59 ft-lb (68-80 Nm).
4. Install drive motor.
O ring Location
NOTE: Photo is a representation
of transmission assembly.
222
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5. Connect all electrical connections.

6. Refill transmission with fluid as needed.
7. Test steering and truck operation.
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1. General
The braking, steering, and travel control systems on the
reach truck are electrically controlled and monitored. The lift/
lower and auxiliary function systems are electrically controlled
and hydraulically operated. See Electrical Schematics
page 277, page 289, page 301, or page 313 and Hydraulic
Schematics page 442.
The control system of the reach truck consists of the following
components: movable ergonomic control pod; main electronic
card containing steer control; drive motor transistor regulator;
pump motor transistor regulator; steering components; and
brake. An operator instrument panel displaying direction of
travel, drive wheel indicator, actual time, hourmeter/error
code, parking brake indicator, right foot switch indicator, and
parameter set mode. For a listing of error codes see pages
page 393 and page 394. For a listing of parameters see
page 401. For information on the fuses and their location see
page 347.
1.1. Directional/Speed Control Lever
R11
R12 R13
R14
3 4
1 2
7 8
5 6
The directional/speed control lever is the operators input

interface to the truck. There are five basic control functions
available on the control pod which allows the operator to
perform work with the truck. These functions include: travel;
lift/lower; reach/retract; tilt; and sideshift, which can be further
broken down for more specialized control.
9 0
Travel Direction
R1
After each initial startup, a travel direction must be selected.

The default travel direction is always forks first. Moving the
direction control lever (R1) to the left will select the default
travel direction. Moving the directional control lever to the left
again will select the next travel direction. Moving the direction
control lever (R1) to the right will increase the travel speed.
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
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hydraulic lever (R12) is used for reach extend and retract.

Pushing forward on the lever causes the reach to extend.
Pulling rearward on the lever causes the reach to retract. The
third hydraulic lever (R13) is used for tilt. Pulling rearward on
the lever causes the forks to tilt up. Pushing forward on the
lever causes the fork to tilt down. The fourth hydraulic lever
(R14) is used for side shift. Pulling rearward on the lever
causes the carriage to side shift right. Pushing forward on the
lever causes the forks to side shift left. A horn push button is
also located on the control lever.
1.2. Main Electronic Card

NOTE!
A5
To determine the software version on the

truck, turn the key switch ON. Software
version is shown on the dash display at the
initial power up.
The
main
electronic
card
(A5)
contains
three
microprocessors. One microprocessor operates as a master
and the other two as slaves. The three microprocessors
share various digital and analog input functions. The
microprocessors monitor the state of switches, sensors,
control pod functions, system functions, and other input
devices. The master microprocessor makes decisions based
on the information received from its inputs and the two slave
processors. The results of the decisions are communicated to
the slaves. All three microprocessors share in control of
digital and analog outputs. Output devices controlled include:
solenoids; contactors; motor controllers; steer motor; brake;
and optional equipment.
The main electronic card (A5) performs diagnostic tests at
start-up and during truck operation. The diagnostic tests
assist in repair by identifying problems and minimizing truck
downtime. For any identified problems, the operator is alerted
by a visible tool bar icon and error code numbers displaying
on the operator display. An audible alarm is sounded when
an error is detected. A history log records error codes by date
and time.
The main electronic card (A5) contains a clock/calendar chip
with an internal battery. The combination of a chip and battery
allows clock and date settings to remain in memory when the
trucks battery is disconnected.
224
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The main electronic card is connected to the trucks circuitry

by nine connectors. To remove the connectors one through
eight, depress the connectors latch and unplug the
connector. To install the connectors, push the connectors
together until the latch snaps into position. To remove
connector nine, grasp the connector (do not grasp the wires)
and, with a slight rotational wiggling action, unplug the
connector. To install, push the connector onto the pins
making sure all of the pins are captured by the connector.
The nine connectors are grouped functionally from the top
down: digital inputs (2); communications (2); analog inputs
(1); analog outputs (1); digital outputs (2); and power output
(1). The main electronic cards top eight connectors and light
emitting diodes (LED) are clearly identified by numbers.
When the main electronic card is connected correctly to the
trucks battery, the digital input LEDs light green indicating
that the input is on and battery voltage is present at the input
pin. The digital output LEDs light red when the output is on
and battery voltage is present at output pin. The
communications and analog voltage inputs and outputs do
not have LEDs. The ninth connector is power for the steer
motor. Six green LEDs near connector 9 indicate the main
electrical card status. For the truck to be operational, all six
LEDs must be ON.
The main electronic card is located on the right side of the
electrical compartment and enclosed in a protective casing.
Replacement of the main electronic card should be as an
entire unit (card and enclosure).
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K10
K10
A1
F1
A2
M1
F55
ARMATURE
A1
K11
A5
S21
34
101
902
40
K13
M1
K11
B7
2
15
ACC
RELAY 1
B+
44
K13
8
M
1
805
64
Y1
803
51
K11
802
808
36V only
501
S48
43 111
52
K13
22
F51
25
F50
S108
21
S21
24
S17
49 102
22 809
901
LEGEND
Pressure Oil
Return Oil
Start Up Battery Connected
Electric Positive
Electric Negative
LED Off (Not Lit)
LED Input (Lit)
LED Output (Lit)
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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.
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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
Start Up E- Stop Released/Key ON
Pressure Oil
Return Oil
Electric Positive
Electric Negative
LED Off (Not Lit)
LED Input (Lit)
LED Output (Lit)
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Start Up E- Stop Released/Key ON

By closing the emergency disconnect switch (S21) and key
switch (S17), electricity flows through wire #22 to the main
electronic card (A5) input 809 and the normally closed brake
switch (S48), and main electronic card (A5) input 111. With
power at input 809, the main electronic card (A5) performs a
start-up diagnostic test and, if successful, applies power to
the cards outputs. Electricity also flows through wire #22 to
the drive transistor regulator (A1) connector pin 1 and to the
pump transistor regulator (A2) connector pin 1. The drive
transistor regulator (A1) performs an internal safety test. If the
test is successful, output at connector pin 7 wire #34 goes to
the battery voltage. Wire #34 supplies an input to terminal
101 of the main electronic card (A5). Wire #34 carries
electricity to the second section of the emergency disconnect
(S21) switch and connects to wire #44 connected to the coil
of the main contactor (K10). K10 energizes and applies
battery voltage to the drive transistor regulator B+ terminal
through fuse (F1) and the pump transistor regulator B+
terminal through fuse (F3). The main electronic card (A5)
monitors the state of wire #34 through input 101. If all tests
are successful, the truck is now powered and ready to begin
operation.
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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)
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3. Steering Components
3.1. Steering System
The steering system is electrically controlled. The input is a
tachometer (DC generator (U1) connected to the steering
wheel. The faster the steering wheel is turned, the higher the
voltage is produced by the tachometer (U1). The direction of
tachometer (U1) rotation determines the polarity of the signal.
The tachometer (U1) is connected to the main electronic card
(A5) by wire #62 to input 503 (-) and by wire #63 to input 502
(+). The master processor on the main electronic card (A5)
processes the tachometer signal and communicates the
result to the steer slave processor. The steer slave processor
controls the steer chopper to obtain the appropriate output
voltage and polarity to drive the steer motor (M6). The steer
motor is connected to the main electronic card (A5) through
wire #60 output 903 (+) and wire #61 output 904 (-). Current
through the main electronic card (A5) connector pins 903 (+)
and 904 (-) determines the steer motor direction. Electrical
power for the steer motor is supplied through wire #1 to fuse
(F51) and through wire #25 to the main electronic card (A5) at
connector pin 901. The negative is wire #40 connected to the
main electronic card (A5) connector pin 902.
The main electronic card (A5) monitors the steer system. If a
fault is sensed in the steer tachometer, steer controller, steer
motor, or wiring, an error code will appear on the Operator
Display (A6) indicating the steering problem.
Three parameters can be modified to adjust the steering for
custom control. Parameter 1 adjusts speed sensitive steering
(reduced steering sensitivity at high speed). Parameter 2
adjusts steering sensitivity (tachometer response). Parameter
11 adjusts steer direction (backward or forward).
Turning the steering wheel clockwise directs B- current to the
steer motor through a series of steps:
The steer tachometer determines the rate and direction of
steer wheel rotations.
Turning the steer tachometer clockwise sends 0 to +2.9
volts (depending upon the rate of rotation of the steering
wheel) to the main electronic card (A5) at input 502 with
respect to connector pin 503.
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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.
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A5
F53
67
31
810 12V +
811 -
32
S66
58
204
STEERING ANGLE A
S67
22
S65
59
57
203
STEERING ANGLE B
202
STEER WHEEL POSITION
40 902 (OV)
40
LEGEND
Pressure Oil
Wheel Direction Sensors
Return Oil
Electric Positive
Electric Negative
LED Off (Not Lit)
LED Input (Lit)
LED Output (Lit)
234
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3.2. Wheel Direction Sensors

This diagram covers the channel A steering angle proximity
sensor (S66), channel B steering angle proximity sensor
(S67), fuse (F53), steering wheel position sensor (S65), and
main electronic card (A5). The steer wheel position proximity
sensor and the steer angle proximity sensors work in
conjunction to determine drive wheel position information and
direction of travel. The three sensors, steer wheel position
(S65), steering angle A (S66), and steering angle B (S67),
monitor the drive wheel steering position and relay the ON or
OFF state to the main electronic card (A5). S66 connector is
grey in color. S67 connector is blue in color.
The 12-Volt power supply is covered on page 254. It provides
power to the steering angle A sensor (S66) and steering
angle B sensor (S67). The Steer wheel position sensor (S65)
requires battery voltage to operate. S65 is connected to the
main electronic card input 202 (wire #57). S66 is connected
to the main electronic card input 204 (wire #58). S67 is
connected to the main electronic card input 203 (wire #59).
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K10
K10
A1
F1
A2
B+
ARMATURE
M1
44
B34
7
2
A1
R3
22
101
29
FIELD
K11
K13
M1
K11
K13
8
A5
S21
65
30
M
1
902
504 +7.35V
511
510 OV
805
64
Y1
51
K11
802 52
K13
803
F50
808
36V only
501
S48
43
111
S108
49
102
21
S21
24
S17
22
40
809
LEGEND
Pressure Oil
Brake Release
Return Oil
Electric Positive
Electric Negative
LED Off (Not Lit)
LED Input (Lit)
LED Output (Lit)
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4. Brake Release
Brake release occurs when the brake pedal is fully
depressed. The emergency switch (S21) ON, key switch
(S17) ON and the brake pedal fully depressed (down) causes
the brake switch (S48) to open removing the input to the main
electronic card (A5) terminal 111 (wire #43). The brake
potentiometer (R3) output goes to a lower voltage than when
the brake pedal is released (up). The main electronic card
(A5) senses the decrease in voltage at terminal 511 (wire
#65). The main electronic card (A5) responds by turning on
output 805 (wire #64) sending current to the magnetic brake
coil (Y1), lighting the main electronic card (A5) 805 LED. The
energizing of the brake coil (Y1) causes the brake pressure
plate to move from the brake friction plate, releasing the
brake and allowing the truck to travel.
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K10
K10
A1
F1
3
A2
B+
M1
44
B-
2
K11
29
R1
K13
K13
M1
K11
50
30
M
1
101
34
A1
29
22
R3
F50
65
36V only
S48
21
S108
S21
24
S17
43
49
22
A6
123
Rx +
Rx -
LEGEND
Pressure Oil
A5
S21
124
902
40
504 +7.35V
505 +3.65V
510 OV
805
64
Y1
803
51
K11
802
52
K13
511
808
501
111
102
809
303 Tx +
304 Tx -
Direction Selection
Return Oil
Electric Positive
Electric Negative
LED Off (Not Lit)
LED Input (Lit)
LED Output (Lit)
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5. Direction Selection
4
1 2 3
7 8
5 6
9 0
CAUTION Releasing parking brake and accidentally

moving direction/speed joystick to the right
causes unexpected truck travel.
After each initial start up, a travel direction must be selected,
by moving the direction control lever (R1) to the left. The
default travel direction is always forks first. Moving the
direction control lever (R1) to the left approximately 0.1875
inch (4.7625 mm) will select the next travel direction. Moving
the direction control lever (R1) to the left will decrease voltage
from 3.65 volts to approximately 3 volts.
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+
K10
K10
A1
F1
3
A2
M1
B+
ARMATURE
2
A1
FIELD
K11
K11
M1
A5
44
B7
36
10
11
35
6
S21
34
29
R1
8
1
610
611
609 -
37
K13
K13
50
30
M
1
22
R3
F50
65
36V only
S48
43
21
S108
S21
24
S17
49
22
S60
101
39
902
40
504 +7.35V
505 +3.65V
510 OV
805
64
Y1
803
51
K11
802
808
501
52
K13
511
111
102
809
104
LEGEND
Pressure Oil
Travel Request, Forks First
Return Oil
Electric Positive
Electric Negative
LED Off (Not Lit)
LED Input (Lit)
LED Output (Lit)
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6. Travel Request, Forks First

After moving the lever to the left to select direction, forks first
travel occurs when the brake pedal is depressed and the
control lever is moved to the right. With the emergency switch
(S21) ON, key switch (S17) ON, and the brake pedal
depressed, moving the directional/speed control lever to the
right causes the travel potentiometer (R1) to output a voltage
higher than when in the neutral position. The travel
potentiometer (R1) sends the travel request signal to the
main electronic card (A5) input 505. The main electronic card
(A5) responds by turning on output 803 (wire #51) and sends
current to the fork direction contactor (K11), closing the
normally open (NO) contact tips and opening the normally
closed (NC) contact tips. The (forks trailing) direction
contactor (K13) remains in the de-energized state. The
electrical path created by the contact position of K11 and K13
allows current to flow from the battery to the motor terminal
(A2), through the motor brushes and armature to motor
terminal (A1), through K11 (NO), the motor field, K13 (NC) to
drive transistor (A1) regulator terminal M- in a direction to
cause the drive motor to rotate counter-clockwise and move
the truck in the forks first direction.
NOTE!
When the drive wheel hub bolts are turned

out in the forward position K11 pulls in.
When the transmission bolts are turned out
in the forward direction K13 pulls in.
A battery voltage potential is provided to the drive transistor

(A1) regulator terminal A. The main electronic card (A5) turns
on speed request output 610 (wire #36) to a level proportional
to the control lever travel request. This signal is sent to the
drive transistor (A1) regulator input pin 10. A current limit
signal proportional to the control lever travel request is sent
from the main electronic card (A5) output 611 (wire #37) to
the A1 drive transistor regulator input pin 11 limiting the
current from the transistor regulator to the motor. Both speed
request and current limit signals range from 0 volts to
approximately 5.0 volts and are measured with respect to the
main electronic card (A5) output 609 (wire #35) to drive
transistor (A1) regulator input pin 6 (wire #35). The drive
transistor (A1) regulator sends the amplified signal to the
drive motor commanding travel. The main electronic card
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(A5) monitors the drive motor temperature limit. A drive

temperature switch (S60), located on the motor and
connected to main electronic card (A5) input 104 (wire #39),
opens if the motor frame exceeds 257 F (125 C). The main
electronic card (A5) reduces the drive speed request and the
drive transistor regulator responds by reducing the
commanded motor speed.
Travel speed is proportional to directional/speed lever
movement. A reduction in maximum travel occurs for the
following conditions:
1. A drive motor over temperature condition (S60).
2. A steer controller over temperature (internal to the main
electronic card (A5).
3. The mast is extended above free lift height (S31). (See
page 257 and page 259.)
4. Mast switches (S31 and S45) sequence error. (See
The main electronic card (A5) will request less speed from
the drive transistor regulator if any of these conditions occur
by reducing the speed request signal. Error codes will be
displayed for condition numbers 1 and 2. When the truck is
traveling and the right foot pedal is not depressed, the
warning triangle on the operator display will flash signaling
the operator to depress the right foot pedal switch (S108).
The relationship between the drive transistor (A1) regulator
speed request voltage and travel potentiometer (R1) is an
approximate relationship and include the following:
The travel speed request voltage range is 0 to 5 volts. The
travel potentiometer (RI) voltage is approximately 0.6 to
7.35 volts with the center at approximately 3.65 volts.
Moving the control lever to the right causes voltage to
increase from 3.65 to 7.35 volts. For every 0.5 volt
increase of the travel potentiometer (R1), the speed
request will increase approximately 1 volt.
The speed request voltage is from the main electronic card
(A5) terminal 610 through wire #36 to the drive transistor
(A1) regulator pin 10.
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Wire #35, connecting the drive transistor (A1) regulator pin

6 and the main electronic card (A5) pin 609, is the common
reference for the speed request/current limit voltages.
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+
K10
K10
A1
F1
A2
B+
ARMATURE
M1
A1
FIELD
K11
K11
M1
A5
B7
10 36
44
101
34 S21
11
A
6 35
29
K13
K13
R1
8
610
611
609 -
37
50
30
M
1
22
R3
F50
902
40
504 +7.35V
505 +3.65V
510 OV
805
64
Y1
803
51
K11
802
808
501
43
111
49
102
22
809
52
K13
65
511
36V only
S48
21
S108
S21
24
S17
S60
LEGEND
39
104
Travel Request, Forks Trailing
Pressure Oil
Return Oil
Electric Positive
Electric Negative
LED Off (Not Lit)
LED Input (Lit)
LED Output (Lit)
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7. Travel Request, Forks Trailing

After moving the lever to the left to select direction, forks
trailing travel occurs when the brake pedal is depressed and
the control lever is moved to the right. With the emergency
switch (S21) ON, key switch (S17) ON and the brake pedal
depressed, moving the directional/speed control lever to the
right causes the travel potentiometer (R1) to output a voltage
higher than when in the neutral position. The travel
potentiometer (R1) sends the travel request signal to the
main electronic card (A5) input 505. The main electronic card
(A5) responds by turning on output 802 (wire #52) and
sending current in the forks trailing direction to the direction
contactor (K13), closing the normally open (NO) contact tips
and opening the normally closed (NC) contact tips. The forks
first wheel direction contactor (K11) remains in the deenergized state. The electrical path created by the contact
position of K13 and K11 allows current to flow from the
battery to the motor terminal (A2), through the motor brushes
and armature to motor terminal (A1), through K13 (NO), the
motor field, K11 (NC) to drive transistor regulator (A1)
terminal M- in a direction to cause the drive motor to rotate
clockwise and move the truck in the forks trailing direction.
NOTE!
When the drive wheel hub bolts are turned

out in the forward position K11 pulls in.
When the transmission bolts are turned out
in the forward direction K13 pulls in.
A battery voltage potential is provided to the drive transistor

(A1) regulator terminal A. The main electronic card (A5) turns
on speed request output 610 (wire #36) to a level proportional
to the control lever travel request. This signal is sent to the
drive transistor (A1) regulator input pin 10. A current limit
signal proportional to the control lever travel request is sent
the A1 drive transistor regulator input pin 11 limiting the
current from the transistor regulator to the motor. Both speed
approximately 5.0 volts and are measured with respect to the
main electronic card (A5) output 609 (wire #35) to A1 drive
transistor (A1) regulator input pin 6 (wire #35). The drive
transistor (A1) regulator sends the amplified signal to the
drive motor commanding travel. The main electronic card
(A5) monitors the drive motor temperature limit. A drive
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temperature switch (S60), located on the motor and

connected to main electronic card (A5) input 104 (wire #39),
opens if the motor frame exceeds 257 F (125 C). The main
electronic card (A5) reduces the drive speed request and the
drive transistor regulator responds by reducing the
commanded motor speed.
Travel speed is proportional to directional/speed lever
movement. A reduction in maximum travel occurs for the
following conditions:
1. A drive motor over temperature condition (S60).
2. A steer controller over temperature (internal to the main
electronic card (A5).
3. The mast is extended above free lift height (S31). (See
4. Mast switches (S31 and S45) sequence error. (See
5. The main electronic card (A5) will request less speed from
the drive transistor regulator if any of these conditions
occur by reducing the speed request signal. Error codes
will be displayed for condition numbers 1 and 2. When the
truck is traveling and the right foot pedal is not depressed,
the warning triangle on the operator display will flash signaling the operator to depress the right foot pedal switch
(S108).
The relationship between the drive transistor (A1) regulator
speed request voltage and travel potentiometer (R1) is an
approximate relationship and include the following:
The travel speed request voltage range is 0 to 5 volts. The
travel potentiometer (RI) voltage is approximately 0.6 to
7.35 volts with the center at approximately 3.65 volts.
Moving the direction control lever (R1) to the right causes
voltage to increase from 3.65 to 7.35 volts. For every 0.5
volt increase of the travel potentiometer (R1), the speed
request will increase approximately 1 volt.
The speed request voltage is from the main electronic card
(A5) terminal 610 through wire #36 to the drive transistor
regulator (A1) pin 10.
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Wire #35, connecting the drive transistor (A1) regulator pin

6 and the main electronic card (A5) pin 609, is the common
reference for the speed request/current limit voltages.
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248
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+
K10
395/396/397/398/399
K10
A1
F1
3 B+
A2
ARMATURE
M1
A1
K11
K11
FIELD
M1
A5
B7
8
10
A
44 S21
34
38
36
35
37
11
29
K13
K13
R1
8
M
1
R3
101
103
610
902
609 611
65
40
504 +7.35V
50 505 +3.65V
30
22
F50
C-code
S5.0
5000
805
510 OV
803
511
64
Y1
51
K11
52
K13
802
21
S21
24
S17
LEGEND
810 +
22
808 811 36V only
501
S48
43
111
102
S108
49
105
22
201
809
S125
S64
23
56
Plug Braking
Pressure Oil
Return Oil
Electric Positive
Electric Negative
LED Off (Not Lit)
LED Input (Lit)
LED Output (Lit)
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8. Plug Braking
CAUTION Releasing the brake pedal while on an
incline will cause the truck to move.
There are two methods of plug braking available on the reach
truck. The first method is using the directional/speed control
lever. The second method is accomplished through raising
the brake pedal and is detailed second.
8.1. Directional/Speed Control Lever

Method
Control lever plugging is used to slow or stop the truck. A
momentary movement of the direction control lever (R1) to
the left causes the travel potentiometer to output a voltage to
the main electronic card (A5) requesting travel in the opposite
direction. The directional contactor for the current travel
direction is de-energized and the directional contactor for
traveling in the opposite direction is energized as the control
lever is moved from travel to plugging. The main electronic
card (A5) begins to ramp up speed request output 610 (wire
#36) from zero volts. This signal is sent to the drive transistor
regulator (A1) input pin 10 (wire #36). The drive transistor
regulator (A1) sends the amplified signal to the drive motor
commanding plugging. At approximately 0.5 volts speed
request the drive transistor regulator (A1) recognizes the
drive motor is plugging and the drive switches to plug brake
mode. The drive transistor regulator (A1) output pin 8 (wire
#38) signals the main electronic card (A5) input 103, lighting
LED 103, that the drive motor and drive transistor regulator
(A1) are in plug brake mode.
The main electronic card (A5) responds by setting speed
request output 610 (wire #36) at 2.5 volts locking the
system of the drive motor, the drive transistor regulator (A1)
and the main electronic card (A5) into plug braking. Speed
request output 610 (wire #36) from the main electronic card
(A5) remains at 2.5 volts as long as the drive transistor
regulator (A1) output pin 8 (wire #38) signals the main
electronic card (A5) that the drive transistor regulator (A1)
and the drive motor are in plug brake mode. A current limit
signal proportional to the control lever plug request is sent
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the drive transistor regulator (A1) input pin 11. The current
limit signal ranges from 0 volts to approximately 4.5 volts and
controls the plugging force.
Plug braking force is regulated with the direction/speed
control lever movement. The greater the movement of the
control lever, the higher the current limit signal voltage and
the greater the plug braking force. Both speed and current
limit signals are measured with respect to the main electronic
card (A5) output 609 (wire #35).
8.2. Brake Pedal Method

The second plug brake method available on the reach truck is
used for slowing the truck. The direction of travel is not
changed when using this method of plug brake. To use the
plug brake method, raise the brake pedal while the truck is
moving. Releasing the brake pedal more than 1.5 to 2 inches
disables travel and applies the parking brake, stopping the
truck in the shortest possible distance. Completely releasing
the brake pedal is the method used for emergency braking.
Direction control lever (R1) must be returned to neutral to
continue travel. Raising the brake pedal while the truck is
moving causes an increase in voltage from the brake
transducer (R3) to the main electronic card (A5) input 511
(wire #65). With the pedal depressed, the voltage at the main
electronic card (A5) input 511 should read approximately 3.0
volts with respect to main electronic (A5) input 510 (wire #30).
The voltage increases toward 4.0 volts as the pedal is raised.
The increase in voltage signals the main electronic card (A5)
to the pedal brake request.
The main electronic card (A5) looks at the drive motor speed
sensor (S64) and drive motor direction sensor (S125) to
determine the current drive motor speed/travel direction. The
drive speed sensor (S64), located on top of the drive motor,
sends pulses to the main electronic card (A5) input 201 (wire
#56). The drive direction sensor (S125), located on top of the
drive motor, sends pulses to the main electronic card (A5)
input 105 (wire #23). Drive motor direction is determined by
using both S64 and S125 and the relationship between the
pulses from each device.
Knowing the drive motor direction, the main electronic card
(A5) de-energizes the directional contactor for the current
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travel direction and energizes the directional contactor for

plug braking as the brake pedal is raised. The main electronic
card (A5) begins to ramp up speed request output 610 (wire
#36) from zero volts. This signal is sent to the drive transistor
regulator (A1) input pin 10 (wire #36). The drive transistor
regulator (A1) sends the amplified signal to the drive motor
commanding plugging. At approximately 0.5 volts speed
request the drive transistor regulator (A1) recognizes the
drive motor is plugging and the drive switches to plug brake
mode. The drive transistor regulator (A1) output pin 8 (wire
#38) signals the main electronic card (A5) input 103, lighting
LED 103, that the drive motor and drive transistor regulator
(A1) are in plug brake mode. The main electronic card (A5)
responds by setting speed request output 610 (wire #36) at
2.5 volts locking the system of the drive motor, the drive
transistor regulator (A1) and the main electronic card (A5)
into plug braking.
Speed request output 610 (wire #36) from the main electronic
card (A5) remains at 2.5 volts as long as the drive transistor
regulator (A1) output pin 8 (wire #38) signals the main
electronic card (A5) that the drive transistor regulator (A1)
and the drive motor are in plug brake mode. A current limit
signal proportional to the brake pedal request is also sent
the drive transistor regulator (A1) input pin 11.
The current limit signal ranges from 0 volts to approximately
4.5 volts and controls the plugging force. Plug braking force is
regulated with the brake pedal. When the brake pedal is
raised, the current limit signal voltage and plug braking force
are higher. Both speed request and current limit signals are
measured with respect to the main electronic card (A5) output
609 (wire #35). The main electronic card (A5) monitors the
truck speed using the speed sensor (S64). If the truck speed
drops below approximately 0.25 mph (0.40 kph) before the
brake pedal is pushed down, the parking brake is applied and
the truck is stopped.
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To return control to the direction control lever (R1) pot, the

brake pedal must be fully depressed again. Fully releasing
the brake pedal at any time will immediately apply the parking
brake. During pedal plugging, the main electronic card (A5)
will only process the signal from the brake pedal pot (R3).
Travel input from the direction control lever (R1) brake is
ignored. If plug braking is request from both the control lever
and the bake pedal simultaneously, the input requesting the
greatest plug braking force controls plugging and the other is
ignored.
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9. 12-Volt Power Supply

A power supply on the main electronic card (A5) produces
12-Volts. It supplies power to the drive motor speed sensor
(S64), the drive motor direction sensor (S125), steering angle
A sensor (S66), steering angle B sensor (S67) and height
counter (U10). This supply has limited power capacity and is
not designed for user connection.
A5
32
31
105
S125
32
31 F53
S64
67
811 810 +
56
201
S66
204
S67
203
205
U10
206
LEGEND
Pressure Oil
Return Oil
12-Volt Power Supply
Electric Positive
Electric Negative
LED Off (Not Lit)
LED Input (Lit)
LED Output (Lit)
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R1
50
30
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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
10. 7.35-Volt Power Supplies

LEGEND
Pressure Oil
Return Oil
Electric Positive
Electric Negative
LED Off (Not Lit)
A power supply on the main electronic card (A5) produces

7.35-Volts. It supplies power to the brake pedal potentiometer
(R3), direction control lever (R1) potentiometer, reach
potentiometer (R12), tilt potentiometer (R13), sideshift
potentiometer (R14), and lift/lower (R11). This is a precision
supply with limited power capability and not designed for user
connection.
LED Input (Lit)

LED Output (Lit)
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256
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S45
22 40
A5
106
S31
207
107
79
22 40
29
504 7.35 V
50
R1
505 6.35V
30
201
31
32
LEGEND
Pressure Oil
A1
501 OV
610
35
10
56
S64
Speed Limit (S31) and Mast (S45) Switches
Return Oil
Electric Positive
Electric Negative
LED Off (Not Lit)
LED Input (Lit)
LED Output (Lit)
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11. Limit Switches

11.1. Truck Travel Speed Limiting
The speed limit proximity switch (S31) is located on the mast
tie bar at the bottom of the mast. It 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 turns ON supplying voltage to the main electronic
card (A5) input 107 (wire #79). The main electronic card (A5)
limits the speed request to the drive transistor regulator (A1)
limiting truck travel speed proportional to the value
programmed by the Reduce Speed Parameter 4. 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 (A5). The speed request to the
drive transistor (A1) regulator is no longer limited and the
truck is allowed to return to full travel speed.
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S45
22 40
A5
106
207
79
S31
107
22 40
88
40
Y10
LEGEND
Pressure Oil
A2
804
10
75
702
Speed Limit (S31) and Mast (S45) Switches
Return Oil
Electric Positive
Electric Negative
LED Off (Not Lit)
LED Input (Lit)
LED Output (Lit)
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11.2. Mast Staging Speed Limiting

Carriage lift speeds are limited during the transition from free
height to staging. The mast proximity switch (S45) is located
on the carriage. It senses the presences or absence of the
inner column. When the carriage is raised the mast switch
(S45) exits the top of the inner column at the end of free
height, and the absence of the inner column is detected. The
mast switch turns ON supplying voltage to the main electronic
card (A5) input 207 (wire #106). The main electronic card
limits the speed request to the lift transistor regulator (A2)
during the transition. The speed limit proximity switch (S31) is
also used to signal the main electronic card (A5) for staging
speed limiting. The speed limit proximity switch (S31) is
located on the mast tie bar at the bottom of the mast. It
senses the presence or absence of the lower mast tie bar on
the inner column. When the inner column begins to lift the
absence of the lower mast tie bar is detected. The speed limit
switch turns ON supplying voltage to the main electronic card
(A5) input 107 (wire #79). The speed request to the lift
transistor regulator (A2) is no longer limited. The lift is allowed
to return to full lift speed.
Carriage lowering speeds are limited during the transition
from staging to free height. As the inner column lowers the
presence of the lower mast tie bar is detected. The speed
limit switch (S31) turns OFF removing voltage to the main
electronic card (A5) input 107 (wire #79). The main electronic
card limits the signal to the proportional lowering valve (Y10),
limiting lowering speed during the transition. As the carriage
is lowered, the mast switch (S45) enters the top of the inner
column at the beginning of free height, and the presence of
the inner column is detected. The mast switch turns OFF
removing voltage to the main electronic card (A5) input 207
(wire #106). The signal to the proportional lowering valve
(Y10) is no longer limited. The lowering is allowed to full
lowering speed.
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A8
3+
+5
4 OV
-2
A7
A5
125
+7
40
22
F52
6 OV
-3
4+
+1
126
127
128
-5
402 403 +
404 -
106
S45
67
F53
31
405 +
U10
+
207
810 12 Volt Supply
98
205 A
99
206 B
32
811
LEGEND
Height Indicator and Preset Selector
Pressure Oil
Return Oil
Electric Positive
Electric Negative
LED Off (Not Lit)
LED Input (Lit)
LED Output (Lit)
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12. Height Indicator

The height indicator is designed to display the fork height in
the main lifting zone. The components of the height indicator
system include: height counter (U10); fuse F52, height
display (A8); staging switch (S45); and main electronic card
(A5). The height counter is a two-counter pulse generator
(encoder). The height indicator provides a digital display of
fork height in English or metric units. The staging switch
(S45) signals the beginning and end of freelift. The main
electronic card (A5) processes the information from the
height counter (U10), mast switch (S45), and Fork Reference
Parameter 10. The result of the processed information is a
fork height value to be displayed by the height display.
Communication to the height display from the main electronic
card (A5) is by a two wire proprietary data communication
scheme.
With the battery connected, emergency switch ON and the
key OFF, the height display (A8) will display four vertical half
bars. This is the correct indication showing the height display
not communicating with the main electronic card (A5). When
the key is turned ON, the height display will go to four solid
decimal points. If the decimal points flash, lower the forks
below the reference height, into the freelift zone. Set the
Special Height Parameter 9 to the lift limit height or to the
maximum mast height. If the decimal points continue to flash,
check for a broken communication wire (wire #125 and #126),
a failed staging switch (S45), a failed height display (A8), or a
failed main electronic card (A5). When lifting, the height
display will show solid decimal points until the staging switch
(S45) turns ON, supply voltage to the main electronic card
(A5) input 207 (wire #106). The main electronic card (A5)
responds by communicating the Fork Reference Parameter
10 to the height display from outputs 405 (wire #125) and 402
(wire #126). The height display shows the Fork Reference
Parameter value. When the intermediate columns begin to
lift, the mast cable turns the height counter.
The height counter is powered from the main electronic card
(A5) 12 volt supply, output 810 (wire #67), fuse F53 (wire
#31) and common, output 811 (wire #32). As the counter
turns, the two outputs (A and B) send pulses to the main
electronic card (A5), inputs 205 (wire #98) and input 206 (wire
# 99). The counter signals pulse between +12V and Gnd and
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can be monitored with a VOM while lifting slowly. The number

of pulses indicates the distance the mast has moved. The
phase relationship between the pulses indicates the direction
the mast is moving. As the main electronic card (A5)
processes the information from the height counter (U10), the
height display (A8) is continually updated with the new fork
height. As the mast approaches the value of the Special
Height Parameter 9 while lifting, the main electronic card (A5)
reduces and then stops the speed request to the pump
transistor (A2) regulator at the Special Height.
If the truck is equipped with an over-ride push button, the
operator can continue work above Special Height after
pushing the over-ride button. While lowering, the main
electronic card (A5) processes the information from the
height counter. The height display is continually updated with
the new fork height. When the staging switch (S45) enters the
inner column, the main electronic card (A5) stops counting
and resets to the Fork Reference height. The height display
(A8) shows four solid decimal points.
12.1. Height Preset Selector

The height preset selector (A7) works with the same
information supplied to the height indicator (A8) from the main
electronic card (A5), with the exception of height
programmable reference points (fork heights). Once the fork
height stop positions are entered in the height preset selector
(A7), fork heights can be selected at any time. After lifting
forks to the selected fork height, the height preset selector
(A7) allows electricity to flow to main electronic card (A5,
terminal 403 and 404) through wire #127 and #128, disabling
the lift for a brief period of time. When the program has been
executed, the lift/lower resumes normal operation. The height
preset selector (A7) has 99 possible fork height positions.
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13. Drive Motor Brush Wear Indicator

Switches
The diagram covers the drive motor brush indicator switches
(SA1) and (SA2). The drive motor on the reach truck contains
a pair of brush wear indicator switches. When the brushes
need replacing, an error code 17 will display on the operator
display. They will not disable the lift of the truck. This is
accomplished by metal bars, connected by wires to a
connector in the motor frame, contacting the brush spring as
the brush wears down. This completes a circuit allowing high
side armature voltage to main electronic card (A5) input 209
(wire #42) and/or low side armature voltage to main electronic
card (A5) input 208 (wire #41) depending on whether the
north or south pole brushes are worn, lighting the main
electronic card (A5) 208 and/or 209 LED. Brushes should be
inspected on a regular basis and replaced when the error
code displays.
K10
SA2
A1
F1
M1
SA1
K10
3
B+
ARMATURE
2
FIELD
K11
K13
M1
K13
K11
44
B7
34
S21
A5
101
902
40
803 51
K11
802 52 K13
41
LEGEND
42
Pressure Oil
208
209
Return Oil
Electric Positive
Electric Negative
Drive Motor Brush Wear Indicator Switches
LED Off (Not Lit)

LED Input (Lit)
LED Output (Lit)
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14. Pump Motor Brush Indicator

Switch
The pump motor brush indicator switches (SA1) and (SA2)
indicate when the pump motor brushes need replacing by
displaying the error code 16 on the dash display. They will not
disable lift of this truck. Inspect brushes and replace if
necessary. When brushes are worn and require servicing, the
pump motor brush indicator switches (SA1) and (SA2) close
the circuit and allow electricity to the main electronic card (A5,
terminal 210 and/or 211) through wire #77 and #78, lighting
the main electronic card (A5) 210 and/or 211 LED.
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)
Pump Motor Brush Wear Indicator Switches
LED Input (Lit)

LED Output (Lit)
Return
2002-01-09
265
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PS
S5.0
5000
Version no
T-code
002
395/396/397/398/399
15. Safety Check

Diagrams (Safety Check A and B) cover the safety checks on
the drive transistor regulator (A1). Once a year a safety check
of the system must be performed. The safety check is
performed by connecting the battery, turning the emergency
switch ON, turning the key switch ON, and placing a jumper
from the drive transistor regulator B-terminal to connector pin
2. The jumper will cause the line contactor (K10) to open and
the main electronic card (A5) to respond with an error code
E102. Successful completion of check confirms the circuit is
operating.
+ K10
K10
A2
F1
3 B+
A2
M1
ARMATURE
2 A
K11
K11
B7
A1
A5
44
S21
34
101
902
40
FIELD
K13
M1
K13
8
LEGEND
Pressure Oil
Return Oil
Safety Check A
Electric Positive
Electric Negative
LED Off (Not Lit)
LED Input (Lit)
LED Output (Lit)
266
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2002-01-09
F-code
Section
PS
C-code
S5.0
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
Safety Check B
Return Oil
Electric Positive
Electric Negative
LED Off (Not Lit)
LED Input (Lit)
LED Output (Lit)
Return
2002-01-09
267
F-code
Section
PS
S5.0
C-code
5000
Version no
T-code
002
395/396/397/398/399
16. Shunt Power Cable

The shunt power cable measures the total truck current
flowing to the negative side of the battery. This is a special
length and gauge of wire and must be replaced with the
correct parts for proper operation. Polarity of the two shunt
power cable lead wires (#606 + and #607 -) must be
observed when connecting to the main electronic card (A5).
The voltage measured by the main electronic card (A5)
across the shunt is used for battery discharge indication.
Shunt Wire
+
40
A5
606 606 -(+)
607 607 - (-)
608
608 +
LEGEND
Pressure Oil
Return Oil
Shunt Power Cable
Electric Positive
Electric Negative
LED Off (Not Lit)
LED Input (Lit)
LED Output (Lit)
268
Return
2002-01-09
F-code
PS
Version no
002
Section
C-code
S5.0
5000
T-code
395/396/397/398/399
List of Symbols
Symbol
Designation
Function
A1
Drive transistor regulator
Drive Motor
A2
Pump transistor regulator
Pump Motor
A5
Electronic card
Main Card
A6
Electronic card
Display
A7
Electronic card
Height Preset
A8
Electronic card
Height Indication
A60
Drive module
Electronic unit
A61
Drive module
Electronic unit
A62
Drive module
Electronic unit
BT
Battery
C1
Capacitor
Suppressor H1
E1
Light
Overhead Guard
E3
Light
Work
E4
Light
Work
E21
Heater
A1/A2
E22
Heater
Lever
E23
Heater
Lever
E24
Heater
Left Foot Switch
E25
Heater
Right Foot Switch
E26
Heater
A5
Fuse
Drive Motor
F1
Return
Remark
24/36 Volt
Horn
250 Amp
2002-01-09
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5000
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List of Symbols
Symbol
270
Designation
Function
Remark
F3
Fuse
Pump Motor
RRX35/RSX40
425A 24V/355A 36V
RRX45/RDX30/RSX50
250A 36V
F4
Fuse
Pump Motor
RRX45/RDX30/RSX50
250A 36V
F50
Fuse
Control Circuit
10 Amp
F51
Fuse
Steering Motor
30 Amp
F52
Fuse
Lift Height Indicator
1/4 Amp
F53
Fuse
12 Volt Sensor Feed
1/4 Amp
F54
Fuse
Display Power
1/4 Amp
F55
Fuse
Relay 1
10 Amp
F81
Fuse
Main Electronic Card and Control

Lever Heaters (Option)
10 Amp
F82
Fuse
Transistor Regulators and Pedal

Switch Heaters (Option)
10 Amp
H1
Horn
Alarm
H2
Flashing light
Light
option
H3
Traction
Alarm
option
K10
Contactor
Main Contactor
K11
Contactor
Directional
K13
Contactor
Directional
K34
Contactor
Bypass Lift
M1
Motor
Drive Motor
M3
Motor
Pump Motor
M6
Motor
Steering Motor
M11
Fan
Drive
Return
RRX45/RDX30/RSX50
2002-01-09
F-code
PS
Version no
002
Section
C-code
S5.0
5000
T-code
395/396/397/398/399
List of Symbols
Symbol
Designation
Function
Remark
M12
Fan
Electronics
M13
Fan
Overhead guard
R1
Potentiometer
Travel
R3
Potentiometer
Brake
R11
Potentiometer
Speed control, fork lift/lower
R12
Potentiometer
Speed control, reach/retract
R13
Potentiometer
Speed control, tilt
R14
Potentiometer
Speed control, sideshifter
R20
Resistor
Plug-in Module
R21
Resistor
Output Load
R22
Resistor
Output Load
S17
Switch
Key
S18
Switch
Horn
S21
Switch
Emergency stop
S31
Switch
Speed Limit
S33
Switch
Lift Limit Override
S45
Inductive sensor
Carriage Sensor
S48
Switch
Brake, Left Foot
S60
Thermostat
Drive Temperature
S64
Inductive sensor
Drive Speed
S65
Inductive sensor
Steer Wheel Reference
S66
Inductive sensor
Steer Angle A
S67
Inductive sensor
Steer Angle B
S96
Switch
Fan
Push Button
S97
Switch
Work Light
Push Button
Return
Inside component, not

serviced separately
Not used
2002-01-09
Push Button
271
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PS
S5.0
5000
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002
395/396/397/398/399
List of Symbols
Symbol
272
Designation
Function
Remark
S99
Switch
Light
Push Button
S108
Switch
Right Foot
S111
Switch
A1 & A2 Thermostat
S112
Switch
Ambient Temperature Thermostat
S113
Switch
A5 Thermostat
S125
Inductive sensor
Drive Direction
SA1
Switch
Carbon Brush Indicator, Drive/pump Motor (-)
SA2
Switch
Carbon Brush Indicator, Drive/pump Motor (+)
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
Proportional Valve, Lower Of Forks
Y12
Valve
Direction A
Y13
Valve
Direction B
Y14
Valve
Reach Out
Y15
Valve
Reach In
Y16
Valve
Sideshift
Y17
Valve
Tilt
Return
Inside component, not

serviced separately
2002-01-09
F-code
Section
PS
C-code
S5.0
5000
Version no
T-code
002
395/396/397/398/399
Component Location (Figure 1 of 2)

RRX45/RDX30/RSX50
K11
K13
A2
R14
K10
3 4
1 2
7 8
5 6
9 0
S17
R12 R13
2
3
R11
U1
A1
R1
K34
1
2
3
4
A1
1
2
3
4
F1
F3
A2
K10
K11
K13
RRX35/RSX40
Y14
Y15
Y17
Y16
Return
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5000
Version no
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002
395/396/397/398/399
Component Location (Figure 2 of 2)

Y11 Y12
M3
S125
S64
Y13
A5
H1
Y1
M11
S65
M1
S60
M6
CONTROL
FUSES
S48
274
Return
R3
2002-01-09
F-code
PS
Version no
000
Section
C-code
S5.1
5000
Electrical Symbols
T-code
395/396/397/398/399
Electrical Symbols
Electrical Symbols
Symbol
BT Prime-Mover Inc.
Return
Symbol
Description
Battery
Brake (coil)
Contactor
Diode
Emergency stop
Fuse
Horn
Inductive sensor
(normally closed)
Inductive sensor
(normally open)
Key switch
Magnet switch
(normally closed)
Magnet switch
(normally open)
Motor
Potentiometer
A1
Description
A2
Service Manual
2001-03-15
275
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S5.1
Electrical Symbols
C-code
5000
Version no
T-code
000
395/396/397/398/399
Electrical Symbols
Symbol
Description
Push button switch
(normally closed)
Symbol
Description
Push button switch
(normally open)
Resistor
Switch
Switch
(normally closed)
Switch
(normally open)
Valve
276
Return
Service Manual
2001-03-15
F-code
Section
C-code
PS
5.2
5000
Electrical Schematics (Serial numbers 27163000-28105000)
Version no
002
T-code
395/396/397/398/399
Electrical Schematics (Serial numbers

27163000-28105000)
Sh. = Sheet or page of Diagram

First number = Previous page wire was found.
Second number = Next page wire is found.
Legend
1. Circuit Diagram 1(11)
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278

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5000
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Return
15A

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280
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PS
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5000
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S108

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282

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PS
5.2
5000
Version no
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Return
RRX45
RDX30
RSX50
RRX45
RDX30
RSX50

Legend
2000-08-04
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284

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5000
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286

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288
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28105001-28126000)

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5000
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290

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PS
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5000
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Legend
Input
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291
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PS
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5000
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292
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Legend
2000-08-04
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PS
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5000
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000
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Legend
S108
Return
2000-08-04
293
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Section
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PS
5.3
5000
Version no
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294

Legend
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Section
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PS
5.3
5000
Version no
000
T-code
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Return
RRX45
RDX30
RSX50
RRX45
RDX30
RSX50

Legend
2000-08-04
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PS
5.3
5000
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296

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PS
5.3
5000
Version no
000
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298

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PS
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5000
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Note: This page shows optional Cold Storage / Freezer components.

Legend
300
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5000
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28126001-31285000)

Legend
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301
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PS
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5000
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302

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PS
5.4
5000
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Legend
Inputs
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PS
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5000
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304
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Legend
2002-02-07
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PS
5.4
5000
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000
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Legend
S108
Return
2002-02-07
305
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PS
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5000
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306

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PS
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000
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307
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5000
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308

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310

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Return
Do Not Connect Fan

on Freezer Models

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Legend
312
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Section
C-code
PS
5.5
5000
Electrical Schematics (Serial numbers 31285001-UP)
Version no
000
T-code
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5000
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314

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PS
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5000
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PS
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5000
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316
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5000
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PS
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5000
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318

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PS
5.5
5000
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5000
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320

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PS
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5000
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324
Section
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Legend
F-code
PS
5.5
5000
C-code
2002-02-07
F-code
Section
PS
S5.5
Version no
000
C-code
5110
Battery
T-code
395/396/397/398/399
Battery
CAUTION Before working on the battery, review
Battery Safety, beginning on page 21.
Batteries may weigh more than 2,900
pounds (1315 kg). Use extreme care during
replacement. Use a suitable battery
replacement device or hoist for lifting.
Battery
Connector
1. Removal
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. Disconnect battery connector from the truck

located at the top of truck cover.
Battery
Retainer
Plate
3. Position battery replacement device in accordance

with the manufacturers recommendations.
f
4. Lift battery retainer plate upward, tilt the edge

toward the mast slightly forward to disengage the
tongue on the operator compartment end.
5. Remove battery with lifting device.
2. Installation
1. With a fully charged and tested battery on the lifting
device, position the lifting device at the truck
according to the manufacturers recommendations.
2. Position the battery in the compartment. Be sure
the battery has no more than 0.50 inch (13 mm) of
free play movement in the battery compartment.
3. Install the battery retainer plate (see page 106).
4. Move lifting device from the area.
5. Connect battery connector to the truck, turn key
switch ON, and test operation of truck.
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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.
3.1. Battery Inspection and Care

NOTE!
Read, understand, and follow procedures,

recommendations, and specifications in the
battery and battery charger manufacturers
manuals.
Batteries in industrial trucks pick up various kinds of dirt and

dust depending on their surroundings and the types of
material handled. If cells are overfilled and electrolyte collects
on the covers, the following occurs:
1. The top of the battery becomes wet and stays wet,
since the acid in the electrolyte does not
evaporate.
2. This moist surface, in combination with certain
kinds of dirt, becomes electrically conductive and
permits stray currents to flow externally over the
top of the battery. This degrades battery
performance and truck operation.
3. The acid also causes corrosion of cell posts, nuts,
connectors and the steel battery case.
When inspecting batteries, check the following:
1. Wet covers can indicate overfilling, leaky seals at
posts, or excessive gassing during charge. If
covers are wet, determine the cause and correct
the problem.
2. Make sure batteries cannot move more than 0.5
inch (13 mm) in any horizontal direction. Shim or
block to restrain them.
326
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S5.5
Version no
000
C-code
5110
Battery
T-code
395/396/397/398/399
3.2. Battery Exterior Cleaning

Refer to recommended battery manufacturers guidelines for
details.
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.
Read, understand, and follow procedures, recommendations

and specifications in the battery and battery charger
manufacturers manuals.
CAUTION NEVER plug the battery charger into the

truck. This will severely damage the trucks
electrical system. Plug the charger ONLY
into the connector from the battery.
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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.
5. Battery History Record

A battery record system is essential because battery failure
can cause production slowdowns and increased battery
operating costs. A properly supervised record system can
detect and call attention to such operating irregularities as:
Overcharging
Undercharging
Over-discharging
Excessive water consumption
Excessive dirt and corrosion
Worn-out batteries
Excessive current consumption of trucks
Records should be kept for each battery. Your battery
supplier should be able to provide maintenance record
sheets. Each report should contain:
Battery number, type, serial number, and service data
Specific gravity and voltage readings for each cell
Temperature of the air and electrolyte
Electrolyte
Amperes
Condition of connectors, covers, sealing compound
and tray
General cleanliness
Number of total cycles
Average specific gravity drop
Watering frequency
User comments and observations
328
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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
2. From the top of the overhead guard, remove four
screws securing light/fan assembly.
3. Lower light/fan assembly enough to disconnect it
from the harness.
4. Remove light/fan assembly from truck.
5. Repair or replacement of light is achieved by
removing four screws in the side of light/fan dash
assembly to detach hanger bracket from the top of
the dash.
Item No.
1
Description
Bezel light
Light, dome
Tie, wire
1.2. Installation
1. Reassemble light/fan dash assembly. Be sure clip
nuts are positioned over mounting holes for
attachment to overhead guard.
2. Reconnect harness connections.
3. Install mounting screws through the top of
overhead guard to secure assembly.
Return
2000-08-04
329
F-code
Section
C-code
PS
5.6
Light Assemblies
5121
Version no
T-code
000
395/396/397/398/399
5. Test operation of light assembly, then return truck

to service.
2. Warning Lights (Option)

The warning lights are strobe lights. The color of the lights are
by customer request. Warning lights are mounted at the back
of the overhead guard, to the right of back post.
2.1. Removal
2. Disconnect electrical connection at warning light.
3. Remove two hex head screws (1) securing light
assembly (2) to overhead guard bracket (4).
4. Replace light bulb or light assembly as required.
Item No.
3
Description
Screw
Light
Bulb
Bracket, mounting
Alarm, travel
Screw
Fitting
330
Return
2000-08-04
F-code
Section
PS
5.6
5121
Light Assemblies
Version no
000
C-code
T-code
395/396/397/398/399
2.2. Installation
1. Secure light assembly to overhead guard bracket
(4) with two hex head screws (1).
2. Reconnect wiring harness.
4. Test operation of warning lights, then return truck
to service.
3. Working Lights (Option)

Light
The working lights option consists of two flood lights mounted

on the underside of the overhead guard.
3.1. Removal
2. Disconnect electrical connection at working light.
3. Remove screws
overhead guard.
securing
light
assembly
to
4. Replace light bulb or light assembly as required.
3.2. Installation
1. Secure light assembly to overhead guard.
4. Test operation of working lights, then return truck
to service.
Return
2000-08-04
331
F-code
Section
PS
5.6
Light Assemblies
C-code
5121
Version no
T-code
000
395/396/397/398/399
4. Travel Alarm (Option)

The travel alarm option is installed on the bottom of the
overhead guard. The alarm is on when the truck is moving.
4.1. Removal
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).
4. Test operation of alarm, then return truck to
service.
332
Return
2000-08-04
F-code
Section
PS
5.6
5121
Light Assemblies
Version no
C-code
T-code
000
395/396/397/398/399
5. Operator Fan (Option)

The operator fan/overhead light is located in the compartment
on the left side of the overhead guard. The operator fan/
overhead light is an option and may not be on your truck.
There are separate switches for the operator fan and
overhead light located to the right of the key switch on the
dash.
5
2
3
6
Item No.
Return
Description
Bracket, fan
Shroud, fan
Screw
Louver with bezel
Screw
Console, overhead
Tie, wire
2000-08-04
333
F-code
Section
PS
5.6
Light Assemblies
C-code
5121
Version no
T-code
000
395/396/397/398/399
5.1. Removal
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.
5. Test operation of light assembly, then return truck
to service.
334
Return
2000-08-04
F-code
Section
PS
S5.7
Version no
000
C-code
5160
Horn
T-code
395/396/397/398/399
Horn
1. Removal
2. Open motor compartment door to access the horn.
3. Disconnect wires from the horn.

4. Remove horn mounting bolt (2) using a 0.51 inch
(13 mm) socket and ratchet.
Item No.
2
Description
Horn
Screw
Switch, horn push button
Capacitor
Clamp
2. Installation
1. Attach horn to truck frame and tighten mounting
bolt (2).
2. Attach three wires.
3. Connect battery connector to the truck and test
operation.
4. Close motor compartment door.
Return
2000-08-04
335
F-code
Section
C-code
PS
Horn
S5.7
5160
Version no
T-code
000
395/396/397/398/399
336
Return
2000-08-04
F-code
PS
Version no
000
Section
C-code
S5.9
5311
Start/Stop Switches
T-code
395/396/397/398/399
Start/Stop Switches
1. General
Refer to the electrical schematics to identify the electrical
circuit location of switches (see applicable electrical
schematics page 277, page 289, page 301 or page 313).
1.1. Test/Inspection
Examine the switch for signs of arcing, overheating,
discoloration, cracking, or other physical damage. Replace
switch if necessary.
To test switch, isolate it from the electrical circuit. Remove all
connections from switch, making sure all wires are labeled
and identified for reconnection.
Use an ohmmeter set to a low resistance scale to measure
resistance across the switch. In a closed position, the switch
should be less than 1 ohm. In an open position, the switch
should show a resistance greater than 10 megohms.
Key Switch
4
2 3
7 8
5 6
9 0
2. Key Switch (S17)

The reach truck is equipped with a two position (off/on) key
switch, which energizes all truck operations, excluding the
horn. The horn can be sounded with the emergency
disconnect switch (S21) in the ON position. The key switch is
located on the operators pod.
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.
Return
2000-08-04
337
F-code
Section
PS
S5.9
Start/Stop Switches
C-code
5311
Version no
T-code
000
395/396/397/398/399
2.2. Removal
2. Remove pod. Remove bottom half of pod see
page 215).
3. Disconnect wires from the bottom of key switch.
4. Remove mounting nut from stem of key switch.
5. Remove key switch.
2.3. Installation
1. Install new key switch and tighten locking nut.
2. Connect wires to terminals.
3. Connect battery connector to the truck and check
operation.
5. Install bottom half of pod. Install pod.
338
Return
2000-08-04
F-code
PS
Version no
000
Section
C-code
S5.9
5311
Start/Stop Switches
T-code
395/396/397/398/399
3. Emergency Disconnect Switch

(S21)
The truck is fitted with an emergency disconnect or stop
switch (S21) located on the right side of the truck above the
battery connector.
Emergency
Stop
Switch
3.1. Inspection
With the battery plugged in and the emergency disconnect
switch in the out position, battery voltage B+ should be
present on both terminals of the switch. Test the emergency
disconnect switch with an ohmmeter after removing it from
the electrical system. In the OFF position, the ohmmeter
should read greater than 10 megohms. In the ON position,
ohmmeter should read less than 1 ohm. Replace switch if
readings are not within ranges.
3.2. Removal
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.
Return
2000-08-04
339
F-code
Section
PS
S5.9
Start/Stop Switches
C-code
5311
Version no
T-code
000
395/396/397/398/399
3.3. Installation
1. Place switch operator down through the opening in
the frame.
2. Attach the switch body to operator from the
backside of the frame.
3. Turn the halves clockwise to engage the latches.
4. Secure the base of the emergency disconnect
switch to the back of the frame with two screws.
5. Reconnect electrical harness to the base of the
emergency disconnect switch.
6. Position dash and secure in place.
8. Test truck operation, then return to service.
340
Return
2000-08-04
F-code
PS
Version no
000
Section
C-code
S5.8
5190
Battery Connector
T-code
395/396/397/398/399
Battery Connector
2
1
4
Item No.
Description
Connector, SB-350
Cap screw
Cable, Negative
Cable, Positive
1. Location
The battery connector is located on the right side of the truck,
above the battery.
f
Battery
Connector
2. Inspection
2. Check battery connector for damaged cables.
Return
2000-08-04
341
F-code
Section
PS
S5.8
Battery Connector
C-code
5190
Version no
T-code
000
395/396/397/398/399
3. Check to see if battery cables are pulled out of

connector.
4. Check cables at battery terminals. Connections
should be tight, with no corrosion.
5. Check inside connector at internal contacts for
damage, dirt, or corrosion. DO NOT use a metal
object to clean connector.
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 charger 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.
342
Return
2000-08-04
F-code
PS
Version no
000
Section
C-code
S5.10
5332
Mast Switch (S31)
T-code
395/396/397/398/999
Mast Switch (S31)

Mast Switch1 (S31) is a proximity switch located at the
bottom of the mast. The mast switch (S31) serves two
functions: truck speed limiting and mast staging limiting. In
the truck speed limiting function, the mast switch (S31) is
provided to reduce travel speed to approximately 2.5 MPH
after the first stage of lift. The first stage of lift ends when the
mast inner columns begin to extend from main mast frame. In
the mast staging speed limiting function, the mast switch
signals the main electronic card to limit lift speed during the
staging transition.
1. General
Refer to the electrical schematic to identify the electrical
circuit location of the switch (see applicable electrical
schematic on page 277, page 289, page 301 or page 313).
Examine switch for signs of arcing, overheating,
switch if necessary.
connections from switch, making sure all wires are labeled
For trucks with serial numbers before 27272000, use an
ohmmeter set to a low resistance scale to measure
resistance across the switch. In a closed position, the switch
should be less than 1 ohm. In an open position, the switch
should show a resistance greater than 10 megohms.
For trucks with serial numbers after 27272000, the switch
(S31) senses the presence or absence of the lower mast tie
bar on the inner column. When the inner columns are
elevated, and the load is above freelift, the absence of the
lower mast tie bar is detected. Speed limit mast switch (S31)
turns ON supplying voltage to the main electronic card input
107. When the mast is lowered and the presence of the lower
mast tie bar is detected, the speed limit switch turns OFF
removing voltage to the main electronic card. For electrical
operation see page 258 and/or 260.
Return
2001-08-20
343
F-code
Section
PS
S5.10
Mast Switch (S31)
C-code
5332
Version no
T-code
000
395/396/397/398/999
Before Serial number 27272000

3
4
After Serial number 27272000
Item No.
344
Return
Description
Bracket, switch
Screw, bracket mounting
Switch, limit
Screw, switch mounting
Screw, bracket mounting
Bracket, switch
Sensor
2001-08-20
F-code
PS
Version no
000
Section
C-code
S5.10
5332
Mast Switch (S31)
T-code
395/396/397/398/999
1.2. Adjustment
1. Raise empty carriage until the bottom of tie bar is
even with bottom of mast switch.
2. Secure the carriage with blocks and a hoist to
prevent any movement.
3. Loosen jam nut securing the mast switch to the
mast.
4. Adjust switch to 0.187 inch (4.76 mm) between the
tie bar and the face of the switch. Allowable
tolerance is +0.0625 inch (1.59 mm) and -0 mm.
5. Tighten jam nut.
6. Check clearance with jam nut tightened.
7. Remove blocks and hoist.
8. Place a maximum capacity load on forks. Verify
that the tie bar does not contact switch under
normal working conditions.
9. Adjust the clearance as necessary to achieve
proper clearance when fully loaded.
10. Remove the load from forks.
11. Test the truck operation to verify normal travel
speed with mast lowered.
Return
2001-08-20
345
F-code
Section
PS
S5.10
Mast Switch (S31)
C-code
5332
Version no
T-code
000
395/396/397/398/999
1.3. Removal
1. Raise the empty carriage until the bottom of the tie
bar is above the mast switch.
2. Secure the carriage with blocks and a hoist to
prevent any movement.
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.
5. Adjust switch following the procedure on page 345.
346
Return
2001-08-20
F-code
PS
Section
C-code
S5.11
5391
Control Cable and Harness
Version no
T-code
000
395/396/397/398/399

Located on right side of
Operator Compartment
1. Fuses
Examine the fuse for signs of overheating, discoloration,
cracking, or other physical damage. Replace fuse if
damaged.
F81
To test a fuse, remove it or isolate it from the electrical circuit.

Remove fuse from truck or by removing all the connections
from one side of the fuse.
Use an ohmmeter set to Rx1 scale and measure the
resistance across the fuse. The resistance should be less
than 1 ohm.
F82
F55
F54
F53
Fuse
No.
Amp
F1
250
Drive Motor Circuit
F3
425
Pump Circuit, 24 volt (RRX35/RSX40)
355
Pump Circuit, 36 volt (RRX35/RSX40)
250
Pump Circuit, 36 volt - (2) 250 Amp fuses

(RRX45/RDX30/RSX50)
F52
F50
F4
F51
F50
15/
10
Control Handle Circuit

15A (RRX35/45 S/N 27091000-27135000)
10A (RRX35/45 S/N 27135001 - UP)
F51
30
Steering Circuit
F52
1/4
Height Indicator Circuit
F53
1/4
Sensor & Height Circuit
F54
1/4
Operator Display Circuit
F55
10
Fan/light, Flashing Display Circuit
F81
10
Main Electronic Card and Control

Handle Heaters (Optional)
F82
10
Pedal Switch Heaters (Optional)
Located under Dash
F1
F3 or F4
Return
Function
2000-08-04
347
F-code
Section
C-code
PS
S5.11
5391
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.
Do not pull on wires.
Carefully mate and unmate all connectors.
Do not pry apart connectors with unspecified tools.
Examine and maintain any added materials used

to dress or protect wire. This includes spiral wrap,
brackets, cable ties, fasteners, flexible conduit, etc.
Check harness wires for abrasions, scrapes, nicks

in wire, damage from overheating or burns, or
other general insulation damage.
Replace terminations with exposed wire visible at

connectors. Damaged terminations, exposed
wires, or damaged connectors can cause operational failure of truck.
During troubleshooting and repairs, it is sometimes

necessary to unmate a connector, move a harness, cut a
cable tie, or remove wire from a bracket. Note carefully the
location of wire and all protective or securing attachments
before moving harness.
After repair, return or replace all protective and/or securing
hardware to its original condition. Protective materials are
necessary to provide reliable performance of interconnect
system.
There should be a wire marker at each termination. If marker
is missing or unreadable, remark wire to allow easier
identification.
NOTE!
348
Return
It is normal to find unused connectors for

uninstalled options that have had heat
shrink applied over them and have been
strapped to harness.
2000-08-04
F-code
PS
Section
C-code
S5.11
5391
Version no
000
T-code
395/396/397/398/399
2.2. Power Cables

Power cables should be checked for damage including:
Evidence of overheating
Burned spots in cable
Nicks in insulation
Damaged or overheated terminal lugs
Damaged mounting hardware or brackets
Repair or replace damaged cables or mounting hardware as

necessary. Power cables are marked on terminal lug with
location where they belong. If marking is missing or is not
readable, remark cable with correct information. The terminal
lugs should be crimped tightly and securely on the wire.
Replace lug if overheating is evident and repair or replace
faulty connectors as necessary.
Return
2000-08-04
349
F-code
Section
C-code
PS
S5.11
5391
Version no
T-code
000
395/396/397/398/399
350
Return
2000-08-04
F-code
Section
PS
S5.12
Version no
000
C-code
5441
Contactors
T-code
395/396/397/398/399
Contactors
1. General
1.1. Resistance Testing
Visually inspect the contactor for any signs of burning or
physical damage.
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.
1.2. Contactor Tip Inspection
Severe Pitting
Return
Use the following guidelines when inspecting contactor tips:

Disconnect battery before inspecting or servicing
contactor tips.
Darkened points do not indicate burning.
Burning indicates a loss of contact point material.
Replace contact points if there is not enough
contact point material to last until the next regular
inspection.
The silver alloy part of the point is usable contact
material; the copper backing is not.
Do not file contact points to remove discoloration or
minor irregularities. This practice produces a
surface more susceptible to sticking.
If a cone and/or crater appear, replace contactor
tips.
2000-08-04
351
F-code
Section
C-code
PS
S5.12
Contactors
5441
Version no
T-code
000
395/396/397/398/399
2. Direction Contactors
4
3
Item No.
352
Return
Description
Item No.
Description
Contactor assembly
Base
Screw
Kit, service
Contactor
2000-08-04
F-code
Section
PS
S5.12
Version no
000
C-code
5441
Contactors
T-code
395/396/397/398/399
2.1. Removal
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.
5. Turn key switch ON and test truck operation.
6. Turn the key switch OFF. Disconnect battery
7. Install dash.
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
3. Lift Bypass Contactor

(RRX45/RSX50/RDX30)
Item No.
354
Return
Description
Contactor
Kit, service
Screws
2000-08-04
F-code
Section
PS
S5.12
Version no
000
C-code
5441
Contactors
T-code
395/396/397/398/399
3.1. Removal
2. Remove dash.
4. Remove contactor coil wires by pulling the wire
necessary.
5. Remove two screws (3) holding the contactor to
the mounting 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
securely.
5. Turn key switch ON and test truck operation.
6. Turn key switch OFF.
Disconnect
battery
7. Install dash.
Return
2000-08-04
355
F-code
Section
C-code
PS
S5.12
Contactors
5441
Version no
T-code
000
395/396/397/398/399
4. Main Contactor
2
3
Item No.
356
Return
Description
Screws
Contactor
Cover, bridge
Kit, service
2000-08-04
F-code
Section
PS
S5.12
Version no
000
C-code
5441
Contactors
T-code
395/396/397/398/399
4.1. Removal
2. Remove dash.
4. Remove contactor coil wires by pulling wire
necessary.
5. Remove two screws (1) holding contactor to
mounting 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
securely.
5. Turn the key switch ON and test truck operation.
6. Turn the key switch OFF. Disconnect battery
7. Install dash.
Return
2000-08-04
357
F-code
Section
PS
S5.12
Contactors
C-code
5441
Version no
T-code
000
395/396/397/398/399
358
Return
2000-08-04
F-code
PS
Section
C-code
S5.13
5460
Transistor Panel (Drive)
Version no
T-code
000
395/396/397/398/399

2
3
4
1
Item No.
NOTE!
Return
Description
Transistor panel, drive
Screw
Lockwasher
Nut
Screw
Screw
When the drive transistor controller is

replaced, the logic chip in the A5 logic card
for software versions P5-04, P5-05, and
P5-06 needs to be updated.
initial power up.
2000-08-04
359
F-code
Section
C-code
PS
S5.13
5460
Version no
T-code
000
395/396/397/398/399
1. Motor Connections
The transistor regulator for the drive has four connections for
power cables, as set out in the table below.
Terminal Number
Function
Brake diode to the motor's series

field and armature (Drive control
only)
B-
Battery minus
B+
Battery plus
Minus connection to the motor's

series field
Connections for controls

Terminal
Number
Connection
Supply voltage
Safety test
Not used
Not Used
Not Used
Negative speed/current reference
Safety signal for main contactor
Plug braking
360
Return
Function
Not Used
10
Reference value 0-5 V
11
Current limit 0-5 V
LED No.
Color
Green
Supply voltage
Yellow
Upper/lower temperature
Red
Fault in power circuits
Red
Fault in reference value

circuit
Function
2000-08-04
F-code
Section
PS
C-code
S5.13
5460
Transistor Panel (Lift)
Version no
000
T-code
395/396/397/398/399

6
3
4
Item No.
Return
Description
Transistor panel, lift
Screw
Lockwasher
Nut
Screw
Screw
2000-08-04
361
F-code
Section
PS
S5.13
C-code
5460
Version no
T-code
000
395/396/397/398/399
The transistor regulator for the lift has four connections for
power cables, as set out in the table below.
Terminal Number
Function
B-
Battery minus
B+
Battery plus
Minus connection to the motor's

series field
Connections for controls

Terminal
Number
Connection
362
Supply voltage
Not Used
Liftreg. current
Liftreg. voltage
Minus Liftreg. temp and liftreg. current
Minus Liftreg. speed reference value

and liftreg current
Minus bypass contactor
Liftreg. temp
Return
Function
Not Used
10
Reference value 0-5 V and Liftreg.

speed request
11
Current limit 0-5 V and liftreg. current
LED No.
Color
Green
Supply voltage
Yellow
Upper/lower temperature
Red
Fault in power circuits
Red
Fault in reference value

circuit
Function
2000-08-04
F-code
PS
Version no
000
Section
C-code
S5.13
5460
T-code
395/396/397/398/399
2. Circuit Check, Drive Only

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 217 and
page 100).
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 see Power
Circuit Checks on page 397, and replace the
entire transistor regulator.
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.
Return
2000-08-04
363
F-code
Section
PS
S5.13
C-code
5460
Version no
T-code
000
395/396/397/398/399
364
Return
2000-08-04
F-code
Section
PS
S5.14
5511
Micro Switches
Version no
000
C-code
T-code
395/396/397/398/399
Micro Switches
1. General
To identify the electrical schematic for circuit location of
switches, see applicable electrical schematic page 277,
page 289, page 301 or page 313. Examine switch for signs of
arcing, overheating, discoloration, cracking, or other physical
damage. Replace switch if necessary.
connections from the switch, making sure all wires are
labeled and identified for reconnection. Use an ohmmeter set
to a low resistance scale to measure resistance across the
switch. In a closed position, the switch should be less than 1
ohm. In an open position, the switch should show a
resistance greater than 10 megohms. With the battery
plugged in and the key switch in the ON position, equal
voltage should be present on both terminals of the switch.
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
2. Lift Limit Override Switch (S33)

Optional
Lift Limit
Override
Switch
The lift limit override switch (S33) is located in the switch

cluster to the left of key switch on the pod. The lift limit cutout
height is a programmable parameter setting on the main
electronic card. If the lift limit with override option is available,
pressing the switch on the dash will allow the lift to function
above the cutout height. As long as the carriage remains
above the preset cutout height, the operator can lift and lower
without pressing the override switch again. If the carriage
drops below cutout height or hydraulic system is inactive for a
set time, the override switch must be pressed again to
reactivate lift.
2.1. Removal
2. Loosen pod and remove lower control pod panel to
allow access to wiring harness connection at
switch cluster.
3. Pull two wires off tabs on back of switch.
4. Unscrew nut securing switch in switch cluster.
5. Lift switch from switch cluster.
2.2. Installation
1. Place a new switch in the switch cluster.
2. Secure switch with nut.
3. Attach two wires to tabs on back of switch.
4. Secure pod to truck.
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
3. Optional Light and Fan Switches

(S96, S97 and S99)
The optional light and fan switches are located in a switch
cluster to the left of the key switch on the pod. A blank cap
indicates option is unavailable.
The operator fan switch (S96) is in the upper left corner of the
cluster. The overhead light switch (S99) is located in the
lower left corner. The working lights (S97) switch is in the
upper right corner of the cluster.
Operator
Fan
Switch
Working
Light
Switch
3.1. Removal
2. Loosen the pod and remove lower control pod
panel to allow access to wiring harness connection
at the switch cluster.
3. Pull two wires off the tabs on the back of switch.
4. Unscrew nut securing the switch in the switch
cluster.
5. Lift switch from the switch cluster.
3.2. Installation
1. Place a new switch in the switch cluster.
2. Secure switch with nut.
3. Attach two wires to the tabs on the back of the
switch.
4. Secure pod to truck.
6. Check operation of truck, then return truck to
service.
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

1. Connectivity to Truck
NOTE!

initial power up.
The main electronic card is connected to the trucks circuitry

by nine connectors. To remove the connectors one through
eight, depress the connectors latch and unplug the
connector. To install the connectors, push the connectors
together until the latch snaps into position. To remove
connector nine, grasp the connector (do not grasp the wires)
and, with a slight rotational wiggling action, unplug the
connector. To install, push the connector onto the pins
making sure all of the pins are captured by the connector.
The nine connectors are grouped functionally from the top
down: digital inputs (2); communications (2); analog inputs
(1); analog outputs (1); digital outputs (2); and power output
(1). The main electronic cards top eight connectors and light
emitting diodes (LED) are clearly identified by numbers.
When the main electronic card is connected correctly to the
trucks battery, the digital input LEDs light green indicating
that the input is on and battery voltage is present at the input
pin. The digital output LEDs light red when the output is on
and battery voltage is present at output pin. The
communications and analog voltage inputs and outputs do
not have LEDs. The ninth connector is power for the steer
motor. Six green LEDs near connector 9 indicate the main
electrical card status. For the truck to be operational, all six
LEDs must be ON.
The main electronic card is located on the right side of the
electrical compartment and enclosed in a protective casing.
Replacement of the main electronic card should be as an
entire unit (card and enclosure).
Return
2001-10-31
369
F-code
Section
PS
S5.15
C-code
5710
Version no
T-code
001
395/396/397/398/399
2. Transistor Controller Replacement

NOTE!

initial power up.
For truck serial numbers 28126001 - 31155000, when the

transistor controller is replaced the logic chip in the A5 logic
card needs to be updated to the P5-07 software. To up date
the logic card proceed as follows:
1. Record all current parameter settings of the A5
logic card.
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.
3. Remove the drivers compartment right side panel

(exposing the A5 logic card) by loosening the lower
two allen 0.19 inch (5mm) bolts. Remove the upper
370
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2001-10-31
F-code
PS
Version no
001
Section
C-code
S5.15
5710
T-code
395/396/397/398/399
two allen bolts. Carefully pull the panel towards the

centerline of the truck and lift. Set the panel aside.
4. Remove the two lower screws holding the
aluminum cover on the A5 card.
5. Remove two 0.19 inch (5mm) bolts holding the A5
card to the frame at the top of the A5 card.
6. Carefully tip the A5 card toward the centerline of
the truck far enough to allow access to the two
screws holding the aluminum cover on the card
and remove cover.
NOTE!
Cutting the warranty seals will not affect

applicable product warranty.
7. Cut the Warranty Seals and remove the aluminum

cover.
8. Install one of the top allen bolts to hold the A5 card
in place while changing the logic chip.
Alligator clip on
the end of the
static strap.
Logic chip
extractor tool.
Wrist strap on
the end of the
static strap.
9. Attach static strap to the wrist of the working hand

and then to the A5 card frame.
Return
2001-10-31
371
F-code
Section
PS
S5.15
C-code
5710
Version no
T-code
001
395/396/397/398/399
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.
NOTE!
When removing the logic chip, be careful to

grasp only the logic chip and not the chip
socket with the extraction tool.
10. Using the chip removal tool carefully remove the

chip and set aside.
11. Carefully remove the new logic chip from its
container.
12. Install the new chip with the notch in the chip
located toward the top of the A5 card in the lower
372
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2001-10-31
F-code
PS
Version no
001
Section
C-code
S5.15
5710
T-code
395/396/397/398/399
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 not 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. Connect battery connector to truck 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.
Return
2001-10-31
373
F-code
Section
PS
S5.15
C-code
5710
Version no
T-code
001
395/396/397/398/399
3. Removal
2. Remove main
page 103).
electronic
card
panel
(see
3. Disconnect all electrical cables from the main

electronic card. Be sure to note connection points
for installation.
4. Remove four Allen head mounting screws.
5. Remove the main electronic card unit from the
truck.
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.
5. Perform RV2
page 382).
adjustment
procedure
(see
6. Test operation of truck.

7. Install the main electronic card panel.
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
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
Main Electronic Card with Terminal Locations

I=Input, green LED; O=Output, red LED
Terminal
Number
LED No.
Connection
101
101
Drive chopper - OK
102
102
Right foot switch
103
103
Plug braking
104
104
Drive motor thermal sensor (see page 303)

For serial number break of this usage see page 279
105
105
Drive direction
106
106
Lift limit override
107
107
Speed reduction
111
111
Brake switch
Return
Function
2001-10-31
375
F-code
Section
C-code
PS
S5.15
5710
Version no
T-code
001
395/396/397/398/399
LED No.
376
Color
Function
TX
Green
Height indication/height preset -TX, transmits data
RX
Green
Height preset - RX, receives data
Terminal
Number
LED No.
Connection
201
201
Drive measuring
202
202
Steering wheel reference 180
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
Brush wear indicator -
209
209
Brush wear indicator +
210
210
Brush wear indicator -
211
211
Brush wear indicator +
Function
Terminal Number
Connection
Function
301
Display power +
302
Display power -
303
TX positive display
304
TX negative display
Terminal Number
Connection
402
TX negative height unit
403
RX positive height unit
404
RX negative height unit
405
TX positive height unit
Return
Function
2001-10-31
F-code
Section
PS
Version no
T-code
001
395/396/397/398/399
Terminal
Number
LED No.
Connection
501
501
24/36 Volt select
502
Steering/tach +
503
Steering/tach -
504
Positive 7.35 V
505
Speed reference value
506
Lift/lower potentiometer
507
Reach/retract potentiometer
508
Tilt potentiometer
509
Sideshifter potentiometer
510
Function
Zero Voltage
511
Analog brake transducer
Terminal Number
Connection
601
Negative for 602-604
602
Lift reg. temperature
603
Lift reg. voltage
604
Lift reg. current
606
Battery indicator current +
607
Battery indicator current -
608
Battery indicator +
609
Speed/current reference -
610
Speed reference value +
611
Current limit +
Return
C-code
S5.15
5710
Function
2001-10-31
377
F-code
Section
C-code
PS
S5.15
5710
Version no
T-code
001
395/396/397/398/399
Terminal
Number
LED No.
Connection
Function
701
Negative for 702-703
702
Lift reg. speed reference value +
703
Lift reg. current limit +
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
Drive, operator direction (forks trailing)
803
803
Drive, fork direction (forks first)
804
804
Fork lower
805
805
Brake coil
808
+24/36 Volt
809
INP. +24/36 V
810
Sensor feed + 12V
811
Sensor feed -
Function
806
807
378
Return
2001-10-31
F-code
PS
Version no
001
Terminal
Number
LED No.
901
+24/36 V steer motor
902
Zero Voltage
903
+ steer motor
904
- steer motor
LED
Color
Indication, all voltage is fed to the electronic card
STEER PWR
Green
Voltage feed to control electronics
STEER OK
Green
Steering OK
Switch
395/396/397/398/399
Function
SW 1
Switch to program parameters and error codes
SW 2
SW 3
Potentiometer
T-code
Function
Green
Return
C-code
S5.15
5710
Connection
POWER
RV2
Section
Function
Adjustment of lowering speed (see page 382)
2001-10-31
379
F-code
Section
C-code
PS
S5.15
5710
Version no
T-code
001
395/396/397/398/399
SW1
SW2
5. Display
SW3
NOTE!

initial power up.
It is possible to review the trucks specific register and

program the clock. The truck cannot be driven with any
functions when it is in the programming mode.
Review trucks specific register:
1. Remove right-hand access panel in operators
compartment.
2. Turn the key switch so the main electronic card is
ON.
3. Press button SW3 three times on the main
electronic card to view specific registers.
Press SW1 to see date error code was

registered.
Press SW1 again see time error code was

registered.
Press SW1 to see next registered error code.
Turn key switch OFF or wait approximately 20

seconds to return to run mode.
4. Press SW3 once again to view parameters setting.
Press SW2 to scroll through parameters
SW1 has no function at this time.
The character window (C) will present the different functions:
Warning and error codes
Parameters
Running time
The address register will be shown in the left-hand section

and the value in the right-hand section for the Warning/Error
Codes and Parameters.
J
380
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I H G FE
D
2001-10-31
F-code
Section
PS
Version no
T-code
001
SW1
SW2
SW3
C-code
S5.15
5710
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;
Press SW3 three more times.
Waiting approximately 20 seconds.
Turn key switch OFF.

Function
Value
Hours
09=9h
Minutes
35=35 min.
When error codes are displayed in the character window (C),

the character box (G) will light. The character box (F) will light
when the parameters are displayed in the character window
(C). It is not possible to reprogram the parameters in this
mode. To change to the programming mode, see page 401.
Complete programming by turning the key switch off and on
once. Programming mode will quit if the key is not pressed
within 10 seconds.
7. Effect on Truck
All hydraulic functions except fork lowering are stopped.
Return
2001-10-31
381
F-code
Section
PS
S5.15
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
9. RV2 Adjustment Procedure
RV2 Trim Pot
382
Return
2001-10-31
F-code
PS
Version no
001
Section
C-code
S5.15
5710
T-code
395/396/397/398/399
1. Remove the main electronic card panel.

2. Raise fork carriage so that it is visible from the
operator compartment.
3. Locate RV2 trim pot on the main electronic card.
The RV2 trim pot will be above the right corner of
the #4 electrical connector.
NOTE!
The RV2 trim pot is a 270 degree turn pot.

Over turning the pot can cause damage to
the Pot.
4. Turn RV2 Trim Pot fully clockwise.

NOTE!
The adjustment must be performed each

time the main electronic card is replaced.
5. While standing on the brake pedal switch, move

the lift/lower lever 0.0787 inch (2 mm) towards
lower. Adjust the RV2 trim pot so the fork carriage
will begin to lower.
10. Adjustment Procedures for

Setting Brake Switch and Brake
Transducer
1. Remove cover panel from main electronic card.
2. Remove floor plate.
NOTE!

initial power up.
3. Go into programming mode (see page 401). Note

the current parameter settings.
Return
Set parameter 12 at 4
Set parameter 15 at 50 (P5-04 and P5-05);

16 at 50 (P5-06 and P5-07)
2001-10-31
383
F-code
Section
PS
S5.15
C-code
5710
Version no
T-code
001
395/396/397/398/399
4. After changing these parameters, turn key switch

OFF and turn back ON.
5. The display should read 10 with the brake pedal all
the way up.
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. (The LED on input 111 on
the A5 card will flash on and off as the brake switch
actuates.)
9. After making adjustments, go back into the
programming mode.
Set parameter 12 at 2 or current setting.
Set parameter 15 at 50 (P5-04 and P5-05);

16 at 50 (P5-06 and P5-07)
10. Reinstall floor plate and cover.
11. Battery Discharge Indicator

Parameter Adjustment
Parameter 13 is the battery type that will allow the
programmer a variety of options relating to the battery
discharge indicator (BDI) display reading. This parameter
may be programmed to manipulate the BDI display so the
battery voltage reading at 80% discharge will reflect a voltage
reading other than 1.75 volts per cell under load (see
Parameter 13 Initial Value on page 386). The parameter 13
has a value setting between 1 and 30. A setting of 1 will result
in the most shallow discharge. A setting of 29 will result in the
deepest discharge. A setting of 30 will force the BDI to reset
to full charge, this is not a permanent setting.
Parameter 13 should be adjusted so the 10 bar BDI display
will reflect the battery discharge as the BDI display
decrements down from the fully charge level, to the 80%
384
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2001-10-31
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PS
Version no
001
Section
C-code
S5.15
5710
T-code
395/396/397/398/399
discharged level (see page 387 or page 388.) A full charge

level on the BDI display should have an open battery voltage
of approximately 2.1 volts per cell. The 80% discharged level
on the BDI display should reflect the preferred battery
discharge level.
Full charged battery BDI full scale reset voltage:
- 24 volt truck is 25 volts
- 36 volt truck is 37.5 volts
Full discharged battery voltage:
The minimum shunt current necessary to activate the BDI is
approximately 150 Amps. Fully discharged battery BDI
response time is approximately 2 operating hours from full
battery indication with parameter 13 set to value 20 at
minimum shunt current. Response time decreases with
smaller parameter 13 values and larger shunt currents.
Response time will increase with larger parameter 13 values.
Parameter 13 values listed below represent a starting guide
only. The final value depends on the application, battery
condition, battery capacity, etc. Final values are valid only for
different batteries of equal performance characteristics and
equal applications. Typical RRX35 and RSX40 applications
are for light duty and RRX45, RDX30 and RSX50 are
medium duty.
To initially set parameter 13, select the operating duty of the
truck. Select the desired discharged battery voltage under
load. Program parameter 13 with the value from the table.
The parameter 13 table represents the discharge voltage the
BDI will measure the under load.
Return
2001-10-31
385
F-code
Section
C-code
PS
S5.15
5710
Version no
T-code
001
395/396/397/398/399
Parameter 13 Initial Value
Parameter
13 Value
Operating Light
Duty Battery Voltage/
Cell
Operating Medium
Cell
Operating Heavy
Cell
RRX35/RSX40
RRX35/45/RSX40/50/RDX30
RRX45/RDX30/RSX50
2.09
1.94
1.87
2.03
1.88
1.81
1.96
1.81
1.74
1.89
1.73
1.66
1.81
1.66
1.57
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
BATTERY EXCEEDS
FULL DISCHARGE
23
24
25
1.74
1.59
1.52
26
27
NOT VALID
28
386
Return
29
1.67
1.53
30
Force Reset
Force Reset
Force Reset
2001-10-31
F-code
PS
Version no
001
Section
C-code
S5.15
5710
T-code
395/396/397/398/399
Battery Discharge Indicator Bar Level Chart (24 Volt)

COLOR
OPEN
CELL
VOLTAGE
OPEN
CELL
VOLTAGE
OPEN
CELL
VOLTAGE
OPEN
CELL
VOLTAGE
OPEN
CELL
VOLTAGE
10 MINIMUM
GREEN
25.00
25.00
25.00
25.00
25.00
9 MAXMUM
GREEN
24.79
24.83
24.86
24.90
24.94
9 MINIMUM
GREEN
24.58
24.65
24.73
24.80
24.88
8 MAXMUM
GREEN
24.36
24.48
24.59
24.70
24.81
8 MINIMUM
GREEN
24.15
24.30
24.45
24.60
24.75
7 MAXMUM
GREEN
23.94
24.13
24.31
24.50
24.69
7 MINIMUM
GREEN
23.73
23.95
24.18
24.40
24.63
6 MAXMUM
GREEN
23.51
23.78
24.04
24.30
24.56
6 MINIMUM
GREEN
23.30
23.60
23.90
24.20
24.50
5 MAXMUM
GREEN
23.09
23.43
23.76
24.10
24.44
5 MINIMUM
GREEN
22.88
23.25
23.63
24.00
24.38
4 MAXMUM
YELLOW
22.66
23.08
23.49
23.90
24.31
4 MINIMUM
YELLOW
22.45
22.90
23.35
23.80
24.25
3 MAXMUM
YELLOW
22.24
22.73
23.21
23.70
24.19
3 MINIMUM
YELLOW
22.03
22.55
23.08
23.60
24.13
2 MAXMUM
RED
21.81
22.38
22.94
23.50
24.06
2 MINIMUM
RED
21.60
22.20
22.80
23.40
24.00
1 MAXMUM
RED
21.39
22.03
22.66
23.30
23.94
1 MINIMUM
RED
21.18
21.85
22.53
23.20
23.88
1.8
1.85
1.9
1.95
2.0
BAR
LEVEL
OPEN CIRCUIT VOLTAGE

DISCHARGE LEVEL
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2001-10-31
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Battery Discharge Indicator Bar Level Chart (36 Volt)

COLOR
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
OPEN CIRCUIT VOLTAGE

DISCHARGE LEVEL
388
Return
OPEN CELL OPEN CELL OPEN CELL OPEN CELL OPEN CELL
VOLTAGE
VOLTAGE
VOLTAGE
VOLTAGE
VOLTAGE
BAR LEVEL
2001-10-31
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Version no
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Section
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S5.15
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Due to the variety of different batteries available, parameter

13 should be set to the specific battery that will be used to
insure an accurate BDI reading. To verify the BDI display
reflects the preferred battery discharge the following
procedures should be followed:
1. Install a fully charged battery into the truck.
2. Take an open voltage reading across the battery
terminals. A full charged 24 volt battery should
have an approximate open voltage of 25.20 volts.
A full charged 36 volt battery should have an
approximate open voltage of 37.80 volts.
3. Power up truck and verify the 10 bar indicator is lit
to the top bar (green). This indicates a fully
charged battery.
4. Put the truck into service for an 8 hour shift.
NOTE!
Do not charge the battery at anytime during

the shift until adjustment of parameter 13 is
complete.
5. If the voltage reading matches the corresponding

bar level, battery parameter 13 needs no further
adjustment. If further adjustment is needed go to
step 7.
6. If open circuit voltage of battery is lower than
corresponding BDI bar level from the table,
parameter 13 should be decreased. If open voltage
of battery is higher than corresponding BDI bar
level from table parameter 13 should be increased.
7. Repeat steps 1 through 7.
Return
2001-10-31
389
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Section
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S5.15
C-code
5710
Version no
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001
395/396/397/398/399
12. A5 Jumper Harness Kit Installation
(Serial numbers 28126000 - below)
The purpose of the jumper harness is to supply power from

wire number 22 to wire number 39 at A5 input 104. The kit
contains a jumper harness and an assortment of 0.25 inch
(6.35 mm) quick connectors. The previous A5 logic box can
be reinstalled by removing the jumper harness and
reconnecting cut wires using the quick connectors. To
determine if the truck has the jumper harness installed, turn
the key switch to OFF, then ON. If the dash display shows
88:88, the truck has the jumper harness installed. Use the
following procedures to install jumper harness. For location of
wires and connectors see Jumper Harness Drawing on
page 391:
2. Remove main
page 103).
electronic
card
panel
(see
3. Disconnect all electrical cables from the main

electronic card. Be sure to note connection points
for installation.
4. Locate wire number 39 in connector 100, pin
number 4, input 104 on the A5 logic box. Cut this
wire midway between A5 connector 100 and the
main harness bundle.
5. Strip about 0.25 inch (6.35 mm) of insulation from
both ends of wire number 39 and install correct
quick connectors. Determine if the harness is of 16
or 18 gauge wire. Be sure to install the correct size
quick connectors on the wire ends that have been
stripped (see page 391).
6. Locate wire number 22 in connector 800, pin
number 8, input 809 on the A5 logic box. There
may be one or two number 22 wires connected to
A5 input 809. Cut only one of the number 22 wires
midway between the A5 card connector 800 and
the main harness bundle.
7. Strip about 0.25 inch (6.35 mm) of insulation from
both ends of wire number 22 and install the correct
quick connectors. Determine if the harness is of 16
390
Return
2001-10-31
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Section
C-code
S5.15
5710
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395/396/397/398/399
or 18 gauge wire. Be sure to install the correct size

quick connectors on the wire ends that have been
stripped.
8. Tape and wire tie wire 39 from the main harness to
the main harness bundle so it is not lying loose in
the A5 logic box compartment.
9. Connect wires 22 to the new jumper harness.
Connect wire 39 to the opposite end (long end) of
the jumper harness.
Harness End
A5 Connector End
Wire 39
Wire 22
Wire 39
Input 104
No longer used
Tie wire back
Key Lock
Harness Bundle
Wire 22
Connector 100
(Connector Plug-in # 1)
308035-000
Jumper Harness
A5 Control Module
A5 Logic Box
Connector 800
(Connector Plug-in # 8)
Input 809
Wire 22
Wire 22
Key Lock
Wire 22
Wire 22
Figure 1 Installation Instructions Drawing
Jumper Harness Drawing
Return
2001-10-31
391
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10. Replace A5 logic box with new logic box. Install the
main harness to the A5 logic box, plug the battery
into the truck. Check the parameter settings and
adjust as needed.
11. Check the operation of the truck to be sure it
performs properly.
12. Install main electronic card panel (see page 103).
392
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2001-10-31
F-code
Section
PS
C-code
S5.15
5710
Version no
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001
395/396/397/398/399
13. Warning\Caution Codes

Character
Error
Warning
When an error has occurred, a signal sounds and a code is

displayed for 10 seconds in the right-hand section of the
character window (C). The character box (G) illuminates. If
the error remains after 1 minute the warning and signal will be
activated again for a 2 seconds period. This happens as long
as the error is not rectified. The truck can still be driven with
all functions, as set out in the Warning Code table as follows:
WARNING Ignoring error indications.
The safety of the truck is jeopardized.
Always check the operation of the truck
before use.
Warning Codes without Registering
Error No.
Comment
10
Pump Chopper Lim
Not used
11
Steer Chopper Lim
Steer chopper high temperature current limiting
12
Wheel Ind Error
Not used
13
Height Ind Error
Height counter error
16
Pump Brush Error
Worn pump motor brush
17
Drive Brush Error
Worn drive motor brush
18
Nov Ram Error
Control module internal error
19
Default Par
Not used
20
Pump Voltage Error
Not used
21
Lift Pot Z Error
Lift pot not centered at key on time
22
Tilt Pot Z Error
Tilt pot not centered at key on time
23
Reach Pot Z Error
Reach pot not centered at key on time
24
Sideshifter Pot Z Error
Sideshifter pot not centered at key on time
27
Bat Measure Error
Low battery voltage detected
28
Motor Over Temp
Drive motor over temperature
Return
Error Code Name
2001-10-31
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Section
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5710
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Warning Codes with Registering

Error No.
Error Code Name
Comment
52
O Lift Error
Shorted or opened lift valve output
53
O Tilt Error
Shorted or opened tilt valve output
54
O Dir A Error
Shorted or opened direction A valve output
55
O Dir B Error
Shorted or opened direction B valve output
56
O sideshifter Error
Shorted or opened sideshifter valve output
57
O Spare In Error
Unused output/input
58
O Alarm Out Error
Shorted or opened alarm output
59
O Reach In Error
Shorted or opened reach in valve output
60
O Reach Out Error
Shorted or opened reach out valve output
61
O Lower Prop Error
Shorted or opened lowering proportional valve output
63
O Forward Contactor Error
Shorted or opened forward contactor output
64
O Backward Contactor Error
Shorted or opened backward contactor output
90
Lift Pot Error
Shorted or opened lift potentiometer input
91
Tilt Pot Error
Shorted or opened tilt potentiometer input
92
Reach Pot Error
Shorted or opened reach potentiometer input
93
Sideshifter Pot Error
Shorted or opened sideshift potentiometer input
95
Pot Ref Error
Potentiometer supply voltage
When the warning code is displayed, it is automatically

registered. Registration takes place in the first of 80 possible
positions and moves the previous error one step downward.
With warning errors 52-64, the valve, contactor or wires are
either broken or short circuited. With warning errors 90-95,
the potentiometer or wires are broken. Only the actual
function is disabled; other functions are not affected.
394
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2001-10-31
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Section
Version no
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001
SW1
SW2
SW3
C-code
S5.15
5710
395/396/397/398/399
14. Error Codes

Character
Error
Error
When an error has occurred, a buzzer sounds at the same

time an error code is displayed in the right-hand section of the
character window (C). The character box (G) illuminates. The
signal sounds until the key switch is switched off.
If the error remains when the key switch is switched on again,
the codes will be shown and the signal will sound again. The
truck can still be used with the hydraulic functions listed in the
Error Codes table on the next page.
When an error code is shown, the code is automatically
registered in the error register. Registration takes place in the
first of 80 possible positions and moves the previous error
one step downward.
When the register is shown in the character window by
pressing SW3 three times, the latest codes are shown with
the error code. To see the date when the error occurred,
press SW1 once and to see the time press SW1 again. To
see more of the registered errors, press SW2.
WARNING Ignoring error indications.
The safety of the truck is jeopardized.
Always check the operation of the truck
before use.
Return
2001-10-31
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Error Codes with Registering

Error
No.
Error Code Name
Comment
100
Pump Temp Error
Pump chopper over or under temperature
101
Pump Current Error
Not used
102
Drive Chopper Error
See E102 Troubleshooting Procedures on page 397.
110
P Brake Pot Ref Error
Pedal/parking brake potentiometer supply voltage
111
P Brake Pot Error
Pedal/parking brake potentiometer adjustment or failure
112
P Brake Switch Error
Pedal/parking brake switch adjustment or failure
113
P Brake Out Error
Shorted or open parking brake output
115
Spd Sensor Error
Drive motor speed sensor failure
116
Dir Sensor Error
Drive motor direction sensor failure
117
Rev Signal Error
Drive chopper reversing signal failure
120
Steer Data Error
Steer Chopper Error
Steer chopper error (internal to the A5 card)
122
Steer Temp Error
Steer chopper over temperature
123
Steer Volt Error
Steer chopper voltage low
124
Steer Curr Error
Steer chopper current limit
125
Steer Tacho Error
Steer tacho motor error
126 *
Steer Conn Error
Opened steer motor output - motor or connection failure
127
Steer Comm Error
130
Slave Comm Error
131 *
Sec Rel Error 1
Security relay error 1 (internal to the A5 card)
132 *
Steer Pwr Error
Steer chopper supply voltage under voltage (internal to the A5 card)
133 *
Sec Rel Error
Security relay error 2 (internal to the A5 card)
Check Sum Error
121 *
140
* If these error codes are displayed, parameter 13 may need to be properly set (see Battery Discharge Indicator
Parameter Adjustment on page 384).
396
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Version no
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Section
C-code
S5.15
5710
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14.1. E102 Troubleshooting Procedures

Remove dash cover to expose drive chopper (A1). The drive
chopper (A1) will have 4 LED indicators to assist in
determining faults. (See applicable electrical schematic
page 277, page 289, page 301 or page 313.) The LEDs are
as follows:
1
Green
Drive chopper detects no faults.
Yellow
Drive chopper upper/lower temperature. (Will not

display an error code)
Red
Fault in power circuits (See Power Circuit Checks)
Red
Fault in reference value circuit (See Reference

Value Circuit Checks)
If truck is cold storage verify that all thermostats and heaters

are working. Moisture contamination at drive chopper (A1),
pump chopper (A2) or logic card (A5) may cause this error.
Verify that wire #16 and #17 wires have not been placed on
the normally opened side of main contactor (K10), drive
chopper (A1), internal capacitors will not be allowed to charge
correctly and will cause this error code.
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.
14.1.1. Power Circuit Checks
NOTE!
Do not manually close the main contactor

(K10) when battery is plugged into truck.
If main contactor (K10) does not close when the truck is

powered up, the following checks should be performed:
1. Check 250 amp drive fuse. A blown fuse will cause
this error when the truck is powered up. A partially
severed fuse will not cause this error until the
operator attempts to accelerate. Both symptoms
are typically caused from the operator pushing
loads.
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2001-10-31
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2. Check for welded main contactor (K10) tips.

3. Check for loose or open connections at main
contact (K10) coil wire #44 or #40.
4. Check for loose or open connections at emergency
stop (S21).
5. Check voltage at control plug on drive chopper
(A1) at pin #1, wire #22 with respect to battery
negative. This input should be battery voltage
when the truck is powered up. If 0 volts (there will
be no LED indicator lit at drive chopper (A1), check
for open wire from key switch to drive chopper
(A1).
(A1) at pin #7, wire #34 with respect to battery
negative. This output should be battery voltage
when drive chopper (A1) detects no faults.
7. Check voltage at pin #101, wire #34, at the logic
card (A5) with respect to battery negative. This
input voltage from drive chopper (A1) should be
battery voltage when drive chopper (A1) detects no
faults. If 0 volts, check for open line on wire #34
between drive chopper (A1) and logic card (A5).
8. Check voltage at wire #34 at the emergency stop
(S21) with respect to battery negative. This should
be battery voltage when drive chopper (A1) detects
no faults. If 0 volts, check for open line on wire #34
between drive chopper and emergency stop (S21).
9. Check voltage on wire #44 at emergency stop
(S21). This should be battery voltage when the
truck is powered up. If 0 volts, check for loose or
missing connection on wire #44 at emergency stop
(S21), check for open line on wire #44 between
emergency stop (S21) and the connections at the
main contactor (K10). Check for defective
emergency switch (S21).
398
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S5.15
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If main contactor (K10) closes when the truck is powered up

the following checks should be performed:
1. Check for battery voltage through main contactor
K10) with respect to battery negative when
contactor is closed.
2. Check for pitted or burned contactor tips.
3. Check for dirt or dust contamination at contactor
tips.
4. Check 250 amp drive fuse. A partially severed fuse
will not cause this error until the operator attempts
to accelerate. A blown fuse will cause this error
when the truck is powered up. Both symptoms are
typically caused from the operator pushing loads.
5. Check for loose or shorted power cable
connections at 250 amp drive power fuse, main
contactor (K10), drive chopper (A1) and pump
chopper (A2) may cause this error. If a pump
chopper (A2) or related power cable is suspected
to be shorted or defective, it may be disconnected
from the system to verify that it is causing the error.
NOTE!
Care must be taken to keep power cables

that are removed from shorting. All cable
ends should be wrapped with electrical
tape.
14.1.2. Reference Circuit Value Checks (LED #4)

(A1), pin #10, wire #36 with respect to pin #6, wire
#35. Voltage should be 0.15 volts when the
accelerator is in the static position. When the
accelerator is at full throttle, voltage should be
approximately 4.93 volts.
(A1), pin #11, and wire #37 with respect to pin #6,
wire #35. Voltage should be 0.75 volts when the
accelerator is in the static position. When the
accelerator is at full throttle, voltage should be
approximately 4.3 volts.
Return
2001-10-31
399
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(A1), pin #8, wire #38, with respect to battery
negative. Voltage should be 0 volts when the
accelerator is in the static position.
4. When checks are performed and an error still exist,
contact a BT Prime-Mover service representative.
NOTE!
400
Return
All warranty claims concerning the

replacement of the drive chopper (A1) will
be expected to have checks performed and
documented on the warranty claim to
receive warranty consideration.
2001-10-31
F-code
PS
Version no
001
SW1
SW2
SW3
Section
C-code
S5.15
5710
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395/396/397/398/399
15. Programming Parameter

NOTE!

initial power up.
For the significance of the different parameters, see the

following tables To see the different parameters, press SW2
or SW3.
1. Press SW3 on the main electronic card at the
same time key switch is turned ON.
2. Step using SW2 (up) and SW1 (down) to the
parameter to be changed.
3. Press SW3 (the character window flashes).
4. Change the value using SW1/SW2.
5. Press SW3 to accept the value (the character
window stops flashing).
To change additional parameters, step using SW1/SW2 to
the parameter of the change and repeat from Press SW3
(the character window flashes).
NOTE!
Return
Truck handling.
Modifying specific truck parameters will
change the driving characteristics of the
truck. Do not change any parameters
without the necessary knowledge.
2001-10-31
401
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Section
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001
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Programming Parameters (P5-04)

No.
Parameter
Name
Value
Range
Default
Inc
Steer Prog Par
1-6
1-Least sensitivity
5-Most sensitivity
6-Test curve
Speed curve selection

has a greater affect at
high speeds.
Steer Wheel
Par
0-2
0-Least sensitivity
2-Most sensitivity
Steer tacho motor

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
acceleration
Acceleration reduction.
Reach Scale
Par
10-100%
80
% of maximum reach
speed
Reach movement speed

reduction.
Spare Scale
Par
10-100%
20
Spare function speed

reduction. Not used.
Spare Curr Par
0-100%
100
Spare function current

limit reduction. Spare
function is disabled
when this valve is set to
zero. Not used.
Spec Height
Par
0-531
Maximum allowed lifting

height (see tables)
Special height
10
Fork Ref Par
60-177 inch
90
Mast free height (see table)
Mast reference height.
11
Steer Dir Par
0-1
0-Backward (Eur.)
1-Forward (US) (see table)
Steer direction.
12
Timer Sel Par
1-4
1-Key time (total time)

2-Drive and pump time
(active time)
3-Drive time
4-Pump time
Displayed timer.
13
Battery Par
1-30
12
1-Shallow discharge
29-Deep discharge
30-Force BDI to full charge
battery indication (not a
permanent parameter)
Battery type.
402
Return
Values
Comment
2001-10-31
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001
Section
C-code
S5.15
5710
T-code
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No.
Parameter
Name
Value
Range
Default
Inc
Values
0-36V Std (RRX35/RSX40)
2-36V HD (RRX45/RDX30/
RSX50)
Comment
14
Pump Type
Par
0-2
15
Clock Year
0-99
Clock year.
16
Clock Day
0-31
Clock day.
17
Clock Month
0-12
Clock month.
Return
2001-10-31
Hydraulic pump type.
403
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Section
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No.
Parameter
Name
Value
Range
Default
Inc
Steer Prog Par
1-6
1-Least sensitivity
5-Most sensitivity
6-Test curve

high speeds.
Steer Wheel
Par
0-2
0-Least sensitivity
2-Most sensitivity
Steer tacho sensitivity.
Top Speed Par
10-100%
100
% of maximum speed
Red Speed
Par
10-100%
40
% of maximum speed
Accel Par
10-100%
50
% of maximum
acceleration
Reach Scale
Par
10-100%
80
% of maximum reach
speed

reduction.
Spare Scale
Par
10-100%
20
Spare function speed

reduction. Not used.
Spare Curr Par
0-100%
Spare function current

limit reduction. Spare
function is disabled
when this value is set to
zero. Not used.
Spec Height
Par
0-531

height (see tables)
Special height
10
Fork Ref Par
60-177
90
Mast free height

(see table)
11
Steer Dir Par
0-1
0-Backward (Eur.)
Steer direction.
12
Timer Sel Par
1-4

2-Drive & pump time
(active time)
3-Drive time
4-Pump time
Displayed timer.
13
Battery Par
1-30
20
1 -Shallow discharge
29-Deep discharge
Battery type.
404
Return
Values
Comment
2001-10-31
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5710
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No.
Parameter
Name
Value
Range
Default
Inc
Values
Comment
14
Pump Type
Par
0-2

RSX50)
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.
Parameter No. 9 (P5-04 and P5-05)

Without U10 pulse counter
With U10 pulse counter and with

customer specified value
Customer value (inch)

range 0-531
With U10 pulse counter & without

Mast height (inch)

(see table)

(With U10 pulse counter and without customer specified value)
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
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Mast Height
(inch)
RRX35/RSX40
RRX45/RDX30/RSX50
192
72
210
78
76
240
90
88
270
102
100
300
111
330
123
360
135
402
152
406
Return
Customer Specified - Backward

(Euro. style)
Standard - Forward
(U.S. style)
2001-10-31
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PS
Version no
001
Section
C-code
S5.15
5710
T-code
395/396/397/398/399
Programming Parameters (P5-06 and P5-07)

No.
Parameter
Name
Value
Range
Default
Inc
Steer Prog Par
1-6
1-Least sensitivity
5-Most sensitivity
6-Test curve

high speeds.
Steer Wheel
Par
0-3
0-Least sensitivity
3-Most sensitivity
Steer tacho sensitivity.
Top Speed Par
10-100%
100
% of maximum speed
Red Speed
Par
10-100%
40
% of maximum speed
Accel Par
10-100%
50
% of maximum
acceleration
Reach Scale
Par
10-100%
80
% of maximum reach
speed

reduction.
Spare Scale
Par
10-100%
Spare parameter.
Not used
Spare Curr Par
0-100%
Spare parameter.
Not used.
Spec Height
Par
0-531

height (see tables)
Special height.
10
Fork Ref Par
60-177
90
Mast free height

(see tables)
11
Steer Dir Par
0-1
0-Backward (Eur.)
Steer direction.
12
Timer Sel Par
1-4

2-Drive pump and lowering
time (active time)
3-Drive time
4-Pump time
Displayed timer.
13
Battery Par
1-30
15
1 -Shallow discharge
29-Deep discharge
Battery type.
14
Pump Type
Par
0-2

RSX50)
Return
Values
2001-10-31
Comment
407
F-code
Section
PS
S5.15
C-code
5710
Version no
T-code
001
395/396/397/398/399
Programming Parameters (P5-06 and P5-07)

No.
Parameter
Name
Value
Range
Default
Inc
Values
Comment
15
Option Par
0-5
Value determines option(s)

enabled.
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

Without U10 pulse counter
With U10 pulse counter and with

With U10 pulse counter and without
Customer value (inch)

range 0-531
Mast height (inch)
(see table)

408
Return
Mast Height
(inch)
RRX35/RSX40
RRX45/RDX30/RSX50
192
192
210
210
210
240
240
240
258
258
270
270
270
300
300
330
330
360
360
390
390
402
402
2001-10-31
F-code
PS
Version no
001
Section
C-code
S5.15
5710
T-code
395/396/397/398/399
Parameter No. 9 (NON- STANDARD) (P5-06 and P5-07)

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
Return
Mast Height
(inch)
RRX35/RSX40
RRX45/RDX30/RSX50
192
72
210
78
75
240
90
87
258
95
270
102
99
300
111
330
123
360
135
390
147
402
151
2001-10-31
409
F-code
Section
PS
S5.15
C-code
5710
Version no
T-code
001
395/396/397/398/399
Parameter No. 10 (NON-STANDARD) (P5-06 and P5-07)

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

Customer Specified - Backward
(Euro. style)
Standard - Forward
(U.S. style)

Option
410
Return
All Trucks
None
Direction Change Beep
Travel Alarm
Direction Change Beep with Travel Alarm
Backup Alarm
Direction Change Beep with 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. General
To identify the electrical circuit location of switches see
applicable electrical schematics page 277, page 289,
page 301 or page 313.
Examine switch for signs of arcing, overheating,
switch if you see such damage.
-
+
1
1/2
To test a switch, isolate it from the electrical circuit. Remove

all connections from switch, making sure all wires are labeled
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.
With the battery plugged in and the key switch in the ON
position, equal voltage should be present on both terminals of
the switch.
2. Platform (Right Foot) Switch (S108)

The platform (right foot) switch (S108) is located under the
floor board of the operator compartment. Activation of the
platform switch allows lift and auxiliary functions to operate
without depression of the brake pedal.
Brake
Pedal
While selecting a hydraulic function, if either brake pedal (left

foot) or platform (right foot) switch is not successfully
engaged a red triangle (H) (reminder light) will be displayed
on the instrument panel The indicator also lights if the truck is
driven without the platform (right foot) switches engaged.
Right
Foot
Pedal
Return
2000-08-04
411
F-code
Section
C-code
PS
S5.16
5751
Version no
T-code
000
395/396/397/398/399
2.1. Removal
3. Remove two screws (1) securing switch (2) to twin
nut (3) at switch bracket.
2.2. Installation
f
1. Install two screws (1) through switch (2) into twin

nut (3) on opposite side of switch bracket.
1
3
2
412
Return
4. Test operation of platform switch before returning

truck to service.
Item No.
Description
Screw, machine
Switch, brake
Nut, twin
2000-08-04
F-code
PS
Version no
000
Section
C-code
S5.16
5751
T-code
395/396/397/398/399
3. Staging Switch (S45)

The staging switch (S45) is a proximity sensor located on the
outside of the carriage. Its function is to let the main electronic
card know when the carriage has almost completed the first
stage of lift (freelift). When the sensor extends beyond the
limits of the inner columns, the main electronic card receives
a signal. This triggers a slowing of the lift and allows a
smoother transition as the columns begin to move, preventing
the load on forks from being jarred.
Forks
Mast
Sensor
Return
2000-08-04
413
F-code
Section
C-code
PS
S5.16
5751
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.
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.
5. Adjust switch.
414
Return
2000-08-04
F-code
PS
Section
C-code
S5.16
5751
Version no
000
T-code
395/396/397/398/399
4. Wheel Direction Sensor

S65
The wheel direction sensor (S65) detects travel direction

information from the top of the drive unit. This sensor works in
conjunction with the steer angle proximity sensors (S66) and
(S67) located in front of the drive unit and accessed from the
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.
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
7. Tighten jam nut securing the sensor to the frame.

9. Test operation of the sensor.
Return
2000-08-04
415
F-code
Section
C-code
PS
S5.16
5751
Version no
T-code
000
395/396/397/398/399
4.2. Removal
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.
416
Return
2000-08-04
F-code
PS
Section
C-code
S5.16
5751
Version no
000
T-code
395/396/397/398/399
5. Steer Proximity Sensors A and B

(S66 and S67)
The steer proximity sensors (S66 and S67) are located on the
truck frame in front of the drive unit and accessed from the
battery compartment. The steer proximity sensors work as a
pair in conjunction with switch S65 to detect drive wheel
direction and position information from the top of drive unit.
Steering
sensors
optional
mounting
styles
5.1. Adjustment
1. Remove battery from truck.
2. Center a steering gear tooth crest on the face of
wheel angle sensor to be adjusted.
3. Loosen jam nut.
4. Adjust sensor to 0.089 inch (2.26 mm) between
sensor and steering gear tooth crest. Tolerance is
0.002 inch (+0 mm, -0.05 mm).
NOTE!
Do not overtighten jam nut. Overtightening

can cause sensor damage.
5. Tighten jam nut carefully so sensor does not move.

6. Check clearance with jam nut tightened.
Return
2000-08-04
417
F-code
Section
C-code
PS
S5.16
5751
Version no
T-code
000
395/396/397/398/399
7. Repeat steps 2 through 6 for remaining sensor.

8. Install battery in truck.
9. Test operation of truck. Verify wheel angle display
smoothly follows the rotation and drive direction of
drive wheel.
10. Adjust as necessary to achieve smooth rotation of
wheel angle display.
5.2. Removal
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.
2. Secure sensor to bracket with a jam nut.

4. Adjust sensor (see page 417).
5. Test operation of truck. Verify that wheel angle
display smoothly follows the rotation and drive
direction of drive wheel.
418
Return
2000-08-04
F-code
PS
Section
C-code
S5.16
5751
Version no
000
T-code
395/396/397/398/399
6. Adjust as necessary to achieve smooth rotation of

wheel angle display.
6. Drive Motor Speed(S64)/Direction

Sensors (S125)
The drive motor speed (S64)/direction (S125) sensors are
located in the spacer mounted on top of the brake assembly.
Their purpose is to detect speed and directional information
from the sensor nut attached to the top of drive motor. These
drive motor speed/direction sensors are not adjustable.
6.1. Removal
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.
Return
Description
Spacer
Sensor, speed (male plug)
10
Screw, cap
11
Nut, sensor
12
Screw
13
Sensor, direction (female plug)
14
Spacer, brake sensor
2000-08-04
419
F-code
Section
C-code
PS
S5.16
5751
Version no
T-code
000
395/396/397/398/399
6.2. Installation
1. Install sensor (9 or 13) in spacer (8). Be sure the
wire ends and location match the ones noted in
removal. Sensors that are improperly installed will
result in an error code appearing when truck is
returned to service.
2. Install cap screw (10).
3. Reconnect sensor to main harness assembly.
4. Connect battery connector to truck.
5. Test operation of truck before returning to service.
420
Return
2000-08-04
F-code
Section
PS
S6.0
6000
Hydraulic System
Version no
000
C-code
T-code
395/396/397/398/399
Hydraulic System
WARNING DO NOT use your hands to check for
hydraulic leakage. Use a piece of
cardboard or paper to search for leaks.
Escaping fluid under pressure can
penetrate the skin causing injury. Relieve
pressure before disconnecting hydraulic or
other lines. Tighten all connections before
applying pressure. Keep hands and body
away from pinholes and nozzles which
eject fluids under high pressure.
1. Operation
See RRX35 Hydraulic Schematic on page 442, RRX45
Hydraulic Schematic on page 443, RDX30 Hydraulic
Schematic on page 444, RSX40 Hydraulic Schematic on
page 445, or RSX50 Hydraulic Schematic on page 446. For
a listing of error codes see page 393 and page 394. For a
listing of parameters see page 402, page 404, or page 407.
For a listing on the fuses and their location see page 347.
NOTE!
Return

initial power up.
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
R11 R12 R13
506
507
R14
508 509
701
74
702
75
6
(-)
A5
703
76
10
11
40
10
B-
A2
B+
M3
(+)
Supply
LEGEND
Pressure Oil
Return Oil
Electric Positive
Electric Negative
LED Off (Not Lit)
LED Input (Lit)
LED Output (Lit)
422
Return
2001-11-08
F-code
Section
PS
S6.0
6000
Hydraulic System
Version no
000
C-code
T-code
395/396/397/398/399
1.1. Supply
A voltage from lift (R11), reach (R12), sideshift (R14), or tilt
(R13) on the control pod to the main electronic card (A5)
initiates a pump request to the pump transistor regulator (A2).
The electronic card (A5) turns on speed request output 702
(wire #75) to a level proportional to the control handle
request. This signal is sent to the pump transistor regulator
(A2) input pin 10. A current limit signal is also sent from the
main electronic card (A5) output 703 (wire #76) to the pump
transistor regulator (A2) input pin 11 limiting the current from
the pump transistor regulator (A2) to the motor. Both speed
approximately 4.5 volts and are measured with respect to
main electronic card (A5) output 701 (wire #74). The pump
transistor regulator sends the amplified signal to the pump
motor (M3) commanding pumping.
Hydraulic functions can be performed by using the brake
pedal, the right foot pedal, or both. By depressing the right
foot pedal and releasing the brake pedal setting the parking
brake, hydraulic functions can be performed with the truck
parked in position.
Oil is pumped by the pump from the hydraulic tank into the
hydraulic system. The pump is used for both the lift and
auxiliary functions. Appropriate solenoids are activated,
opening valves and the hydraulic functions are performed. If
the pressure in the system increases to the preset value of
the relief valve, it will open directing oil back to the hydraulic
tank. The lowering function is powered by gravity and
proportionally controlled. Returned oil is filtered at the
hydraulic tank.
Return
2001-11-08
423
F-code
Section
PS
S6.0
Hydraulic System
C-code
6000
Version no
T-code
000
395/396/397/398/399
1.2. Lifting
With the key switch ON and brake pedal and/or right foot
switch depressed, by pulling potentiometer (R11) back
causes output voltage to be different than when in the neutral
position. The main electronic card (A5) senses this change in
voltage at input 506 (wire #82). The main electronic card (A5)
responds by enabling voltage to the lift valve coil (Y10-2)
output 704 (wire 89). The lift speed can be infinitely varied to
the maximum lift speed.
Oil is fed from the pump to the lift valve (Y10) and from the
valve to the free lift and main lift cylinders. The free lift
cylinder, having less weight on it, will lift first. After the free lift
cylinder has reached full extension, the main lift cylinders will
begin to lift. If the pressure in the system increases to the
relief valves preset value, oil flows back to the hydraulic tank.
LEGEND
Pressure Oil
Return Oil
Electric Positive
Electric Negative
LED Off (Not Lit)
LED Input (Lit)
LED Output (Lit)
29
30
R11
A5
804
88
506
704
(-)
89
2
3
Y10-3
40
Y10-2
Lifting
424
Return
2001-11-08
F-code
Section
PS
S6.0
6000
Hydraulic System
Version no
C-code
T-code
000
395/396/397/398/399
1.3. Lowering
With the key switch ON and brake pedal and/or right foot
switch depressed, by pushing forward potentiometer (R11)
causes output voltage to be different than when in the neutral
voltage at input 506 (wire #82). The main electronic (A5) card
enables voltage to the proportional lower solenoid coil (Y103) from output 804 (wire 88). The lowering speed is regulated
by the proportional lowering valve (Y10-3) in direct proportion
to the voltage from (R11). Proportional lower solenoid coil
(Y10-3) is normally closed. Oil flows from the cylinders
through the valve, returning to the hydraulic tank. A reach, tilt,
or sideshift function can be performed while lowering.
LEGEND
Pressure Oil
Return Oil
Electric Positive
Electric Negative
LED Off (Not Lit)
LED Input (Lit)
LED Output (Lit)
29
30
R11
A5
82
804
88
506
704
89
2
3
Y10-3
(-)
40
Y10-2
Lowering
Return
2001-11-08
425
F-code
Section
C-code
PS
S6.0
Hydraulic System
6000
Version no
T-code
000
395/396/397/398/399
LEGEND
Pressure Oil
Return Oil
Electric Positive
Electric Negative
LED Off (Not Lit)
LED Input (Lit)
LED Output (Lit)
29
Y14
30
83
A5
707
507 708
706
705
(-)
Y15
R12
40
92
93
91
90
Y13
Y12
Reach
426
Return
2001-11-08
F-code
Section
PS
S6.0
6000
Hydraulic System
Version no
000
C-code
T-code
395/396/397/398/399
1.4. Reach
Reach extends the forks away from the mast assembly. With
the key switch ON and brake pedal and/or right foot switch
depressed, by pushing forward potentiometer (R11) causes
output voltage to be different than when in the neutral
responds by:
Enabling voltage to the direction A solenoid coil (Y12) from
output 705 (wire #90).
Enabling the reach solenoid(s) (Y14) and (Y15) on the
reach carriage from outputs 707 (wire #92) and 708 (wire
#93).
Sending a speed request to the pump transistor regulator.
The extend speed can be infinitely varied to the maximum
extend speed. The maximum speed is configured by
Reach Scale Parameter 6. The truck voltage and reach
model is configured by pump type parameter 14.
The speed request signal to the pump transistor regulator
provides the PWM frequency rate to pulse the pump motor.
Oil is fed through direction A (Y12) valve, through reach valve
(Y14) to the rear ports on the reach cylinders, and drives the
pistons outwards. The oil flows from the front ports of the
cylinders, through reach valve (Y15) to direction A (Y12)
valve, and back to the hydraulic tank.
Return
2001-11-08
427
F-code
Section
PS
S6.0
Hydraulic System
C-code
6000
Version no
T-code
000
395/396/397/398/399
LEGEND
Pressure Oil
Return Oil
Electric Positive
Electric Negative
LED Off (Not Lit)
LED Input (Lit)
LED Output (Lit)
29
R12
83
A5
707
507 708
706
705
(-)
Y15
Y14
30
40
92
93
91
90
Y13
Y12
Retract
428
Return
2001-11-08
F-code
Section
PS
S6.0
6000
Hydraulic System
Version no
000
C-code
T-code
395/396/397/398/399
1.5. Retract
Retract withdraws the forks toward the mast assembly. With
the key switch ON and brake pedal and/or right foot switch
depressed, by pulling forward potentiometer (R11) causes
output voltage to be different than when in the neutral
responds by:
Enabling voltage to the direction B solenoid coil (Y13) from
Enabling the reach solenoid(s) (Y14) and Y15) on the
reach carriage from outputs 707 (wire #92) and 708 (wire
#93).
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.
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.
Return
2001-11-08
429
F-code
Section
C-code
PS
S6.0
Hydraulic System
6000
Version no
T-code
000
395/396/397/398/399
1.6. Reach Relief (RRX35 Only)

If the pressure in the reach cylinders increase to the preset of
the 1800 PSI relief valve, it will open directing oil back to the
hydraulic tank.
LEGEND
Pressure Oil
Return Oil
Electric Positive
Electric Negative
LED Off (Not Lit)
LED Input (Lit)
LED Output (Lit)
1800 PSI
0.020
300 PSI
29
30
83
Y14
A5
707
507 708
706
705
(-)
40
Y15
R12
92
93
91
90
Y13
Y12
Reach Relief
430
Return
2001-11-08
F-code
Section
PS
S6.0
6000
Hydraulic System
Version no
C-code
T-code
000
395/396/397/398/399
1.7. Reach Impact (RRX35 Only)

When the operator is traveling with a fully or partially
extended reach and drives against an object with the ends of
the forks or any other part of the reach, the 300 PSI check
valve opens reducing the risk of damage. With the reach
valves Y14 and Y15 being in neutral, the oil can then pass the
300 PSI check valve to the tank.
LEGEND
Pressure Oil
Return Oil
Electric Positive
Electric Negative
LED Off (Not Lit)
LED Input (Lit)
LED Output (Lit)
1800 PSI
0.020
300 PSI
29
Y14
30 R12
83
A5
507
707
708
706
705
Y15
92
93
91
90
(-) 40
Y12
Y13
Reach Impact
Return
2001-11-08
431
F-code
Section
C-code
PS
S6.0
Hydraulic System
6000
Version no
T-code
000
395/396/397/398/399
LEGEND
Pressure Oil
Return Oil
Electric Positive
Electric Negative
LED Off (Not Lit)
LED Input (Lit)
LED Output (Lit)
Y17
29
30
R13
84
A5
710
508
706
705
(-)
40
94
91
90
Y13
Y12
Tilt Up
432
Return
2001-11-08
F-code
Section
PS
S6.0
6000
Hydraulic System
Version no
000
C-code
T-code
395/396/397/398/399
1.8. Tilt Up
Fork tilt allows the operator to raise or lower the tips of the
forks. Standard fork tilt is 4 up and 3 down.
With the key switch ON and the brake pedal and/or right foot
pedal depressed, by pulling back potentiometer (R13) causes
voltage to be different at the main electronic (A5) card input
508 (wire #84). The main electronic (A5) card responds by:
Enabling the tilt solenoid (Y17) on the reach carriage from
The tilt speed can be infinitely varied to the maximum tilt
speed.
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.
Return
2001-11-08
433
F-code
Section
C-code
PS
S6.0
Hydraulic System
6000
Version no
T-code
000
395/396/397/398/399
LEGEND
Pressure Oil
Return Oil
Electric Positive
Electric Negative
LED Off (Not Lit)
LED Input (Lit)
LED Output (Lit)
29
30
Y17
R13
84
A5
94
710
508
706
705
(-)
40
91
90
Y13
Y12
Tilt Down
434
Return
2001-11-08
F-code
Section
PS
S6.0
6000
Hydraulic System
Version no
000
C-code
T-code
395/396/397/398/399
1.9. Tilt Down

Fork tilt allows the operator to raise or lower the tips of the
forks. Standard fork tilt is 4 up and 3 down.
pedal depressed, by pushing potentiometer (R13) causes
Enabling the tilt solenoid (Y17) on the reach carriage from
The tilt speed can be infinitely varied to the maximum tilt
speed.
Oil is fed through direction A (Y12) valve, to the front port of
the tilt cylinder, driving the piston inward. The oil flows from
the rear port of the cylinder, to the tilt (Y17) valve, to the
direction A (Y12) valve, returning to the hydraulic tank.
Return
2001-11-08
435
F-code
Section
C-code
PS
S6.0
Hydraulic System
6000
Version no
T-code
000
395/396/397/398/399
LEGEND
Pressure Oil
Return Oil
Electric Positive
Electric Negative
LED Off (Not Lit)
LED Input (Lit)
LED Output (Lit)
29
30
Y16
R14
84
A5
709
509
706
705
(-)
40
95
91
90
Y13
Y12
Side Shifting Right
436
Return
2001-11-08
F-code
Section
PS
S6.0
6000
Hydraulic System
Version no
000
C-code
T-code
395/396/397/398/399
1.10. Side Shifting Right

Sideshift allows the operator to move the fork carriage to the
right or left in relation to the mast. The amount of sideshift is 2
or 4 inches (50 or 100 mm) depending on the baseleg
opening (BLO).
pedal depressed, by pulling back potentiometer (R14) causes
Enabling the sideshift solenoid (Y16) on the reach carriage
from output 709 (wire #95).
The side shift speed can be infinitely varied to the
maximum side shift speed.
Oil is fed through direction B (Y13) valve to the sideshift (Y16)
valve, to the rear port of the sideshift cylinder driving the
piston outward. The oil flows from the front port of the
cylinder, to the sideshift (Y16) valve, to the direction B (Y13)
valve, and returns to the hydraulic tank.
Return
2001-11-08
437
F-code
Section
C-code
PS
S6.0
Hydraulic System
6000
Version no
T-code
000
395/396/397/398/399
LEGEND
Pressure Oil
Return Oil
Electric Positive
Electric Negative
LED Off (Not Lit)
LED Input (Lit)
LED Output (Lit)
29
30
Y16
R14
84
A5
709
509
706
705
(-)
40
95
91
90
Y13
Y12
Side Shifting Left
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
1.11. Side Shifting Left

Sideshift allows the operator to move the fork carriage to the
right or left in relation to the mast. The amount of sideshift is 2
or 4 inches (50 or 100 mm) depending on the baseleg
opening (BLO).
pedal depressed, by pushing potentiometer (R12) causes
voltage to be different at main electronic (A5) card input 509
(wire #85). The main electronic (A5) card responds by:
Enabling the sideshift solenoid (Y16) on the reach carriage
from output 709 (wire #95).
The side shift speed can be infinitely varied to the
maximum side shift speed.
Oil is fed through direction A (Y12) valve, to the sideshift
(Y16) valve, to the front port of the sideshift cylinder, driving
the piston inward. The oil flows from the rear port of the
cylinder, to the sideshift (Y16) valve, to the direction A (Y12)
valve, and returns to the hydraulic tank.
Return
2001-11-08
439
F-code
Section
C-code
PS
S6.0
Hydraulic System
6000
Version no
T-code
000
395/396/397/398/399
Symbol
Designation
1-2
Cylinder
Staging
Cylinder
Free lift
Cylinder
Reach/retract
Cylinder
Tilt
Cylinder
Sideshifter
11-12
Valve
Staging velocity fuse
13
Valve
Free lift velocity fuse
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
Speed control, fork lift/lower
R12
Potentiometer
Speed control, reach/retract
R13
Potentiometer
Speed control, tilt
R14
Potentiometer
Speed control, sideshifter
Y10
Valve
Lift/lower
Y10-2
Valve
Lift
Y10-3
Valve
Lower of Forks
440
Return
Function
Remarks
2001-11-08
F-code
Section
PS
S6.0
6000
Hydraulic System
Version no
000
Symbol
Designation
Y12
Valve
Direction A
Y13
Valve
Direction B
Y14
Valve
Reach out
Y15
Valve
Reach in
Y16
Valve
Sideshifter
Y17
Valve
Tilt
Return
Function
2001-11-08
C-code
T-code
395/396/397/398/399
Remarks
441
F-code
Section
C-code
PS
S6.0
Hydraulic System
6000
Version no
T-code
000
395/396/397/398/399
Y10-2
Y10-3
2. RRX35 Hydraulic Schematic
442
Return
2001-11-08
F-code
Section
PS
S6.0
6000
Hydraulic System
Version no
000
C-code
T-code
395/396/397/398/399
4
Y10-2
Y10-3
3. RRX45 Hydraulic Schematic
Return
2001-11-08
443
F-code
Section
C-code
PS
S6.0
Hydraulic System
6000
Version no
T-code
000
395/396/397/398/399
4
Y10-2
Y10-3
4. RDX30 Hydraulic Schematic
444
Return
2001-11-08
F-code
Section
PS
S6.0
6000
Hydraulic System
Version no
000
C-code
T-code
395/396/397/398/399
Y10-2
Y10-3
5. RSX40 Hydraulic Schematic
Return
2001-11-08
445
F-code
Section
C-code
PS
S6.0
Hydraulic System
6000
Version no
T-code
000
395/396/397/398/399
Y10-2
Y10-3
6. RSX50 Hydraulic Schematic
446
Return
2001-11-08
F-code
Section
PS
S6.1
6112
Hydraulic Fluid
Version no
000
C-code
T-code
395/396/397/398/399
Hydraulic Fluid
1. Hydraulic Fluid Selection
Before adding or changing hydraulic fluid, determine the
environment and usage of truck. To make proper oil/lubricant
selection see page 84.
2. Changing Hydraulic System Fluid

1. Be sure truck is in a clean area, away from any
possible contaminating elements that could enter
the hydraulic system during the changing process.
Check that carriage is fully lowered, reach
retracted, and tilt is full down.
2. Drain hydraulic reservoir completely (see
page 448). Drain as much oil as possible from
hydraulic lines and cylinders.
3. Fill hydraulic reservoir with proper fluid.
4. With lift system running, operate lift/lower and
auxiliary functions for approximately 2 minutes to
purge the system.
5. Check for possible hydraulic leaks.
6. Bleed entire hydraulic system before placing truck
into service (see page 450).
7. Check reservoir oil level.
The remainder of the original hydraulic fluid left in the system,
(approximately 5%), should not be harmful to the operation of
truck.
Return
2000-08-04
447
F-code
Section
C-code
PS
S6.1
Hydraulic Fluid
6112
Version no
T-code
000
395/396/397/398/399
3. System Draining
1. Lower the carriage fully, tilt forks down completely
and retract reach mechanism fully.
3. Remove dash and open motor compartment door
(see page 100).
4. Use female half of the diagnostic fitting (24 inch
hose) and direct the hydraulic fluid into a waste
container with a capacity greater than 5 gallons (19
liters).
switch ON.
6. Operate lift until air in the system is heard.
8.
Remove female half of diagnostic fitting and hose.
9.
If it is necessary to flush reservoir, remove

reservoir.
10. Dispose of old hydraulic fluid according to local

regulations for hazardous materials.
448
Return
2000-08-04
F-code
Section
PS
S6.1
6112
Hydraulic Fluid
Version no
000
C-code
T-code
395/396/397/398/399
4. Refilling System
1. If reservoir was removed for flushing, install
reservoir.
2. Install hydraulic filter.
3. Fill hydraulic reservoir through bleeder cap/fill hole.
Be sure to use proper grade of fluid. The reservoir
holds 5 gallons (19 liters) of fluid.
switch ON.
5. Bleed hydraulic system (see page 450).
6. Install dash and secure motor compartment door.
Return
2000-08-04
449
F-code
Section
C-code
PS
S6.1
Hydraulic Fluid
6112
Version no
T-code
000
395/396/397/398/399
5. Bleeding Hydraulic System

Bleed hydraulic system to remove any trapped air whenever
the following take place:
Change a hydraulic hose
Disconnect a hydraulic fitting
Remove a hydraulic cylinder
Remove hydraulic pump
Remove hydraulic reservoir
Notice that load is bouncing
1. Elevate forks 2 to 3 inches (50 to 76 mm) off the
floor.
CAUTION Use caution. The mast may drop when
bleeding the cylinder
3. Use an Allen wrench to loosen (but do NOT
remove) bleed screw at the top of freelift cylinder.
Hold a rag close to and beneath bleed screw to
keep hydraulic fluid from spraying out.
4. When hydraulic fluid starts flowing from bleed
screw hole, securely tighten bleed screw.
5. Repeat steps 3 and 4 for each of two staging
cylinders.
switch ON.
7. Lower forks all the way down to the floor.
8. Fully extend and retract reach mechanism several
times.
9. If truck is equipped with tilt, tilt carriage all the way
forward and backward several times.
10. If truck is equipped with sideshift, shift carriage all
the way to the left and right several times.
450
Return
2000-08-04
F-code
Section
PS
S6.1
6112
Hydraulic Fluid
Version no
000
C-code
T-code
395/396/397/398/399
11. Thoroughly clean up any spilled hydraulic fluid.

12. Check hydraulic reservoir level and refill as
necessary.
Return
2000-08-04
451
F-code
Section
C-code
PS
S6.1
Hydraulic Tank
6112
Version no
T-code
000
395/396/397/398/399
Hydraulic Tank
1
Item No.
452
Return
Description
Tank, hydraulic (RRX35/RSX40)
Tank, hydraulic (RRX45/RSX50/RDX30)
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.
3. Drain hydraulic system (see page 448).
4. Remove left side panel (see page 102).
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.
Return
2000-08-04
453
F-code
Section
C-code
PS
S6.1
Hydraulic Tank
6112
Version no
T-code
000
395/396/397/398/399
2. Installation
1. Install hydraulic filter adapter.
2. Install hydraulic filter.
3. Angle mast end of reservoir down and push
forward to truck frame. Let truck end of reservoir
drop straight down at this point.
4. Install pump and motor assembly.
5. Connect hoses to reservoir.
6. Fill hydraulic reservoir.
7. Install drive motor and brake assembly.
8. Install left side panel.
10. Bleed hydraulic system (see page 450).
connector from the truck. Install dash. Connect
battery connector to the truck.
454
Return
2000-08-04
F-code
Section
PS
S6.1
6112
Hydraulic Tank
Version no
000
Return
2000-08-04
C-code
T-code
395/396/397/398/399
455
F-code
Section
C-code
PS
S6.2
6131
Hydraulic Filter Assembly
Version no
T-code
000
395/396/397/398/399

13
7
11
8
1, 2
3, 4
5, 6
12
10
Item No.
456
Return
Description
Item No.
Description
Screw
O-ring
Washer
Ring
Screw
10
Element, filter
Washer
11
U-gasket
Plate
12
Gasket, tank
Gasket
13
Cap, filter
Filter assembly
2000-08-04
F-code
PS
Section
C-code
S6.2
6131
Version no
000
T-code
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
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.
4. Check hydraulic fluid level and refill as needed.
5. Replace dash.
7. Return to service.
Return
2000-08-04
457
F-code
Section
C-code
PS
S6.2
6131
Version no
T-code
000
395/396/397/398/399
2. Hydraulic Filter Adapter

2.1. Removal
2. Remove dash.
3. Drain hydraulic system.
4. Remove blue cap and filter.
5. Remove four mounting screws attaching the collar
assembly to plastic hydraulic tank.
2.2. Installation
1. Clean all parts thoroughly. Clean mating surface of
the hydraulic tank.
2. Align collar mounting holes with hydraulic tank
holes. Torque four mounting screws to 44.4 in-lb
(5.01 Nm).
3. Install cap and filter.
4. Check fill level fluid in the hydraulic tank.
6. Bleed hydraulic system.
9. Install dash.
458
Return
2000-08-04
F-code
PS
Section
Version no
000
Return
2000-08-04
C-code
S6.2
6131
T-code
395/396/397/398/399
459
F-code
Section
C-code
PS
S6.3
Hydraulic Pump
6141
Version no
T-code
000
395/396/397/398/399
Hydraulic Pump
Hydraulic Pump Detail
1. Removal
Remove pump motor (see page 141). Remove hydraulic
pump from pump motor.
2. Repair
Contact your local BT Prime-Mover distributor for repair
procedures on the hydraulic pump.
Pump
Motor
Hydraulic
Pump
460
Return
2000-08-04
F-code
Section
PS
S6.4
6211
Control Valve
Version no
000
Y10 Lift and

Prop. Lower
C-code
T-code
395/396/397/398/399
Control Valve
To
Mast
1. Removal
To
Reservoir

Y12 DIRA
3. Remove motor compartment rear door.

WARNING Take precautions to prevent fluid from
getting into the drive motor and/or brake
assembly when removing fittings from
control valve.
To
Pump
To Aux.
Functions
4. Loosen fittings on two large hoses, toward the lift

motor, with a 1-1/8 inch (28.58 mm) wrench.
Y13 DIRB
5. Disconnect the electrical wires from Y10, Y12, and

Y13.
6. Use a 13/16 inch (20.64 mm) wrench to loosen
fittings on two smaller hoses.
7. Loosen hose clamp to remove return hose from
reservoir.
8. Using a 1/2 inch (13 mm) socket, remove 3 bolts
securing the control valve to bracket.
Mounting Bolt
(one shown)
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)
Return
461
F-code
Section
C-code
PS
S6.4
Control Valve
6211
Version no
T-code
000
395/396/397/398/399
- Two small hoses 13/16 inch (20.64 mm) on

the front of control valve. Hose with 90 degree
fitting goes on the bottom, tighten before
installing the top hose. Install 90 degree fitting
in the top port of control valve, then install
remaining small hose.
4. For large hoses, finger tighten fittings until both
ends are attached. Torque nut to 480 + 25 in-lb (54
Nm).
5. Connect the electrical wires from Y10, Y12, and
Y13.
6. Install dash.
7. Install motor compartment rear door.
NOTE!
462
Return
To service either the drive motor or pump

motor, control valve may be removed from
the bracket (leaving all hoses attached) and
laid up over the reservoir.
If the reservoir needs to be replaced, leave
the control valve on the bracket. Remove
return hose at reservoir. Lay hose over
control valve and let the loose end drop into
the operator compartment.
F-code
Section
PS
S6.4
6211
Control Valve
Version no
000
FUNCTION
MALFUNCTION
Lifting Function
Forks do not lift or

lift too slow.
C-code
T-code
395/396/397/398/399
POSSIBLE CAUSE
POSSIBLE REPAIR
1. 2/2-way seated valve does

not open (only if forks do not
raise).
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.
2.Delivery flow of the pump is

too low.
Check pump delivery flow.
3.Pressure limiting valve is open

or leaking (pressure relief).
Compare actual pressure setting

of the pressure limiting valve with
specifications from service manual
(see Pressure at rated load on
page 58).
Dismantle the pressure relief valve
and clean valve seat.
Replace the main valve block.
Unintentionally lift
during the actuation
of auxiliary
functions.
4.Simultaneous actuation of the

auxiliary functions.
Check for proper electrical control

of valves.
1.Electrical actuation 2/2

directional valve (in front of
piloting part) is open or
leaking.
Check valve insert under the on/

off section of the twin solenoids:
Is the valve operation smooth?
Is there any contamination?
Replace the main control block.
2.Main piston of the 2/2 way

directional valve is not closed.
Check the orifice in the main

piston for contamination and clean
it.
Check 2/2-way main piston for
smooth operation.
Replace the piston.
Replace the main control block.
Return
463
F-code
Section
C-code
PS
S6.4
Control Valve
6211
Version no
T-code
000
395/396/397/398/399
FUNCTION
Lowering
Function
MALFUNCTION
Forks do not drop
or drop too slow.
POSSIBLE CAUSE
POSSIBLE REPAIR
1.Electrical actuation (see

LIFTING/LOWERING TIME
on page 60).
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.

proportional section of the Y10
solenoid for: - Deformation,
contamination and smooth
operation - Seals damaged at the
valve insert (Teflon ring in the seat
and O ring) - Replace the valve
insert.
3.Maximum drop rate is too slow

due to setting of adjustment
screw (see page 469).
Check the setting of the lowering

adjustment screw (lowering rate
increases when screw is turned
counter clockwise).
4.Throttle piston or flow control

valve piston of the controller is
sticking.
Replace piston or main control

valve block.
1.Flow controller is open or

leaks too much (see LIFTING/
LOWERING TIME on
page 60).
Check the electrical connections

for the proportional lowering valve
Y10. Is it electrically activated?
lowering section of the Y10 lift/
lower solenoid valve for: Deformation, contamination,
smooth operation - Seals
damaged at the valve insert
(Teflon ring in seal and O ring) Replace the valve insert.
Check the lowering adjustment
screw for proper adjustment.
464
Return
F-code
Section
PS
S6.4
6211
Control Valve
Version no
000
FUNCTION
Auxiliary
Functions
Main control
valve (general)
Return
MALFUNCTION
Auxiliary functions
(reach, tilt,
sideshift) do not
operate or operate
too slowly.
(See page 461.)
C-code
T-code
395/396/397/398/399
POSSIBLE CAUSE
POSSIBLE REPAIR
1.Functions are not electrically

actuated.
Check electrical control and plugs

for proper electrical actuation.
2.Valve spool in the add on

block (Y12, Y13 solenoid
valves) is sticking.
Replace the auxiliary control block

and solenoids.
1.Y10 solenoid is leaking at the

plug.
Replace the solenoid.
2.Tapped plugs are leaking.
Retighten the tapped plugs.

Replace the seals.
3.Peening plugs are leaking.
Replace the main block.
4.Leakage between the add-on

auxiliary block.
Retighten the tension bolts

(maximum torque 14.75 ft-lb (20
Nm).
Replace the O rings.
465
F-code
Section
C-code
PS
S6.4
6211
Control Valve Assembly
Version no
T-code
000
395/396/397/398/399

52
1
17
2
18
3
4
4a
20
4b
13
14
19
5
6
15
21
22
10
23
11
12
16
24
25
29A
29
49
26
27 47
28
20
30
31
32
47
33
53
48
41
40
46
40
20
36
41
20
43
37
466
Return
41
50
51
F-code
PS
Version no
000
Item
No.
Description
1
Valve assembly, control
2
Plug
3
O ring
4
Insert
4a
O ring
4b
Seal ring
5*
Rod
6*
Screw (torque 8.85 ft-lb (12 Nm)
7*
Pin
8*
Valve core
9*
Seal
10*
Return Spring
11*
Spring
12*
Seal
13*
14
Seal
15*
Spring
16*
Damping insert
17
Screw
18
Nut
19
Screw
20
Ring, seal
21
Disc
22
Spring
23
Guide spring
* Not sold separately (NSS)
Return
Section
C-code
S6.4
6211
T-code
395/396/397/398/399
Item
No.
Description
24
25
26
27
28*
29*
29A*
30*
31
32*
33*
36
37
40
41*
43*
46*
47
48
49
50
51
52
53
Piston
Spring
Spring
Sleeve
Ball
Screw
Screw
Seal
Spring
Guide, ball
Locknut
Screw
Seal
Plug
Screw
Plug (torque11.06 ft-lb (15 Nm)
O ring
Valve, assembly
Plate, end
Washer
Screw (torque14.75 ft-lb (20 Nm)
Solenoid, double
Valve assembly
467
F-code
Section
C-code
PS
S6.4
6211
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).
3.2. Valve Assembly SWR14

1. Remove two screws (51) and washers (50).
Separate SWR14 valve (48) from the lift control
valve assembly.
2. Remove end plate (49).
3. Inspect O rings (47) and replace if necessary.
4. Install end plate (49).
5. Install SWR14 valve (48) on control valve
assemble.
6. Screw two washers (50) and screws (51). Torque
screws (51) at 14.75 ft-lb (20 Nm).
468
Return
F-code
PS
Version no
000
Section
C-code
S6.4
6211
T-code
395/396/397/398/399
3.3. Pressure Limiting Valve Assembly

1. Remove screw (19). Screw (17) and nut (18) will
remain intact. Inspect seal ring (20) for damage
and replace if necessary.
NOTE!
Items 27 and 28 are very small, use caution

not to lose them.
2. Pull out inner parts (21) through (28). Do not

damage the surface of the dampening piston (24)
or the bore of valve seat.
3. Install inner parts (21) through (28) using light
grease. Make sure dampening piston (24) operates
smoothly.
4. Install screw (19) and (17) and new nut (18) as an
assemble. Install new seal ring (20).
5. Check the pressure setting with a pressure gauge.
3.4. Setting Lift/Auxiliary Pressure Relief

with a Rated Load
NOTE!
Relief
Valve
Adjusting
Screw
To set the system pressure, a calibrated

pressure gauge capable of measuring 300
psi (2068 kPa) at mid-range is needed.
The lift/auxiliary pressure relief adjusting screw is located on

top of the main control valve, near solenoid Y10. The relief
pressure test port is on the side of the control valve, to the
right of hydraulic lines to reservoir and pump.
1. Lift a rated load (maximum capacity listed on the
specification plate plus 10%).
Relief Pressure
Test Port
(beneath
reservoir hose)
2. Loosen locknut (18) so adjuster screw (17) can be

turned. Turn adjuster screw counter-clockwise to
reduce pressure and clockwise to increase
pressure.
3. The pressure at rated load should be the truck
capacity weight +10%. Turn adjuster screw (17)
until the load can be lifted.
Return
469
F-code
Section
C-code
PS
S6.4
6211
Version no
T-code
000
395/396/397/398/399
4. Be sure locknut (18) is secure when adjustment is

complete.
3.5. Hydraulic Lowering Rate Adjustment

1. Loosen sealed locknut (36) so adjustment screw
(37) can be turned.
2. To increase lowering rate of speed, adjust screw
(37) counter clockwise.
3. To decrease lowering rate of speed, adjust screw
(37) clockwise.
4. For lowering rates for truck type mode, see
Technical Service Data on page 57.
5. After adjustment is complete, tighten sealed
locknut (36).
470
Return
F-code
PS
Section
C-code
S6.4
6211
Version no
000
T-code
395/396/397/398/399
3.6. Recondition Seal Kit

1. See Proportional Pre-Pressure Reducing Valve
on page 468.
2. Remove screw (13). Spring (15) is inserted in
screw (13).
3. Check damping
contamination.
insert
(16) for damage
or
4. Install seal (14) and assemble. Take care that

spring (15) stays inside screw (13). Torque screw
(13) to 5.9 ft-lb (8 Nm).
5. Remove screw (30) and pull out spring (32) with
check ball (33). Inspect for contamination or
damage.
6. Replace seal (31). During assembly ensure that
spring (32) and ball (33) are correctly installed (see
Valve Assembly SWR14 on page 468). Torque
value of screw (30) is 8.85 ft-lb (12 Nm).
7. Loosen locknut (36) and remove adjustment screw
(35). Replace locknut (36) with new.
8. Remove plug (29) and replace seal (20).
9. Remove plug (29a) and replace seal (20).
10. Remove plug (43) and replace seal (20).
11. Remove plug (41) and replace seals (40).
12. Tighten all plugs.
13. Replace o rings (47) (see Valve Assembly
SWR14 on page 468).
Return
471
F-code
Section
C-code
PS
S6.4
6211
Version no
T-code
000
395/396/397/398/399
472
Return
F-code
Section
C-code
PS
S6.5
6610
Staging Cylinder, Three Stage Mast
Version no
T-code
001
395/396/397/398/399
Staging Cylinder, Three Stage

Mast
7
3
1
2
4
10
11
12
13
16
15
Item No.
Description
Item No.
Description
Screw
Ring, wear
Washer, seal
10
Piston
Cylinder tube, 1 port
11
Ring, retainer
Cylinder tube, 2 ports
12
Rod, cylinder
Plugger assembly
13
O ring
Spring
14
Bearing
Plug
15
Seal, rod
O ring
16
Wiper
Return
14
2002-01-15
473
F-code
Section
C-code
PS
S6.5
6610
Version no
T-code
001
395/396/397/398/399
1. Bearing Removal
1. Park the truck on a level surface and apply the
brake.
2. Fully extend the cylinders to inspect rod (12) for
gouges or pits. If gouges or pits are detected,
remove cylinder for repair.
DANGER Securely block columns to prevent
lowering. If not blocked, unexpected
movement could occur resulting in personal
injury or death.
3. Lift mast so inner column is raised approximately
12 inches (305 mm). Securely block mast.
4. Remove bolts from top end of staging cylinder
rods. Lower cylinder rods hydraulically.
and then only with effective chip guarding
and personal protective equipment.
6. Clean the exterior of the lift cylinder.
474
Return
2002-01-15
F-code
Section
C-code
PS
S6.5
6610
Version no
001
T-code
395/396/397/398/399
2. Disassembly
1. Remove bearing (14) from the cylinder tube.
2. Remove and discard rod wiper (16), seal (15),
wear ring (9) and O ring (13) from the bearing (14).
Discard seal (15). Use care NOT to damage the
inside of the bearing.
3. Assembly
1. Install new bearing (14), seal (15), wear ring (9), O
ring (13) and rod wiper (16).
2. The lip of the wiper must face outward.
3. It is not necessary to replace wear ring (9), unless
the cylinder was removed for rod repair.
4. Installation
1. Install bearing in the cylinder tube.
2. Raise cylinder rods hydraulically.
3. Install bolts in the top end of the staging cylinder.
5. Test for proper operation.
Return
2002-01-15
475
F-code
Section
C-code
PS
S6.5
6610
Version no
T-code
001
395/396/397/398/399
476
Return
2002-01-15
F-code
Section
C-code
PS
S6.6
6620
Freelift Cylinder, Three Stage Mast
Version no
001
T-code
395/396/397/398/399
Freelift Cylinder, Three Stage

Mast
K
2
3
15
14
13
7
12
6
11
5
10
Return
2000-08-04
477
F-code
Section
C-code
PS
S6.6
6620
Version no
T-code
001
395/396/397/398/399
Item
No.
Item
No.
Description
Washer, seal
Screw
10K
O ring
Tube cylinder
11K
Ring, back-up
Ring, retainer
12
Bearing
Plunger assembly
13K
Ring, guide
Spring
14K
Seal
Ring, guide
15K
Wiper
7K
8
Description
Piston
Rod cylinder
Kit, Seal (items marked with K)
The lift cylinders are the positive displacement type, meaning

there are NO seals on the lower end of the cylinder rod. The
lift cylinder can be resealed without removing from the truck.
NOTE!
478
Return
CLEANLINESS! Perform procedures in a

clean environment. Make sure all parts are
cleaned before disassembly and kept clean
during assembly.
2000-08-04
F-code
Section
C-code
PS
S6.6
6620
Version no
001
T-code
395/396/397/398/399
1. Removal
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.
injury or death.
3. Lift carriage/reach and securely block.
4. Lower cylinder so chains, hoses, and electric
cables are loose.
6. Remove chains, hoses, and electric cables from
the crosshead.
7. Remove crosshead from cylinder rod.
8. Clean the exterior of the lift cylinder.
Return
2000-08-04
479
F-code
Section
C-code
PS
S6.6
6620
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.
3. Test for proper operation.
480
Return
2000-08-04
F-code
PS
Section
C-code
S6.7
6650
Reach Cylinder Assembly
Version no
T-code
002
395/396/397

7
10
11
12
13
14
15
24
25
23
21
20 19
18
17
16
22
1
6
2
6
3
Return
2000-08-04
481
F-code
Section
C-code
PS
S6.7
6650
Version no
T-code
002
395/396/397
Item
No.
Description
Item
No.
Description
Reach cylinder
assembly, right
10K
Ring, guide
19Q
Piston
Reach cylinder
assembly, left
11K
Seal
20K
Ring, guide
Pin, roll
12K
Wiper
21Q
Nut, lock
Pin, clevis
13Q
Rod cylinder
22K
Retainer
Pin, clevis
14
Nut
23
Tube cylinder, right
Fitting, grease
15
Clevis
24
Tube cylinder, left
7K
O ring
16
Spacer
25
Bearing
8K
Ring, backup
17K
Ring, backup
Kit, seal Items marked

with K
Bearing
18K
O ring
Kit, rod assembly

items marked with Q
NOTE!
482
Description
Return
Item
No.
Items 13, 19, and 21 come as an assembly.

Assembly together using Loctite 277 and let
set for 24 hours to cure.
2000-08-04
F-code
PS
Section
Version no
002
C-code
S6.7
6650
T-code
395/396/397
1. Removal
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
Return
2000-08-04
483
F-code
Section
C-code
PS
S6.7
6650
Version no
T-code
002
395/396/397
2. Disassembly
be reduced to less than 30 psi (206 kPa),
NOTE!

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.
484
Return
2000-08-04
F-code
PS
Section
Version no
002
C-code
S6.7
6650
T-code
395/396/397
3. Inspection
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.
Return
2000-08-04
485
F-code
Section
C-code
PS
S6.7
6650
Version no
T-code
002
395/396/397
4. Assembly
1. Install new O ring (7), back-up ring (8), ring guide
(10), seal (11), and rod wiper (12) in bearing
assembly (9). The lip of the wiper must face
outward.
2. Install new ring guide (20), back-up rings (17) and
(8) on piston (19).
3. Apply clean hydraulic fluid to rod cylinder (13).
Coat inside of cylinder tube and bearing assembly
with clean fluid.
4. Carefully slide spacer (16) (if used) and bearing
assembly (9) onto cylinder rod. Be sure rod end
does not cut or nick wiper upon installation.
5. Install cylinder assembly consisting of the rod (13),
piston (19) and lock nut (21) into cylinder tube (23
or 24). Be careful not to nick or cut piston seals on
the edge of cylinder tube or when sliding over
groove within tube. Torque cylinder piston lock nut
(21) to 47.94 ft-lb (65 Nm).
6. Install bearing assembly into cylinder tube. Use
care not to nick or cut seals upon installation.
7. Install retainer (22).
8. Check installation by making sure piston rod
assembly moves smoothly within tube assembly
without binding.
9. Install bearing (25).
486
Return
2000-08-04
F-code
PS
Section
C-code
S6.7
6650
Version no
002
T-code
395/396/397
5. Installation
1. Connect battery connector to the truck. Turn key
switch to ON.
2. Raise reach to full freelift height. Install reach
cylinder rear cylinder mounting pins (5). Secure
mounting pins with roll pins (3).
3. Lower reach assembly. Install reach cylinder front
mounting pins (4). Secure mounting pins with roll
pins (3).
4. Connect correct hydraulic hoses to reach cylinders.
5. Remove blocking and chains.
6. Fill hydraulic reservoir with new clean oil.
7. Operate reach to remove air from hydraulic hoses
and check operation of the whole hydraulic system.
CAUTION DO NOT use your hands to check for
8. After running the hydraulic system, check and fill
hydraulic reservoir with new clean oil.
Return
2000-08-04
487
F-code
Section
C-code
PS
S6.7
6650
Version no
T-code
002
395/396/397
488
Return
2000-08-04
F-code
Section
C-code
PS
S6.8
6660
Tilt Cylinder Assembly, RRX35/RSX40/RSX50
Version no
T-code
002
395/398/399
Tilt Cylinder Assembly, RRX35/RSX40/

RSX50
13
14
11
8
7
5
12
10
1
2
3
4
Return
Item
No.
Description
Item
No.
Tilt cylinder assembly
Seal
11
O Ring
Bushing
Bearing, cylinder
12
Ring, back-up
Retainer, cylinder
Ring, back-up
13
Retainer
Screw, cap
O Ring
14
Tube, cylinder
Wiper
10
Rod, cylinder
Description
2000-08-04
Item
No.
Description
489
F-code
Section
C-code
PS
S6.8
6660
Version no
T-code
002
395/398/399
1. Removal
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
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
8. Remove tilt cylinder assembly (1) from the truck.
490
Return
2000-08-04
F-code
Section
C-code
PS
S6.8
6660
Version no
002
T-code
395/398/399
2. Disassembly
NOTE!
Perform
procedures
in
a
clean
environment. Make sure all parts are
during assembly.
1. Before disassembly, clean exterior of tilt cylinder

(1) in a cleaning solution to remove all
contamination.
cylinder. Stroking piston rod will help force fluid out.
3. Put trunnion of cylinder in a vise equipped with soft
jaws.
4. Remove bearing retainer (13) 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.
Return
2000-08-04
491
F-code
Section
C-code
PS
S6.8
6660
Version no
T-code
002
395/398/399
3. Inspection
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.
replacement.
4. Check threaded section of cylinder tube to be sure
threads have not been damaged.
492
Return
2000-08-04
F-code
Section
C-code
PS
S6.8
6660
Version no
002
T-code
395/398/399
4. Assembly
1. Install new seals (6), O ring (9), backup ring (8),
and rod wiper (5) in bearing assembly. The lip of
the wiper must face outward.
2. Install new O ring (11) and back-up ring (12) on
cylinder rod (10).
3. Apply clean hydraulic fluid to cylinder rod
assembly. Coat the inside of the cylinder barrel and
bearing assembly with clean fluid.
4. Carefully slide bearing assembly on cylinder rod.
Be sure rod end does not cut or nick wiper (5) and
seal (6) upon installation.
5. Install rod into cylinder barrel. Be careful not to nick
or cut piston seals on the edge of cylinder barrel or
when sliding over groove within barrel.
6. Install bearing assembly into cylinder barrel. Use
care not to nick or cut seals upon installation.
7. Check installation by making sure cylinder rod
assembly moves fairly easy within barrel assembly
without binding.
8. Install bearing fastening ring and retainer.
Return
2000-08-04
493
F-code
Section
C-code
PS
S6.8
6660
Version no
T-code
002
395/398/399
5. Installation
1. Install cylinder on reach front frame.
2. Install retainer (3) and secure with four cap screws
(4).
3. Properly connect correct hydraulic hoses to front
and rear of tilt cylinder.
7. Operate tilt to remove air from hydraulic hoses and
check operation of whole hydraulic system.
hydraulic reservoir with more new clean oil.
494
Return
2000-08-04
F-code
Section
C-code
PS
S6.9
6660
Tilt Cylinder Assembly, RRX45/RDX30
Version no
T-code
001
396/397
23
22
21 20
18
19
24
25
26
9
12
13
16
11
15 14
17
10
5
6
1
4
2
3
2
Return
2000-08-04
495
F-code
Section
C-code
PS
S6.9
6660
Version no
T-code
001
396/397
Item
No.
496
Description
Item
No.
Description
Item
No.
Description
Pin, roll
10
Retainer
19
Ring, sealing
Washer
11
Nut, lock
20
Bearing
Bearing
12
Washer, flat
21
Ring, guide
Pin
13
Ring, guide
22
Seal, rod
Pin
14
Piston
23
Wiper, rod
Pin, roll
15
O ring
24
Rod, cylinder
Tilt cylinder
assembly
16
Ring, sealing
25
Nut
Bearing
17
O ring
26
Clevis
Tube, cylinder
18
O ring
Return
2000-08-04
F-code
Section
C-code
PS
S6.9
6660
Version no
001
T-code
396/397
1. Removal
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.
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.
Return
2000-08-04
497
F-code
Section
C-code
PS
S6.9
6660
Version no
T-code
001
396/397
2. Disassembly
NOTE!

during assembly.
1. Before disassembly, clean exterior of tilt cylinder in

a cleaning solution to remove all contamination.
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) 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.
498
Return
2000-08-04
F-code
Section
C-code
PS
S6.9
6660
Version no
001
T-code
396/397
3. Inspection
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.
replacement.
4. Check threaded section of cylinder tube (9) to be
sure threads have not been damaged.
Return
2000-08-04
499
F-code
Section
C-code
PS
S6.9
6660
Version no
T-code
001
396/397
4. Assembly
1. Install new guide ring (21), seal (22) and rod wiper
(23) in gland assembly. The lip of the wiper must
face outward.
2. Install new piston seals (15) and (17), guide ring
(13), and sealing ring (16) on piston (14).
3. Install piston (14) on rod (24).
4. Install nut (11) on cylinder rod (24). Torque cylinder
piston nut to 60-65 ft-lb (81-88 Nm).
5. Apply clean hydraulic fluid to piston rod assembly.
Coat inside of cylinder tube (9)
and gland
assembly with clean fluid.
6. Carefully slide gland assembly onto piston cylinder
rod (24). Be sure rod end does not cut or nick wiper
(23) and seal (22) upon installation.
7. Install piston and rod into cylinder tube (9). Be
careful not to nick or cut piston seals on the edge
of cylinder tube or when sliding over groove within
tube.
8. Install gland assembly into cylinder tube (9). Use
care not to nick or cut seals are upon installation.
9. Install retainer (10).
10. Check installation by making sure piston rod
assembly moves fairly easy within tube assembly
without binding.
11. Install bearing (20).
12. If removed, install roller bearing and clevis
assembly.
500
Return
2000-08-04
F-code
Section
C-code
PS
S6.9
6660
Version no
001
T-code
396/397
5. Installation
1. Install tilt cylinder on carriage/reach front frame.
Secure with mounting pin (5) with roll pin (6).
2. Properly connect correct hydraulic hoses to the top
and bottom of tilt cylinder.
6. Operate tilt to remove air from hydraulic hoses and
check operation of the whole hydraulic system.
hydraulic reservoir with new clean oil.
Return
2000-08-04
501
F-code
Section
C-code
PS
S6.9
6660
Version no
T-code
001
396/397
502
Return
2000-08-04
F-code
Section
PS
S7.0
7110
Mast, 3 Stage
Version no
C-code
T-code
001
395/396/397/398/399
Mast, 3 Stage
RRX35/RSX40
33
27
32
34
5
34
35
29
30
31
28
28
10
3
1
7
4
11
22
14
12
15
26
3
21
20
13
14
15
23
38
36
37 36
17
40
25
24
18
5
Return
17 19
2000-08-04
16
39
503
F-code
Section
C-code
PS
S7.0
Mast, 3 Stage
7110
Version no
T-code
001
395/396/397/398/399
Item
No.
504
Description
Item
No.
Description
Item
No.
Description
Anchor, chain
15
Nut, jam
29
Sheave, chain
Chain, Staging lift
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
Screw, button head
22
Sheave
36
Spacer
Column, inner
23
Screw, cap
37
Sheave, hose
10
Chain, Free lift
24
Washer, flat
38
Screw, cap
11
Freelift cylinder
assembly
25
Screw, cap
39
Shaft, sheave
12
Pin, anchor
26
Column, outer
40
Sheave, hydraulic,
and electrical
13
Pin, cotter
27
Shaft
14
Nut
28
Washer, shim
Return
2000-08-04
F-code
Section
PS
S7.0
7110
Mast, 3 Stage
Version no
C-code
T-code
001
395/396/397/398/399
RRX45/RSX50/RDX30
28
29
30
5
31
6
24
25
26
27
24
10
6
1
7
4
11
18
14
37
15
19
12
13
3
14
15
22
38
17
4
16
23
5
6
20
32
33
32
21
35
34
Return
36
2000-08-04
505
F-code
Section
C-code
PS
S7.0
Mast, 3 Stage
7110
Version no
T-code
001
395/396/397/398/399
Item
No.
506
Description
Item
No.
Description
Item
No.
Description
Anchor, chain
14
Nut
27
Race, inner
Chain, Staging lift
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
Screw, button head
21
Shaft, sheave
34
Screw, cap
Column, inner
22
Column, outer
35
Washer, shim
10
Chain, Free lift
23
Screw, cap
36
Sheave, hydraulic,
and electrical
11
Freelift cylinder
assembly
24
Washer, shim
37
Manifold
12
Pin, anchor
25
Sheave, chain
38
Screw
13
Pin, cotter
26
Bearing, roller
Return
2000-08-04
F-code
Section
PS
S7.0
7110
Mast, 3 Stage
Version no
001
C-code
T-code
395/396/397/398/399
1. Shimming Carriage with Mast on

Truck
rolling. Park the truck on a level surface and
make sure all wheels are blocked to
connector from the truck. Remove battery from
truck.
injury or death.
2. Attach a hoist to the top of carriage assembly.
Hoist to loosen lift chains. Jack truck up (see
Jacking Truck Off The Floor on page 66). This will
allow removal of lift chain anchor pins, electrical
cable, and hydraulic hoses.
3. Thoroughly clean off all outside dirt around the
mast roller bearings.
4. Determine amount of shims required. Pry carriage
to one side and slip shims between bearings and
web on the column. Add shims by hand until no
more can be added.
5. Divide shims as equally as possible between the
two bearings. Install under bearings.
6. Hydraulically lift up inner column enough to remove
reach carriage assembly.
7. Lower carriage down through the inner column to
expose bearings. Remove bearings to install shims
behind the bearings.
Return
2000-08-04
507
F-code
Section
C-code
PS
S7.0
Mast, 3 Stage
7110
Version no
T-code
001
395/396/397/398/399
8. Raise carriage up through the inner column as far

as it will go under normal operation. Check bearing
shimming as carriage is raised. Remove shims as
required if tight spots are encountered where an
assembler cannot move the carriage smoothly.
Check for excessive bearing clearance with the
carriage in fully raised position. Pry carriage 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).
9. Lower carriage to install hydraulic hoses, lift chain
anchor pins, and electrical cable. When installing
lift chains, chains are to be free of twists and
adjusted for equal tension with adjusting nuts
(wheel nuts) and locknuts (jam nuts) torqued to
200 ft-lb (271 Nm). Chains are to be centered on
the sheave within 0.03125 inch (0.8 mm)
10. Remove hoist from carriage and test operation of
unit. Check operation first with no load, then with a
capacity rated load.
508
Return
2000-08-04
F-code
Section
PS
S7.0
7110
Mast, 3 Stage
Version no
001
C-code
T-code
395/396/397/398/399
2. Three Stage Mast

2.1. Removal
connector from the truck. Remove battery from
truck.
Bolts

injury or death.
2. Attach a hoist to the top of carriage assembly.
Hoist to loosen lift chains. Jack truck up (see
Jacking Truck Off The Floor on page 66). This will
allow removal of lift chain anchor pins, electrical
cable, and hydraulic hoses.
3. Hydraulically lift up inner column enough to remove
4. Disconnect hydraulic supply line which is located in
the lower left corner of the battery box and cap.
5. Disconnect two hydraulic supply lines located by
the emergency disconnect and cap.
6. Disconnect electric wiring harness located by the
emergency disconnect.
Plate
7. If truck is equipped with a light and/or fan package,

disconnect harness located at the base of
overhead guard post.
8. Connect a hoist to the top tie bars of mast. Tighten
enough to remove all slack in chains.
9. Remove two mast bolts located in the middle of the
battery box.
10. Remove two side mounting plates at the pivot
points on mast.
Return
2000-08-04
509
F-code
Section
C-code
PS
S7.0
Mast, 3 Stage
7110
Version no
T-code
001
395/396/397/398/399
11. Remove two bolts at the base of overhead guard

post.
12. Lift mast enough to clear chassis and lay mast on
the floor.
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.
510
Return
2000-08-04
F-code
Section
PS
S7.0
7110
Mast, 3 Stage
Version no
001
C-code
T-code
395/396/397/398/399
2.3. Assembly
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.
two bearings. Install shims under the bearings.
6. Extend intermediate column through the outer
column as far as it will go under normal operation.
Check bearing shimming as column is extended.
Remove shims as required if tight spots are
encountered where an assembler cannot roll the
mast by hand.
Check for excessive bearing clearance with
columns in the fully extended position. Pry column
to one side and check with a 0.030 inch (0.76 mm)
shim. Maximum clearance must not exceed 0.030
inch (0.76 mm).
7. Assemble inner column in intermediate column.
Slide columns together.
8. Determine amount of shims required. Pry inner
column to one side and slip shims between bearing
and web on the mast. Add shims by hand until no
more can be added.
two bearings. Install shims under bearings.
10. Extend inner column through the intermediate
column as far as it will go under normal operation.
Return
2000-08-04
511
F-code
Section
C-code
PS
S7.0
Mast, 3 Stage
7110
Version no
T-code
001
395/396/397/398/399
Check bearing shimming as the 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 the
fully closed position. Pry column to one side and
check with a 0.060 inch (1.5 mm) shim. Maximum
clearance must not exceed 0.060 inch (1.5 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).
11. Install staging lift cylinder assembly in outer
column lower end.
12. Press roller bearings in lift chain sheaves. Grease
roller bearings, then slide inner races in roller
bearings.
13. Install shim washers on either side of lift chain
sheaves and install in intermediate column. Slide
pins through sheaves and secure pins with two cap
screws and lockwashers. Complete this for both
chain sheave pins.
14. Install a bearing in the electrical sheave. Grease
bearing and install spacers on either side of
bearing.
15. Install electrical sheave in the proper location on
intermediate column. Secure sheave with one cap
screw and lockwasher.
16. Push intermediate and outer columns together.
Install a cap screw in intermediate column to
secure staging lift cylinder.
17. Install lift chain anchors through outer column.
Thread a wheel nut on each anchor and secure
with a jam nut.
18. Install lift chain on chain anchors and secure with
chain pins. After chain pins have been installed,
run lift chain over chain sheaves. Make sure chain
and sheaves are properly aligned.
512
Return
2000-08-04
F-code
Section
PS
S7.0
7110
Mast, 3 Stage
Version no
001
C-code
T-code
395/396/397/398/399
19. Install freelift cylinder assembly on inner column.

Secure with four cap screws and nuts.
20. Connect hydraulic lines to lift cylinder.
21. Lubricate grease fittings using a standard lube gun
(see Approved Oils and Grease on page 84).
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
7. Connect all electrical connectors.
8. Adjust lift chains.
Loosen jam nut and tighten staging chains equally
until the top of the rails are level in the fully lowered
position. Retighten jam nut and torque to 200 ft-lb
(271 Nm).
Freelift chains should be adjusted in the fully
lowered position. Adjust chains until the top of forks
are 2.0 inches (50 mm) off the floor.
9. Grease all chain sheaves.
10. Bleed any air from cylinders.
11. Connect battery connector to the truck. Test
operations of mast and unit.
Return
2000-08-04
513
F-code
Section
C-code
PS
S7.0
Mast, 3 Stage
7110
Version no
T-code
001
395/396/397/398/399
3. Lift Chain
Lift chains are very important components of the truck. The
chain system on the mast was designed for efficient, reliable
transmission of lifting force from the hydraulic cylinder to the
forks. Safe, uninterrupted use of the truck depends on proper
care and maintenance of lift chains.
After 100 hours of truck operation, lift chains should be
inspected and lubricated. When operating in unfamiliar
corrosive environment, inspect chains every 50 hours.
3.1. Lift Chain Adjustment

1. Loosen locking nuts on chain anchors.
2. Tighten adjusting nuts until both chains are free of
twist and of equal tension. Lift chain tension is
correct if lift chains can be forced sideways
approximately 0.5 to 1 inch (12.7 to 25.4 mm)
before lift frame raises slightly.
3. Retighten locking nut on chain anchors.
3.2. Lift Chain Maintenance

Unsatisfactory chain performance can be traced directly to
inadequate maintenance. Highly stressed precision chains
require periodic maintenance to deliver maximum service life.
3.3. Lift Chain Inspection

After every 100 hours of truck operation, lift chains should be
inspected and lubricated. Inspect chains every 50 hours
when operating in unfamiliar corrosive environment. When
performing inspection, observe the following chain conditions:
chain wear; rust and corrosion; cracked plates; protruding or
turned pins; and chain side wear.
514
Return
2000-08-04
F-code
Section
PS
S7.0
7110
Mast, 3 Stage
Version no
001
T-code
395/396/397/398/399
3.3.1. Wear
As the chain flexes on and off the sheaves, the joints
gradually wear. The stretch a chain develops in service is
due to material being worn off the pin on the outside diameter
and the pitch hole inside diameter on the inside plates.
Chain
Wear
Scale
Chain wear can be measured by using a wear scale or a steel

tape. Discard chains when elognated 3%. (For example, one
foot of chain contains 16 pitches (links). When 16 pitches
measures 12.375 inches (314 mm), replace chains.) When
checking chain wear, measure a segment of chain that
operates over a sheave.
NOTE!
New Chain
C-code
Do not repair chains by cutting out the worn

section and splicing in a new piece.
Stretched 3.3.2. Rust and Corrosion

Lift chains are highly stressed precision components. It is
Chain
very important that maintenance is performed throughout the
chain service life. Corrosion will cause a major reduction in
the load-carrying capacity of the lift chain or roller chain
because corrosion causes sideplate cracking. It is extremely
important to protect the lift chain from corrosion, whether in
service or in storage.
NOTE!
Do not steam clean or degrease new lift

chains.
Lift chain lubricant serves both as a joint lubricant and

corrosion inhibitor. During inspection, carefully examine the
external lift chain surfaces for the presence of an oily film.
Under normal operating conditions, oil lift chains every 100
hours and more frequent under adverse conditions.
NOTE!
Stress-corrosion Cracking
In all cases, the external surface of the lift

chains must be protected with a film of oil.
Outside plates are susceptible to stress-corrosion cracking. If

lift chains are heavily rusted or corroded, remove them from
the mast to thoroughly inspect for cracked plates. Replace all
lift chains on the truck if the plates are cracked. Lubricate the
chains when reinstalled on the truck.
Return
2000-08-04
515
F-code
Section
C-code
PS
S7.0
Mast, 3 Stage
7110
Version no
T-code
001
395/396/397/398/399
3.3.3. Cracked Plates

Fatigue failure is the most common cause of plate cracking.
After many repeated heavy loads, the plates may crack
causing the chains to eventually break (loads higher than the
trucks capacity). Fatigue cracks are almost always found
through the pitch holes perpendicular to the pitch line. If
cracks are present, replace all lift chains on truck.
Ultimate Strength Failure

This type of failure is caused by overload in excess of the
truck design load.
Broken Plate Caused by Overload

All joints in roller chain or lift chain should flex freely. Tight
joints resist flexure, increase internal friction, increasing chain
tension required to lift a given load. Increased tension
accelerates wear and fatigue problems.
In roller chain, tight joints are usually caused by rust or inside
plates moving outward on bushings. Replace chains if rusty.
516
Return
2000-08-04
F-code
Section
PS
S7.0
7110
Mast, 3 Stage
Version no
001
C-code
T-code
395/396/397/398/399
Tight joints prevent proper flexing of roller chain
Bent or peened plates on lift chains can

cause tight joints and prevent flexing.
Tap bushing plates inward to remedy a plate walking
problem. If plate walking persists, replace lift chain. This
type of link plate displacement is accelerated by poor
lubrication. The majority of roller chains with tight joints have
been run with little or no lube.
Tight joints in lift chains can be caused by the following:
Bent pins or plates
Rusty joints
Peened plate edges
Oily rusty chains with bent or peened components
Peening of plates edges may be caused by worn sheaves,

unusually heavy loads or chain sliding past a guide in the
mast.
Return
2000-08-04
517
F-code
Section
C-code
PS
S7.0
Mast, 3 Stage
7110
Version no
T-code
001
395/396/397/398/399
3.3.4. Protruding or Turned Pins

Heavily loaded chains operating with little lube cause wear
between the pin and plates (pin and bushing in roller chain).
In some extreme cases, the torque in the joint can turn pins in
the press-fit outside plate.
If the chain is allowed to operate in this condition, the pins
slowly work out of the chain, causing chain failure. Turned
pins can be quickly spotted because the flats on the V head
are no longer in line.
NOTE!
Pins have turned 90o. Chains with turned or

protruding pins should be replaced. Do not
attempt to repair the chain by driving the
pins back into the chain.
Protruding Pins
MA0633.ill
MA0000.ill
Turned Pins
Out-of-line flats on V heads indicate that pins have turned in

place.
518
Return
2000-08-04
F-code
Section
PS
S7.0
7110
Mast, 3 Stage
Version no
001
C-code
T-code
395/396/397/398/399
3.3.5. Chain Side Wear

A wear pattern on pin heads and outside plates indicates
misalignment. This condition damages chain and sheaves as
well as increasing internal wear in the chain system.
3.3.6. Chain Anchors and Sheaves
An inspection of the chain system includes a close look at the
chain anchors and sheaves. Check chain anchors for wear,
breakage, and misalignment. Anchors with worn or broken
fingers should be replaced. Anchors should be adjusted to
eliminate twisting or other misalignment in the chain. When
chain is misaligned, load is not spread uniformly between the
plates. Prolonged operation will result in premature failure.
Sheaves with badly worn flanges and outside diameter
should be replaced. Heavy flange wear indicates chain
misalignment.
3.3.7. Lift Chain Lubrication
Lubrication of the lift chain in field maintenance is a very
important duty. Hard working, heavily loaded chains cannot
be expected to give satisfactory wear life without scheduled
periodic relubrication. Like all bearing surfaces, a film of oil
between mating parts is required to prevent rapid wear.
Maintaining an oil film on all chain surface will cause the
following:
Minimize joint wear (chain stretch)
Prevent corrosion
Reduce possibility of pin turning
Minimize tight joints in roller chain
Promote smooth, quiet chain action
Lower chain tension by reducing internal wear in

the chain system
Heavy motor oil is an excellent chain lubricant (even used oil

drained from truck engines is adequate for lubricating
exposed lift chains). Brush chains with heavy motor oil (#40
weight oil) to lubricate lift chain rather than #10 weight oil or
automatic transmission fluid. Lubricate the entire length of all
strands every 100 hours (50 hours in corrosive environment).
Do not use dry film lubes on lift chain.
Return
2000-08-04
519
F-code
Section
C-code
PS
S7.0
Mast, 3 Stage
7110
Version no
T-code
001
395/396/397/398/399
The oil must penetrate chain joint to prevent wear. Applying

oil to the external surface will prevent rust, but oil must flow
into the live bearing surface for maximum wear life.
Lubricate
Lubricate
Apply oil to chains with a narrow paint brush. A plastic liquid

detergent bottle makes a handy lube applicator. Flood the
chain with oil over its entire length.
The best estimate of lube period is 100 hours (or 4 weeks)
actual truck operating time. Trucks in severe service (or
parked outside) may require more frequent relube to maintain
an oil film on all chain surfaces.
520
Return
2000-08-04
F-code
Section
PS
S7.0
7110
Mast, 3 Stage
Version no
001
C-code
T-code
395/396/397/398/399
3.4. Lift Chain Replacement

1. All chains should be replaced if any strand has
wear elongation of 3% or if any of the conditions
listed in Lift Chain Inspection on page 514 are
evident during inspection.
2. Replace all chains as a set.
3. Do not degrease or paint new chains.
4. Replace anchors and anchor pins when installing
new chains.
Return
2000-08-04
521
F-code
Section
C-code
PS
S7.0
Mast, 3 Stage
7110
Version no
T-code
001
395/396/397/398/399
522
Return
2000-08-04
F-code
Section
PS
C-code
7.1
7170
Lifting Gear (Crosshead)
Version no
T-code
000
395/396/397/398/399

1
2
3
RRX35/RSX40
4
5
6
3
7
9
3
10
6
5
4
3
2
1
Freelift Cylinder
Item
No.
Return
Description
Item
No.
Description
Fitting, grease
Sheave, chain
Ring, retainer
Head, sheave
Shim
Sheave, hydraulic and electrical
Race
Shaft
Bearing, roller
10
Screw, set
2000-08-04
523
F-code
Section
C-code
PS
7.1
7170
Version no
T-code
000
395/396/397/398/399
RRX45/RSX50/RDX30
3
4
5
6
8
7
9
3
10
6
5
4
3
2
1
Item
No.
524
Return
Description
Item No.
Description
Fitting, grease
Sheave, chain
Ring, retainer
Head, sheave
Shim
Sheave, hydraulic and electrical
Race
Shaft
Bearing, roller
10
Screw, set
2000-08-04
F-code
PS
Version no
000
Section
C-code
7.1
7170
T-code
395/396/397/398/399
The lifting gear is located on the top of the freelift cylinder.
1. Lifting Gear Repair

1.1. Removal
rolling. Part the truck on a level surface and
1. Park truck on a level surface and apply brake.
DANGER When blocking mast columns to prevent
lowering, always block both sides of
column. If both sides are not blocked,
unexpected
movement
could
occur
resulting in personal injury or death.
2. Lift carriage/reach approximately 6 inches (152
mm). Securely block carriage/reach to prevent
lowering.
3. Lower freelift cylinder so chains, hoses, and
electric cables are loose.
5. Remove chains, hoses, and electric cables from
lifting gear sheaves (6 and 8).
6. Loosen set screw (10) at the base of sheave head
(7).
7. Lift lifting gear assembly off the freelift cylinder rod.
Clean lifting gear.
Return
2000-08-04
525
F-code
Section
C-code
PS
7.1
7170
Version no
T-code
000
395/396/397/398/399
1.2. Disassembly
1. Remove retaining ring (2) from one end of the
lifting gear assembly.
2. Slide shim (3), bearing roller and race (5 and 4),
chain sheave (6) and the second shim (3) off the
shaft (9).
3. Repeat steps 1 and 2 for the opposite side.
4. Loosen set screw (10) in the side of the sheave
head (7).
5. Remove shaft (9) from sheave head (7) releasing
the hydraulic/electric sheave (8).
1.3. Assembly
1. Place hydraulic/electric sheave (8) into the sheave
head.
2. Insert shaft (9) into sheave head (7), through the
hydraulic/electric sheave (8).
3. Secure shaft in position with a set screw (10).
4. Install one shim (3), one chain sheave (6) with
bearing assembly (5, 4), a second shim (3), and a
retaining ring (2) on shaft (9).
5. Repeat step 4 for the opposite side.
6. Install a grease fitting (1) in each end of the shaft
(9).
1.4. Installation
1. Place lifting gear assembly on top of freelift
cylinder.
2. Tighten set screw (10) in the base of sheave head
(7) to secure the lifting gear to the cylinder.
3. Grease chain sheaves. Install chains, hoses, and
electric cables.
5. Remove blocking and test for proper operation.
526
Return
2000-08-04
F-code
Section
C-code
PS
7.2
7210
Sideshifter, RRX35/45/RDX30
Version no
T-code
000
395/396/397
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
Return
2000-08-04
527
F-code
Section
C-code
PS
7.2
7210
Version no
T-code
000
395/396/397
Item
No.
528
Description
Item
No.
Description
Item
No.
Slide, top
Screw, set
Anchor, cylinder
10
Screw
Spacer
11
Lockwasher
Fitting
12
Frame, sideshifter
Ring, retainer
13
Nut
Slide, lower
14
Spacer
21
Ring, retainer
Nut
15
Cylinder assembly
Kit, seal (items marked with K)
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
Version no
T-code
000
395/396/397
1. Mounting Instructions
1.1. Installation
WARNING Clean the fork carriage and inspect to be
sure it is free of damage or grooves before
installing the sideshift carriage. Apply
grease to the fork carriage frame where the
lower pads slide.
1. Remove lower
assembly.
hooks
(8)
from
sideshifter
2. Lift sideshifter onto the trucks carriage holding up

the cylinder to keep the upper slides in place.
3. Make sure centering lug (X) on cylinder anchor (2)
fits completely in the center notch of truck carriage.
4. Remount the lower hooks (8) with a minimum
clearance of 0.0625 inch (1.59 mm) and a
maximum clearance of 0.125 inch (3.175 mm).
Torque bolts to 55 ft-lb (74 Nm).
WARNING Clearance between the lower hooks and
the truck carriage is very important. The
centering lug on the sideshifter can jump
out of the center notch of the truck carriage
if this distance is not set accordingly.
5. Secure the lower hook (8) in place by tightening
the set screws (9). Torque to 42 ft-lb (57 Nm).
6. Connect the hydraulic fittings (4) to the sideshifter
cylinder (15). Side shift the unit several times to
insure there are no leaks. Check the sideshifter for
smooth operation with no interference.
Return
2000-08-04
529
F-code
Section
C-code
PS
7.2
7210
Version no
T-code
000
395/396/397
2. Operation and Maintenance

Always operate the truck controls in a smooth manner.
Sudden movements of the sideshifter at high lifts can
compromise the stability of the truck, as well as cause
damage to the overall system. Maintenance on the sideshifter
is minimal. Lubrication is not required due to special oil
impregnated nylon slides. However, lubrication will extend the
life of the slides if the unit is not operated in extremely dirty
environments. In a dirty environment, the lubrication may
attract contamination, causing increased wear. The top slides
are completely covered and protected from contamination.
The lower slides have a wiper that protects the slide from
contamination as long as the truck carriage is not nicked or
grooved. It is recommended that an Inspection be conducted
every 1000 hours:
1. Inspect hydraulic hoses for wear.
2. Inspect the cylinder (15) and fittings (4) for leaks.
3. Clean the lower slides (6) and truck carriage lower
bar. Inspect for wear.
4. Inspect and adjust the lower hooks (8) for the
proper clearance adjustment.
5. Check the torque on the lower hook mounting bolts
(10) and set screws (9).
NOTE!
In a dirty environment or rough operations,

it is necessary to inspect the sideshifter
more frequently.
2.1. Lower Slides

1. The original thickness of a lower slide is
approximately 0.1875 inch (4.76 mm) and has a
useful life of half its thickness.
2. Replace the lower slide if contamination is present
or excessive play becomes evident.
530
Return
2000-08-04
F-code
Section
C-code
PS
7.2
7210
Version no
000
T-code
395/396/397
2.2. Upper Slides

1. The original thickness of upper slide (1) is
approximately 0.125 inch (3.175 mm) and should
be replaced if the slide is worn beyond 0.0625 inch
(1.59 mm) at any point on the round surface.
2. Replace the upper slides (1) if there is an
unacceptable clearance (greater then 0.125 inch
(3.175 mm) after adjustment) between the lower
hooks (8) and the truck carriage.
3. When replacing the upper slides (1), always
replace all of the slides at the same time to ensure
even wear and proper sideshifter movement.
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.
Return
2000-08-04
531
F-code
Section
C-code
PS
7.2
7210
Version no
T-code
000
395/396/397
532
Return
2000-08-04
F-code
Section
C-code
PS
S7.3
7210
Sideshifter, RRX35/45/RSX40/50/RDX30
Version no
001
T-code
395/396/397/398/399
1
2
25
24
21
23
22
20
19
18 17
16
26
15
14
29
3
X
7
28
10
27
13
12
Return
11
2000-08-04
Serial Number
RRX35 28075001 - UP
RRX45 28266001 - UP
RSX40 28308000 - UP
RSX50 28308000 - UP
RDX30 28266001 - UP
533
F-code
Section
C-code
PS
S7.3
7210
Version no
T-code
001
395/396/397/398/399
Item
No.
Description
Item
No.
Description
Item
No.
Description
Screw
11
Hook, lower
21
Ring, cylinder cap
Bracket
12
Pad, lower
22
Cap, left cylinder
Support
13
Plate, lower hook
23
Seal
Pad, upper
14
Cap, right
24
Seal
Frame
15
Body, cylinder
25
Rod
Bolt, lower hook
16
Seal
26
Cylinder
Bolt, stop
17
Piston
27
Washer
Screw, lower hook

set
18
O-ring
28
Screw
Washer, stop bolt
19
Ring
29
Restrictor, flow
10
Washer, lower
hook
20
Bushing
534
Return
2000-08-04
F-code
Section
C-code
PS
S7.3
7210
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. 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).
5. Remove safety screw (28) located between lower
hook mounting bolts (6).
6. Torque set screw (8) to 21 ft-lb (28 Nm).
7. Install safety screw (28) into the hole with screw
(8). Torque safety screw to 70 ft-lb. (95 Nm).
8. Connect hydraulic fittings to sideshifter cylinder.
Torque fittings to 56 ft-lb (76 Nm).
9. Mount forks in notches on upper bar of sideshifter
carriage.
10. Install fork stop bolt (7) with washer (9 and 10) into
lower bar of sideshifter carriage.
11. Sideshift unit several times to insure there are no
leaks. Check sideshifter unit for smooth operation
with no interference.
Return
2000-08-04
535
F-code
Section
C-code
PS
S7.3
7210
Version no
T-code
001
395/396/397/398/399
NOTE!
Following assembly, check operation of

sideshifter unit by sideshifting first without a
load, then with a load.
2. Operation
Always operate lift truck controls in a smooth manner.
Sudden movements of sideshifter at high lifts can
compromise stability of truck, as well as cause damage to
overall system.
3. Maintenance
Maintenance on sideshifter unit should be performed on a
regular basis to receive the best performance from the unit.
(See Planned Maintenance Schedule on page 71.)
Perform the following every 100-hour maintenance:
Check torque of lower hook mounting bolts (6)
Inspect hydraulic hoses for wear
Inspect cylinder (26) and fittings for wear or leaks
In addition to the 100-hour maintenance procedures
perform the following:
Grease lower hook (11) where the pads (12) slide.
Check thickness of upper pads (4). If thickness
measures 0.0625 inch (1.5 mm) or less, replace
upper pads.
Check thickness of lower pads (12). If thickness
measures 0.020 inch (5 mm) or less, replace lower
pads.
Perform the following procedures every 2000 hours.
Replace upper (4) and lower (12) pads.
NOTE!
536
Return
In a dirty environment or rough operations,

it is necessary to inspect sideshifter unit
more frequently.
2000-08-04
F-code
Section
C-code
PS
S7.3
7210
Version no
001
T-code
395/396/397/398/399
3.1. Carriage Removal

1. Remove fork stop bolt (7) from sideshifter carriage.
2. Remove forks.
3. Detach hoses from sideshifter cylinder. Cap ends
of hoses to prevent contamination of hydraulic
system.
NOTE!
Be sure pressure is relieved from hydraulic

system before detaching hoses from
sideshifter cylinder.
4. Remove safety screws (28). Loosen lower hook

mounting bolts (6) and screws (8) until lower hooks
(11) are completely lowered.
5. Lift sideshifter unit from lift trucks carriage using a
lifting device with a minimum capacity of 1000 lb
(454 kg).
3.2. Upper Pad Replacement

Always replace all upper pads at the same time to ensure
even wear and proper movement. The upper pad (4) should
be replaced if pad is worn to 0.0625 inch (1.5 mm) or less at
any point on the round surface.
1. Remove sideshifter carriage from truck. See
previous paragraph 3.1.
2. Lift upper pads (4) from cylinder support bracket
(3).
3. Install new pads on cylinder support bracket. Be
sure centering pins on each pad are seated in the
notches in the support bracket.
4. Lubricate upper pads with grease.
5. Install sideshifter carriage on lift truck. See
Mounting Instructions on page 535.
Return
2000-08-04
537
F-code
Section
C-code
PS
S7.3
7210
Version no
T-code
001
395/396/397/398/399
3.3. Lower Pad Replacement

Replace lower pads (12) if pad is worn to 0.020 inch (5 mm)
less at any point. The sideshifter carriage does not need to be
removed to replace lower pads. It is recommended to replace
lower hook plates (13) each time lower pads are replaced.
1. Remove fork stop bolt (7) from sideshifter carriage.
2. Remove forks.
NOTE!
Be sure pressure is relieved from hydraulic

system before detaching hoses from
sideshifter cylinder.
3. Detach hoses from sideshifter cylinder. Cap the

ends of the hoses to prevent contamination of
hydraulic system.
4. Remove safety screws (28).
5. Loosen lower hook mounting bolts (6) and screws
(8) until lower hooks are completely lowered.
6. Lift lower part of sideshifter carriage away from fork
carriage (leave top of sideshifter attached to fork
carriage).
7. Securely block sideshifter carriage away from fork
carriage with a 3 inch (76 mm) spacer.
8. Remove lower pads (12) using a screwdriver.
9. Lubricate lower pads with grease, then place new
pads into lower hook (11). Be sure they are seated.
10. Remove blocking spacer and lower sideshifter
carriage to fork carriage.
11. Lift lower hook (11), bringing plastic pad (12) in
contact with the underside of lift truck carriage.
Torque securing bolts (6) to 65 ft-lb (88 Nm).
12. Torque screw (8) to 21 ft-lb (28 Nm).
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).
538
Return
2000-08-04
F-code
Section
C-code
PS
S7.3
7210
Version no
001
T-code
395/396/397/398/399
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 537.
2. Remove cylinder from cylinder support. Loosen
locking screws (1). Remove brackets (2). Lift
cylinder assembly (26) from cylinder support.
3. Secure body of cylinder in a vice equipped with soft
jaws. The bracket slots should be facing upwards.
4. Use a wrench to turn cap (22) until ring (21) comes
out. Turn ring, slowly removing cap. Check that
seal passes through recess (press seals through
recess with a screwdriver).
NOTE!
When replacing seals, follow the correct

mounting sequence.
5. Reassemble cylinder.
6. Secure cylinder in cylinder support (3) using
brackets (2) and screws (1).
NOTE!
If cylinder rod (25) becomes scored, a

minimal amount of scoring may be removed
by polishing with a fine emery cloth. Deep
scoring requires that cylinder (26) be
replaced.
7. Install sideshifter carriage on lift truck.

Return
2000-08-04
539
F-code
Section
C-code
PS
S7.3
7210
Version no
T-code
001
395/396/397/398/399
4. Troubleshooting
Below are three symptoms and the corrective actions to be
taken for each.
4.1. No Sideshifting
1. Check that input pressure is not greater than 3200
psi (22063 kPa). Average working pressure should
be 1000 psi (6895 kPa). Recommended oil flow is
2 gallons (9 liters) per minute and should be a
minimum of 1 gallon (4 liters) per minute.
2. Check carriage frame for damage.
3. Check relationship of lower hook (11) to truck
carriage.
4. Check for leaks in hydraulic circuit or cylinder.
4.2. Sideshifting Very Slow

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 (7.5 liters) per minute and should be a
minimum of 1 gallon (4 liters) per minute.
2. Check carriage frame for damage.
3. Check that lower hook pads (4) and (12) are not
too tight against truck fork carriage.
4. Check hydraulic lines and cylinder for leaks.
5. Remove flow restrictor (29). If necessary, enlarge
the hole in flow restrictor disk.
6. Check oil level in hydraulic tank.
7. Check upper and lower pads (4) and (12) for wear.
Replace as necessary.
4.3. Irregular Sideshifting

1. Check hydraulic system to be sure there is no air.
Bleed hydraulic system if necessary (see
page 450).
2. Check upper and lower pads (4) and (12) for wear.
Replace as necessary.
540
Return
2000-08-04
F-code
Section
PS
C-code
S7.4
7241
Single Reach, RRX35
Version no
T-code
002
395
Single Reach, RRX35
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
Serial numbers 27091000 - 28163000
Return
2001-09-10
541
F-code
Section
PS
S7.4
Single Reach, RRX35
Version no
T-code
002
395
Item
No.
542
C-code
7241
Description
Item
No.
Description
Item
No.
Description
Nut, lock
17
Screw
33
Bearing
Washer
18
Cover, valve
34
Bumper
Frame, rear
19
Manifold
35
Shim
Screw
20
Frame, forward
36
Screw, cap
Arm, left
21
Pin, roll
37
Manifold
Bushing
22
Pin
38
Shim
Fitting, grease
23
Bushing
39
Shaft
Arm, inner
24
Bar, fork
40
Nut
Valve, control
25
Screw, cap
41
Clamp
10
Screw
26
Shaft, pivot
42
Screw
11
Bushing
27
Arm, right
43
Washer
12
Plug, wear
28
Washer, flat
44
Bracket
13
Bearing
29
Nut, jam
45
Screw, socket head
14
Washer
30
Set, bearing
46
Bushing
15
Clamp, poly
31
Screw
16
Cover
32
Cap
Return
2001-09-10
F-code
Section
PS
Version no
T-code
002
395
19
18
5
8
12
7
10
13
21
22
16
11
9
45 46
Reach
Cylinders
24
44
42
Tilt
Cylinder
7
23
26
36
40
35
36
38
23
25
34
41
39
14 15
2
43 1
20
17
7
6
C-code
S7.4
7241
Single Reach, RRX35
33
27
35
28
29
32
37
31
32
30
Serial numbers 28163001 - 29032000
Return
2001-09-10
543
F-code
Section
PS
S7.4
Single Reach, RRX35
Version no
T-code
002
395
Item
No.
544
C-code
7241
Description
Item
No.
Description
Item
No.
Description
Screw, cap
17
Frame, forward
33
Bushing
Pin
18
Pin, roll
34
Screw
Frame, rear
19
Pin
35
Bumper
Screw
20
Bushing
36
Shim
Arm, left
21
Bar, fork
37
Shim
Bushing
22
Screw, cap
38
Screw, cap
Fitting, grease
23
Washer
39
Manifold
Bushing
24
Washer
40
Screw
Arm, inner
25
Pin
41
Clamp
10
Control, valve
26
Arm, right
42
Washer
11
Screw
27
Washer, flat
43
Bracket
12
Cover, valve
28
Nut, jam
44
Nut
13
Clamp, poly
29
Set, bearing
45
Cap, bearing
14
Cover
30
Screw
46
Bearing
15
Screw
31
Cap
16
Manifold
32
Bearing
Return
2001-09-10
F-code
Section
PS
Version no
T-code
002
395
19
18
6
2
1
5
48
8
12
7
10
13
14 15
9
45 46
Reach
Cylinders
47
24
23
42
26
36
44
41
40
36
38
35
34
39
21
22
16
11
43
20
17
C-code
S7.4
7241
Single Reach, RRX35
Tilt
Cylinder
7
6
23
25
1
33
27
35
28
29
32
37
31
32
30
Serial number 29032001 - UP
Return
2001-09-10
545
F-code
Section
PS
S7.4
Single Reach, RRX35
Version no
T-code
002
395
Item
No.
546
C-code
7241
Description
Item
No.
Description
Item
No.
Description
Screw, cap
17
Frame, forward
33
Bushing
Pin
18
Pin, roll
34
Screw
Frame, rear
19
Pin
35
Bumper
Screw
20
Bushing
36
Shim
Arm, left
21
Bar, fork
37
Shim
Bushing
22
Screw, cap
38
Screw, cap
Fitting, grease
23
Washer
39
Manifold
Bushing
24
Washer
40
Screw
Arm, inner
25
Pin
41
Clamp
10
Control, valve
26
Arm, right
42
Washer
11
Screw
27
Washer
43
Bracket
12
Cover, valve
28
Nut, jam
44
Nut
13
Clamp, poly
29
Set, bearing
45
Cap, bearing
14
Cover
30
Screw
46
Bearing
15
Screw
31
Cap
47
Nut
16
Manifold
32
Bearing
48
Washer
Return
2001-09-10
F-code
PS
Section
C-code
S7.4
7241
Single Reach, RRX35
Version no
002
T-code
395
1. Maintenance
1.1. Inspection
It is critical that proper inspection, adjustment and
maintenance be performed at the normal Planned
Maintenance per the schedule (page 71) to ensure maximum
performance and reliability and eliminate costly premature
failures. The reach bumpers are critical to the proper
operation of the reach assembly and must be inspected at
every Planned Maintenance visit. The carriage/reach
bumpers assure that carriage remains square with the truck
in its nested position. The reach uses rectangular bumpers
attached to each side and at the bottom of carriage/reach
rear frame. The bumpers are attached with screws.
1. Inspect the reach for damage.
2. Inspect the rear frame for cracks.
3. Inspect the upper rear pin holes to ensure that they
have not wallowed out.
4. Inspect cylinders for cracks in the cylinder tube or
bent cylinder rods.
5. Check to make sure that the correct cylinders are
installed on the truck.
6. Verify that reach bumpers are in good condition.
Bumpers that show signs of wear, cracking,
splitting, or deformation must be replaced.
Return
2001-09-10
547
F-code
Section
PS
S7.4
Single Reach, RRX35
Version no
T-code
002
395
C-code
7241
1.2. Adjustment
1. As a starting point, install one 0.1196 inch 3.03
mm) shim behind each reach bumper.
Install one shim

behind each reach
bumper
CAUTION The cylinder rod should never be adjusted

to the point that the rod end touches the
inner arm assembly through the clevis.
2. Fully extend reach assembly. Loosen reach rod
jam nuts. Adjust reach cylinder rods so reach
assembly extends evenly and in time.
Use spanner wrench

to adjust reach
Reach rod jam nut
548
Return
2001-09-10
F-code
PS
Version no
002
Section
C-code
S7.4
7241
Single Reach, RRX35
T-code
395
3. Fully retract reach assembly. The reach assembly

must retract evenly to all three reach bumpers. If it
does not retract evenly, add a 0.1196 inch (3.03
mm) or 0.060 inch (1.52 mm) shim accordingly to
the bumper to achieve proper retraction to all three
reach bumpers.
4. Fully retracted the reach assembly. Measure from
the face of the inner column rail to the backside of
the fork hanger carriage, noting this measurement.
Measure face of inner

column rail to backside
of fork hanger
5. Fully extend the reach assembly. Measure from

the face of the inner column to the backside of the
fork hanger carriage, noting this measurement.
Measure face of inner

column rail to backside
of fork hanger carriage
Return
2001-09-10
549
F-code
Section
PS
S7.4
Single Reach, RRX35
Version no
T-code
002
395
C-code
7241
6. Subtract the retracted measurement from the

extended measurement. This is your overall reach
stroke. (Example: Extended measurement of 25.75
inches (654.05 mm) minus retracted measurement
of 2.75 inches (69.85 mm) equals an overall reach
stroke of 23 inches (584.2 mm). Specifications
allow a maximum overall reach stroke between
22.75 (577.85 mm) and 23 inches (584.2 mm).
where rod end touches the inner arm
assembly. The pins and bushings for the
inner arms should be inspected if the
amount of threads above the jam nuts are
excessively less or greater than three
threads.
7. Adjust the reach cylinder rods so that overall reach
stroke is between 22.75 (577.85 mm) and 23
inches (584.2 mm). If the measurement is correct,
there should be approximately three full threads
showing above the jam nuts at the clevis end of
both reach cylinders.
CAUTION The piston threads must be cleaned, dried,
and have Loctite 243 applied whenever
the reach assembly is readjusted. The jam
nuts must be inspected for tightness at
every Planned Maintenance visit to ensure
proper operation of the reach assembly.
550
Return
2001-09-10
F-code
PS
Version no
002
Section
C-code
S7.4
7241
Single Reach, RRX35
T-code
395
8. When proper adjustment is achieved, clean the rod

rod and apply Loctite 243 thread locking
compound. Lock down the jam nuts.
Approximately three full
threads are exposed
above jam nut when rods
are adjusted correctly
Apply Loctite 243 to the

rod threads when proper
adjustment is achieved
Return
2001-09-10
551
F-code
Section
PS
S7.4
Single Reach, RRX35
Version no
T-code
002
395
C-code
7241
2. Reach Repair
2.1. Removal
NOTE!
The reach can be repaired without removal

from the mast.
1. Remove forks.
2. Remove load backrest (see page 604).
3. Jack truck up (see page 66).
4. Extend reach approximately half way. Securely
block reach so it will not retract.
5. Park truck on a level surface. Turn key switch OFF
and disconnect battery connector from the truck.
Remove battery from truck.
2.1. Disassembly
2.1.1. Front Frame Removal
1. Disconnect hydraulic hoses from tilt and sideshift
cylinders from the input side of junction block. Cap
hoses with plugs to prevent contamination.
NOTE!
Secure front frame with a hoist to prevent

movement before removing cap screw (1)
and pins (25).
2. Remove cap screw (1) at the forward frame (17).

3. Drive pins (25) to the outside by hitting with a soft
hammer.
4. Remove forward frame (17) from inner arm (9)
bearings (46).
552
Return
2001-09-10
F-code
PS
Section
C-code
S7.4
7241
Single Reach, RRX35
Version no
002
T-code
395
2.1.2. Outer Arm Removal

1. Remove nut (28) and washer (27).
2. Remove outside bearing (29).
3. Remove right outer arm (26).
4. Repeat steps 1 thru 3 to remove left outer arm (5).
5. Remove screws (30), caps (31), and bearings (32)
from outer arms.
2.1.3. Inner Arm Removal
1. Drive pins out of reach cylinder rod end pins.
2. Disconnect hydraulic lines from manifold block.
Plug to prevent contamination.
3. Secure inner arms to prevent movement when roll
pins are removed from inner frame.
4. Remove reach cylinder rod end pins from inner
frame.
5. Remove cap screws (1) at rear frame (3).
6. Drive pins (2) out by hitting with a soft hammer.
7. Remove inner arms (9).
2.1.4. Rear Frame Removal
1. Lift rear frame (3) until all tension is removed from
lift chains.
2. Remove lift chain anchors from rear frame.
3. Disconnect hydraulic hoses. Plug to prevent
contamination.
4. Disconnect electrical cable.
5. Lower rear frame (3).
NOTE!
Connect a hoist to the rear frame to prevent

it from dropping when the channel is raised.
6. Raise inner mast channel.

7. Remove rear frame (3).
8. Remove bearings (32). Keep track of shims (37) to
each roller and roller to pin location.
Return
2001-09-10
553
F-code
Section
PS
S7.4
Single Reach, RRX35
Version no
T-code
002
395
C-code
7241
9. Clean and inspect all bearing, pins, bearings,

washers, and wear strips for damage or wear.
2.1.5. Reach Cylinder Removal
WARNING Block reach to keep it from collapsing.
1. Disconnect hydraulic hoses. Plug to prevent
contamination.
2. Remove lock pins from rear frame.
3. Remove cylinder tube mounting pins.
4. Repair reach cylinders as needed.
2.2. Assembly
Install new bearing, rollers, and pins as needed.
2.2.1. Reach Cylinder Installation
1. Install rear frame pins.
2. Install locking pins.
3. Connect hydraulic hoses.
2.2.2. Rear Frame Installation
NOTE!
Install same number of shims as removed

for initial adjustment.
1. Install shims (37) and bearings (32).

NOTE!
Adjust frame rollers so there is 0.000 to

0.030 inch (0 to 0.76 mm) side movement
of the rear frame at tightest part of the inner
mast channel.
2. Lower inner mast channel onto rear frame bearings

(32).
4. Connect electrical cable.
5. Install lift chain anchors.
554
Return
2001-09-10
F-code
PS
Version no
002
Section
C-code
S7.4
7241
Single Reach, RRX35
T-code
395
2.2.3. Inner Arm Installation

1. Install upper end of inner arms (9) into rear frame
(3).
2. Install a new bushing (8) in each side arm.
3. Install pins (2) in the rear frame and inner arms (9).
4. Apply Loctite 243 on cap crews (1). Install cap
screw (1). Arms should pivot freely with some drag.
5. Apply Loctite 609 on bearings (46). Install
washers (24), bearings (46), and cap (45).
6. Connect hydraulic hoses to the reach cylinder.
7. Install pins in the rod end of the reach cylinder.
8. Install roll pins into the cylinder rod pins.
2.2.4. Outer Arm Installation
1. Install bearings (32), caps (31) and screws (30) on
outer arms (5) and (26).
2. Install bearing (29) in outer arms (5) and (26).
3. Install outer arms (5) and (26) on the center stud of
inner arm (9).
4. Apply Loctite 243 on nut (28). Install washer (27)
and nut (28) and torque nut to 34.66 ft-lb (47 Nm).
5. Check for side clearance. Arms should pivot freely
with some drag.
6. Install front frame (17) (see page 556).
7. Connect tilt cylinder hoses.
8. Grease all fittings on reach.
9. Test for proper operation of reach. Install forks and
load backrest.
Return
2001-09-10
555
F-code
Section
PS
S7.4
Single Reach, RRX35
Version no
T-code
002
395
C-code
7241
2.2.5. Front Frame Installation

1. Install front frame (17) onto inner arm (9) bearings
(46).
2. Install washer (23) and pivot shaft (25) in bushing
in outer arm.
3. Apply Loctite 243 on cap screw (1). Install cap
screw (1).
4. Reconnect hydraulic hoses to the tilt and sideshift
cylinders at junction box.
3. Carriage Bumpers
The carriage/reach retract bumpers assure that the carriage
remains square with the truck in its nested position. The
RRX35 reach uses rectangular bumpers (35) attached to
each side and at the bottom of the carriage/reach rear frame.
These bumpers are attached with socket head screws (34).
Verify that the three reach retract bumpers (35) are in good
condition. There should be no splitting, cracking, or
deformation on the bumpers. The reach retract bumpers are
critical to the proper operation of the reach assembly and
must be inspected at every Planned Maintenance visit.
Bumpers that show signs of wear, cracking, splitting, or
deformation must be replaced.
3.1. Reach Adjustment

1. Install a 0.1196 inch (3.03 mm) shim (36) behind
each reach retract bumper (35).
where the rod end touches the inner arm
assembly.
2. Fully extend the reach assembly. Loosen reach rod
jam nuts. Adjust reach cylinder rods so the reach
assembly extends in time.
3. Fully retract reach assembly.
4. The reach assembly must retract evenly to all three
retract bumpers (35). If the reach assembly does
556
Return
2001-09-10
F-code
PS
Version no
002
Section
C-code
S7.4
7241
Single Reach, RRX35
T-code
395
not retract to all bumpers evenly, use a 0.1196 inch

(3.03 mm) or 0.060 inch (1.52 mm) shim (36)
accordingly to achieve proper retraction to all three
reach bumpers.
5. Repeat steps 2 through 4 until proper retraction is
achieved.
6. With the reach fully retracted, measure from the
face of the inner column to the backside of fork
hanger carriage (21). Note this measurement.
7. Subtract the retracted measurement from the
extended measurement. This is your overall reach
stroke. (Example: Extended measurement of 25.75
inches (654 mm) minus retracted measurement of
2.75 inches (70 mm) equals an overall reach stroke
of 23 inches (584 mm)).
8. Specifications allow a maximum overall reach
stroke between 22.75 and 23 inches (578 and 584
mm).
where the rod end touches the inner arm
assembly. The pins and bushings for the
inner arms should be inspected if the
amount of threads are excessively less or
greater than the three threads.
9. Adjust cylinder rods so that the overall reach stroke
is between 22.75 and 23 inches (578 and 584
mm). When measurement is correct, there should
be approximately three full threads showing above
the jam nuts at the clevis end of reach cylinders.
CAUTION The piston threads must be cleaned and
have Loctite applied whenever the reach
assembly is readjusted. The jam nuts must
be inspected for tightness at every Planned
Maintenance visit to insure proper
operation of the reach assembly.
10. When proper adjustment is achieved, clean rod
threads and apply Loctite 243 thread locking
compound. Lock down jam nuts.
Return
2001-09-10
557
F-code
Section
PS
S7.4
Single Reach, RRX35
Version no
T-code
002
395
C-code
7241
4. Fork Carriage Pivot Pins

RRX35 reach trucks use a pin (19) and roll pin (18)
combination for the fork carriage pivot pin.
5. Carriage Roller Bearings

Two roller bearings (32) are located within the mast assembly
on either side. The carriage must be removed to access
these bearings.
The lower bearings are shimmed at the factory so that no play
exists between the carriage and inner columns. If carriage
becomes loose within inner columns, lower roller bearings
may require additional shims. If possible, maintain an equal
amount of shim thickness on each side. If carriage hangs up
in the column during lowering, one or more of the roller
bearings may be damaged or worn and requires
replacement.
5.1. Removal
1. Remove carriage/reach.
2. The carriage bearing should slide off the shaft with
hand pressure. If necessary, a suitable bearing
puller may be required for removal.
3. Repeat step 2 for the other three bearings.
5.2. Installation
1. Install new bearing on shaft.
2. Repeat step 1 for the other three bearings.
3. Reinstall carriage/reach (see page 507).
4. Test lift/lower functions of the carriage.
558
Return
2001-09-10
F-code
Section
PS
C-code
S7.5
7242
Single Reach, RRX45
Version no
T-code
001
396
Single Reach, RRX45

1. Maintenance
The only maintenance required on the reach mechanism is
the normal Planned Maintenance per the schedule (see
page 71)
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
Serial numbers 27135000 - 27328000

Return
2001-10-03
559
F-code
Section
PS
S7.5
Single Reach, RRX45
Version no
T-code
001
396
Item
No.
560
C-code
7242
Description
Item
No.
Description
Item
No.
Description
Spacer
14
Screw
27
Reach cylinder
assembly
Tilt cylinder
assembly
15
Shim
28
Screw
Frame, forward
16
Bearing
29
Cap, bearing
Screw
17
Fitting, grease
30
Bearing
Pin
18
Arm, outer right

hand
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
Arm, outer left hand
10
Bumper
23
Bearing
36
Screw
11
Pin, roll
24
Arm, inner
37
Cover, valve
12
Pin, roll
25
Shim
38
Valve, control
13
Pin
26
Nut
Return
2001-10-03
F-code
Section
PS
Version no
T-code
001
4
39
C-code
S7.5
7242
Single Reach, RRX45
396
38
37
1
36 10
9
47 46
35
12
34
43
33
23
12
12
45
44 42
22
40
13
41
14
48 46 45
15
32
16
24
15
31
30
26
29
27
28
22
11
30
25
44
12
15
17
16
22
21
20
31
43
23
15
18
19
21
20
17
19
Serial numbers 27328001 - 28166000

Return
2001-10-03
561
F-code
Section
PS
S7.5
Single Reach, RRX45
Version no
T-code
001
396
Item
No.
562
C-code
7242
Description
Item
No.
Description
Item
No.
Description
Spacer
17
Fitting, grease
33
Screw
Tilt cylinder
assembly
18
Arm, outer right

hand
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
Bracket, left hand

clamp
16
Bearing
32
Frame, rear
48
Bracket, right hand

clamp
Return
2001-10-03
F-code
Section
PS
Version no
T-code
001
37
39
38
C-code
S7.5
7242
Single Reach, RRX45
396
17
49
49
36 10
9
47 46
35
12
34
33
43
23
12
12
45
44 42
22
40
13
41
14
48 46 45
15
32
16
24
15
31
30
26
29
27
28
22
11
30
25
12
15
17
16
22
21
20
31
43
23
44
15
18
19
21
20
17
19
Serial numbers 28166001 - 29004000

Return
2001-10-03
563
F-code
Section
PS
S7.5
Single Reach, RRX45
Version no
T-code
001
396
Item
No.
564
C-code
7242
Description
Item
No.
Description
Item
No.
Description
Spacer
18
Arm, outer right

hand
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
Bracket, left hand

clamp
15
Shim
32
Frame, rear
48
Bracket, right hand

clamp
16
Bearing
33
Screw
49
Washer
17
Fitting, grease
Return
2001-10-03
F-code
Section
PS
Version no
T-code
001
4
3
37
396
17
39
C-code
S7.5
7242
Single Reach, RRX45
38
49
50
51
51
36 10
8
9
47 46
35
12
34
33
43
23
12
12
45
44 42
22
40
13
41
14
48 46 45
15
32
16
24
15
31
30
26
29
27
28
22
11
30
25
12
15
17
16
22
21
20
31
43
23
44
15
18
19
21
20
17
19
Serial numbers 29004001 - UP

Return
2001-10-03
565
F-code
Section
PS
S7.5
Single Reach, RRX45
Version no
T-code
001
396
Item
No.
566
C-code
7242
Description
Item
No.
Description
Item
No.
Description
Spacer
18
Arm, outer right

hand
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
Bracket, left hand

clamp
14
Screw
31
Shim
48
Bracket, right hand

clamp
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

removing from the mast.
without
1. Remove forks.
2. Remove load backrest.
3. Raise and block reach at a height for easy repair.
4. Extend reach approximately half way and block so
it will not retract.
2.1. Disassembly
NOTE!
For item call outs see page 564.
2.1.1. Forward Frame Removal

1. Disconnect hydraulic hoses to tilt cylinders and
plug to prevent contamination.
NOTE!
Roll pins (12) can be driven through front

frame after outer arms (18) and (35) are
removed.
2. Drive roll pins (12) into front frame so screws (14)

can be loosened.
3. Drive pins (13) to the inside by hitting the screws
(14) with a soft hammer.
4. Remove front frame (3) from inner arm (24) roller
bearings (21).
5. Remove wear strips and shims held by head
screws.
2.1.2. Outer Arm Removal
1. Remove roll pin (11) from nut (26).
2. Remove nut (26).
3. Remove inside bearing (22) and shims (25).
Return
2001-10-03
567
F-code
Section
PS
S7.5
Single Reach, RRX45
Version no
T-code
001
396
C-code
7242
4. Remove right outer arm (18).

5. Repeat steps 1 through 4 to remove left outer arm
(35).
6. Remove screws (19), caps (20) and roller bearings
(21) from outer arms.
2.1.3. Inner Arm Removal
1. Drive roll pins out of reach cylinder rod end pins.
2. Disconnect hydraulic lines and plug to prevent
contamination.
3. Drive roll pins out of reach cylinder tube end.
NOTE!
Roll pins (12) can be driven through the

rear frame (32) when inner arms (24) are
removed from rear frame (32).
4. Drive roll pins (12) into rear frame (32) so that

screws (33) can be loosened.
5. Drive pins (34) out by hitting screw (33) with a soft
hammer.
6. Remove inner arms (24).
2.1.4. Rear Frame Removal
1. Lift rear frame (32) until tension is removed from lift
chains.
2. Remove lift chain anchors from rear frame.
3. Disconnect hydraulic hoses and plug to prevent
contamination.
4. Disconnect battery connector from the truck.
5. Lower rear frame.
6. Raise inner mast channel.
NOTE!
Connect a hoist to rear frame to prevent it

from dropping when channel is raised.
7. Remove rear frame.

8. Remove rollers (30). Keep track of shims (31) to
each roller and roller to pin location.
568
Return
2001-10-03
F-code
PS
Version no
001
Section
C-code
S7.5
7242
Single Reach, RRX45
T-code
396
9. Clean and inspect for wear all bearing, pins, rollers,

washers and wear strips.
2.1.5. Reach Cylinder Removal
NOTE!
Block reach to keep it from collapsing.
1. Disconnect hydraulic hoses and plug to prevent

contamination.
2. Remove roll pins.
3. Remove cylinder tube mounting pins.
4. Repair reach cylinders as needed.
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.
2.2.2. Rear Frame Installation
NOTE!
Install same number of shims as removed

for initial adjustment.
1. Install shims (31) and bearings (30).

NOTE!
Adjust frame rollers so there is 0.000 0.030 inch (0-0.762 mm) side movement of
rear frame at tight part of the inner mast
channel.
2. Lower inner mast channel onto rear frame bearings

(30).
4. Install lift chain anchors.
Return
2001-10-03
569
F-code
Section
PS
S7.5
Single Reach, RRX45
Version no
T-code
001
396
C-code
7242
2.2.3. Inner Arm Installation

1. Install upper end of inner arms (24) into rear frame
(32).
2. Install shims (15) equal amount on each side of
arms.
3. Install pins (34) into the rear frame and inner arms
(24).
4. Install screws (33) and tighten until they bottom.
Check for side clearance of the arms. Shim if
necessary. Arm should pivot freely with some drag.
Tighten screws (33).
5. Install roll pins (12). If hole does not line up, tighten
to next hole.
6. Install rollers (21), caps (20) and screws (19) on
lower end of the inner arms (24).
8. Install pins in rod end of reach cylinder.
9. Install roll pins into cylinder rod pins.
2.2.4. Outer Arm Installation
1. Apply Loctite 243 on screws (19). Install bearing
rollers (21), caps (20) and screws (19) on arms
(18) and (35).
2. Install bearing (23) and thrust bearing (22) in inner
arms (24).
3. Install outer arms (18) and (35) center stud through
inner arm (24). At the same time, install bearing
rollers (21) on outer arm (18) and (35) into rear
frame (3).
4. Install inside thrust bearing (22) and nut (26),
tighten until nut bottoms.
5. Check for side clearance. Shimming may be
required. Arms should pivot freely with some drag.
6. Tighten nut (26), align holes, and install roll pins
(11).
570
Return
2001-10-03
F-code
PS
Version no
Section
C-code
S7.5
7242
Single Reach, RRX45
T-code
001
396
2.2.5. Front Frame Installation

1. Install bearing (16) in the top of the outer arms (18)
and (35).
2. Install front frame (3) onto thrust bearings (22) on
the inner arm (24).
3. Install shims (15) and pins (13) in the front frame
and outer arms (18) and (35).
4. Install screws (14) and tighten until they bottom.
Check side clearance of the arms. Shim if
necessary. Arms should pivot freely with some
drag.
5. Tighten screws (14) and install roll pins (12).
6. Connect tilt cylinder (2) and side shift cylinder
hoses.
7. Grease all fittings on the reach.
8. Test for proper operations of the reach.
9. Install forks and load backrest.
3. Fork Carriage Pivot Pins

Trucks use a pin and cap screw combination for fork carriage
pivot pin.
Return
2001-10-03
571
F-code
Section
PS
S7.5
Single Reach, RRX45
Version no
T-code
001
396
C-code
7242
4. Carriage Roller Bearings

Roller bearings are located within the mast assembly on
either side. The carriage must be removed to access
bearings.
The lower bearings are shimmed at the factory so there is no
play between carriage and the inner columns. If carriage
becomes loose with inner columns, the lower roller bearings
may require additional shims. If possible, maintain an equal
amount of shim thickness on each side.
If carriage hangs up in the column during lowering, one or
more of roller bearings may be damaged or worn and
requires replacement.
4.1. Removal
1. Remove carriage reach.
2. A suitable bearing puller will be required if bearings
are removed.
3. Repeat step 2 for remaining three bearings.
4.2. Installation
1. On shaft install new bearing with same thickness of
shims as removed.
2. Install remaining bearings.
3. Reinstall carriage/reach.
NOTE!
Adjust carriage rollers so there is 0.000 0.030 inch (0.762 mm) side movement of
the carriage at the tight part of the inner
mast channel.
4. Test lift/lower functions of carriage.

572
Return
2001-10-03
F-code
Section
C-code
PS
S7.6
7243
Double Reach Mechanism, RDX30
Version no
T-code
000
397
7
39
6
24
37
6
61
59
33
28
67
25
41
27
45
67
26
60
34
40
58
50
63
32
64
47
38
17
19
18
19
57
48
56
26
55
17
18
22
62
46
65
43
49
22
45
11
51
45
54
Return
52
24
2001-12-07
42
20
21
23
53
44
12
13
14
21
20
19
20
25
31
18
20
17
16
19
46
29
30
66
4
45
36
10
35
18
17
15
16
15
573
F-code
Section
C-code
PS
S7.6
7243
Version no
T-code
000
397
574
Return
Item
No.
Description
Item
No.
Description
Item
No.
Description
Rod
24
Bearing
46
Bearing, 3 stage
Arm
25
Ring, Nilos
47
Cap, bearing
Bearing, thrust
26
Set, bearing
48
Screw
Bearing
27
Spacer
49
Bearing
Arm
28
Tilt cylinder assembly
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
Screw, socket head
10
Frame, forward
33
Nut, lock
55
Screw, socket head
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
Reach cylinder assembly
60
Screw, cap
16
Nut, slotted
39
Fitting, grease
61
Manifold
17
Washer
40
Frame, rear
62
Control valve
18
Ring, Nilos
41
Washer, shim
63
Cover
19
Cone, bearing
42
Screw
64
Screw, cap
20
Race, bearing
43
Bar, wear
65
Nut, flanged
21
Ring, retainer
44
Shim
66
Washer
22
Shim
45
Shim
67
Shim
23
Arm
2001-12-07
F-code
Section
C-code
PS
S7.6
7243
Version no
000
T-code
397
1. Theory of Operation
The reach mechanism extends the forks away from the mast
assembly by pushing the potentiometer forward. With the key
switch ON and the brake pedal and/or right foot pedal
depressed, pushing on the lever causes voltage to be sensed
at the main electronic card. Oil is fed through the reach valve
to the rear ports on the reach cylinders and drives pistons
outward. The oil flows from the front ports of the cylinders
through the reach valve and back to the hydraulic tank. (See
Hydraulic System on page 421.)
2. Maintenance
The only maintenance required on the reach mechanism is
the normal Planned Maintenance per the schedule (page 71).
3. Troubleshooting
CAUTION After elevating or reaching the carriage for
troubleshooting, be sure to use blocks to
secure the carriage.
Use extreme care when blocking the mast
for any reason. Never remove a block when
it is supporting the mast.
Lower the carriage fully and retract the reach mechanism
fully. If the truck is equipped with tilt, set the forks level. If the
truck is equipped with sideshift, center the forks horizontally.
When checking the voltage at the solenoids, make sure the
hydraulic lines and components are fully installed. When
possible, keep the key switch OFF and the battery connector
disconnected.
4. Repair
Minor repair of the reach mechanism include replacement of
the grease fittings on the frames, arms and arm assembly.
5. Rebuild
When it is becomes necessary to rebuild the reach
mechanism, replacement of the fork frame, forward frame,
arms and/or rear frame may be required.
Return
2001-12-07
575
F-code
Section
C-code
PS
S7.6
7243
Version no
T-code
000
397
576
Return
2001-12-07
F-code
Section
PS
S7.7
Version no
C-code
7410
Forks
T-code
000
395/396/397/398/399
Forks
Lo
ng
er
Av
ai
la
bl
e
NO
Return
Item No.
Description
Pin, roll
Handle
Spring
Pin
Fork
2000-08-04
577
F-code
Section
C-code
PS
Forks
S7.7
7410
Version no
T-code
000
395/396/397/398/399
1
2
3
4
Item No.
578
Return
Description
Knob
Wedge
Washer
Spring
Pin
Fork
2000-08-04
F-code
Section
PS
S7.7
Version no
000
C-code
7410
Forks
T-code
395/396/397/398/399
1. Removal
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
4. Remove by lifting top of fork up and away from

upper cross member.
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
Inspect forks for the amount of wear on the bottom surface,

as follows:
1. Using Fork Wear Calipers, set the outer-most
points of the wear caliper to the thickness of
unworn vertical shank.
2. Without changing the setting, move to the
untapered portion of fork base. The inner points of
the caliper represent the minimum acceptable
thickness. If inner points pass over any portion of
the untapered fork base, replace fork.
Shank
(unworn portion)
Untapered portion
Return
2000-08-04
579
F-code
Section
C-code
PS
Forks
S7.7
7410
Version no
T-code
000
395/396/397/398/399
3. Installation
1. Place top of fork onto upper cross member, over
cutout in lower cross member.
2. Carefully lower bend in fork toward cutout until fork
is in position at carriage lower cross member.
3. Slide fork to desired location on carriage and
secure in position by pushing fork latch down to
lock it. Latch will engage if fork is over one of the
slots on upper carriage cross member.
Cutout
580
Return
4. Try to slide fork back and forth to be sure it is

locked into position.
2000-08-04
F-code
Section
PS
S9.0
9310
Load Indicator
Version no
C-code
T-code
001
395/398
RRX35/RSX40
Load Indicator
On Mast
Column
11
10
12
5
6
2
1
13
14
15
19
18
Wiring
Harness
16
17
On Mast
Column
Return
2001-11-07
581
F-code
Section
C-code
PS
S9.0
Load Indicator
9310
Version no
T-code
001
395/398
Item
No.
1
2
3
4
5
6
7
582
Return
Description
Screw
Cover
Arm
Screw
Roller
Ring, locking
Bearing
Item
No.
8
9
10
11
12
13
14
Description
Ring, snap
Hub
Screw
Nut
Washer
Screw
Support
Item
No.
15
16
17
18
19
Description
Cable
Spring
Anchor, bottom
Set screw
Device, sensing
2001-11-07
F-code
Section
PS
S9.0
9310
Load Indicator
Version no
001
C-code
T-code
395/398
Load Indicator
RRX45/RDX30/RSX50
On Mast
Column
10
11
13
12
5
2
1
3
6 7 8
4
14
15
20
19
Wiring
Harness
16
18
17
Return
2001-11-07
583
F-code
Section
C-code
PS
S9.0
Load Indicator
9310
Version no
T-code
001
395/398
Item
No.
1
2
3
4
5
6
7
584
Return
Description
Screw
Cover
Arm
Screw
Roller
Ring, locking
Bearing
Item
No.
8
9
10
11
12
13
14
Description
Ring, retainer
Hub
Screw
Nut
Washer
Screw
Support
Item
No.
15
16
17
18
19
20
Description
Cable
Spring
Anchor, bottom
Screw
Screw, set
Sensing device
2001-11-07
F-code
Section
PS
S9.0
9310
Load Indicator
Version no
001
C-code
T-code
395/398
1. Pulse Sensor
1.1. Repair
1. Unplug wiring connector from assembly.
2. Remove screws (1) and remove cover (2).
3. To replace pulse sensor (19) or (20), loosen
setscrew (18) or (19) and remove pulse sensor.
4. Remove screws (4) and remove arm (3). Reverse
procedure to reinstall.
1.2. Cable
1.2.1. Removal
1. To replace cable (15), remove bolt from bottom
anchor (17) relieving spring tension.
2. Remove spring (16) and anchor (17) from cable
(15).
3. Remove cable (15) from top anchor, and remove
from pulley.
1.2.2. Installation
1. Install new cable (15) on top anchor. Wrap cable
once around pulley wheel.
2. Attach spring (16) and bottom anchor (17) to cable
(15).
3. Stretch cable (15) tight and reinstall bottom anchor
bolt.
Return
2001-11-07
585
F-code
Section
C-code
PS
S9.0
Load Indicator
9310
Version no
T-code
001
395/398
1.3. Pulley
1.3.1. Removal
1. To replace roller (5), remove cover (2), pulse
sensor (19) or (20), and cable (15).
2. Remove screw (11) and nut (10). Remove pulley
wheel.
3. Remove hub (9), retaining ring (8), bearing (7) and
locking ring (6).
4. Reverse procedure to reinstall.
586
Return
2001-11-07
F-code
Section
C-code
PS
S9.1
9390
Version no
001
T-code
395/396/397/398/399
Height Indicator and Preset

Selector
1
Item No
Return
Description
Indicator, lift height
Range of lift preseletion
2000-08-04
587
F-code
Section
C-code
PS
S9.1
9390
Version no
T-code
001
395/396/397/398/399
1. General
A height indicator is fit to trucks with high lifting heights which
show the current position of forks within the staging zone.
The character window shows the fork height, based on
information from the sensing device (pulse sensor) (U10)
mounted on mast. For electrical component symbols and
component locations see page 269 and page 273.
2. Operation
The measurement in the staging zone starts when reference
switch (S45) is activated and sends a signal to electronic card
(A5). The pulse sensor (U10) send pulses to (A5) which starts
by indicating preprogrammed free lift height on the display
(2). The pulse sensor has two channels, A and B, which give
signals at 90 degree to each other. This gives information to
(A5) on whether forks are moved up or down.
588
Return
2000-08-04
F-code
Section
C-code
PS
S9.1
9390
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
Return
2000-08-04
589
F-code
Section
C-code
PS
S9.1
9390
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.
Contactor Terminal Number

Terminal
Number
1
Connection
Function
TX (+), transmits data
RX (+), receives data
+48V
TX (-), transmits data
Minus
RX (+), receives data
590
Return
2000-08-04
F-code
Section
C-code
PS
S9.1
9390
Version no
001
T-code
395/396/397/398/399
5. Display Symbols Description

Symbol
Function
Numerical push-buttons for
setting height levels.
For control of the required height

level while driving.
STOP
During automatic mode, height
levels that have been incorrectly
entered can be deleted. This cuts
programming and causes a stop
due to an error.
Save LEAVE level when
programming.
Save COLLECT level when
programming.
LOAD
Push-button to indicate operator
has a load on forks when starting.
Push-button to access
programming routines.
Display for indicating height
levels and error codes.
Return
2000-08-04
591
F-code
Section
C-code
PS
S9.1
9390
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.
6.1. Programming a Level

Programming of lift height can only take place within staging
zone, above initial lift.
NOTE!
Forks not horizontal.

The load can slide off forks or catch on
rack. When the load is left or collected,
forks should always be positioned
horizontally.
6.1.1. Collection Level

1. Press the PROG button briefly. State required level
(e.g., 1+5=level 15). The numbers are shown on
the display.
2. Lift forks to required level and press the button
COLLECT. The LED flashes.
6.1.2. Leaving Level
1. Pick up load and wait three seconds. Lift forks just
enough so pallet can be removed from rack.
Ensure there is sufficient space for safe handling.
2. Now press LEAVE button, both LEDs for collecting
and leaving will start to flash.
3. Press the PROG button until both the LEDs go out
and display indicates PL00, storing information.
4. Repeat from first point to program more levels.
5. Press STOP to return to display mode.
592
Return
2000-08-04
F-code
Section
C-code
PS
S9.1
9390
Version no
001
T-code
395/396/397/398/399
6.2. Erasing Programmed Levels

1. Lower forks to free lift zone when programmed
lifting heights are to be erased.
2. Enter programming mode and state required level
(e.g., 1+5=level 15). The number is shown on the
display.
3. Press the COLLECT button (the LED flashes) and
then press the LEAVE button (both LEDs start to
flash).
4. Press the PROG button until both LEDs stop
flashing and the display shows PL00 to erase the
memory.
5. Press the STOP button to return to the display
mode.
6.2.1. Automatic Operations
There are two different automatic operating modes, one
where forks are raised/lowered to required level without a
load and the other with a load.
6.2.2. Collecting a Load
1. State required height level using buttons 0-9, (e.g.,
1+2=level 12). The display will show LE12.
2. Raise/lower forks until they are automatically
stopped by electronics. If the wrong direction is
chosen, no raise/lower movement will take place.
The program expects the correct direction to be
selected.
3. When forks stop and the COLLECT LED comes
ON, forks can be maneuvered in under the load.
NOTE!

horizontally.
4. Lift forks until they are automatically stopped by

electronics and the LED leave comes ON.
Return
2000-08-04
593
F-code
Section
C-code
PS
S9.1
9390
Version no
T-code
001
395/396/397/398/399
5. Move load from rack. When work cycle has been

completed, the LEDs will go OUT.
6.2.3. Leaving a Load
1. Press the LOAD button (the LED now comes ON).
2. State required height level using buttons 0-9, (e.g.,
5=level 05). The display will show LE05.
3. Raise/lower forks until they are automatically
stopped by electronics. If the wrong direction is
chosen, no raise/lower movement will take place.
The electronics expects the correct direction to be
selected.
4. When forks stop and the LEAVE LED comes ON,
forks can be maneuvered into the rack.
NOTE!

horizontally.
5. Lower forks until they are automatically stopped by

electronics and the COLLECT LED comes ON.
6. Remove forks from load. When the work cycle has
been completed, the LEDs will go OUT.
594
Return
2000-08-04
F-code
Section
C-code
PS
S9.1
9390
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.
Return
2000-08-04
595
F-code
Section
C-code
PS
S9.1
9390
Version no
T-code
001
395/396/397/398/399
4. The last value to enter is the distance between

each leave level, in steps of 10 mm. Press the
PROG to save the programmed values. The
display shows P_.
P3
Programming the crawling speed for braking distances:
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":
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.
P7
Programming of the largest and smallest permitted
programming distance between the levels collect and leave:
1. State parameter 7. The display shows the
previously programmed value for the minimum.
distance. Enter the new value using numerical
keys, (e.g., 030=30 mm). The permitted maximum/
minimum values are shown in the Parameters
table.
596
Return
2000-08-04
F-code
Section
C-code
PS
S9.1
9390
Version no
001
T-code
395/396/397/398/399
2. Press the Load button. The display shows the

previously programmed value for the maximum
distance. Enter the new value using numerical
keys, (e.g., 150=150 mm).
P8
Reset all parameters to the factory settings.
NOTE!
Reset all factory parameters after

upgrading to a new program version.

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.
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_.
Return
2000-08-04
597
F-code
Section
C-code
PS
S9.1
9390
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
Permitted error tolerance in stop

position.
P7
0-255
0-255
030
150
mm
Minimum distance between

leave/collect.
P8
Resetting of all values to factory

settings.
P9
Braking distance before stop:

Lower
Lift
0-255
0-255
598
Measurement unit
Programming of several levels at

equal collect/leave distances.
1-69
0-999
0-255
0-999
Return
Function
050
030
10 mm
10 mm
2000-08-04
F-code
Section
C-code
PS
S9.1
9390
Version no
001
Position
T-code
395/396/397/398/399
Function
Leave level
Collect level
Staging zone
H2
Free lifting zone
P3
P9
A
P7
P5
B
P3
P9
P5
Return
H2
2000-08-04
599
F-code
Section
C-code
PS
S9.1
9390
Version no
T-code
001
395/396/397/398/399
Error Codes
Error
Code
Remark
Err 1
The requested height level is not programmed

or is incorrect.
Err 2
The forks have stopped outside of the

tolerance area (P5).
Err 9
Incorrect values stated when programming.
Err flashes
Communication error between the preset

height and truck computer.
Four lines light up when started. This indicates that no

communication has been established between preset
height and main electronics. These go out when contact
between two units has been established.
Four points are lit in the display when forks are in the free
lift zone.
If the points flash, this indicates that the reference switch

was active when truck was started, e.g., forks were over
the free lift zone. If the points still flash, the preset mast
height could be set to 0; or when forks are lowered, there
can be a fault in the wiring; or the reference height switch
can be faulty.
600
Return
2000-08-04
F-code
Section
PS
s9.2
9501
Load Backrest
Version no
000
C-code
T-code
395/396/397/398/399
Load Backrest
3
2
RRX35/RSX40
Item No
Return
Description
Backrest
Screw, cap
Washer, flat
2000-08-04
601
F-code
Section
C-code
PS
s9.2
Load Backrest
9501
Version noT-code
000
395/396/397/398/399
3
4
2
RRX45/RDX30
Item No
602
Return
Description
Backrest
Screw, cap
Washer, flat
Spacer, with sideshifter
2000-08-04
F-code
Section
PS
s9.2
9501
Load Backrest
Version no
000
C-code
T-code
395/396/397/398/399
3
2
RSX50
Item No
Return
Description
Backrest
Screw, cap
Washer, flat
2000-08-04
603
F-code
Section
C-code
PS
s9.2
Load Backrest
9501
Version noT-code
000
395/396/397/398/399
1. Removal
1. Park truck on a level surface.
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.
604
Return
2000-08-04
Index
A
Alarm
Travel/Back-up . . . . . . . . . . . . . . 332
Application
Intended . . . . . . . . . . . . . . . . . . . . 34
Prohibited . . . . . . . . . . . . . . . . . . . 35
B
Battery
Charging . . . . . . . . . . . . . . . . . . . 327
Cleaning Exterior . . . . . . . . . . . . . 327
History Record . . . . . . . . . . . . . . 328
Inspection and Care . . . . . . . . . . 326
Installation . . . . . . . . . . . . . . . . . . 325
Maintenance . . . . . . . . . . . . . . . . 326
Removal . . . . . . . . . . . . . . . . . . . 325
Retainer Plates . . . . . . . . . . . . . . 106
Rollers . . . . . . . . . . . . . . . . . . . . . 106
Storage . . . . . . . . . . . . . . . . . . . . 328
Battery Connector
Inspection . . . . . . . . . . . . . . . . . . 341
Installation . . . . . . . . . . . . . . . . . . 342
Location . . . . . . . . . . . . . . . . . . . . 341
Battery Safety . . . . . . . . . . . . . . . . . . . 21
Brake
Electromagnetic . . . . . . . . . . . . . 179
Friction Plate . . . . . . . . . . . . . . . . 184
Pedal Adjustment . . . . . . . . 111, 114
Pedal Bearing Replacement 111, 114
Pedal Removal . . . . . . . . . . 110, 113
Braking Caster Assembly
Installation . . . . . . . . . . . . . . . . . . 208
Removal . . . . . . . . . . . . . . . . . . . 207
Braking Caster Wheel
Removal . . . . . . . . . . . . . . . . . . . 203
Bumpers, Retract
Carriage/Reach . . . . . . . . . . . . . . 556
C
Carriage
Roller Bearings . . . . . . . . . . . . . . 558
Installation . . . . . . . . . . . . . . . 558
Return
Removal . . . . . . . . . . . . . . . . .558
Carriage, Reach
Adjustment . . . . . . . . . . . . . . . . . 556
Assembly . . . . . . . . . . . . . . . . . . 554
Disassembly . . . . . . . . . . . . . . . . 552
Repair . . . . . . . . . . . . . . . . . . . . . 552
Carriage/Reach
Bumpers, Retract . . . . . . . . . . . . 556
Chassis
Dash . . . . . . . . . . . . . . . . . . . . . . 100
Left-Hand Side Panel . . . . . . . . . 102
Main Card Access Panel . . . . . . 103
Motor Compartment Door . . . . . . 101
Operator Compartment Panel . . 103
Contactor
Battery Cut-out . . . . . . . . . . . . . . 356
Directional . . . . . . . . . . . . . . . . . . 352
Lift Bypass . . . . . . . . . . . . . . . . . 354
Resistance Testing . . . . . . . . . . . 351
Tip Inspection . . . . . . . . . . . . . . . 351
Control Pod . . . . . . . . . . . . . . . . . . . 217
Control Valve . . . . . . . . . . . . . . . . . . 461
Hydraulic Lowering . . . . . . . . . . . 470
Recondition Seal Kit . . . . . . . . . . 471
Conversion Formulas . . . . . . . . . . . . . 55
Cylinder
Freelift
Assembly . . . . . . . . . . . . . . . . .480
Disassembly . . . . . . . . . . . . . .480
Installation . . . . . . . . . . . . . . . .480
Removal . . . . . . . . . . . . . . . . .479
Reach Assembly
Assembly . . . . . . . . . . . . . . . . .486
Disassembly . . . . . . . . . . . . . .484
Inspection . . . . . . . . . . . . . . . .485
Installation . . . . . . . . . . . . . . . .487
Removal . . . . . . . . . . . . . . . . .483
Tilt Assembly
Assembly . . . . . . . . . . . . .493, 500
Disassembly . . . . . . . . . .491, 498
Inspection . . . . . . . . . . . .492, 499
Installation . . . . . . . . . . . .494, 501
Removal . . . . . . . . . . . . .489, 497
2001-08-21
605
Index
D
Data Plate . . . . . . . . . . . . . . . . . . . . . . 41
Decals . . . . . . . . . . . . . . . . . . . . . . . . 117
Definition
Caution . . . . . . . . . . . . . . . . . . . . . 15
Danger . . . . . . . . . . . . . . . . . . . . . 15
Note . . . . . . . . . . . . . . . . . . . . . . . . 15
Prohibitory . . . . . . . . . . . . . . . . . . . 16
Warning . . . . . . . . . . . . . . . . . . . . . 15
Definitions . . . . . . . . . . . . . . . . . . . . . . 97
Drive Wheel
Installation . . . . . . . . . . . . . . . . . . 186
Removal . . . . . . . . . . . . . . . . . . . 186
Tire Pressing . . . . . . . . . . . . . . . . 187
Driver Controls . . . . . . . . . . . . . . . . . 107
E
Electrical Compartment Fan . . . . . . . 123
12-Volt Power Supply . . . . . . . . . 255
Component Location . . . . . . . . . . 273
Direction Selection . . . . . . . . . . . 239
Forks First Direction . . . . . . . . . . 241
Forks Trailing Direction . . . . . . . . 245
Pump Motor Brush Indicator Switch 274
Electrical Schematics
Serial numbers 27163000 - 28105000
277
Serial numbers 28105001 - 28126000
289
Serial numbers 28126001 - 31285000
301
Serial numbers 31285001 - UP . . 313
Electrical Symbols . . . . . . . . . . . . . . 275
Electronic Card . . . . . . . . . . . . . . . . . 382
Main . . . . . . . . . . . . . . . . . . . . . . 369
F
Fan
Electrical Compartment . . . . . . . . 123
Operator . . . . . . . . . . . . . . . . . . . 333
Fasteners
606
Return
Bolt and Screw Designations . . . . 48

Strength Identification . . . . . . . . . . 47
Torque Nut Designations . . . . . . . 50
Truck Torque Specifications . . . . . 53
Forks
Inspection . . . . . . . . . . . . . . . . . . 579
Installation . . . . . . . . . . . . . . . . . 580
Removal . . . . . . . . . . . . . . . . . . . 579
Fuses . . . . . . . . . . . . . . . . . . . . . 59, 347
G
Grease Location Points . . . . . . . . . . . 85
Guard, Overhead . . . . . . . . . . . . . . . 115
H
Height Indicator
Display . . . . . . . . . . . . . . . . . . . . 590
Display Symbols Description . . . 591
Operation . . . . . . . . . . . . . . . . . . 588
Preset Height . . . . . . . . . . . . . . . 589
Programming . . . . . . . . . . . . . . . 592
Horn . . . . . . . . . . . . . . . . . . . . . . . . . 335
Installation . . . . . . . . . . . . . . . . . 335
Removal . . . . . . . . . . . . . . . . . . . 335
Hydraulic
Filter Adapter . . . . . . . . . . . . . . . 458
Troubleshooting . . . . . . . . . . . . . . 96
Hydraulic Filter . . . . . . . . . . . . . . . . . 457
Hydraulic Fluid
Refilling System . . . . . . . . . . . . . 449
Selection . . . . . . . . . . . . . . . . . . . 447
Hydraulic Pump . . . . . . . . . . . . . . . . 460
Hydraulic System . . . . . . . . . . . . . . . 421
Bleeding . . . . . . . . . . . . . . . . . . . 450
Changing Fluid . . . . . . . . . . . . . . 447
Schematic RRX30 . . . . . . . . . . . 444
Schematic RRX35 . . . . . . . . . . . 442
Schematic RRX45 . . . . . . . . . . . 443
Schematic RSX40 . . . . . . . . . . . 445
Schematic RSX50 . . . . . . . . . . . 446
Hydraulic Tank
Installation . . . . . . . . . . . . . . . . . 454
Removal . . . . . . . . . . . . . . . . . . . 453
2001-08-21
Index
I
Introduction . . . . . . . . . . . . . . . . . . . . . 65
J
Jacking Truck Off The Floor . . . . . . . . 66
K
Key Switch . . . . . . . . . . . . . . . . . . . . 337
L
Lift Chain, 3 Stage Mast . . . . . . . . . . 514
Lifting Gear
Assembly . . . . . . . . . . . . . . . . . . . 526
Disassembly . . . . . . . . . . . . . . . . 526
Installation . . . . . . . . . . . . . . . . . . 526
Removal . . . . . . . . . . . . . . . . . . . 525
Lights
Overhead Guard . . . . . . . . . . . . . 329
Warning . . . . . . . . . . . . . . . . . . . . 330
Working . . . . . . . . . . . . . . . . . . . . 331
Load Backrest
Installation . . . . . . . . . . . . . . . . . . 604
Removal . . . . . . . . . . . . . . . . . . . 604
Load Indicator
Pulse sensor . . . . . . . . . . . . . . . . 585
Load Wheels
Size 10.5 X 3.5 . . . . . . . . . . . . . . 213
Sizes 4 X 3, 5 X 4, and 5 X 3 . . . 209
Lubricants
Cold Storage . . . . . . . . . . . . . . . . . 68
Corrosion . . . . . . . . . . . . . . . . . . . . 68
Freezer Storage . . . . . . . . . . . . . . 70
Standard . . . . . . . . . . . . . . . . . . . . 68
Lubrication
Chart . . . . . . . . . . . . . . . . . . . . . . . 83
Points . . . . . . . . . . . . . . . . . . . . . . 83
Main Electronic Card . . . . . . . . . . . . 369
N
Non-Braking Caster Assembly
Installation . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . .
Non-Braking Caster Wheel
Caster Pivot . . . . . . . . . . . . . . . .
Thrust Bearing . . . . . . . . . . . . . .
200
200
191
193
O
Oils and Grease . . . . . . . . . . . . . . . . . 84
Overhead Guard . . . . . . . . . . . . . . . 115
Return
Battery Discharge Indicator . . . . 384

Brake Switch and Transducer . . 383
Display . . . . . . . . . . . . . . . . . . . . 380
Error Codes . . . . . . . . . . . . . . . . 395
Programming Parameters . . . . . 401
Running time . . . . . . . . . . . . . . . 382
Time Setting . . . . . . . . . . . . . . . . 381
Warning Codes . . . . . . . . . . . . . . 393
Maintenance . . . . . . . . . . . . . . . . . . . 65
Mast Adjustment Points . . . . . . . . . . . 86
Mast, 3 Stage
Lift Chain . . . . . . . . . . . . . . . . . . 514
Motor
Brush Performance . . . . . . . . . . . 127
Drive . . . . . . . . . . . . . . . . . . . . . . 152
General . . . . . . . . . . . . . . . . . .125
Operating Environment . . . . . .125
Troubleshooting . . . . . . . . . . .126
Pump
Component Repair . . . . . . . . .146
Steering . . . . . . . . . . . . . . . . . . . 121
Mounting Points
Drive Motor . . . . . . . . . . . . . . . . . 149
Pump Motor . . . . . . . . . . . . . . . . 141
Transmission . . . . . . . . . . . . . . . 155
Pivot Pins, Fork Carriage . . . . . . . . . 558

Programming Parameters . . . . . . . . 401
2001-08-21
607
Index
R
Reach Carriage
Adjustment . . . . . . . . . . . . . . . . . 556
Assembly . . . . . . . . . . . . . . . . . . . 554
Disassembly . . . . . . . . . . . . . . . . 552
Repair . . . . . . . . . . . . . . . . . . . . . 552
Reach, Double
Maintenance . . . . . . . . . . . . . . . . 575
Theory of Operation . . . . . . . . . . 575
Reach, Single
Carriage Roller Bearings . . . . . . . 572
Maintenance . . . . . . . . . . . . 547, 559
Repair . . . . . . . . . . . . . . . . . . . . . 567
Roller Bearings
Carriage . . . . . . . . . . . . . . . . . . . 558
Installation . . . . . . . . . . . . . . . 558
Removal . . . . . . . . . . . . . . . . . 558
RV2 Adjustment . . . . . . . . . . . . . . . . 382
S
Sensor
Drive Motor Speed . . . . . . . . . . . 419
Steer Stop Proximity . . . . . . . . . . 417
Wheel Direction . . . . . . . . . . . . . . 415
Sideshifter
Installation . . . . . . . . . . . . . . . . . . 535
Maintenance . . . . . . . . . . . . 530, 536
Mounting Instructions . . . . . 529, 535
Operation . . . . . . . . . . . . . . 530, 536
Troubleshooting . . . . . . . . . . . . . 540
Spare Parts, Ordering . . . . . . . . . . . . . 61
Static Safety . . . . . . . . . . . . . . . . . . . . 26
Steering Bearing
Installation . . . . . . . . . . . . . . . . . . 222
Removal . . . . . . . . . . . . . . . . . . . 222
Steering Motor
Installation . . . . . . . . . . . . . . . . . . 121
Steering Tach . . . . . . . . . . . . . . . . . . 219
Steering Wheel . . . . . . . . . . . . . . . . . 218
Switches
Emergency Disconnect . . . . . . . . 339
Key . . . . . . . . . . . . . . . . . . . . . . . 337
608
Return
Lift Limit Override . . . . . . . . . . . . 366

Mast . . . . . . . . . . . . . . . . . . . . . . 343
Overhead Light, . . . . . . . . . . . . . 367
Platform (Right Foot) . . . . . . . . . 411
Staging . . . . . . . . . . . . . . . . . . . . 413
Symbols
Caution . . . . . . . . . . . . . . . . . . . . . 15
Danger . . . . . . . . . . . . . . . . . . . . . 15
Ordinance . . . . . . . . . . . . . . . . . . . 16
Warning . . . . . . . . . . . . . . . . . . . . 15
T
Technical Service Data . . . . . . . . . . . 57
Three Stage Mast
Assembly . . . . . . . . . . . . . . . . . . 475
Disassembly . . . . . . . . . . . . . . . . 475
Installation . . . . . . . . . . . . . . . . . 475
Removal . . . . . . . . . . . . . . . . . . . 474
Transistor Regulator
Motor Connections . . . . . . . . . . . 360
Safety Control . . . . . . . . . . . . . . . 363
Transmission
Axle Sealing Ring . . . . . . . . . . . . 174
Fluid Changing . . . . . . . . . . . . . . 156
Repair
Leakage, Lower Cover . . . . . .177
Leakage, Top Cover . . . . . . . .176
Wheel Bolts . . . . . . . . . . . . . . .178
Troubleshooting
Hydraulic . . . . . . . . . . . . . . . . . . . . 96
Sideshifter . . . . . . . . . . . . . . . . . . 540
Troubleshooting Guidelines . . . . . . . . 89
Truck
Data . . . . . . . . . . . . . . . . . . . . . . . 35
Dimensions (RDX30) . . . . . . . . . . 38
Dimensions (RRX35) . . . . . . . . . . 36
Dimensions (RRX45) . . . . . . . . . . 37
Dimensions (RSX40) . . . . . . . . . . 39
Dimensions (RSX50) . . . . . . . . . . 40
Main Components . . . . . . . . . . . . 42
Truck Side Views . . . . . . . . . . . . . . . . 33
Truck Torque Specifications . . . . . . . 53
2001-08-21
Index
V
Valve
Control . . . . . . . . . . . . . . . . . . . . . 461
Pressure Setting . . . . . . . . . . . . . 469
Wheel Direction Sensor . . . . . . . . . .

Adjustment . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . .
Wiring
Harness . . . . . . . . . . . . . . . . . . .
Power Cables . . . . . . . . . . . . . . .
415
415
416
416
348
349
Welding Safety . . . . . . . . . . . . . . . . . . 27
Return
2001-08-21
609
Return
Return
Back Cover
BT Prime-Mover, Inc., 3305 N. Highway 38, Muscatine, Iowa 52761-8800 U.S.A

Tel
Tel(319)
(563)262-7700
262-7700 Fax
Fax(563)
(319)262-7600
262-7600
Return

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306756-000 2002 - February PDF

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Fron

Master Service Manual

WARNING Read and observe all warnings on this unit

Date: February 07, 2002

Prime-Mover is a trademark of BT Prime-Mover Inc.,

Drive Gear / Transmission

Brake / Wheel System

Master Service Manual

Hydraulic / Pneumatic System

Operating Function-lifting Mast / Cylinders

Peripheral / Installation Equipment

Master Service Manual

Technical Service Data ................................................................................ 57

Master Service Manual

Contents, Section S ..................................................................................... 87

Brake Pedal, RSX50/RRX45/RDX30 ...........................................................

Overhead Guard .......................................................................................... 115

Master Service Manual

Fan Motor ..................................................................................................... 123

Motor Repair ................................................................................................ 133

Electromagnetic Brake ...............................................................................

Master Service Manual

Non-Braking Caster Wheel, RRX35/RSX40 ...............................................

Non-Braking Caster Assembly, RRX35/RSX40 ........................................ 199

Steering Bearing ......................................................................................... 221

Master Service Manual

Electrical Symbols ...................................................................................... 275

Electrical Schematics (Serial numbers 28105001-28126000) ..................

Electrical Schematics (Serial numbers 28126001-31285000) .................. 301

Master Service Manual

Electrical Schematics (Serial numbers 31285001-UP) .............................

Light Assemblies ........................................................................................

Horn .............................................................................................................. 335

Master Service Manual

Mast Switch (S31) ........................................................................................ 343

Transistor Panel (Drive) .............................................................................. 359

Main Electronic Card ..................................................................................

Master Service Manual

Switches and Sensors ................................................................................

Hydraulic System ........................................................................................

Hydraulic Fluid ............................................................................................

Hydraulic Tank ............................................................................................ 452

Master Service Manual

Freelift Cylinder, Three Stage Mast ...........................................................

Reach Cylinder Assembly ..........................................................................

Tilt Cylinder Assembly, RRX35/RSX40/RSX50 .........................................

Tilt Cylinder Assembly, RRX45/RDX30 .....................................................

Mast, 3 Stage ...............................................................................................

Lifting Gear (Crosshead) ............................................................................ 523

Master Service Manual

Single Reach, RRX35 ..................................................................................

Single Reach, RRX45 ..................................................................................

Double Reach Mechanism, RDX30 ............................................................

Load Indicator ............................................................................................. 581

Master Service Manual

Master Service Manual

Master Service Manual

Master Service Manual

OPEN FLAMES PROHIBITED

Master Service Manual

Know the controls on the truck and what they do.

Do NOT operate truck if it needs repair or if it is in any way