306756-000 1998 - April PDF

Service Manual
RRX35/45, RDX30, RSX40/50

Electric Electrical Stand-Up Rider Truck
Effective Serial Number R_X0027135001
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
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Date: April 20, 1998
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F-code
Section
C-code
BT Standard Codes
Version no
T-code
000
BT Standard Codes
B-Code
= Business area
F-Code
= Product family
T-Code
= Product type
C-Code
= Component function
Worksheet standard
W-Code = Working code
R-Code
= Reason code
SO-Code = Assortment
C-Code List
No Function Group
BT Products
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C-Code
Chassis
0000
Drive Motor
1000
Drive Gear / Transmission
2000
Brake / Wheel System
3000
Steering System
4000
Electrical System
5000
Hydraulic / Pneumatic System
6000
Operating Function-lifting Mast / Cylinders
7000
Peripheral / Installation Equipment
8000
Optionals / Attachments
9000
Service Manual
1997-07-15
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Section
C-code
BT Standard Codes
Version no
T-code
000
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Service Manual
1997-07-15
Table of Contents
BT Standard Codes ....................................................................................... 1
Warning Symbols .......................................................................................... 9
Warning Levels .......................................................................................... 9
Prohibitory Symbols .................................................................................... 10
Ordinance Symbols .................................................................................. 10
Introduction, Service Manual ...................................................................... 11
Contents, Section M ..................................................................................... 13
Machine Information ................................................................................. 13
General Product Information ......................................................................
Presentation of the Rider Trucks RRX35/45, RDX30, and RSX40/50. .....
Main Components .....................................................................................
Grease Point Location ..............................................................................
Mast Adjustment Points ............................................................................
15
15
23
25
26
Inch (SAE) and Metric Fasteners ................................................................

Introduction ...............................................................................................
Nomenclature, Threads ............................................................................
Strength Identification ...............................................................................
Conversion of Metric and English Units ....................................................
27
27
28
29
35
Technical Service Data ................................................................................ 37

Ordering Spare Parts ................................................................................... 41
Contents, Section P ..................................................................................... 43
Planned Maintenance ............................................................................... 43
Introduction, Maintenance .......................................................................... 45
Safe Jacking Procedure ............................................................................ 45
Service Schedule ......................................................................................... 47
Planned Maintenance Schedule ............................................................... 47
Planned Maintenance Procedures ............................................................ 50
Lubrication Chart ......................................................................................... 57
Oil and Grease Specifications .................................................................... 59
Approved Oils and Grease ....................................................................... 59
Contents, Section S ..................................................................................... 61
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Table of Contents
Service Instructions .................................................................................. 61
Chassis .........................................................................................................
General .....................................................................................................
Door ..........................................................................................................
Left-Hand Side Panel ................................................................................
Operator Compartment Panel ...................................................................
Main Card Access Panel ..........................................................................
63
63
64
65
65
66
Brake Pedal ...................................................................................................

Pedal Removal .........................................................................................
Pedal Bearing Replacement .....................................................................
Pedal Adjustment ......................................................................................
67
68
69
69
Drive Motor ...................................................................................................

General Information ..................................................................................
Operating Conditions ................................................................................
Troubleshooting ........................................................................................
71
71
71
72
Drive Motor ...................................................................................................

Disassembly .............................................................................................
Inspection and Troubleshooting ................................................................
When Changing Brushes ..........................................................................
79
81
82
87
Caster Brake Assembly ............................................................................... 89

Removal .................................................................................................... 90
Electromagnetic Brake ................................................................................
Installation .................................................................................................
Adjustments ..............................................................................................
Coil Check On Brake ................................................................................
Electromagnetic Brake, Armature and Magnetic Coil. ..............................
93
94
95
95
96
Drive Wheel ................................................................................................... 97

Removal .................................................................................................... 97
Installation ................................................................................................. 98
Support / Swivel Wheel ................................................................................
Caster Pivot .............................................................................................
Thrust Bearing .........................................................................................
Caster Springs .........................................................................................
Caster Spring ...........................................................................................
Caster Stops ............................................................................................
99
100
103
105
107
108
Tandem Load Wheels ................................................................................. 111
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Table of Contents
Removal ................................................................................................... 112
Single Load Wheels .................................................................................... 113
Removal ................................................................................................... 114
Installation ................................................................................................ 114
Caster Wheels .............................................................................................
Removal ...................................................................................................
Installation ................................................................................................
Caster Axle ..............................................................................................
115
116
116
117
Caster Wheels .............................................................................................

Removal ...................................................................................................
Installation ................................................................................................
Caster Axle ..............................................................................................
119
120
121
122
Steering Arm / Wheel / Lever .....................................................................

Control Pod ..............................................................................................
Steering Wheel ........................................................................................
Steering Tach ..........................................................................................
123
124
125
126
Steering Bearing ......................................................................................... 127

Removal ................................................................................................... 128
Installation ................................................................................................ 128
Electrical Functions ....................................................................................
Operating Description ..............................................................................
Start Up ....................................................................................................
Direction Selection ...................................................................................
Reverse Direction Selection ....................................................................
Forward Drive ..........................................................................................
Plug Braking ............................................................................................
Steering Componets ................................................................................
12-Volt Power Supply ..............................................................................
Driving speed reduction switch ................................................................
Height Indicator and Preset Selector .......................................................
Drive Motor Brush Indicator Switch .........................................................
Pump Motor Brush Indicator Switch ........................................................
Safety Check ...........................................................................................
Shunt Wire ...............................................................................................
Circuit Diagram 1(11) ...............................................................................
Circuit Diagram 2(11) ...............................................................................
Circuit Diagram 3(11) ...............................................................................
Circuit Diagram 4(11) ...............................................................................
Circuit Diagram 5(11) ...............................................................................
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129
129
131
133
135
137
139
141
142
143
145
146
147
148
149
156
157
158
159
160
Table of Contents
Circuit Diagram 6(11) ...............................................................................
Circuit Diagram 7(11) ...............................................................................
Circuit Diagram 8(11) ...............................................................................
Circuit Diagram 9(11) ...............................................................................
Circuit Diagram 10(11) .............................................................................
Circuit Diagram 11(11) .............................................................................
161
162
163
164
165
166
Transistor Regulator ................................................................................... 167

Motor Connections ................................................................................... 168
Safety Control .......................................................................................... 169
Electronic Card ............................................................................................
Display .....................................................................................................
Time .........................................................................................................
Warning Codes ........................................................................................
Error Codes .............................................................................................
Effect on the Truck ...................................................................................
Parameters ..............................................................................................
Running time ............................................................................................
Programming Parameters ........................................................................
Adjustment Procedures for Setting Brake Switch and Brake Transducer
171
177
178
179
181
183
183
183
184
187
Pump Motor .................................................................................................

Component Repair ...................................................................................
Inspection and Troubleshooting ...............................................................
When Changing Brushes .........................................................................
189
190
192
197
Hydraulic System ........................................................................................ 199

Operation ................................................................................................. 199
RRX35/45 Hydraulic Schematic .............................................................. 203
Hydraulic System ........................................................................................
Operation .................................................................................................
RRX35/45 Hydraulic Schematic ..............................................................
RDX30 Hydraulic Schematic ...................................................................
RSX40/50 Hydraulic Schematic ...............................................................
205
205
209
210
211
Mast, 3 Stage ............................................................................................... 213

Shimming Mast on Truck ......................................................................... 214
Three Stage Mast .................................................................................... 219
Sideshifter .................................................................................................... 225
Mounting Instructions ............................................................................... 227
Operation and Maintenance .................................................................... 228
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Table of Contents
Reach, Single ............................................................................................... 231
Maintenance ............................................................................................ 231
Reach Repair ........................................................................................... 233
Freelift Cylinder, 3 Stage ............................................................................ 237
Freelift Cylinder Repair ............................................................................ 238
Staging Cylinder, 3 Stage ........................................................................... 241
Tilt Cylinder .................................................................................................
Removal ...................................................................................................
Disassembly ............................................................................................
Inspection ................................................................................................
Assembly .................................................................................................
Installation ................................................................................................
245
246
246
247
247
248
Tilt Cylinder .................................................................................................

Removal ...................................................................................................
Disassembly ............................................................................................
Inspection ................................................................................................
Assembly .................................................................................................
Installation ................................................................................................
251
252
253
254
254
256
Reach Cylinder ............................................................................................

Removal ...................................................................................................
Disassembly ............................................................................................
Inspection ................................................................................................
Assembly .................................................................................................
Installation ................................................................................................
257
258
259
260
261
262
Height Indicator ........................................................................................... 263

Pulse sensor ............................................................................................ 264
Height Indication & Preset Height .............................................................
General ....................................................................................................
Operation .................................................................................................
Preset Height ...........................................................................................
Display .....................................................................................................
Description of the display symbols. .........................................................
Programming ...........................................................................................
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265
266
266
267
268
269
270
Table of Contents
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F-code
Section
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PS
Warning Symbols
Version no
T-code
000
Warning Symbols
Always follow the warnings given in this Instruction Manual
and on the truck to avoid accidents and incidents from
occurring.
1. Warning Levels
Always follow the warnings given in this Instruction
Manual and on the truck to avoid accidents from
occurring.
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 you do not follow the
instructions.
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 a crash/breakdown if the instructions are
not followed.
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Service Manual
1997-07-15
F-code
Section
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PS
Prohibitory Symbols
Version no
T-code
000
Prohibitory Symbols
NO SMOKING
If smoking occurs in situations where a restriction agains
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.
10
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1997-07-15
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 lift trucks.
An Operators Manual is attached to every BT lift truck when
it is manufactured. If the Operators Manual is missing from
the truck, a new manual may be obtained by contacting:
BT Prime-Mover, Inc.
3305 N Highway 38
Muscatine, Iowa
52761-8800
(319) 262-7700
This service manual is not a training manual. The information
contained in this service manual is intended as a guide to
help authorized technicians safely service this truck.
The Service Manual is divided into four separate sections
which cover different kinds of information needed for
servicing these truck types. The main subject for each of
these sections are as described below.
SECTION
BT Products
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SUBJECT
MACHINE INFORMATION
PLANNED MAINTENANCE
SERVICE INSTRUCTIONS
OPTIONS
Service Manual
1997-07-15
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F-code
Section
C-code
M
Version no
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001
395/396/397/398/399
12
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Service Manual
1997-07-15
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Section
C-code
M
Contents, Section M
Version no
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001
Contents, Section M
1. Machine Information
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M1.0
GENERAL PRODUCT INFORMATION
M2.0
TECHNICAL SERVICE DATA
M3.0
ORDERING SPARE PARTS
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1997-07-15
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F-code
Section
C-code
M
Contents, Section M
Version no
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001
14
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F-code
Section
C-code
M1.0
General Product Information
Version no
000
T-code
395/396/397/398/399

1. Presentation of the Rider Trucks
RRX35/45, RDX30, and RSX40/50.
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.
In their standard design, 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).
These trucks are equipped with a 24V or 36V electrical
system and the speed 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. The 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. Intended Application of the Trucks

The trucks are solely designed and manufactured to handle
goods. The trucks should be fitted with the appropriate
accessories relevant to the application.
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M1.0
Version no
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000
395/396/397/398/399
1.2. Forbidden Application of the Truck

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.
1.3. Truck Data

The following table provides information regarding some
technical data which is of value with daily use of the trucks.
Truck data
RRX35/45
RDX30
RSX40/50
3500 / 4500
3000
4000/5000
192-270 / 210-402
210-402
192-270 / 210-402
Operating speed without load, mph

24 Volt
36 Volt
6.0 mph
6.5 mph
6.5 mph
6.0 mph
6.5 mph
Operating speed with load, mph

24 Volt
36 Volt
5.5 mph
6.0 mph
6.0 mph
5.5 mph
6.0 mph
5500 / 5800
6000
5100 / 5200
Above + battery
weight
Above + battery
weight (2600 min)
Above + battery
weight (2400 min)
Lifting capacity rated load, lb

Lift height, inches
Service weight without battery, lb

Service weight including battery, lb
The trucks lifting capacity, lifting height, and weight can be

found on the trucks data plate.
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M1.0
Version no
000
T-code
395/396/397/398/399
1.4. RRX35 Dimensions

The following diagram shows external dimensions for the
RRX35 truck in its standard design.
Fork length
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Version no
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395/396/397/398/399
1.5. RRX45 Dimensions

RRX45 truck in its standard design.
Fork length
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M1.0
Version no
000
T-code
395/396/397/398/399
1.6. RDX30 Dimensions

RDX30 truck in its standard design.
Fork length
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Version no
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1.7. RSX40 Dimensions

RSX40 truck in its standard design.
Fork length
20
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1.8. RSX50 Dimensions

RSX50 truck in its standard design.
Fork length
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1.9. 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
22
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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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M1.0
Version no
000
T-code
395/396/397/398/399
2. Main Components
1
2
3
4
5
8
9
10
11
12
13
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Hydraulic valve:
The valves are located to provide easy access.
Battery:
24/36V with different capacities and weights.
Battery connector:
The battery is charged through the battery connection.
Hydraulic unit:
Pump motor and 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 degree in either direction.
Data plate:
Contains data designation, manufacturing number, year of
manufacture, service weight, battery weight, classified
lifting capacity, battery voltage, and manufacturer.
Cover:
Removable to provide good 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 maybe set in 1 of 3 positions.
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.
Electronics:
The electronics are in a protected compartment.
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14 Control circuit fuse:

15A, BT part number 122308-150
15 Steering circuit fuse:
30A, BT part number 122308-300
16 Drive motor fuse:
500A, Two 250A fuses, BT part number 305656-003
17 Pump motor fuse:
425A, 24V BT part number 305656-002
355A, 36V BT part number 305656-001
18 Right foot pedal
A red triangle (warning light) will be displayed on
instrument panel if right foot pedal is not depressed. This
safety feature is installed so operator keeps right foot
within operators compartment.
19 Emergency stop
The emergency stop switch will stop all control and power
functions.
12
11
10
19
16
17
8
5
4
6
7
9
18
13
14
15
Main Components of Truck

24
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Version no
000
T-code
395/396/397/398/399
3. Grease Point Location
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Version no
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395/396/397/398/399
4. Mast Adjustment Points
26
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Section
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M1.1
Inch (SAE) and Metric Fasteners
Version no
T-code
001
1. Introduction
Threaded fasteners such as bolts, nuts, cap screws, and
studs are made to specifications that describe the mechanical
strength and hardness of the fastener. A fastener used in a
design application is selected in accordance with its
specifications. Parts used on this truck are purchased from
many countries. There are several standards used by these
countries in the manufacture of threaded fasteners. Many of
these fasteners are similar but cannot be used as direct
replacements.
Service persons must use replacement fasteners that have
the same specifications. Fasteners made to each
specification have identification marks for that specification.
This specification is commonly called grade for SAE
standards and property for metric standards. This section
describes the identification of some common fasteners.
The metric system used is described as SI (International
System of Units, also called SI in all languages). The SI
system of measurement is described in ISO Standard 1000,
1973.
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Version no
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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:
INCH
METRIC
1/2 x 13 UNC x 1-1/2

A
B
C
D
M12 x 1.75 x 50
A
B
C
A = SHANK DIAMETER
B = NUMBER OF THREADS PER UNIT
OF LENGTH
C = TYPE OF THREAD
D = SHANK LENGTH
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A = THREAD SIZE
B = PITCH
C = LENGTH
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3. Strength Identification
The most common property classes for metric fasteners are
8.8 and 10.9. The property class is marked with a number on
the head of the cap screw or on a nut. Property classes less
then 8.8 are often not marked. Grades for inch bolts go from 2
to 8. Grade 2 fasteners normally do not have marks. The
following tables show the marks that identify the grades and
property classes for different fasteners.
WARNING When fasteners must be replaced the new

fasteners must be of the same strength or
greater than the original fasteners. The
new fasteners must also be the correct
size.
NOTE! Identification marks are according to bolt
strength. The higher the number, or the
increase in the number of marks, indicates
increased bolt strength.
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Table 1. Bolt and Screw Designations
Types of
Fasteners
Metric Fasteners
Inch Fasteners
Strength Levels: SAE Grades
Strength Levels: Property Classes
* Markings Not Required

2
5.2
Hex Head Bolts

& Cap Screws
5
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
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Table 2. Stud and Nut Designations
Types of
Fasteners
Inch Fasteners
Metric Fasteners

4.6*
4.6
5.2*
5*
4.8
9.8
9.8
8*
4.8* 5.8*
8.8
8.8
5.8
10.9 12.9 Markings

for size
M5 and
Larger
12.9
10.9
8.1
or
Studs
Optional Geometric Symbols for

Size M5 through M11 ONLY.
Hex Nuts
Hex Slotted Nuts
Hex Flange Nuts
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10
12
10
12
10
12
8
or
or
10
12
10
12
10
12
10
12
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Table 3. Torque Nut Designations
Types of
Fasteners
Inch Fasteners
Metric Fasteners
10
10
or
All Metal Prevailing Torque
Nuts
G
9
10
or
All Metal Prevailing Torque
Flange Nuts
10
or
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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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F-code
Section
C-code
M1.1
Version no
T-code
001
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.
34
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Service Manual
1997-09-24
F-code
Section
C-code
M1.1
Version no
T-code
001
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)
BT Products
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Service Manual
1997-09-24
35
F-code
Section
C-code
M1.1
Version no
T-code
001
TEMPERATURE
Multiply
By
To Get
Multiply
By
To Get
(Fahrenheit
-32)
0.56
Celsius (C)
(Celsius x 1.8)
+32
Fahrenheit (F)
By
To Get
TORQUE
Multiply
By
To Get
Multiply
inch pound
0.113
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
36
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
Service Manual
1997-09-24
F-code
PS
Section
C-code
M2.0
Technical Service Data
Version no
002
T-code
395/396/397/398/399

MODEL
RRX35 - RSX40
RDX30
RRX45 - RSX50
Series - DC
Series - DC
Series - DC
1 Hr. Continuous
1 Hr. Continuous
1 Hr. Continuous
.8 in. (20 mm)
.8 in. (20 mm)
.8 in. (20 mm)
Minimum commutator diameter
2.90 in. (74 mm)
2.90 in. (74 mm)
2.90 in. (74 mm)
Minimum brush spring tension
6.4 oz. (180 grams)
6.4 oz. (180 grams)
6.4 oz. (180 grams)
Part number
24 V - 305789-000
36 V - 305790-000
36 V - 305790-000
36 V - 305790-000
Vertical motor spiralbevel output
Gear ratio
17.57
17.57
17.57
Oil volume
1 gal.
1 gal.
1 gal.
SAE 80W90
SAE 80W/90
ATF
SAE 80W90
SAE 80W/90
ATF
SAE 80W90
SAE 80W/90
ATF
13.5 x 5.5 x 10.0
13.5 x 5.5 x 10.0
13.5 x 5.5 x 10.0
95 ft-lb
95 ft-lb
95 ft-lb
5.0 in. x 3.6 in.
5.0 in. x 3.6 in.
5.0 in. x 3.6 in.
DRIVE MOTOR
Type
Power
Duty factor
Minimum brush length
TRANSMISSION/GEAR
Type
Normal temperature
Above 23F (-5C)
Below 23F (-5C)
Below 5F (-15C)
WHEELS
Drive wheel
Drive wheel weight without load
with battery, lb
Drive wheel weight with rated
load and battery, lb
Torque axle nut
Load wheel
Load wheel weight with rated
load, lb
BT Products
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6975 lb
Service Manual
1998-07-22
37
F-code
Section
C-code
PS
M2.0
Version no
T-code
002
395/396/397/398/399
MODEL
RRX35 - RSX40
RDX30
RRX45 - RSX50
2200 rpm.
2550 rpm.
2550 rpm.
20% on 5 min. cycles
.8 in. (20 mm)
.62 in. (16 mm)
.62 in. (16 mm)
Minimum commutator diameter
2.90 in. (74 mm)
2.80 in. (72 mm)
2.80 in. (72 mm)
Minimum brush spring tension
6.4 oz. (180 grams)
40 oz. (1120 grams
40 oz. (1120 grams
Part number
24 V - 307327-000
36 V - 307328-000
307282-000
307282-000
2450 psi
2400 psi
2450 psi
24 V - 13 cc
36 V - 19 cc
36 V - 27 cc
36 V - 27 cc
5 gal - 19 Liters
5 gal - 19 Liters
5 gal - 19 Liters
Sunoco TH
ATF
Texaco 1
Sunoco TH
ATF
Texaco 15
Sunoco TH
ATF
Texaco 15
Drive motor circuit
250 Amp
250 Amp
250 Amp
Pump motor circuit
24 V - 425 Amp
36 V - 355 Amp
500
(2 @ 250 Amp)
500
(2 @ 250 Amp)
10 Amp
10 Amp
10 Amp
14.4 x 38.8 x 32.0

16.4 x 38.8 x 32.0
16.4 x 38.8 x 32.0

21.0 x 38.8 x 32.0
16.4 x 38.8 x 32.0

21.0 x 38.8 x 32.0
24 V - 1395
36 V - 1240
36 V - 1240
36 V - 1240
14.5 in. -1600 lb

(2300 lb)
16.5 in. - 2000 lb
(2300 lb)
16.5 in. -2000 lb

(2300 lb)
21.0 in. - 2600 lb
(2900 lb)
16.5 in. -2000 lb

(2300 lb)
21.0 in. - 2400 lb
(2900 lb)
HYDRAULIC UNIT
Power
Revolutions/minimum at work
pressure
Duty factor
Minimum brush length
Pressure at rated loa

Pump flow
Tank volume
Normal temperature
Above 23F (-5C)
Below 23F (-5C)
Below 5F (-15C)
24 V 36 V - 9.8 Kw 13.1 hp
FUSE
Control circuit
BATTERIES
Dimension W x L x H
Capacity (Max. Amp-hrs.)
Weight Minimum
(Maximum)
38
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Service Manual
1998-07-22
F-code
PS
Version no
002
Section
C-code
M2.0
T-code
395/396/397/398/399
MODEL
RRX35 - RSX40
RDX30
RRX45 - RSX50
24 V - 6.0 mph
36 V - 6.5 mph
36 V - 6.5 mph
36 V - 6.5 mph
24 V - 5.5 mph
36 V - 6.0 mph
36 V - 6.0 mph
36 V - 6.0 mph
24 V - 60 fpm
36 V - 80 fpm
36 V - 94 fpm
36 V - 94 fpm
24 V - 40 fpm
36 V - 60 fpm
36 V - 60 fpm
36 V - 60 fpm
Lower without load, electrical

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

valve
80 fpm
95 fpm
95 fpm
Driving without load
24 V - 140
36 V - 140
36 V - 150
36 V - 150
Driving with rated load
24 V - 160
36 V - 165
36 V - 170
36 V - 170
Lifting without load
24 V 36 V - 240
36 V - 320
36 V - 320
Lifting with rated load
24 V 36 V - 415
36 V - 570
36 V - 570
DRIVING SPEEDS
Without load
With rated load
LIFTING/LOWERING TIME
Lift without load
Lift with rated load
CURRENT CONSUMPTION
NOTE! Performance may vary up to 10% due to

motor and system efficiency tolerance. The
performance shown represents nominal
values obtained under typical operating
conditions.
NOTE! These products and specifications are
subject to change without notice.
BT Products
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Service Manual
1998-07-22
39
F-code
Section
C-code
PS
M2.0
Version no
T-code
002
395/396/397/398/399
40
Return
Service Manual
1998-07-22
F-code
PS
Version no
Section
C-code
M3.0
Ordering Spare Parts
T-code
000

1. Locate the fault on the truck.
2. Find out the machine model and serial number.
3. Locate the page with the exploded diagram and find the
position number for the part you require.
4. Locate the position number in the table. Select the
column for the actual machine model and serial number.
5. Note the part number.
6. Call the local BT dealer and state the part number.
If you cannot find the machine model, serial number, or
the article number, call the local BT dealer and he will
help you.
BT Products
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Service Manual
1997-07-15
41
F-code
Section
C-code
PS
M3.0
Version no
T-code
000
42
Return
Service Manual
1997-07-15
F-code
PS
Version no
Section
C-code
P
Contents, Section P
T-code
000
Contents, Section P
1. Planned Maintenance
BT Products
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P1.0
INTRODUCTION, MAINTENANCE
P2.0
SERVICE SCHEDULE
P3.0
LUBRICATION CHART
P4.0
OIL AND GREASE SPECIFICATIONS
Service Manual
1997-07-15
43
F-code
Section
C-code
PS
P
Contents, Section P
Version no
T-code
000
44
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Service Manual
1997-07-15
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- 8 am-5 pm, 25 hours per week usage
Double shift- 6 am-2 pm, 2 pm-10 pm, 50 hours per
week usage
Triple shift- 6 am-2 pm, 2 pm-10 pm, 10 pm-6 am, 75
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.
- Always clean the equipment and carry out a full safety
check after service.
1. Safe Jacking Procedure

1. Disconnect battery.
2. Read and follow the correct operating procedures
for your jack or hoist.
BT Products
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Service Manual
1997-07-15
45
F-code
Section
C-code
PS
P1.0
Version no
T-code
000
46
Return
Service Manual
1997-07-15
F-code
Section
PS
P2.0
Service Schedule
Version no
C-code
T-code
001
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
0840
0840.1
1700
1700.1
1700.2
1700.3
1700.4
1700.5
2550
2550.1
2550.2
2550.3
3100
3100.1
3100.2
BT Products
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WORK REQUIRED
Interval in Hours
Interval in Days/Weeks/Months
Chassis
Check that the truck identification
plate is legible
Check for damage and cracks
Retighten the truck body bolts (to
the chassis)
Check the cover screws
Operator Controls
Check that the travel direction/
speed selectors operational
Check that the horn button is
operational
Check that the hydraulic levers
are operational
Drivers Protection
Check that the red emergency
stop button is operational
Drive Motor
Check for arcing due to poor
connections
All connections tight
Clean motor of dirt and dust
Check torque of motor bolts
Check for abnormal noise in
motor bearings
Drive Gear
Check for oil leakage
Clean motor of dirt and dust
Check torque of motor bolts
Brake
Clean dust and debris
Check brake shoes for wear
Service Manual
25
100
250
300
600
1200
3600
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
1997-11-07
47
F-code
Section
C-code
PS
P2.0
Service Schedule
Version no
T-code
001
395/396/397/398/399
ITEM
3100.3
3100.4
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
5400
5400.1
5400.2
5400.3
5400.4
5400.5
5710
5710.1
48
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, -e inch above
cell plates
All connections: battery, battery
and charger plugs
All cell and link covers intact
Check battery specific gravity
Instrument Panel
Check battery indicator and hour
meter for correct operation
Electrical Control System
Check key switch
Check brake micro switch
Check control wiring harness for
proper routing
Electrical Panel
Cleaning and mounting to chassis
Tightening of connections
Check contactor tips
Check contactor tips for free
movements
Check all cable insulation for
damage
Electronic Card
Check for connections in harness
connectors
25
100
250
300
600
1200
3600
1d
1w
1m
2m
3m
6m
12 m
36 m
X
X
X
X
X
X
X
X
X
X
X
X
X
Service Manual
X
X
X
X
X
X
X
1997-11-07
F-code
Section
PS
P2.0
Service Schedule
Version no
T-code
001
ITEM
6000
6000.1
6000.2
6000.3
6000.4
6000.5
7100
7100.1
7100.2
7100.3
7100.4
7100.5
7100.6
7100.7
7100.8
7100.9
7310
7310.1
7310.2
7400.
7400.1
7400.2
7400.3
7400.4
7400.5
BT Products
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C-code
395/396/397/398/399
WORK REQUIRED
Interval in Hours
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 the hydraulic oil
Mast
Check for damage and cracks
Retighten the mast mounting
bolts
Check the clearance of the rollers
Check the lateral play of the inner
section
Check for wear on the lift chains
and chain rollers
Check the adjustment of the lift
chains
Clean & lube lift chains
Clean & lube mast rails
Lube chain sheaves
Lift Cylinder
Check for leakage
Check mounting
Lifting Device
Check the clearance of the fork
carriage
Check the fork carriage for
damage and cracks
Check the forks for wear and
cracks
Check the reach attachment for
damage and cracks
Lube all grease fittings on reach
attachment
Service Manual
25
100
250
300
600
1200
3600
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
1997-11-07
49
F-code
Section
C-code
PS
P2.0
Service Schedule
Version no
T-code
001
395/396/397/398/399
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 to be performed daily or at

each 8 hour operating shift:
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, and the truck should not
be operated until it has been inspected and repaired by a
qualified technician. The operator is ultimately responsible for
the safe operation of the reach truck.
2.1.1. Battery Discharge Indicator with slow down
The battery discharge indicator indicates the current charge
status of the trucks battery.
1
Full charge battery
1/2
Half charged battery
Discharged battery
The battery battery discharge indicator has an integrated cutout function that slows down the trucks lift function when a
predetermined charge level has been reached. This prevents
overloading the battery and increases the operating economy
of the 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 the entire truck for leaks, especially around the
hydraulic pump assembly and the lift cylinders. Any sign of oil
on the floor under the truck is an indication that the truck may
be leaking hydraulic oil or transmission fluid. Report any
problems to the proper authorities, and DO NOT operate the
truck until it has been inspected and repaired by a qualified
technician.
50
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Service Manual
1997-11-07
F-code
Section
PS
P2.0
Service Schedule
Version no
001
C-code
T-code
395/396/397/398/399
2.1.3. Frame/Sheet Metal

Inspect the 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 the truck until it
has been inspected and repaired by a qualified 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 the wheels and tires.
2.1.5. Functions/Operations
Test the truck for the proper operation of all functions
including the travel controls, lift and lower functions, the
brakes, and the emergency disconnect button. Safety devices
must be operational. Report any problems to the proper
supervisors. DO NOT operate the truck until it has been
inspected and repaired by a qualified technician.
2.2. Services to be performed monthly or

every 250 operating hours:
The monthly planned maintenance service should be
performed by a qualified technician.
2.2.1. Inspection
All of the 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
The brakes should stop a fully loaded truck at full speed in
approximately one truck length.
2.2.4. Battery
Contact your battery dealer for specific instructions on care
and maintenance of the battery.
BT Products
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Service Manual
1997-11-07
51
F-code
Section
C-code
PS
P2.0
Service Schedule
Version no
T-code
001
395/396/397/398/399
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
All electrical connections should be checked that they are
clean and tight. Plug-in connectors should be unplugged and
plugged back in to clean the terminals. If the truck is equipped
with any of the cold-storage, 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 the tips are
pitted through the tip to the copper bar, the tips should be
replaced. DO NOT file tips. Replace tips only in complete
sets. Some contactors have concealed tips or are fully sealed
so that tips cannot be replaced.
2.2.7. Motor Brushes
The drive motor is equipped with a brush wear sensor which
will indicate when the brushes need replacing. Minimum
brush lengths are given in the specifications section of this
manual. As a rule of thumb, the brushes should be replaced if
the brush spring is within 1/16 in. of touching the brush
holder.
2.2.8. Drive Motor
Blow out the drive motor fan and vents. Check for any signs
of oil on the drive motor fan and air vents. Check for any
damage to the fan or air vents.
WARNING Compressed air used for cleaning MUST

be reduced to less than 30 psi., and then
only with effective chip-guarding and
personal protective equipment worn.
52
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Service Manual
1997-11-07
F-code
Section
PS
P2.0
Service Schedule
Version no
001
C-code
T-code
395/396/397/398/399
2.2.9. Hydraulic Reservoir

Check the fluid level in the hydraulic reservoir.
2.2.10. Frame Lube (Lubrication Chart on page 55)
The pressure type grease fittings (zerk fittings) should be
lubricated with Texas Refineries #880 Crown and Chassis
lubricating grease. The total number of grease fittings
depends on the truck options when built. A truck with a coldstorage, 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 the mast chain sheave shafts.
2.2.11. Pivot Points
There are some 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 wt.
machine oil.
2.3. Services to be performed annually or

every 1200 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.
2.3.1. Inspection
All of the services and inspections listed in sections 5.1 and
5.2 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.
2.3.2. 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 the bolt to drain the
transmission fluid. Flush the transmission case with safety
solvent. Pour clean safety solvent into the fill port accessed
from battery compartment. With drive tire off the floor, allow
solution to run out of drain port while transmission is running.
BT Products
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Service Manual
1997-11-07
53
F-code
Section
C-code
PS
P2.0
Service Schedule
Version no
T-code
001
395/396/397/398/399
Stop flushing when the solution runs clean. Allow the solvent
to drain well before replacing the drain plug bolt. Replace the
drain plug bolt. Refill the transmission with the proper clean
oil before operating truck.
2.3.3. 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 equipped and trained personnel.
2.3.4. 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 raise and
lower function several times to purge air from 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.
2.3.5. 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 in.
(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 in. 0.46
mm) and should remain within 0.003 in. (0.076 mm)
throughout the circumference.
2.3.6. Lift and Carriage Chains.
Lift and carriage chains should be checked every 500 hours.
A chain gauge should be used to check stretch of the links.
To adjust inner rails, loosen jam nut and tighten chains
54
Return
Service Manual
1997-11-07
F-code
Section
PS
P2.0
Service Schedule
Version no
001
C-code
T-code
395/396/397/398/399
equally until the top of the rails 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 heel of the forks are 1/2 in.
(12.7 mm) off of the floor.
BT Products
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Service Manual
1997-11-07
55
F-code
Section
C-code
PS
P2.0
Service Schedule
Version no
T-code
001
395/396/397/398/399
56
Return
Service Manual
1997-11-07
F-code
Section
PS
P3.0
Lubrication Chart
Version no
C-code
T-code
000
395/396/397/398/399
Lubrication Chart
Pos. No
Service Point
Interval/Running Hours
300 h
1
2
3
4
5
6
Wheel bearings
Mast beam
Lifting chains
Hydraulic syste
Steering bearings
Drive gear
600 h
1200 h
Lubricant
(See Chart in
Section 6 for Code)
L
L
L
C
C
L= Lubrication
C = Check
O
L
O
A
A
D
B
A
C
O = Oil change
2
3
5
1
1
Truck Lubrication Points
BT Products
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Service Manual
1997-07-15
57
F-code
Section
C-code
PS
P3.0
Lubrication Chart
Version no
T-code
000
395/396/397/398/399
58
Return
Service Manual
1997-07-15
F-code
Section
C-code
PS
P4.0
Oil and Grease Specifications
Version no
000
T-code
395/396/397/398/399

1. Approved Oils and Grease
Lubricant
A
Grease
B
C
D
E
Hydraulic oil
Transmission oil
Motor oil
Grease
Grease
BT Products
Return
Specification
>14F(-10C) <14F(-10C)
Tex. Ref. C
Mobiltemp
and C #880
SHC 32
Sunoco TH
ATF
SAE 80w/90
SAE 75w
SAE 40
SAE5w-20
Molykote
Molykote
200025
200025
49670-00
49670-00
Service Manual
1997-07-15
Application area
<-13F(-25C)
Mobiltemp
SHC 32
Texaco 15
ATF
SAE5w-20
Molykote
200025
49670-00
Bearings and
bushings
Hydraulic system
Gears
Chains
Mast rails, Reach,
Sideshifter
Mast rails, Reach,
Sideshifter
59
F-code
Section
C-code
PS
P4.0
Version no
T-code
000
395/396/397/398/399
60
Return
Service Manual
1997-07-15
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
CHASSIS
0000
DRIVE MOTOR
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
BT Products
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OPTIONS / ATTACHMENTS
Service Manual
1997-04-15
9000
61
F-code
Section
C-code
PS
S
Contents, Section S
Version no
T-code
000
62
Return
Service Manual
1997-04-15
F-code
Section
PS
S0.1
Version no
C-code
0000
Chassis
T-code
001
395/396/397/398/399
Chassis
1. General
The chassis has several panels and covers that are
removable. During operation of the truck, these 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
16
17
10
18
11
9
8
7
6
5
15
Removal/Installation of Chassis Panels & Covers

BT Products
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Service Manual
1997-07-15
63
F-code
Section
C-code
PS
Chassis
S0.1
0000
Version no
T-code
001
395/396/397/398/399
POS.
NO
DESCRIPTION
POS.
NO
Panel, left hand
Latch
13
Plug, hole
Panel, side
Washer, flat
14
Screw
Grill, fan
Nut
15
Panel, cover
Screw
10
Door
16
Mount, control
Screw
11
Panel, right hand
17
Screw
Washer
12
Dash
18
Plate, heat sink
DESCRIPTION
POS.
NO
DESCRIPTION
2. Door
2.1. Removal
1. Turning screw (5) clockwise one quarter turn.
2. Open door (10) fully and lift door upward to release
hinge pins.
2.2. Installation
1. Set door (10) in place so hinge pins are securely
mounted in panel hinge.
2. Close door. Turn screw (5) counter clockwise one
quarter turn.
CAUTION
64
Return
Service Manual
Do not force screw (5) past quarter turn

or latch can become loose.
1997-07-15
F-code
Section
PS
S0.1
Version no
001
C-code
0000
Chassis
T-code
395/396/397/398/399
3. Left-Hand Side Panel

3.1. Removal
1. Park truck on level surface and block.
2. Disconnect battery at battery plug and remove.
Overhead
guard post
3. Turning screw (5) clockwise one quarter turn.

4. Open door (10) fully and lift door upward to release
hinge pins.
5. Remove console cover (12) by removing seven
screws (14) and control pod.
Control
Pod
6. Remove three flanged nuts. Two are located under

control console by reservoir and the third flanged
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.
8. Remove four bolts securing overhead guard post.
Disconnect harness at post if applicable.
9. Pull left-hand panel (1) outward and set aside.
CAUTION
Side panel is heavy. Help may be

required to remove.
4. Operator Compartment Panel

4.1. 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.
BT Products
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Service Manual
1997-07-15
65
F-code
Section
C-code
PS
Chassis
S0.1
0000
Version no
T-code
001
395/396/397/398/399
5. Main Card Access Panel

5.1. Removal
1. Loosen two lower bolts.
2. Remove two top bolts and lift electrical cover panel
(15) up and set aside.
66
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Service Manual
1997-07-15
F-code
Section
PS
S0.2
Version no
C-code
0640
Brake Pedal
T-code
000
395/396/397/398/399
Brake Pedal
12
2
1
2
5
8
4
3
8
9
13
14
POS.
NO
POS.
NO
DESCRIPTION
10
11
POS.
NO
DESCRIPTION
Pedal, brake
Stop, pedal
11
Screw
Bearing, flanged
Plate
12
Mat, pedal
Bumper
Screw
13
Nut, twin
Bracket, brake
Screw
14
Switch, brake
Spring, return
10
Potentiometer
15
Screw
BT Products
Return
DESCRIPTION
15
Service Manual
1997-07-15
67
F-code
Section
C-code
PS
S0.2
Brake Pedal
0640
Version no
T-code
000
395/396/397/398/399
1. Pedal Removal
1. Park the truck on a flat surface.
2. Disconnect the battery at the battery connector.
Check to make sure the battery retainer plates are
in place.
3. Jack the rear of the truck so the drive and caster
wheels are approximately 1 in. off the ground.
Block the truck in this position.
4. Looking into the operator's compartment, remove
the four screws from the right panel covering the
logics 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.
CAUTION Disconnect wire connections to right

foot pedal switch prior to removal of
floor board.
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.
7. Remove the screws (11) holding the transducer
switch (10) and remove wires from the brake
switch (12).
8. Loosen the four mounting bolts holding brake
pedal assembly to the frame. Remove brake pedal
assembly from truck to service.
68
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Service Manual
1997-07-15
F-code
Section
PS
S0.2
Version no
000
C-code
0640
Brake Pedal
T-code
395/396/397/398/399
2. Pedal Bearing Replacement

1. To replace bearing assemblies on brake pedal (1),
remove the brake pedal return spring (5).
2. Remove the flange bearing mounting screws (8) on
both bearings.
3. Loosen the set screws on bearing collars and slide
bearing assemblies back.
4. Remove brake pedal assembly from bracket (4)
and remove bearings (2). Reverse procedure for
reassembly.
3. Pedal Adjustment
1. See Adjustment Procedures for Setting Brake
Switch and Brake Transducer on p age187.
When replacing the pedal stop (6) it should be
threaded down until the stop makes contact with
the bracket (4).
BT Products
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Service Manual
1997-07-15
69
F-code
Section
C-code
PS
S0.2
Brake Pedal
0640
Version no
T-code
000
395/396/397/398/399
70
Return
Service Manual
1997-07-15
F-code
Section
C-code
PS
S1.0
1700
Drive Motor
Version no
000
T-code
395/396/397/398/399
Drive Motor
1. General Information
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 troublefree operations -- is related to the time spent making
inspections and correcting minor problems as they occur.
The drive motor is equipped with brush sensors. When
brushes are in need of replacement, a warning code C-17 will
show on the dash display.
2. Operating Conditions
Operating environment of lift 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:
Chemical Processing
Freezer operation
Processing plants (poultry, meat)
BT Products
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Service Manual
1997-07-15
71
F-code
Section
C-code
PS
S1.0
Drive Motor
1700
Version no
T-code
000
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.
We have reviewed many troubleshooting guides and have
reduced them to a few which seem to be the most effective
Symptom/Cause relationships.
72
Return
Table 1
Indications, causes, and correction of

unsatisfactory brush performance.
Table 2
Primary sources of unsatisfactory brush

performance.
Service Manual
1997-07-15
F-code
Section
C-code
PS
S1.0
1700
Drive Motor
Version no
000
T-code
395/396/397/398/399
TABLE 1.
Indications, Causes, and Correction of 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
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
7-13-23-34
51-52
See Chattering or Noisy Brushes
55-57-59
50
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
BT Products
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Service Manual
1997-07-15
73
F-code
Section
C-code
PS
S1.0
Drive Motor
1700
Version no
T-code
000
395/396/397/398/399
TABLE 1. Continued
Indications Appearing at Commutator Surface
Indications
Immediate Causes
Primary Faults
Brush Chipping or Breakage

Looseness in machine
Vibration
Chattering

evidence
15-16-17
52
See Chattering or Noisy Brushes
14
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
43-44-45-46-49-59
2-3-46-47-48-61
See Glowing at Brush Face
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 coppe
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
74
Return
Service Manual
1997-07-15
F-code
Section
C-code
PS
S1.0
1700
Drive Motor
Version no
000
T-code
395/396/397/398/399
TABLE 1. Continued
Indications Appearing at Commutator Surface
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

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 coppe
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 Commutato
Heating at Brushes
BT Products
Return
Service Manual
1997-07-15
8-19-22-25-27-28-29-37
7-13-23-24
75
F-code
Section
C-code
PS
S1.0
Drive Motor
1700
Version no
T-code
000
395/396/397/398/399
TABLE 2.
Primary Sources of Unsatisfactory Brush
Performance
Preparation and Care of Machine
20.
21.
22.
23.
24.
25.
Poor preparation of commutator surface

High mica
Feather-edge mica
Bar edges not chamfered after undercutting
Need for periodic cleaning
Clogged ventilating ducts
Machine Adjustment
26.
27.
28.
29.
30.
31.
32.
Brushes in wrong position

Unequal brush spacing
Poor alignment of brush holders
Incorrect brush angle
Incorrect spring tension
Interpoles improperly adjusted
Series field improperly adjusted
Mechanical Fault in Machine

33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
Brushes tight in holders

Brushes too loose in holders
Brush holders loose at mounting
Commutator loose
Loose pole pieces or pole-face shoes
Loose or worn bearings
Unequal air gaps
Unequal pole spacing
Dynamic unbalance
Variable angular velocity
Commutator too small
Electrical Fault in Machine

44.
45.
46.
47.
48.
76
Return
Open or high resistance connection at commutator

Poor connection at shunt terminal
Short circuit in field or armature winding
Ground in field or armature winding
Reversed polarity on main pole or interpole
Service Manual
1997-07-15
F-code
Section
C-code
PS
S1.0
1700
Drive Motor
Version no
000
T-code
395/396/397/398/399
TABLE 2. Continued
Machine Design
49.
50.
51.
52.
53.
54.
55.
56.
Commutating zone too narrow

Commutating zone too wide
Brushes too thin
Brushes too thick
Magnetic saturation of interpoles
High bar-to-bar voltage
High ratio of brush contact to commutator surface area
Insufficient cross connection of armature coils
Load or Service Condition

57.
58.
59.
60.
61.
62.
63.
64.
65.
66.
67.
68.
69.
Overload
Rapid change of load
Reversing operation of non-interpole machine
Plugging
Dynamic braking
Low average current density in brushes
Contaminated atmosphere
Contact poisons
Oil on commutator or oil mist in air
Abrasive dust in air
Humidity too high
Humidity too low
Silicone contamination
Disturbing External Condition

70.
71.
72.
73.
74.
75.
76.
77.
78.
79.
80.
81.
BT Products
Return
Loose or unstable foundation

External source of vibration
External short circuit or very heavy load surge
Commutation factor too high
Commutation factor too low
Contact drop of brushes too high
Contact drop of brushes too low
Coefficient of friction too high
Lack of film forming properties in brush
Lack of polishing action in brush
Brushes too abrasive
Lack of carrying capacity
Service Manual
1997-07-15
77
F-code
Section
C-code
PS
S1.0
Drive Motor
1700
Version no
T-code
000
395/396/397/398/399
78
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Service Manual
1997-07-15
F-code
Section
C-code
PS
S1.1
1700
Drive Motor
Version no
000
T-code
395/396/397/398/399
Drive Motor
1
3
2
4
13
7
14
8
9
10
5
16
15
11
12
25
16
26
27
17
28
29
30
BT Products
Return
18
Service Manual
1997-07-15
79
F-code
Section
C-code
PS
S1.1
Drive Motor
1700
Version no
T-code
000
395/396/397/398/399
Pos. No
80
Return
Description
Pos. No
Description
Pos. No
Description
Screw
Brush
17
Endhead, drive
Band, head
10
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
Endhead, commutator
15
Armature
29
Ring, retainer
Plate, brush
16
Key, woodruff
30
Ring, retainer
Service Manual
1997-07-15
F-code
Section
C-code
PS
S1.1
1700
Drive Motor
Version no
000
T-code
395/396/397/398/399
1. Disassembly
1. Remove the cover band (23) from the commutator
end of the motor.
2. Use a brush hook to reach into the motor and lift
the brush springs (19). Pull the brushes (2) out of
the brush holders. Either position the brushes
outside the motor or remove the brush retaining
screws and remove the brushes from the motor.
3. Scribe or center punch locating marks in the end
head and the frame. Although locating marks are
not always necessary because of locating pins in
some motors, they can save a lot of time when the
motor does not have locating pins.
4. Remove the commutator end head retaining
screws. Most motors have a slip fit bearing at the
commutator end, and the end head can be
removed with very little trouble.
5. Remove the drive end head retaining screws, if
necessary. Separate the armature (9) and drive
end head (11) as an assembly from the frame and
field coil assembly.
6. Separate the armature (9) from the drive end head
(11). This operation is usually done by pressing the
armature out of the drive end bearing. Remove
with a puller. When a puller is used, protect the end
of the armature shaft with a nut or a thick flat
washer.
CAUTION If the shaft, coupling, or spline is

damaged when removing the end
head, the armature or the drive spline
usually has to be replaced. Use
caution, and DO NOT damage the
armature.
7. Remove snap ring from the end head. Then press
the bearing (17) out of the end head (21).
8. After the motor has been separated into all its
major subassemblies, the components should be
cleaned and inspected for wear or damage.
BT Products
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Service Manual
1997-07-15
81
F-code
Section
C-code
PS
S1.1
Drive Motor
1700
Version no
T-code
000
395/396/397/398/399
2. Inspection and Troubleshooting

After the motor components have been thoroughly cleaned
and dried, they should be inspected for the following:
2.1. Drive End Head

1. Check bearing recess for any signs of wear.
2. Check mounting holes for any stripped or crossed
threads or broken studs.
2.2. Commutator End Head

2. Check brush holder insulation for cracks or any
signs of burning.
3. Check brush holders and springs for wear.
2.3. Bearings
1. Check bearings by turning them with your fingers.
Feel for binding or gritty effects and excessive
looseness or wobble. A good bearing should also
have a small amount of drag or stiffness caused by
the lubrication but should turn smoothly. If the
bearing turns very freely, it should be replaced.
Bearings should also be changed if worn out,
damaged, or removed from armature shaft.
Ball bearings that have been pulled off shafts,
pressed out of end heads, or side loaded in such a
way as to apply pressure on the balls and races
must be replaced.
82
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1997-07-15
F-code
Section
C-code
PS
S1.1
1700
Drive Motor
Version no
000
T-code
395/396/397/398/399
2.4. Brush and Commutator

The brushes and commutator should be inspected for even
wear and good commutation.
Good Commutation: A dark uniform coloring pattern at the
brush wearing surface.
Poor Commutation: The surface of the commutator
appearing rough, pitted, or scored, or showing signs of
burning or heavy arcing between bars. The color pattern will
be:
Streaky film with commutator wear.
Bar edge burning.
Uneven film.
Carbon dust bridging between bars.
Brushes should be inspected for uneven wear and signs of
overheating, i.e.:
Discolored brush shunts.
Discolored brush springs.
Refer to the Brush Chart at the end of this section.
2.5. Armature
1. Check for loose commutator bars. Loose
commutator bars will usually be indicated by
excessive wear or burning on one bar. The
commutator can be checked for loose bars by
lightly tapping all of the bars with the handle of a
plastic or wooden handled screwdriver. A
contrasting dull thud or vibration will indicate a
loose bar. Replace the armature if the commutator
bars are loose.
2. Check for grounded circuits using a test light. Most
commercial growlers incorporate a test light.
Check the armature for grounded circuits by
placing one test lead of the test lamp on the
commutator and the other test lead on the
armature shaft. If the test light lights, the armature
is grounded.
Grounded Circuit Test
3. Standard Winding Armatures are tested on a

growler using a steel strip or hacksaw blade to
locate any shorted windings.
BT Products
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1997-07-15
83
F-code
Section
C-code
PS
S1.1
Drive Motor
1700
Version no
T-code
000
395/396/397/398/399
Check for shorted windings by slowly rotating the

armature in the growler while holding the strip or
blade so that it passes over each armature core
slot. If a winding is shorted, the strip or blade will
vibrate and the blade will get hot.
Test for Shorted Windings on

Armature
NOTE! If the armature has been turned and

undercut prior to testing, check for and
remove any copper buildup or filings
between commutator bars and at the
commutator riser. This condition will cause
an armature to check shorted and usually
results from a dull undercutting tool.
4. Check commutator bars for any signs of burning. If
deep burned sections are evident, either in the
brush track or on the riser ends of the commutator
bars, an open or short circuit in the armature
windings is indicated.
2.6. Frame and Field Assembly

Check the condition of all insulation. If the insulation on the
field coils appears blackened or charred, the serviceability of
the coils is questionable. Burned or charred insulation is a
result of coil overheating due to overloading conditions,
grounded or shorted coil windings. Check the condition of all
other insulation such as brush rigging, under coil connections
and around terminal studs.

Armature
2.6.1. Testing
After thorough inspection, the Frame and Field Assembly
should be checked for grounded, open, or shorted circuits.
Grounded and open circuits can be checked using a test light.
Most commercial growlers incorporate a test light as shown in
opposite illustration.
Grounded Circuit
Touch one test lead to a clean bare metal spot on
the frame and check all terminals with the other
lead. If a grounded condition exists, the test light
will light.
84
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1997-07-15
F-code
Section
C-code
PS
S1.1
1700
Drive Motor
Version no
000
T-code
395/396/397/398/399
Open Circuit
Check between all connecting terminals with test
leads. If the bulb fails to light, an open circuit is
indicated.
Shorted Circuit
Shorted windings in series coils are very difficult to
detect. Generally, if the coil insulation is sound and
these are no signs of overheating, the coil can be
presumed good.
2.6.2. Frame and Field Service Notes

If the inside of the motor is exceptionally dirty and there is
evidence of a grounding condition caused by the dirt, the
inside of the motor can be given an additional coat of
insulating varnish. Red glyptol can be used if a better material
is not available, however, we recommend using a class H
Polyurethane air drying insulating varnish. This is readily
available under various brand names from electrical repair or
parts houses in aerosol type dispensers.
Before spraying field coils, make sure they are absolutely
clean and dry. Protect brush rigging, pole shoe faces, and
end head seats to keep varnish off.
BT Products
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Service Manual
1997-07-15
85
F-code
Section
C-code
PS
S1.1
Drive Motor
1700
Version no
T-code
000
395/396/397/398/399
2.7. Assembly
2.7.1. Field Coil Installation
Good solder connections are important due to the vibration
characteristics encountered by these motors which can cause
cold or poorly soldered connections to break.
1. Prior to installing the field coils, the connections
which require soldering should be buffed or wire
brushed clean to remove any oxidation. The
connections should then be tinned with a soldering
iron.
NOTE! We do not recommend using a soldering gun
or torch. A soldering gun cannot provide the
heat concentration required, and a soldering
torch can damage the insulation.
2. After field coil installation, connect the solder
joint, making sure the solder is flowing properly to
avoid a cold soldered joint.
Pole Shoe Screw Removal & Installation

(Field Coil Removal & Installation)
Continue assembly in the reverse of disassembly, paying
particular attention to the following points.
2.7.2. Bearing Installation
1. Whenever ball bearings are pressed into an end
head or onto a shaft, always press against the race
that is absorbing the pressure.
86
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F-code
Section
C-code
PS
S1.1
1700
Drive Motor
Version no
000
T-code
395/396/397/398/399
Press on the outer race when installing into end

heads.
Press against the inner race when installing onto a
shaft.
2. End heads having slip-fit bearings are normally
retained by a snap ring. Always install new snap
ring(s).
2.7.3. After Assembly
1. The motor should be connected as specified in
Troubleshooting, and tested to the specifications.
2. When testing motors, the voltmeter connections
must be made at the motor terminals.
3. When Changing Brushes

When changing brushes, the commutator must be serviced
as follows:
Resurface the commutator by taking only light cuts
each time, 0.005 in. (0.12 mm).
If reslotting/undercutting is necessary, the final
operation is to lightly sand the commutator with a
fine sandpaper to remove any burrs left from the
undercutting operation.
BT Products
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Service Manual
1997-07-15
87
F-code
Section
C-code
PS
S1.1
Drive Motor
1700
Version no
T-code
000
395/396/397/398/399
88
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Service Manual
1997-07-15
F-code
PS
Version no
001
Section
C-code
S3.0
3540
Caster Brake Assembly
T-code
396/397/398

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
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15
17
Service Manual
1997-07-15
89
F-code
Section
C-code
PS
S3.0
3540
Version no
T-code
001
396/397/398
POS.
NO
DESCRIPTION
POS.
NO
DESCRIPTION
POS.
NO
DESCRIPTION
Lock, nut
10
Nut
19
Washer
Lockwasher
11
Screw, cap
20
Screw, cap
Ring, Nilos
12
Nut
21
Shaft
Bearing
13
Pivot, caster
22
Bracket
Screw, cap
14
Bearing, thrust
23
Bearing, flanged
Nut
15
Caster assembly
24
Pin, roll
Guide, spring
16
Block
25
Pivot
Spring
17
Fitting, grease
26
Screw, cap
Screw, set
18
Bushing
1. Removal
NOTE! For models with brake on caster wheels.
1.1. Caster Brake Adjustment

in place.
4. Looking into the operator's compartment, remove
the four screws from the right-hand panel covering
the logics card. Take panel out and set to the side.
CAUTION
90
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Service Manual
Pinch point. Keep fingers clear of floor

foot brake pedal.
1997-07-15
F-code
PS
Section
C-code
S3.0
3540
Version no
001
T-code
396/397/398

floor board.
5. Push down on the left foot brake pedal with one

pivoting the plate toward the motor compartment.
Release the left foot brake pedal as the floor board
pivots up.
7. Total travel of the left foot brake pedal from up to
down is 3.5 in. The pedal setpoint is 50 percent
down or 1.8 in. This can be felt by a change in
force at the pedal by the spring tension.
Adjuster nuts
8. 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.
Rod
9. When the cable can no longer be adjusted for

caster braking, the brake must be adjusted at the
caster wheels.
Spring
10. Run the cable adjustment back to the original

position. Full threads toward the caster assembly.
11. Remove only one caster wheel. Refer to caster
wheel removal, section 3560.
12. Remove brake assembly for the caster wheel.
13. 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.
Adjusting
nuts
14. Lock the double nuts together.

15 Reassemble and test truck for braking.
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1997-07-15
91
F-code
Section
C-code
PS
S3.0
3540
Version no
T-code
001
396/397/398
92
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Service Manual
1997-07-15
F-code
PS
Section
C-code
S3.1
3370
Electromagnetic Brake
Version no
T-code
000
395/396/397/398/399
13
02
01
08
09
07
Air Gap
06
05
03
04
11
10
12
POS.
NO
DESCRIPTION
POS.
NO
POS.
NO
DESCRIPTION
01
Brake assembly
06
Plate, mounting
11
Screw, socket head
02
Coil
07
Spacer
12
Screw
03
Armature
08
Spring
13
Nut, jam
04
Hub
09
Screw, socket head
05
Plate, friction
10
Washer
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DESCRIPTION
1997-07-15
93
F-code
Section
C-code
PS
S3.1
3370
Version no
T-code
000
395/396/397/398/399
WARNING Magnetic coil and armature are under

pressure. DO NOT remove retaining
screws without manual release screws in
place.
1. Installation
1. Park truck on level surface and block securely.
2. Disconnect the battery.
3. Fully tighten two manual release screws (11).
WARNING Two manual release screws must be fully
tightened before removing three brake
retaining screws.
4. Remove the three screws (09) which hold brake
parts and set aside, ensuring all parts are clean
and dry. Avoid moving adjustable spacers (07) if
possible, thus maintaining correct axial air gap
when reassembled.
5. Secure the mounting plate (06) to the electric drive
motor taking care to make sure the head of the
screws (12) are recessed and do not protrude
above the counter bore.
6. Secure the brake hub (04) to the motor shaft. It
should not interfere with the mounting plate (06).
7. Slide friction plate (05) onto the hub spline and up
to the mounting plate (06).
8. Hold the main body of the brake up to the mounting
plate (06) and line up the screws (09).
Carefully secure in place.
9. Once the brake is fully secured in position, remove
and set aside the manual release screws (11).
10. Check the air gap and adjust if necessary (See
adjustments instructions).
11. After making adjustments, check that brake will
release when power is applied.
94
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PS
Section
C-code
S3.1
3370
Version no
000
T-code
395/396/397/398/399
2. Adjustments
1. Adjustment is carried out by using a 14 mm open
end wrench and a 6 mm socket key.
2. Loosen three retaining screws (09) to release the
threaded spacers (07).
NOTE! Do Not remove retaining screws.
3. Using the 14 mm open end wrench, the threaded
spacers (07) can now be threaded in or out of the
magnet which changes the relative position of the
armature and end plate, thus changing the air gap.
4. The air gap should be set to 0.008 in. to 0.014 in.
and be within 0.003 in. throughout entire
circumference.
3. Coil Check On Brake
BT Products
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Service Manual
24V coil at 70F (20C) should be 9 ohms
36V coil at 70F (20C) should be 22 ohms
1997-07-15
95
F-code
Section
C-code
PS
S3.1
3370
Version no
T-code
000
395/396/397/398/399
4. Electromagnetic Brake, Armature

and Magnetic Coil.
4.1. Removal
WARNING Magnetic coil and armature are under
pressure. Do not remove retaining screws
without manual release screws in place.
1. Park truck on level surface and block securely.
2. Disconnect the battery.
3. Fully tighten two manual release screws (11).
4. Remove three brake retaining screws (09).
5. Electrically disconnect brake assembly and lift
upwards to remove.
4.2. Installation
1. Make certain brake friction plate (05) and armature
(03) are clean and free of oil.
2. Set armature (03) and magnetic coil (02) on base
plate (06).
3. Align and tighten three brake retaining screws (09).
4. Remove two manual release screws (11) and
electrically connect brake.
5. The air gap should be set to 0.008 in. to 0.014 in.
and be within 0.003 in. throughout entire
circumference.
6. Test operation of brake by connecting battery, turn
key switch ON, and depress brake foot pedal. This
will allow truck to operate.
96
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1997-07-15
F-code
Section
C-code
PS
S3.2
3530
Drive Wheel
Version no
000
T-code
395/396/397/398/399
Drive Wheel
3
4
POS.
NO
DESCRIPTION
POS.
NO
DESCRIPTION
Tire
Nut
Wheel, drive
Washer, spherical
1. Removal
in place.
4. Remove seven wheel retaining nuts (3) and
spherical washers (4). Pull tire (1) and drive wheel
(2) from transmission drive axle hub.
5. Press tire (1) from drive wheel (2).
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1997-07-15
97
F-code
Section
C-code
PS
S3.2
Drive Wheel
3530
Version no
T-code
000
395/396/397/398/399
2. Installation
1. Press drive tire on wheel hub. This is usually done
while pressing off old tire. Press hub to center of
tire (1).
2. Install drive tire assembly on transmission axle
hub. The seven drive tire retaining nuts should be
torqued to 95 ft-lb (130 Nm).
98
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1997-07-15
F-code
PS
Version no
001
Section
C-code
S3.3
3540
Support / Swivel Wheel
T-code
395/396/397/398/399

1
3
6
4
7
8
9
17
10
11
12
19
20
18
13
14
17
15
16
BT Products
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Service Manual
1998-03-05
99
F-code
Section
C-code
PS
S3.3
3540
Version no
T-code
001
395/396/397/398/399
POS.
NO
DESCRIPTION
POS.
NO
DESCRIPTION
POS.
NO
DESCRIPTION
Lock, nut
Spring
15
Caster assembly
Lockwasher
Screw, set
16
Block
Ring, Nilos
10
Nut
17
Fitting, grease
Bearing
11
Screw, cap
18
Bushing
Screw, cap
12
Nut
19
Washer
Nut
13
Pivot, caster
20
Screw, cap
Guide, spring
14
Bearing, thrust
1. Caster Pivot
1.1. Removal
in place.
wheels are approximately 1 in. [25.4 mm] off the
ground. Block the truck in this position.
4. Looking into the operator's compartment remove
the four screws from the right-hand panel covering
the logics card. Take panel out and set to the side.
CAUTION
Pinch point. Keep fingers clear of floor

foot brake pedal.

floor board.
100
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1998-03-05
F-code
PS
Section
C-code
S3.3
3540
Version no
001
T-code
395/396/397/398/399

pivots up.
6. Remove floor plate and disconnect wires from right
foot switch setting floor plate to one side.
WARNING Secure transmission before removing
mounting bolts (20). Serious injury
could occur.
7. Turn and secure transmission so that you can
access mounting bolts (20).
NOTE! For models with brake on caster wheels,
the cable linkage must be disconnected
before removal of foot pedal.
12. Remove four bolts securing brake pedal assembly.
13. Remove foot pedal.
14. Bend lockwasher (2) tab down and remove lock nut
(1).
15. Remove Nilos ring (3) and bearing (4).
16. Remove caster assembly.
17. Remove mounting bolts (20).
18. Remove caster pivot (13). Inspect and replace
bushings and bearings as needed.
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1998-03-05
101
F-code
Section
C-code
PS
S3.3
3540
Version no
T-code
001
395/396/397/398/399
1.2. Installation
1. Install pivot block
compartment first.
(16)
closest
to
battery
2. Install rear pivot block (16) on caster pivot (13).

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. Torque locknut (1).
6. Bend tab on lock washer (2) up to secure lock nut
(1).
7. Install foot pedal.
the cable linkage must be installed.
8. Set spring tension and stops. Refer to section
3540.
9. Install shielding and test truck operation.
102
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PS
Version no
001
Section
C-code
S3.3
3540
T-code
395/396/397/398/399
2. Thrust Bearing
2.1. Removal
in place.
4. Look into the operator's compartment, remove four
screws from the right-hand panel covering the
CAUTION Pinch point. Keep fingers clear of floor
board cutout while holding down left foot
brake pedal.
CAUTION Disconnect wire connections to right foot
pedal switch prior to removal of floor
board.
pivots up.
remove brake arm.
7. Bend tab down on lock washer (2).
8. Remove lock nut (1), lock washer (2) and Nilos ring
(3).
9. Inspect and replace bearings as needed.
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103
F-code
Section
C-code
PS
S3.3
3540
Version no
T-code
001
395/396/397/398/399
2.2. Installation
1. The truck must be properly blocked at this time.
2. Install race (4) in caster pivot and thrust bearing
(14) on caster assembly.
3. Install caster assembly in caster pivot (13).
4. Install bearing (4), Nilos ring (3), lock washer (2)
and lock nut (1).
5. Tighten lock nut (1) while turning caster wheel
assembly until tight, then back off 1/4 in. [6.35 mm]
turn.
6. Bend lock washer tab (2) up to secure lock nut (1).
install brake arm.
7. Test caster operation.
104
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PS
Version no
001
Section
C-code
S3.3
3540
T-code
395/396/397/398/399
3. Caster Springs
3.1. Removal
in place.
New Free Length
is 7 in. [178 mm]
4. Look into the operator's compartment, remove four

screws from the right-hand panel covering the
brake pedal.
board.
Worn Free Length

is 6.5 in. [165 mm]
or Less.

pivots up.
7. Remove right-hand side electronics panel cover.
8. Loosen jam nuts (6) and release all spring tension
with adjusting bolts (5). Remove bolts (5).
9. Remove jam nut (10) and loosen stop bolt (9) to
allow caster pivot to rest on frame stop.
10. Springs must be removed from the side.
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1998-03-05
105
F-code
Section
C-code
PS
S3.3
3540
Version no
T-code
001
395/396/397/398/399
3.2. Installation
1. Install adjusting bolts (5).
2. Lower truck to the floor and remove hoist.
5-3/8 in.
3. Tighten adjusting bolts (5) until you have 5-3/8 in.

[136.5 mm] from top of cap and bottom of spring.
4. Adjust stops bolts (11) and (9) to 1/8 in. [3 mm]
clearance on each stop.
brake pedal.
board.
5. Push down on the brake pedal with one hand and
install the floor board by pushing down and pivoting
the plate toward the motor compartment. Release
the brake pedal as the floor board pivots down.
6. Test truck operation.
106
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PS
Section
C-code
S3.3
3540
Version no
001
T-code
395/396/397/398/399
4. Caster Spring
4.1. Adjustments
1. Park truck on level surface.
5-3/8 in.
2. Disconnect battery and securely block truck.

3. Remove right-hand side electronics panel cover.
4. Measure from top of springs to the caster pivot
plate. The measurement should be 5-3/8 in. [136.5
mm].
5. To change adjustment, loosen jam nuts (6) and
tighten or loosen bolts (5).
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1998-03-05
107
F-code
Section
C-code
PS
S3.3
3540
Version no
T-code
001
395/396/397/398/399
5. Caster Stops
5-3/8 in.
5.1. Adjustment
1. Park truck on level surface and disconnect battery.
2. Remove four cap screws securing right side A5
logic card panel cover.
3. Remove floor plate, and disconnect wiring harness
to right side foot pedal switch.
4. Spring compression from caster pivot plate to top
of spring spacer must measure 5-3/8 in. [136.5
mm]. If not adjust spring bolts accordingly.
NOTE! Spring compression measurement must be
taken when stop bolts are not touching stop
blocks.
Stop Bolt
5. Factory recommended dimension between upper

stop bolt (11) and upper stop block is 1/4 in. [6.35
mm], however it is possible to increase this
dimension to 3/8 in. [9.5 mm] on some models. See
chart to determine maximum dimension between
upper stop bolt (11) and upper stop block for your
particular truck.
CAUTION
Verify battery compartment size, battery

weight, and mast height. Failure to do so
could result in serious injury.
Mast Height
Battery
Compartment
14 in. [356 mm]
Minimum 1600 lb battery
16 in. [406 mm]
21 in. [533 mm]
21 in. [533 mm]
108
Return
192
210
240
270
300
330
3/8 in.
3/8 in.
3/8 in.
3/8 in.
3/8 in.
3/8 in.
3/8 in.
3/8 in.
1/4 in.
1/4 in.
3/8 in.
3/8 in.
3/8 in.
3/8 in.
1/4 in.
1/4 in.
Service Manual
360
402
1/4 in.
1/4 in.
1998-03-05
F-code
PS
Version no
001
Section
C-code
S3.3
3540
T-code
395/396/397/398/399
6. Dimension between bottom stop bolt (9) and

bottom stop block must be 1/8 in. [3 mm].
7. Install floor plate and connect wiring harness to
right side foot pedal switch.
8. Install A5 logic card panel cover.
9. Connect battery and test truck operation.
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1998-03-05
109
F-code
Section
C-code
PS
S3.3
3540
Version no
T-code
001
395/396/397/398/399
110
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Service Manual
1998-03-05
F-code
Section
PS
C-code
S3.4
3550
Tandem Load Wheels
Version no
000
T-code
395/396/397/398/399
Tandem Load Wheels
POS.
NO
BT Products
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DESCRIPTION
POS.
NO
DESCRIPTION
Axle
Washer, 16 gauge
Toe box
Bearing
Plate, rocker
Wheel, load
Ring, retainer
10
Nut
Fitting, grease
11
Bolt, shoulder
Washer, 10 gauge
Service Manual
1997-07-15
111
F-code
Section
PS
S3.4
Tandem Load Wheels
C-code
3550
Version no
T-code
000
395/396/397/398/399
1. Removal
in place.
3. Hoist machine so load wheels are approximately 2
in. off the floor, and securely block.
4. Remove retainer ring (4) from axles.
5. Remove axle (1) and load wheel assembly from
toe box (2).
6. Inspect bearings (8).
7. Install new load wheel (9) and bearings (8) as
needed.
WARNING Install bearing shield and 10 gauge spacer

properly.
8. Install load wheel assembly in toe box (2). Install
axle (1) and rocker plate (3).
9. Install retainer rings (4) to axle (1).
112
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Service Manual
1997-07-15
F-code
Section
PS
C-code
S3.5
3551
Single Load Wheels
Version no
000
T-code
395/396/397/398/399
Single Load Wheels
11
POS.
NO
BT Products
Return
DESCRIPTION
POS.
NO
DESCRIPTION
Toe box, right
Toe box, left
washer, 10 gauge
Fitting, grease
Washer, 18 gauge
Nut
Bearing
10
Bolt, shoulder
Tire, load
11
Nut
Wheel
Service Manual
1997-07-15
113
F-code
Section
PS
S3.5
Single Load Wheels
C-code
3551
Version no
T-code
000
395/396/397/398/399
1. Removal
in place.
2. Hoist machine so load wheels are approximately 2
in. off the floor, and securely block.
3. Remove toe box retaining nuts (9) and bolts (10).
4. Remove axle nut (11).
5. Remove right toe box (1) and load wheel (6).
6. Press load tire (5) from wheel (6).
WARNING
Install bearing shield and 10 gauge

spacer properly.
2. Installation
1. Inspect and replace bearing (4) as needed.
2. Press load tire (5) on wheel (6).
3. Install load tire assembly on toe box axle.
4. Install right toe box (1).
5. Install axle nut (11).
6. Install toe box assembly on support arm. Apply
loctite #242 to nuts (11) and bolts (10).
7. Test operation of load wheel and truck.
114
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Service Manual
1997-07-15
F-code
Section
PS
S3.6
3560
Caster Wheels
Version no
C-code
T-code
000
395/398
Caster Wheels
1
4
1
5
6
6
5
7
8
10
9
POS.
NO
BT Products
Return
DESCRIPTION
POS.
NO
DESCRIPTION
Wheel, caster
Bearing
Bracket, caster
Lockwasher
Screw, set
Locknut
Axle, caster
Fitting, grease
Ring, Nilos
10
Cap, wheel
Service Manual
1997-07-15
115
F-code
Section
C-code
PS
S3.6
Caster Wheels
3560
Version no
T-code
000
395/398
1. Removal
in place.
4. Remove wheel cap (10)
5. Bend lockwasher (7) tab down and remove axle
nut (8).
6. Remove caster wheel assembly
7. Inspect and replace race and bearing (6) as
needed
2. Installation
1. Install Nilos ring (5) on axle.
2. Install caster wheel assembly.
3. Install Nilos ring (5), lockwasher (7) and axle nut
(8).
4. Tighten axle nut (8) while turning caster wheel until
wheel becomes tight.
5. Back off axle nut (8) until caster wheel turns freely.
Axle nut (8) and lockwasher (7) tab are aligned.
6. Bend lockwasher (7) tab to secure axle nut (8).
7. Grease as needed.
8. Replace wheel cap (10).
116
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Service Manual
1997-07-15
F-code
Section
PS
S3.6
3560
Caster Wheels
Version no
000
C-code
T-code
395/398
3. Caster Axle
3.1. Removal
1. Remove caster wheels.
2. Remove two set screws (3). One set screw locks
the other in place.
3. Tap axle (4) out of caster bracket (2).
3.2. Installation
1. Install caster axle (4) in caster bracket (2).
2. Align setscrew holes.
3. Install set screws (3).
4. Install caster wheels.
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Service Manual
1997-07-15
117
F-code
Section
C-code
PS
S3.6
Caster Wheels
3560
Version no
T-code
000
395/398
118
Return
Service Manual
1997-07-15
F-code
Section
PS
S3.7
3560
Caster Wheels
Version no
C-code
T-code
000
396/397/399
Caster Wheels
18
17
15
11
16
13
12
15
14
3
4
11
12
13
1
6
6
10
8
9
BT Products
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Service Manual
1997-07-15
119
F-code
Section
C-code
PS
S3.7
Caster Wheels
3560
Version no
T-code
000
396/397/399
POS.
NO
DESCRIPTION
POS.
NO
DESCRIPTION
POS.
NO
DESCRIPTION
Wheel, caster
Lockwasher
13
Screw, cap
Bracket, caster
Locknut
14
Nut
Screw, set
Fitting, grease
15
Washer
Axle, caster
10
Cap, wheel
16
Pivot, brake
Ring, Nilos
11
Ring, E
17
Spring
Bearing
12
Brake assembly
18
Plunger, brake
1. Removal
in place.
4. Remove wheel cap (10)
5. Bend lockwasher (7) tab down and remove axle
nut (8).
6. Remove caster wheel assembly
7. Inspect and replace race and bearing (6) as
needed
8. Remove E ring (11) and remove cap screws (13) if
brake assembly is to be replaced otherwise
replace brake shoes.
9. Remove nuts (14), washer (15), and slide brake
plunger (18) up to remove brake pivot (16) and
other washer (15).
10. Remove brake plunger (18) and spring (17).
120
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Service Manual
1997-07-15
F-code
Section
PS
S3.7
3560
Caster Wheels
Version no
000
C-code
T-code
396/397/399
2. Installation
1. Slide spring (17) in caster bracket (2) and install
brake plunger (18).
2. Install washer (15) on brake plunger (18) and slide
brake pivot (16) on brake plunger (18) against
washer (15).
3. Install second washer (15) on brake plunger
against brake pivot (16). Secure assembly together
with nut (14) and install a second nut (14) to lock in
place.
4. Install brake assembly (12) with cap screws (13).
5. Move brake pivot (16) around to install E ring (11)
on both brake assembles (12).
6. Install Nilos ring (5) on axle.
7. Install caster wheel assembly.
8. Install Nilos ring (5), lockwasher (7) and axle nut
(8).
9. Tighten axle nut (8) while turning caster wheel until
wheel becomes tight.
10. Back off axle nut (8) until caster wheel turns freely.
Axle nut (8) and lockwasher (7) tab are aligned.
11. Bend lockwasher (7) tab to secure axle nut (8).
12. Grease as needed.
13. Replace wheel cap (10).
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1997-07-15
121
F-code
Section
C-code
PS
S3.7
Caster Wheels
3560
Version no
T-code
000
396/397/399
3. Caster Axle
3.1. Removal
1. Remove caster wheels.
2. Remove two set screws (3). One set screw locks
the other in place.
3. Tap axle (4) out of caster bracket (2).
3.2. Installation
1. Install caster axle (4) in caster bracket (2).
2. Align setscrew holes.
3. Install set screws (3).
4. Install caster wheels.
122
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Service Manual
1997-07-15
F-code
Section
C-code
PS
S4.0
4110
Steering Arm / Wheel / Lever
Version no
000
T-code
395/396/397/398/399
POS.
NO
POS.
NO
DESCRIPTION
POS.
NO
DESCRIPTION
11
Panel, lower pod
21
Ring, retainer
31
Console
12
Panel, upper pod
22
O ring
32
Arm
13
Screw
23
Spacer / bearing
33
Lever, adjusting
14
Washer, spring
24
Housing, bearing
46
O ring
15
Nut
25
Ring
47
Screw, set
16
Cap, spinner
26
Screw
48
Coupler
17
Nut
27
Motor, tach
49
Washer
18
Washer
28
Bolt, carriage
53
Screw / wave washer
19
Spinner
29
Washer
54
Grip, hand
20
Steering wheel
30
Lever assembly
55
Cushion
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DESCRIPTION
Service Manual
1997-07-15
123
F-code
Section
C-code
PS
S4.0
4110
Version no
T-code
000
395/396/397/398/399
1. Control Pod
1.1. Removal
2. Disconnect battery and block truck.
3. Remove adjusting lever (33) and washer (49).
4. Remove console cover.
5. Lift console (31) approximately 6 in. to access
controls pod's wiring harness connectors.
6. Disconnect harness and remove control pod.
1.2. Installation
1. Route control pod wiring harness through console
(31).
2. Connect control pod harness to trucks main wiring
harness.
3. Install console (31) cover.
4. Install adjusting lever (33) and washer (49).
124
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Service Manual
1997-07-15
F-code
Section
C-code
PS
S4.0
4110
Version no
000
T-code
395/396/397/398/399
2. Steering Wheel
2.1. Removal
3. Remove control pod. Refer to Control Pod 1.1
Removal.
4. Remove sixteen screws (53) on lower control pod
panel (11) and remove lower panel (11).
5. Remove four screws (26).
6. Remove steering wheel (20). Inspect and replace
bearing as needed.
2.2. Installation
1. Install steering wheel (20) in upper control pod
panel (12).
2. Align holes on steering wheel mount and install
four screws (26). Check steering wheel for ease of
turning.
3. Install lower control pod panel (11) and install
sixteen screws (53).
4. Install control pod. Refer to Control Pod 1.2
Installation.
5. Test operation of steering wheel (20) and truck.
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1997-07-15
125
F-code
Section
C-code
PS
S4.0
4110
Version no
T-code
000
395/396/397/398/399
3. Steering Tach
3.1. Removal
1. Park truck on level surface
3. Remove control pod. Refer to Control Pod 1.1
Removal.
4. Remove sixteen screws (53) and remove lower
control pod panel (11).
5. Remove steering wheel (20). Refer to Control Pod
1.2 Installation.
6. Loose setscrew (47) and remove coupler (48).
7. Remove four screws (26) holding tach motor (27)
and electrically disconnect steering tach motor (27)
wires from wiring harness.
3.2. Installation
1. Connect steering tach motor (27) wires from wiring
harness.
2. Install steering tach motor (27) and secure with
four screws (26).
3. Install coupler (48) and tighten set screw (47).
4. Install steering wheel (20). Refer to Steering
Wheel 2.2 Installation.
5. Install lower control pod panel (11) and tighten
sixteen screws (53).
6. Install control pod. Refer to Control Pod 1.2
Installation.
126
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Service Manual
1997-07-15
F-code
Section
PS
S4.1
4180
Steering Bearing
Version no
C-code
T-code
000
395/396/397/398/399
Steering Bearing
12
11
1
POS.
NO
BT Products
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Service Manual
DESCRIPTION
Bearing
11
Screw
12
Screw
1997-07-15
127
F-code
Section
C-code
PS
S4.1
Steering Bearing
4180
Version no
T-code
000
395/396/397/398/399
1. Removal
NOTE! Transmission and drive motor must be
removed from truck to access bearing.

in place.
4. Remove door and left-side panel to access motor
compartment. Refer to Section S0.1.
5. Disconnect all electrical connections on drive
motor and brake assembly.
6. Remove drive motor.
7. Secure transmission and remove six mounting
bolts.
8. Remove mounting ring.
9. Remove fivteen bolt (11) retaining 360 degree
bearing (1).
2. Installation
1. Install new steer bearing (1).
2. Install
transmission
mounting
plate and
transmission in truck and torque six mounting
bolts.
3. Install drive motor.
4 Connect all electrical connections.
5. Refill transmission as needed.
6. Test steering and truck operation.
128
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Service Manual
1997-07-15
F-code
PS
Version no
001
Section
C-code
S5.0
5000
Electrical Functions
T-code
395/396/397/398/399
1. Operating Description
The main electronic card (A5) contains a microprocessor.
This microprocessor monitors the state of switches, sensors,
joysticks (mast and fork functions), and other input devices.
A5 The microprocessor makes decisions based on this
information. Output devices that the microprocessor controls
are solenoids, contactors, drives, and optional equipment to
customize the truck. The microprocessors programming
parameters can be customized for each application. Two of
the parameters that can be customized are the clock and
calendar. The microprocessor has an internal battery with a
ten year life span that can store the customized parameters in
memory when the trucks battery is disconnected.
The microprocessor performs a diagnostic test at start up and
during truck operation. The diagnostic test assists in repair by
identifying problems and minimizing truck downtime. For any
identified problems, the operator is alerted by a visible tool
bar icon displaying error code numbers and an audible alarm.
A history log records error codes by the time and day, using
the clock and calender information stored in the
microprocessor.
The controller card is connected to the truck circuitry by eight
connectors. To remove the controller cards eight connections
depress the connectors latch and disconnect or simply
pushing the connectors back together.
The eight connectors are grouped functionally from the top
down: digital inputs, communications, analog inputs, analog
outputs, digital outputs and power output. The controller
cards eight connectors and light emitting diodes (LEDs) are
clearly identified by numbers. When the controller card is
connected correctly to the trucks battery, the digital input
LEDs light green and battery voltage is present at input pins.
The digital output LEDs light red and battery voltage is
present at output pins. The communications and analog
voltage inputs and outputs do not have LEDs.
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Service Manual
1997-07-24
129
F-code
Section
C-code
PS
S5.0
5000
Version no
T-code
001
395/396/397/398/399
K10
K10
A1
F01
A2
B+
B7
2
A1
K13
M1
K13
A5
44
S21
101
34
902
40
K11
K11
8
M
1
805
64
Y01
802
51
K11
803
52
K13
22
1
F50
S48
43
808
501
111
S23
49
102
36V only
21
S21
24
S17
22
22
809
40
Legend
Battery negative
Battery positive
LED OFF (Not lit)
LED input (lit)
LED output (lit)
130
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Service Manual
1997-07-24
F-code
PS
Version no
001
Section
C-code
S5.0
5000
T-code
395/396/397/398/399
2. Start Up
Electricity from trucks battery flows to drive motor transistor
regulator (A1, terminal B-), and also to main electronic card
(A5, terminal 902) through wire #40.
By closing the emergency disconnect switch (S21) and key
switch (S17), electricity can flow through control circuit fuse
(F50) and to main electronic card (A5, terminal 809).
Electricity is also supplied to main electronic card (A5,
terminal 808). Trucks with a 36-volt electrical system have a
jumper from terminal 808 to terminal 501 on main electronic
card (A5), lighting the LED.
Electricity flows through wire #22 to drive motor transistor
regulator (A1, terminal 1) starting the internal safety test.
Output from drive motor transistor regulator (A1, terminal 7) is
sent through wire #34 to main electronic card (A5, terminal
101), lighting the LED.
Electricity flows through wire #34 to the emergency
disconnect switch (S21) and out through wire #44 to main
contactor coil (K10). This closes contactor tips.
Closing main contactor tips allows electricity to flow through
drive motor fuse (F01) to drive motor transistor regulator (A1,
terminal B+). Electricity is also available at drive motor
transistor regulator (A1, terminal A).
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1997-07-24
131
F-code
Section
C-code
PS
S5.0
5000
Version no
T-code
001
395/396/397/398/399
K10
K10
A1
A5
44
F01
3
A2
B+
B7
2
A1
K13
M1
S21
101
34
902
K11
K13
K11
8
M
1
805
29
22
R01
50
30
F50
64
Y01
505 +3.7V
51
K11
510 0V 802
803
808
52
K13
504 +7.4V
36V only
S48
43
21
S23
S21
40
24
S17
R02
Legend
111
49
22
22
501
102
809
40
511
Battery negative
Battery positive
LED OFF (Not lit)
LED input (lit)
LED output (lit)
132
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Service Manual
1997-07-24
F-code
PS
Version no
001
Section
C-code
S5.0
5000
T-code
395/396/397/398/399
3. Direction Selection
4
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.

The default travel direction is always forks first.
Moving direction/speed control potentiometer (R01) to the left
approximately 3/16 in. will select the next travel direction.
will decrease voltage from 3.7 volts to approximately 3 volts.
The lower voltage sends current from main electronic card
(A5, terminal 802) to direction contactor (K11), opening the
normally closed tips and closing the normally open tips,
lighting the main electronic card (A5) 802 LED.
An electrical path is available for current to flow from drive
motor field (M1) to drive motor transistor regulator (A1,
terminal M)
The brake transducer (R02) is activated by depressing the
pedal.
NOTE! The brake transducer is a potentiometer with
variable resistants.
The decrease in voltage from the transducer (R02) to main

electronic card (A5, terminal 511), and input from brake
switch (S48) to main electronic card (A5, terminal 111) will
send current from main electronic card (A5, terminal 805) to
parking brake coil, lighting the main electronic card (A5) 805
LED.
NOTE! The direction contactors are shown closing with
direction selection for training purposes. They
actually fully close when direction/speed control
potentiometer (R01) is moved to the right for
acceleration.
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Service Manual
1997-07-24
133
F-code
Section
C-code
PS
S5.0
5000
Version no
T-code
001
395/396/397/398/399
K10
K10
A1
A5
44
F01
3
A2
B+
B7
2
A1
K13
M1
K13
K11
6
10
S21
101
34
902
35
40
609-
36
610 +0-5V
K11
8
M
1
805
64
Y01
802
51
K11
803
52
K13
22
1
F50
808
501
36V only
21
S21
24
S17
22
29
R01
50
30
809
504 +7.4V
40
505 +3.7V
510 0V
Legend
Battery negative
Battery positive
LED OFF (Not lit)
LED input (lit)
LED output (lit)
134
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Service Manual
1997-07-24
F-code
PS
Version no
001
Section
C-code
S5.0
5000
T-code
395/396/397/398/399
4. Reverse Direction Selection

CAUTION
Avoid crushing feet by keeping feet

clear of the drive wheel while steering.
Moving direction/speed control potentiometer (R01) again to

the left approximately 3/16 in. will select the next travel
direction.
will decreases voltage from 3.7 volts to approximately 3 volts.
The lower voltage to main electronic card (A5) sends current
from terminal 803 to direction contactor (K13), closing the
normally open contact tips and opening the normally closed
tips, lighting the main electronic card (A5) 803 LED.
An electrical path is available for current to flow from drive
motor field (M1) to drive motor transistor regulator (A1,
terminal M).
NOTE! The direction contactors are shown closing with
direction selection for training purposes. They
actually fully close when direction/speed control
potentiometer (R01) is moved to the right for
acceleration.
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1997-07-24
135
F-code
Section
C-code
PS
S5.0
5000
Version no
T-code
001
395/396/397/398/399
K10
K10
A1
3
A2
B+
B-
S21
2
K13
M1
K11
K13
101
34
A1
A5
44
F01
902
35
609-
36
10
40
610 +0-5V
K11
8
M
1
805
64
Y01
802
51
K11
803
52
K13
22
1
F50
808
36V only
501
21
811810+
S21
24
S17
22
29
50
R01
S64
30
56
809
504 +7.4V
40
505 +3.7V
510 0V
201
Legend
Battery negative
Battery positive
LED OFF (Not lit)
LED input (lit)
LED output (lit)
136
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Service Manual
1997-07-24
F-code
PS
Version no
001
Section
C-code
S5.0
5000
T-code
395/396/397/398/399
5. Forward Drive
This diagram shows forward travel and the relationship
between speed reference voltage and direction/speed control
potentiometers (R01) voltage.
The forward travel speed reference voltage is 0 - 5 volts and
direction/speed control potentiometers (R01) voltage is 3.7 6.5 volts.
When moving direction/speed control potentiometer (R01) to
the right, voltage increases to a maximum of 2.5 volts.
For every 0.5 volt increase of the direction/speed control
potentiometer (R01), the speed reference will increase 1 volt.
The speed reference voltage is the main electronic card (A5,
terminal 610) to drive motor transistor regulator (A1, terminal
10) through wire #36.
Wire #35 is connected to drive motor transistor regulator (A1,
terminal 6) and main electronic card (A5, terminal 609) is the
negative for the speed reference voltage.
The speed sensor (S64) is sending pulses to the main
electronic card (A5, terminal 201) to determine drive motor
speed.
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1997-07-24
137
F-code
Section
PS
S5.0
C-code
5000
Version no
T-code
001
395/396/397/398/399
K10
K10
A1
A5
44
F01
3
A2
B+
B-
S21
7
2
A1
K13
M1
K13
10
K11
902
35
K11
101
34
40
609-
36
610 +0-5V
38
103
M
1
805
64
Y01
802
51
K11
803
52
K13
22
32
31 S125
F50
105
36V only
32
21
31
S21
24
S17
22
29
29
50
R01
30
56
S64
Legend
30
808
501
811810+
809
504 +7.35V
40
505+3.7V
510 0V
201
29
Battery negative
Battery positive
LED OFF (Not lit)
65
30
R02
511
LED input (lit)

LED output (lit)
138
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Service Manual
1997-07-24
F-code
PS
Version no
001
Section
C-code
S5.0
5000
T-code
395/396/397/398/399
6. Plug Braking
CAUTION Releasing parking brake while on incline
will couse truck to move.
A momentary movement left of the directional/speed control
potentiometer (R01) causes the main electronic card (A5) to
de-energize the forward contactor (K11) and energize the
reverse contactor (K13), lighting the main electronic card (A5)
805 LED.
The drive motor transistor regulator (A1) reads the signal
from the drive motor armature EMF generator, located on top
of drive motor.
Electricity from the drive motor transistor regulator (A1,
terminal 8) flows to the main electronic card (A5, terminal
103) through wire #38 indicating plug braking, lighting the
main electronic card (A5) 103 LED.
Plug braking may be regulated with the direction/speed
control potentiometer (R01). Moving to the right will increase
plugging.
There is a second plug brake available on this truck. This
second plug brake uses a drive motor direction sensor
(S125), drive motor speed sensor (S64), and a brake
transducer (R02).
To use the second plug brake, raise the brake pedal
approximately 1 in. This causes a decrease in voltage at
brake transducer (R02) to main electronic card (A5, terminal
511) through wire #65.
The drive motor direction sensor (S125) tells the main
electronic card (A5, terminal 105) which direction the drive
motor is rotating. This information is then processed and the
opposite directional contactor closed.
Located on top of the drive motor, the drive motor transistor
regulator (A1, terminal A) reads the signal from the drive
motor armature EMF generator.
Electricity from the drive motor transistor regulator (A1,
terminal 8) flows to main electronic card (A5, terminal 103)
through wire #38 indicating plug braking, lighting the main
electronic card (A5) 103 LED.
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1997-07-24
139
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S5.0
C-code
5000
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001
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The drive motor speed sensor (S64) tells the main electronic
card (A5, terminal 201) how fast the drive motor is rotating.
During this phase, the main electronic card (A5) takes over all
speed control, ignoring any information from the directional/
speed control potentiometer (R01).
To regain control of direction/speed control potentiometer
(R01), the brake pedal must be fully depressed again.
140
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A5
58
203 A
S66
32
59
S67
22
204 B
57
S65
202 180
40
902 (0V)
F51
25
1
60
M6
901
903 +
Legend
61
Battery negative
Battery positive
LED OFF (Not lit)
904 -
62
503 IN
U1
G
63
LED input (lit)
502 IN
LED output (lit)
7. Steering Componets
This diagram covers the channel A steering wheel sensor
(S66), channel B steering wheel sensor (S67), 180 degree
steering wheel sensor (S65), fuse (F51), steer motor (M6),
steering tachometer (U1), and main electronic card (A5).
Electrical power for steer motor (M6) and steering tachometer
(U1) is supplied through wire #1 to fuse (F51) and through
wire #25 to main electronic card (A5, terminal 901).
The channel A steering wheel sensor (S66), channel B
steering wheel sensor (S67), and 180 degree steering wheel
sensor (S65) receive directional information from drive gear
rotation.
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141
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A5
56
S64
+12V
(-)
31
201
58
S66
203 A
32
59
S67
22
57
S65
40
40
F51
25
60
M06
204 B
202 180
902 (-)
901
903 (+)
Legend
61
Battery negative
Battery positive
LED OFF (Not lit)
62
U01
503 IN
G
63
LED input (lit)
904 (-)
502 IN
LED output (lit)
8. 12-Volt Power Supply

This diagram covers the common 12-volt power supply
produced by main electronic card (A5) to drive motor speed
sensor (S64), channel A steering wheel sensor (S66), and
channel B steering wheel sensor (S67).
The 180 degree sensor requires battery voltage to operate.
142
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22
S31
A5
22
79
29
Legend
50
Battery negative
Battery positive
LED OFF (Not lit)
R01
32
LED input (lit)
31
S64
30
56
809
107
504 +12V
505
510 0V
201
LED output (lit)
9. Driving speed reduction switch

This diagram covers the driving speed reduction switch(S31).
Driving speed reduction switch (S31) operates when forks are
raised above freelift height. This closes the circuit and allows
electricity to the main electronic card (A5, terminal 107)
through wire #79, lighting the main electronic card (A5) 107
LED.
Main electronic card (A5) processes the information that is
received from the drive motor speed sensor (S64) to
determine the speed on the drive motor rotation. Using this
information, the main electronic card (A5) reduces the overall
truck speed to a pre-programmed value.
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A8
3+
+5
4 0V
-2
A5
A7
+7
40
-3
6 0V
22
4+
+1
-5
S45
125
405 +
126
402 127
128
403 +
404 -
106
207
31
98
U10
+
205 A
99
206 B
Legend
Battery negative
Battery positive
LED OFF (Not lit)
LED input (lit)
LED output (lit)
144
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PS
Version no
001
Section
C-code
S5.0
5000
T-code
395/396/397/398/399
10. Height Indicator and Preset

Selector
10.1. Height Indicator
This diagram covers the interface between the height counter
(U10) (a pulse sensor), main electronic card (A5), and back to
the height indicator (A8) (a digital display of fork height).
Raising the forks to and above freelift height closes mast
upper position switch (S45) allowing electricity to flow to main
electronic card (A5, terminal 207) through wire #106, lighting
the main electronic card (A5) 207 LED.
A pulsed signal is sent by the height counter (U10) to main
electronic card (A5, terminal 205 and 206).
This information is then processed and sent out main
electronic card (A5, terminal 405 and 402) through wire #125
and #126 to the height indicator (A8).
10.2. Height Preset Selector

This diagram also covers the height preset selector (A7).
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.
Once 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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1997-07-24
145
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K10
K10
A5
A1
44
3
SA2
B+
B-
S21
101
34
902
M
2
SA1
K13
40
K11
M1
K13
K11
8
M
802
41
208
51
K11
52
K13
803
42
209
Legend
Battery negative
Battery positive
LED OFF (Not lit)
LED input (lit)
LED output (lit)
40
11. Drive Motor Brush Indicator

Switch
This diagram covers the drive motor brush indicator switches
(SA1 and SA2).
These switches indicate when drive motor brushes need
replacing by displaying the error code on the dash display.
These switches will not disable travel or lift on this truck, but
brushes should be inspected or replaced.
When brushes are worn and require servicing, the drive
motor brush indicator switches (SA1 and SA2) close the
circuit and allow electricity to the main electronic card (A5,
terminal 208 and/or 209) through wire #41 and #42, lighting
the main electronic card (A5) 208 and/or 209 LED.
146
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A2
14
F03
M03A
SA2
M03F
10
B+
B-
40
SA1
A5
77
Legend
210
Battery negative
Battery positive
78
LED OFF (Not lit)
211
LED input (lit)

LED output (lit)
12. Pump Motor Brush Indicator

Switch
This diagram covers the pump motor brush indicator switches
(SA1 and SA2).
These switches indicate when pump motor brushes need
replacing by displaying the error code on the dash display.
These switches will not disable travel or lift on this truck, but
brushes should be inspected or replaced.
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.
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147
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K10
K10
A1
3
A2
B+
M01
B7
2
A1
A5
44
F1
S21
34
101
902
40
K11
K13
M01
K13
K11
8
Legend
Battery negative
Battery positive
LED OFF (Not lit)
LED input (lit)
LED output (lit)
13. Safety Check

This diagram covers the safety check on the main electronic
card (A5) .
Once a year a safety check of the system must be done .
The safety check is done by turning the key switch ON,
placing a jumper from drive motor transistor regulator (A1,
terminal B-) to drive motor transistor regulator (A1, terminal
2).
The jumper will cause the line contactor (K10) to open and
confirm that the safety circuit is in operating condition.
148
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Shunt Wire
40
A5
606
607
608
606 -(+)
607 -(-)
608 +
Legend
Battery negative
Battery positive
LED OFF (Not lit)
LED input (lit)
LED output (lit)
14. Shunt Wire

The shunt measures the + and - voltage on the negative side
for battery indication. This is a special length of wire and must
be replaced with the correct parts for proper operation.
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149
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Symbol
Designation
Function
A1
Transistor regulator
Drive motor
A2
Transistor regulator
Pump motor
A5
Electronic card
Main card
A6
Electronic card
Display
A7
Electronic card
Height preset
A8
Electronic card
Height indication
A22
Key Pad
Coded access
BT
Battery
C1
Capacitor
Suppressor H
F1
Fuse
Drive motor
250 Am
F3
Fuse
Pump motor
24V-425A
36V-355A
F4
Fuse
(2) 250 Amp fuses
RRX45/RDX30/
RSX50 only
F50
Fuse
Control circuit
10 Amp
F51
Fuse
Steering motor
30 A
H1
Horn
K10
Contactor
Main contactor
K11
Contactor
Driving in direction of forks
Forward
K13
Contactor
Driving in direction of operator
Reverse
K34
Contactor
Bypass lift
RRX45/RDX30/
RSX50 only
150
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Remark
1997-07-24
F-code
PS
Version no
001
Symbol
Designation
Function
M1
Motor
Drive motor
M3
Motor
Pump motor
M6
Motor
Steering motor
M11
Fan
Drive motor
M12
Fan
Electronics
R1
Potentiometer
Speed control, travel direction
R2
Potentiometer
Brake transducer
R2
Resistor
R3
Resistor
R4
Resistor
R11
Potentiometer
Speed control, fork lift/lower
R12
Potentiometer
Speed control, reach in/out
R13
Potentiometer
Speed control, tilt
R14
Potentiometer
Speed control, sideshifter
BT Products
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Service Manual
1997-07-24
Section
C-code
S5.0
5000
T-code
395/396/397/398/399
Remark
151
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Symbol
Designation
Function
S17
Switch
Key
S18
Switch
Horn
S21
Switch
Emergency stop
S23
Switch
Right foot
S28
Switch
Travel direction
S31
Switch
Speed reduction, driving
S32
Switch
Lift limit
S33
Switch
Lift limit override
S45
Inductive sensor
Mast, upper position
S48
Switch
(Left foot) Brake switch
S64
Inductive sensor
Drive motor speed
S65
Inductive sensor
Steering wheel sensor, 180
S66
Inductive sensor
Steering wheel sensor, channel A
S67
Inductive sensor
Steering wheel sensor, channel B
S125
Inductive switch
Drive motor direction
SA1
Switch
Carbon brush indicator, drive/pump motor (-)
SA2
Switch
Carbon brush indicator, drive/pump motor (+)
152
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Remark
optional
1997-07-24
F-code
PS
Section
Version no
001
Symbol
Designation
Function
V1
Zener diode
Voltage regulator
U1
Tachometer
Steering
U10
Pulse sensor
Height counter
Connectors
Y1
Brake coil
Parking brake
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
Sideshifter
Y17
Valve
Tilt
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1997-07-24
C-code
S5.0
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Remark
153
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Component Location (Figure 1 of 2)

K11
A2
K10
4
2 3
7 8
5 6
9 0
S17
R14
U01
R12 R13
2
3
R11
A1
K13
S28
K34
1
2
3
4
1
2
3
4
A1
F01
F03
A2
K10
K11
K13
Y14
Y15
Y17
Y16
154
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Component Location (Figure 2 of 2)

Y12
M03
S64
Y13
A5
S18
Y01
M11
F50
F51
M01
M06
S48
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R02
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155
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156
Return
Sh. = Sheet or page of Diagram

First number = Previous page wire was found.
Second number = Next page wire is found.
Legend
15. Circuit Diagram 1(11)
Service Manual
1997-07-24
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PS
Section
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Version no
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BT Products
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Service Manual
1997-07-24
157
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5000
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001
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158
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Legend
Service Manual
1997-07-24
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PS
Section
C-code
S5.0
5000
Version no
001
T-code
395/396/397/398/399
BT Products
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Legend
Service Manual
1997-07-24
159
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Section
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5000
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001
395/396/397/398/399
160
Return

Legend
Service Manual
1997-07-24
F-code
PS
Section
C-code
S5.0
5000
Version no
001
T-code
395/396/397/398/399

Legend
BT Products
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Service Manual
1997-07-24
161
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Section
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S5.0
C-code
5000
Version no
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001
395/396/397/398/399
162
Return

Legend
Service Manual
1997-07-24
F-code
PS
Section
C-code
S5.0
5000
Version no
001
T-code
395/396/397/398/399
BT Products
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Legend
Service Manual
1997-07-24
163
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PS
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001
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164
Return

Legend
Service Manual
1997-07-24
F-code
PS
Version no
001
Section
C-code
S5.0
5000
T-code
395/396/397/398/399
BT Products
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Legend
Service Manual
1997-07-24
165
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PS
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001
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166
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Legend
Service Manual
1997-07-24
F-code
PS
Version no
000
Section
C-code
S5.1
5460
Transistor Regulator
T-code
395/396/397/398/399
BT Products
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Service Manual
1997-07-15
167
F-code
Section
C-code
PS
S5.1
5460
Version no
T-code
000
395/396/397/398/399
1. Motor Connections
The transistor regulator has four connections for power
cables, as set out in the table below.
Terminal
Number
Function
Brake diode to the motor's series field and armature
B-
Battery minus
B+
Battery plus
Minus connection to the motor's series field
1.1. Connections for controls

Terminal
Connection
Number
1
Supply voltage
Safety test
7 1
168
Return
Function
Not used
Common connection B -
Common connection B -
Negative speed/current reference
Safety signal for main contactor
Plug braking
Stabilizing voltage 13,5 V
7
8
9
10
Reference value 0-5 V
11
Current limit 0-5 V
10
11
3
4
6
LED No.
Color
Green
Supply voltage
Yellow
Upper/lower temperatur
Red
Fault in power circuits
Red
Fault in reference value circuit
Service Manual
Function
1997-07-15
F-code
PS
Version no
000
Section
C-code
S5.1
5460
T-code
395/396/397/398/399
2. Safety Control
2.1. Checking Transistor Regulators
Safety Circuits.
This check applies to all BT trucks equipped with a transistor
regulator type.
1. Jack up the truck.
2. Block truck securely.
WARNING The truck can overturn. Risk of great

personal injury and damage to property.
Ensure the truck is stable and that the drive
wheel does not have contact with the
ground.
3. Remove control pod and console cover.
71
7
8
9
10
11
4. Reinstall control pod.
1
2
3
4
5
6
5. Turn the key switch so that the electronic card is

on.
6. Connect jumper wire between the battery negative
(B-) (1) and the contact for the control current (pin
number 2) on the transistor regulator. The main
contactor, K10, should now open to indicate that
the transistor regulators safety system is
functioning. If K10 does not open, replace the
entire transistor regulator.
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.
BT Products
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1997-07-15
169
F-code
Section
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S5.1
C-code
5460
Version no
T-code
000
395/396/397/398/399
170
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Service Manual
1997-07-15
F-code
Section
PS
S5.2
5710
Electronic Card
Version no
C-code
T-code
000
395/396/397/398/399
Electronic Card
101
to
111
201
to
211
301
to
304
402
to
405
501
to
511
601
to
611
701
to
710
801
to
811
901
to
904
Terminal Locations
BT Products
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Service Manual
1997-07-15
171
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PS
S5.2
Electronic Card
5710
Version no
T-code
000
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I=Input, green LED; O=Output, red LED

Terminal
Number
172
Return
LED
no.
Connection
Function
101
101
Drive chopper - OK
102
102
Right foot switch
103
103
Plug braking
104
104
Drive, change direction
105
105
Drive direction
106
106
Lift limit override
107
107
Speed reduction
111
111
Brake switch
LED No.
Color
Function
TX
Green
Height indication/height preset--TX, transmits data
RX
Green
Height preset--RX, receives data
Terminal
Number
LED
no.
Connection
Function
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 +
Service Manual
1997-07-15
F-code
Section
PS
S5.2
5710
Electronic Card
Version no
000
Terminal
Number
Connection
Display power -
303
TX positive display
304
TX negative display
Connection
Function
402
TX negative height unit
403
RX positive height unit
404
RX negative height unit
405
TX positive height unit

LED
No.
501
Connection
Function
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
511
BT Products
Function
302
510
Return
395/396/397/398/399
Display power +
Terminal
Number
501
T-code
301
Terminal
Number
C-code
Service Manual
Zero Voltage
I
Analog brake transducer
1997-07-15
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S5.2
Electronic Card
5710
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T-code
000
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Terminal
Number
Terminal
Number
174
Return
Connection
Function
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 +
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
Sideshfter
710
710
Tilt
711
711
Spare 2A
Service Manual
1997-07-15
F-code
Section
PS
S5.2
5710
Electronic Card
Version no
000
Terminal
Number
LED
No.
C-code
T-code
395/396/397/398/399
Connection
Function
801
801
Spare 2B
802
802
Drive, operator direction

(reverse)
803
803
Drive, fork direction (forward)
804
804
Fork lower
805
805
Brake coil
808
+24/36 Volt
809
+24/36 Volt supply outputs
806
807
810
Sensor feed +
811
Sensor feed -
Terminal
Number
BT Products
Return
Connection
Function
901
+24/36 V steer motor
902
Zero Voltage
903
+ steer motor
904
- steer motor
LED
Color
Function
POWER
Green
Indication, all voltage is fed to the electronic card
STEER PWR
Green
Voltage feed to control electronics
STEER OK
Green
Steering OK
Service Manual
1997-07-15
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F-code
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C-code
PS
S5.2
Electronic Card
5710
Version no
T-code
000
395/396/397/398/399
Switch
Function
SW 1
Switch to program parameters and error codes
SW 2
SW 3
Potentiometer
RV2
176
Return
Function
Adjustment of lowering speed
Service Manual
1997-07-15
F-code
Section
PS
S5.2
5710
Electronic Card
Version no
000
C-code
T-code
395/396/397/398/399
1. Display
It is possible to look at the trucks specific register and
program the clock. The truck cannot be driven with any
functions when it is in the programming mode.
To look at the trucks specific register:
1. Remove right-hand access panel in operators
compartment.
2. Turn the key switch so that the electronic card is
ON.
3. Press button SW3 three times on the electronic
card to view specific registers.
SW1
SW3
SW2
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:
J
BT Products
Return
I H G F
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.
D
Service Manual
1997-07-15
177
F-code
Section
C-code
PS
S5.2
Electronic Card
5710
Version no
T-code
000
395/396/397/398/399
2. 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 dose in three ways;
Press SW3 three more times.
Waiting approximately 20 seconds.
Turn key switch OFF.
SW1
SW3
Function
SW2
Value
Hours
09=9h
Minutes
35=35 min.
When error codes are displayed in the character window (C),

the character box (G) will light. When the parameters are
displayed in character window (C), the character box (F) will
light. However, it is not possible to reprogram the parameters
in this mode. To change to the programming mode, see
Programming Parameters.
Complete programming by turning the key switch off and on
once. Programming mode will quit if you do not press a key
within 10 seconds.
178
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1997-07-15
F-code
Section
PS
S5.2
5710
Electronic Card
Version no
C-code
T-code
000
395/396/397/398/399
3. Warning 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 below and
on next page.
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.
BT Products
Return
Error Code Name
Comment
10
Pump Chopper Lim
11
Steer Chopper Lim
12
Wheel Ind Error
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
20
Pump Voltage Error
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
Sideshfter Pot Z Error
Sideshfter pot not centered at key on time
27
Bat Measure Error
Low battery voltage detected
Service Manual
Steer chopper current limit
1997-07-15
179
F-code
Section
C-code
PS
S5.2
Electronic Card
5710
Version no
T-code
000
395/396/397/398/399
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 Sideshfter Error
Shorted or opened sideshfter valve output
57
O Spare In Error
Unused output/input
58
O Spare Out Error
Unused 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
Sideshfter Pot Error Shorted or opened sadist 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.
180
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Service Manual
1997-07-15
F-code
Section
PS
S5.2
5710
Electronic Card
Version no
C-code
T-code
000
395/396/397/398/399
4. 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 next page.
SW1
SW3
SW2
When an error code is shown, the code is automatically

registered in the error register. (The meaning of the error
code is shown in the Error Codes table on next page.)
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, 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.
BT Products
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1997-07-15
181
F-code
Section
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PS
S5.2
Electronic Card
5710
Version no
T-code
000
395/396/397/398/399
Error Codes with Registering

Error No.
182
Error Code Name
Comment
100
Pump Temp Error
Pump chopper over or under temperature
101
Pump Curr Error
102
Drive Chopper
Error
Drive chopper internal error
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 Sw Error
Pedal/parking brake switch adjustment or failure
113
P Brake Out Error
Shorted or open parking brake output
115
Spd Sens Error
Drive motor speed sensor failure
116
Dir Sens Error
Drive motor direction sensor failure
117
Rev Signal Error
Drive chopper reversing signal failure
120
Steer Data Error
Control module internal error
121
Steer Chopper
Error
Steer chopper error
122
Steer Temp Error
Steer chopper over temperature
123
Steer Volt Error
124
Steer Curr Error
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
132
Steer Pwr Error
Steer chopper supply voltage under voltage
133
Sec Rel Error
Security relay error 2
140
Check Sum Error
Return
Service Manual
1997-07-15
F-code
Section
PS
S5.2
5710
Electronic Card
Version no
C-code
T-code
000
395/396/397/398/399
5. Effect on the Truck

All hydraulic functions except fork lowering are stopped.
6. Parameters
The significance of the different parameters is shown in the
table in section Program parameters on next page. To see
the different parameters, press SW2 or SW3.
7. Running time
When running time reading is shown, the character box (E) is
illuminated. The time is shown as follows:
Character
SW1
SW3
Time
Key time
SW2
Total running time

Drive motor time
Pump motor time
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183
F-code
Section
C-code
PS
S5.2
Electronic Card
5710
Version no
T-code
000
395/396/397/398/399
8. Programming Parameters
1. Press SW3 on the electronic card at the same time
as you turn the key switch ON.
2. Step using SW2 (up) and SW1 (down) to the
parameter you wish to change.
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).
If you wish to change more parameters, step using SW1/SW2
to the parameter you wish to change and repeat from Press
SW3 (the character window flashes).
NOTE! Truck handling.
Modifying specific truck parameters will
change the driving characteristics of the
truck. Do not change any parameters
without the necessary knowledge.
SW1
SW3
SW2
Programming Parameters
No.
Parameter Name
Values
Comment
Steer Prog Par 1-6
1-Least sensitivity
5-Most sensitivity
6-Test curve
Speed curve
selection. Speed
curve selection has a
greater affect at high
speed.
Steer Wheel
Par
(1)
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.
184
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Value Rang
0-2
Default
Inc
Service Manual
1997-07-15
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Section
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S5.2
5710
Electronic Card
Version no
000
C-code
T-code
395/396/397/398/399
No.
Parameter Name
Value Rang
Reach Scale
Par
10-100%
(80RR35)
(45RR45)
Spare Scale
Par
10-100%
20
Spare function
speed reduction Not
used.
Spare Curr
Par
0-100%
(0)
Spare function
current limit
reduction. Spare
function is disabled
when this valve is set
to zero. Not used.
Spec Height
Par
0-531 in.
(0)
Maximum
allowed lifting
height
Special height
10
Fork Ref Par
60-177 in.
(90)
Mast free height
Mast reference
height
11
Steer Dir Par
0-1
(1)
0-Backward (Eur.)
1-Forward (US)
Steer direction
12
Timer Sel Par
1-4
(2)
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
(20)
1-Shallow
discharge
29-Deep
discharge (not a
permanent
parameter)
Battery type
BT Products
Return
Default
Service Manual
Inc
Values
% of maximum
reach speed
1997-07-15
Comment
Reach movement
speed reduction.
185
F-code
Section
C-code
PS
S5.2
Electronic Card
5710
Version no
T-code
000
395/396/397/398/399
No.
Parameter Name
Value Rang
14
Pump Type
Par
0-2
{2}
15
Clock Year
0-99
Clock Year
16
Clock Day
0-31
Clock Day
17
Clock Month
0-12
Clock Month
186
Return
Default
Inc
Service Manual
Values
0-36V Std.
1-24V Std.
2-36V HD.
Comment
Hydraulic pump type
1997-07-15
F-code
Section
PS
S5.2
5710
Electronic Card
Version no
000
C-code
T-code
395/396/397/398/399
9. Adjustment Procedures for Setting

Brake Switch and Brake Transducer
1. Remove cover panel for A5 card.
2. Remove floor plate.
3. Go into programming mode. Refer to Programming
Parameters.
Set parameter 12 at 4
Set parameter 15 at 50
6. After changing these parameters, turn key switch OFF

and turn back ON.
7. The display should read 10 with the brake pedal all the
way up.
8. Press brake pedal all the way down and the display
should read 247.
9. To adjust with the pedal all the way up, bend pedal
stop bracket down until you read 10 on the display.
10. To adjust with the pedal all the way down loosen the
bolts on the brake transducer and adjust until 247
appears on the display.
11. The brake switch should be adjusted so it actuates
between 45 and 52 on the display when depressing
the pedal.
12. After making adjustments, go back into programming
mode.
Set parameter 12 at 2.
Set parameter 15 and 97.
13. Reinstall floor plate and cover.
BT Products
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1997-07-15
187
F-code
Section
C-code
PS
S5.2
Electronic Card
5710
Version no
T-code
000
395/396/397/398/399
188
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Service Manual
1997-07-15
F-code
Section
PS
S5.3
Version no
C-code
5810
Pump Motor
T-code
000
395/396/397/398/399
Pump Motor
ROTATION
C.C.W.C.E.
Counterclockwise
when viewed from
commutator end.
BT Products
Return
POS.
NO
DESCRIPTION
POS.
NO
DESCRIPTION
Cover band
Terminal stud
Head, commutator end
Field coil
Thrust washer
10
Head, drive end
Bearing, ball sealed
11
Bearing, ball sealed
Brush plate assembly
12
Armature & fan assembly
Spring, brush
13
Fan
Brush
Service Manual
1997-07-15
189
F-code
Section
C-code
PS
S5.3
Pump Motor
5810
Version no
T-code
000
395/396/397/398/399
1. Component Repair
1.1. Motor Disassembly
1. Remove the cover band (1) from the commutator
end of the motor.
2. Use a brush hook to reach into the motor and lift
the brush springs (6). Pull the brushes (7) out of
the brush holders. Either position the brushes
outside the motor or remove the brush retaining
screws, and remove the brushes (7) from the
motor.
3. Scribe or center punch locating marks in the end
head and the frame. Although locating marks are
not always necessary, they can save time when
the motor does not have locating pins.
4. Remove the commutator end head retaining
screws. Most motors have a slip fit bearing at the
commutator end, and the end head can 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.
5. Remove the drive end head retaining screws if
necessary. Some of the smaller pump motors
retain the drive end head with the motor through
bolts. Separate the armature (12) and drive end
head (10) as an assembly from the frame and field
coil assembly.
6. Separate the armature (12) from the drive end
head (10). This operation is usually done by
pressing the armature out of the drive end bearing.
On some of the larger motors, the end head and
bearing will have to be removed with a puller.
When a puller is used, protect the end of the
armature shaft with a nut or a thick flat washer.
190
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PS
S5.3
Version no
000
CAUTION
C-code
5810
Pump Motor
T-code
395/396/397/398/399
If the shaft, coupling, or spline is

damaged when removing the end head,
the armature or the drive spline usually
has to be replaced. Use caution, and
DO NOT damage the armature.
7. Separate the bearing (4) from the end head (2). On

larger motors, the bearing is retained with a snap
ring. Remove the snap ring. Then press the
bearing out of the end head.
8. The ventilation fans (13) are cast aluminum. Once
these fans have been pressed onto the armature,
they must be heated to be removed without
damage.
Install a puller and apply slight pressure against the
fan. 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.
9. When the fan (13) 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.
10. After the motor has been separated into all its
major subassemblies, the components should be
cleaned and inspected for wear or damage.
Use Loctite on
this area of shaft
BT Products
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191
F-code
Section
C-code
PS
S5.3
Pump Motor
5810
Version no
T-code
000
395/396/397/398/399
2. Inspection and Troubleshooting

After the motor components have been thoroughly cleaned
and dried, they should be inspected for the following:
2.1. Drive End Head

2. Check mounting holes for any stripped or crossed
threads or broken studs.
2.2. Commutator End Head

2. Check brush holder insulation for cracks or any
signs of burning.
3. Check brush holders and springs for wear.
2.3. Bearings
1. Check bearings by turning them with your fingers.
Feel for binding or gritty effects and excessive
looseness or wobble. A good bearing should also
have a small amount of drag or stiffness caused by
the lubrication but should turn smoothly. If the
bearing turns very freely, it should be replaced.
Bearings should also be changed if worn out,
damaged, or removed from armature shaft.
Ball bearings that have been pulled off shafts,
pressed out of end heads, or side loaded in such a
way as to apply pressure on the balls and races
must be replaced. Although the bearing may
appear or feel good, the bearing races have been
brinelled and will fail within a relatively short period
of service.
192
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PS
S5.3
Version no
000
C-code
5810
Pump Motor
T-code
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2.4. Brush and Commutator

The brushes and commutator should be inspected for even
wear and good commutation.
Good Commutation: A dark uniform coloring pattern at the
brush wearing surface.
Poor Commutation: The surface of the commutator
appearing rough, pitted, or scored, or showing signs of
burning or heavy arcing between bars. The color pattern will
be:

Streaky film with commutator wear.

Bar edge burning.
Uneven film.
Carbon dust bridging between bars.
Brushes should be inspected for uneven wear and signs of

overheating, i.e.:

Discolored brush shunts.

Discolored brush springs.
Refer to the Brush Chart at the end of this section.
2.5. Armature
1. Check security of fan.
2. Check for loose commutator bars. Loose
commutator bars will usually be indicated by
excessive wear or burning on one bar. The
commutator can be checked for loose bars by
lightly tapping all of the bars with the handle of a
plastic or wooden handled screwdriver. A
contrasting dull thud or vibration will indicate a
loose bar. Replace the armature if the commutator
bars are loose.
3. Check for grounded circuits using a test light. Most
commercial growlers incorporate a test light.
Check the armature for grounded circuits by
placing one test lead of the test lamp on the
commutator and the other test lead on the
Grounded Circuit Test
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193
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PS
S5.3
Pump Motor
5810
Version no
T-code
000
395/396/397/398/399
armature shaft. If the test light lights, the armature

is grounded.
4. Standard Winding Armatures are tested on a
growler using a steel strip or hacksaw blade to
locate any shorted windings.
Check for shorted windings by slowly rotating the
armature in the growler while holding the strip or
blade so that it passes over each armature core
slot. If a winding is shorted, the strip or blade will
vibrate and the blade will get hot.

Armature
NOTE! If the armature has been turned and

undercut prior to testing, check for and
remove any copper buildup or filings
between commutator bars and at the
commutator riser. This condition will cause
an armature to check shorted and usually
results from a dull undercutting tool.
5. Check commutator bars for any signs of burning. If
deep burned sections are evident, either in the
brush track or on the riser ends of the commutator
bars, an open or short circuit in the armature
windings is indicated.
2.6. Frame and Field Assembly

Check the condition of all insulation. If the insulation on the
field coils appears blackened or charred, the serviceability of
the coils is questionable. Burned or charred insulation is a
result of coil overheating due to overloading conditions,
grounded or shorted coil windings. Check the condition of all
other insulation such as brush rigging, under coil connections
and around terminal studs.

Armature
194
Return
2.6.1. Testing
After thorough inspection, the Frame and Field Assembly
should be checked for grounded, open, or shorted circuits.
Grounded and open circuits can be checked using a test light.
Most commercial growlers incorporate a test light as shown in
opposite illustration.
Service Manual
1997-07-15
F-code
Section
PS
S5.3
Version no
000
C-code
5810
Pump Motor
T-code
395/396/397/398/399
Grounded Circuit
Touch one test lead to a clean bare metal spot on
the frame and check all terminals with the other
lead. If a grounded condition exists, the test light
will light.
Open Circuit
Check between all connecting terminals with test
leads. If the bulb fails to light, an open circuit is
indicated.
Shorted Circuit
Shorted windings in series coils are very difficult to
detect. Generally, if the coil insulation is sound and
these are no signs of overheating, the coil can be
presumed good.
2.6.2. Frame and Field Service Notes

If the inside of the motor is exceptionally dirty and there is
evidence of a grounding condition caused by the dirt, the
inside of the motor can be given an additional coat of
insulating varnish. Red glyptol can be used if a better material
is not available, however, we recommend using a class H
Polyurethane air drying insulating varnish. This is readily
available under various brand names from electrical repair or
parts houses in aerosol type dispensers.
Before spraying field coils, make sure they are absolutely
clean and dry. Protect brush rigging, pole shoe faces, and
end head seats to keep varnish off.
BT Products
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1997-07-15
195
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Section
C-code
PS
S5.3
Pump Motor
5810
Version no
T-code
000
395/396/397/398/399
2.7. Assembly
2.7.1. Field Coil Installation
Good solder connections are important due to the vibration
characteristics encountered by these motors which can cause
cold or poorly soldered connections to break.
1. Prior to installing the field coils, the connections
which require soldering should be buffed or wire
brushed clean to remove any oxidation. The
connections should then be tinned with a soldering
iron.
NOTE: We do not recommend using a soldering gun

or torch. A soldering gun cannot provide the
heat concentration required, and a soldering
torch can damage the insulation.
2. After field coil installation, connect the solder joint,
making sure the solder is flowing properly to avoid a
cold soldered joint.
Pole Shoe Screw Removal & Installation

(Field Coil Removal & Installation)
Continue assembly in the reverse of disassembly, paying
particular attention to the following points.
2.7.2. Bearing Installation
1. Whenever ball bearings are pressed into an end head
or onto a shaft, always press against the race that is
absorbing the pressure.
Press on the outer race when installing into end heads.
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S5.3
Version no
000
C-code
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Pump Motor
T-code
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Press against the inner race when installing onto a

shaft.
2. End heads having slip-fit bearings are normally
retained by a snap ring. Always install new snap
ring(s).
2.7.3. After Assembly
1. The motor should be connected as specified in
Troubleshooting, and tested to the specifications.
2. When testing motors, the voltmeter connections must
be made at the motor terminals.
3. When Changing Brushes

When changing brushes, the commutator must be serviced
as follows:
Resurface the commutator by taking only light cuts
each time, 0.005 in. (0.12 mm).
If reslotting/undercutting is necessary, the final
operation is to lightly sand the commutator with a fine
sandpaper to remove any burrs left from the
undercutting operation.
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1997-07-15
197
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Section
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PS
S5.3
Pump Motor
5810
Version no
T-code
000
395/396/397/398/399
198
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1997-07-15
F-code
Section
PS
S6.0
6000
Hydraulic System
Version no
000
C-code
T-code
395/396
Hydraulic System
Valid from machine number: 27091001 to 27135000
1. Operation
Refer to Hydraulic Schematics in this Section
1.1. Supply
A voltage to controller (A5) from one of the hydraulic function
potentiometers (R11 to R14) gives a signal to the transistor
regulator (A2) to drive the pump motor (M3). Oil is feed feed
from the pump (P) out into the system. If the pressure in the
system increases to the relief valves preset value, this opens
and oil flows back to the tank.
1.2. Lifting
By pulling back potentiometer (R11), there is an decrease in
voltage from (R11) to (A5) which initiates a voltage to the coil,
connection 2 on valve (Y10). Oil is feed from the valve to the
free lift and staging cylinders. The free lift cylinder having less
weight on it will lift first. After the free lift cylinder has reached
full extension, the staging cylinders will begin to lift.
1.3. Lowering
By pushing potentiometer (R11) forward, there is a increase
in voltage from (R11) to (A5) which initiates a voltage to the
coil, connection 3 on valve (Y10). Oil flows from the cylinders
through valve (Y10) to the tank. The lowering speed is
determined by valve (Y10/3) which is a proportional valve
whose position is in direct proportion to the voltage from
(R11).
1.4. Reach
By pushing potentiometer (R12) forward, there is an
decrease in voltage from (R12) to (A5) which initiates a
voltage to the direction B (Y13) valve coil, connection 2. A
voltage will also be supplied to (Y14 and Y15) valve coil,
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Service Manual
1997-12-16
199
F-code
Section
PS
S6.0
Hydraulic System
Version no
T-code
000
395/396
C-code
6000
connection 2. Oil is feed through (Y13) direction B through

(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 (Y15) to direction A (Y12) to the tank.
1.5. Retract
By pulling back potentiometer (R12), there is a increase in
voltage from (R12) to (A5) which initiates a voltage to the
direction A (Y12) valve coil, connection 2. A voltage will also
be supplied to (Y14 and Y15) coils, connection 2. Oil is feed
through (Y12) direction A through (Y15) to the front port on
the reach cylinders and drives the pistons inwards. The oil
flows from the rear ports through (Y14) to direction B (Y13)
valve to the tank.
1.6. Tilt Up
By pulling back potentiometer (R13) there is an decrease in
voltage from (R13) to (A5) which initiates a voltage to
direction B (Y13) valve coil, connection 2. A voltage is also
supplied to (Y17) valve coil, connection 2. Oil is feed through
direction B (Y13) valve to the rear port of the tilt cylinder
driving the piston outward. The oil flows from the front port of
the tilt cylinder through (Y17) valve to direction A (Y12) valve
to the tank.
1.7. Tilt Down

direction A (Y12) valve coil, connection 2. A voltage is also
direction A(Y12) valve to (Y17) valve to the front port of the tilt
cylinder, driving the piston inward. The oil flows from the rear
port of the tilt cylinder to the direction B (Y13) valve to the
tank.
200
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Service Manual
1997-12-16
F-code
Section
PS
S6.0
6000
Hydraulic System
Version no
000
C-code
T-code
395/396
1.8. Sideshifting Right

direction B (Y13) valve to (Y16) valve to the rear port of the
sideshifter cylinder driving the piston outward. The oil flows
from the front port of the cylinder to direction A (Y12) valve to
the tank.
1.9. Sideshifting Left

direction A (Y12) valve to the front port of the sideshifter
port of the cylinder through the (Y16) valve to direction B
(Y13) valve to the tank.
BT Products
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Service Manual
1997-12-16
201
F-code
Section
PS
S6.0
Hydraulic System
Version no
T-code
000
395/396
C-code
6000
Symbol
Designation
Function
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
Filter
Main filter
M3
Motor
Pump motor
Pump
Hydraulic pump
Y10
Valve
Lift/lower
Y12
Valve
Direction A
Y13
Valve
Direction B
Y14
Valve
Reach out
Y15
Valve
Reach in
Y16
Valve
Sideshifter
Y17
Valve
Tilt
202
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Service Manual
Remarks
1997-12-16
F-code
Section
PS
S6.0
6000
Hydraulic System
Version no
000
C-code
T-code
395/396
2. RRX35/45 Hydraulic Schematic
3
13
1
12
11
6
Y16
3
B
Y17
4
H
Y10
A
1
Y10
Y14
Y13
14
Y15
M
P
Y12
R
F
BT Products
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Service Manual
1997-12-16
203
F-code
Section
PS
S6.0
Hydraulic System
Version no
T-code
000
395/396
204
Return
C-code
6000
Service Manual
1997-12-16
F-code
Section
PS
S6.1
6000
Hydraulic System
Version no
001
C-code
T-code
395/396/397/398/399
Hydraulic System
Valid from machine number: 27135001 and UP
WARNING DO NOT use your hands to check for

hydraulic leakage. Use a piece of
cardboard or paper to search for leaks.
Escaping fluid under pressure can
penetrate the skin causing serious injury.
Relieve pressure before disconnecting
hydraulic or other lines. Tighten all
connections before applying pressure.
Keep hands and body away from pinholes
and nozzles which eject fluids under high
pressure.
1. Operation
Refer to Hydraulic Schematics in this Section
1.1. Supply
A voltage to (A5) controller from one of the hydraulic function
potentiometers (R11 to R14) gives a signal to the transistor
regulator (A2) to drive the pump motor (M3). Oil is feed from
the pump (P) out into the system. If the pressure in the
system increases to the relief valves preset value, this opens
and oil flows back to the tank.
1.2. Lifting
voltage from (R11) to (A5) which initiates a voltage to the coil,
connection 2 on valve (Y10). Oil is feed from the valve to the
free lift and staging cylinders. The free lift cylinder, having
less weight on it, will lift first. After the free lift cylinder has
reached full extension, the staging cylinders will begin to lift.
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Service Manual
1997-12-16
205
F-code
Section
PS
S6.1
Hydraulic System
C-code
6000
Version no
T-code
001
395/396/397/398/399
1.3. Lowering
in voltage form (R11) to (A5) which initiates a voltage to the
coil, connection 3 on valve (Y10). Oil flows from the cylinders
through valve (Y10) to the tank. The lowering speed is
determined by valve (Y10/3) which is a proportional valve
whose position is in direct proportion to the voltage from
(R11).
1.4. Reach
By pushing potentiometer (R12) forward, there is an
decrease in voltage from (R12) to (A5) which initiates a
voltage to the direction B (Y13) valve coil, connection 2. A
voltage will also be supplied to (Y14 and Y15) valve coil,
connection 2. Oil is feed through (Y13) direction B through
(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 (Y15) to direction A (Y12) to the tank.
1.5. Retract
By pulling back potentiometer (R12), there is a increase in
direction A (Y12) valve coil, connection 2. A voltage will also
be supplied to (Y14 and Y15) coils, connection 2. Oil is feed
through (Y12) direction A through (Y15) to the front port on
the reach cylinders and drives the pistons inwards. The oil
flows from the rear ports through (Y14) to direction B (Y13)
valve to the tank.
1.6. Tilt Up
voltage from (R13) to (A5) which initiates a voltage to
direction B (Y13) valve to the rear port of the tilt cylinder,
driving the piston outward. The oil flows from the front port of
the tilt cylinder through (Y17) valve to direction A (Y12) valve
to the tank.
206
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Service Manual
1997-12-16
F-code
Section
PS
S6.1
6000
Hydraulic System
Version no
001
C-code
T-code
395/396/397/398/399
1.7. Tilt Down

direction A(Y12) valve to (Y17) valve to the front port of the tilt
cylinder driving the piston inward. The oil flows from the rear
port of the tilt cylinder to the direction B (Y13) valve to the
tank.
1.8. Sideshifting Right

By pulling back potentiometer (R14) there is an decrease in
direction B (Y13) valve to (Y16) valve to the rear port of the
sideshifter cylinder driving the piston outward. The oil flows
from the front port of the cylinder to direction A (Y12) valve to
the tank.
1.9. Sideshifting Left

direction A (Y12) valve to the front port of the sideshifter
port of the cylinder through the (Y16) valve to direction B
(Y13) valve to the tank.
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Service Manual
1997-12-16
207
F-code
Section
PS
S6.1
Hydraulic System
C-code
6000
Version no
T-code
001
395/396/397/398/399
Symbol
Designation
Function
1-2
Cylinder
Staging
Cylinder
Free lift
Cylinder
Reach/retract
Cylinder
Tilt
Cylinder
Sideshifter
11
Valve
Staging velocity fuse
13
Valve
Free lift velocity fuse
14
Valve
Relief
Filter
Main filter
M3
Motor
Pump motor
Pump
Hydraulic pump
Y10
Valve
Lift/lower
Y12
Valve
Direction A
Y13
Valve
Direction B
Y14
Valve
Reach out
Y15
Valve
Reach in
Y16
Valve
Sideshifter
Y17
Valve
Tilt
208
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Service Manual
Remarks
1997-12-16
F-code
Section
PS
S6.1
6000
Hydraulic System
Version no
001
C-code
T-code
395/396/397/398/399
2. RRX35/45 Hydraulic Schematic
3
13
1
11
6
Y16
3
B
Y17
4
H
Y10
A
1
Y10
Y14
Y13
14
Y15
M
P
Y12
R
F
BT Products
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Service Manual
1997-12-16
209
F-code
Section
C-code
PS
S6.1
Hydraulic System
6000
Version no
T-code
001
395/396/397/398/399
3. RDX30 Hydraulic Schematic
3
13
11
6
A
Y16
3
5
Y17
4
H
Y10
A
1
Y10
Y14
Y13
1
4
Y15
14
P
Y12
R
F
210
Return
Service Manual
1997-12-16
F-code
Section
PS
S6.1
6000
Hydraulic System
Version no
001
C-code
T-code
395/396/397/398/399
4. RSX40/50 Hydraulic Schematic
13
11
H
Y10
Y10
Y13
14
M
P
Y12
BT Products
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Service Manual
1997-12-16
211
F-code
Section
PS
S6.1
Hydraulic System
C-code
6000
Version no
T-code
001
395/396/397/398/399
212
Return
Service Manual
1997-12-16
F-code
Section
PS
S7.0
7110
Mast, 3 Stage
Version no
000
C-code
T-code
395/396/397/398/399
Mast, 3 Stage
BT Products
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Service Manual
1997-07-15
213
F-code
Section
C-code
PS
S7.0
Mast, 3 Stage
7110
Version no
T-code
000
395/396/397/398/399
1. Shimming Mast on Truck

WARNING When blocking mast columns to prevent
lowering always block both side of the
column. If not the truck could tip over on its
side.
1.1. Shimming the Carriage/Reach

1. Disconnect battery and remove battery from truck.
2. Attach a hoist to top of carriage/reach and hoist to
loosen lift chains. Read and follow the correct
operating procedures for your jack or hoist. This
will allow removal of lift chain anchor pins, and
electrical cable.
3. Thoroughly clean off all outside dirt around mast
roller bearings.
4. Determine the amount of shims required by prying
the rear of carriage/reach to one side and slipping
shims between the 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 and install under bearings.
6. Hydraulically lift up inner column enough to remove
carriage/reach.
7. Lower carriage/reach inner column to expose
bearings. Remove bearings to install shims behind
bearings.
8. Raise carriage/reach inner column as far as it will
go under normal operation. Check bearing
shimming as the carriage/reach is raised. Remove
shims as required, if tight spots are encountered
where assembler cannot move carriage/reach
smoothly. Check for excessive bearing clearance
with carriage/reach in fully lowered position by
prying carriage/reach to one side and checking
with a 0.030-in. shim. Maximum clearance must
not exceed 0.030-in. Check for excessive bearing
clearance with carriage/reach in the fully raised
214
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Service Manual
1997-07-15
F-code
Section
PS
S7.0
7110
Mast, 3 Stage
Version no
000
C-code
T-code
395/396/397/398/399
position by prying carriage/reach to one side and

checking with a 0.030-in. shim. Maximum
clearance must not exceed 0.030-in.
9. Lower carriage/reach to install 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 sheave within
1/32 in.
10. Remove hoist from carriage/reach and test
operation of unit. Check operation first with no
load, then with capacity rated load.
1.2. Shimming the Rails.

In order to shim the mast rails the carriage/reach will
have to be removed.
1. Disconnect battery and remove from unit.
2. The truck will have to be hoisted and blocked a foot
off the floor before work can begin. Read and
follow the correct operating procedures for your
jack or hoist.
WARNING Always make sure unit is on level
surface before work can begin.
3. Attach a hoist to top of carriage/reach and raise
carriage/reach. Loosen lift chains.
4. Remove chain anchor pins, attachment hydraulic
hoses and electrical cable. Hydraulically raise inner
column enough to remove carriage/reach.
Lower carriage/reach down and out inner column.
Place it away from truck.
5. Attach hoist to top of inner column and hoist to
loosen lift chain. This will allow removal of lift chain
anchor pins.
6. Before disconnecting hoses and fittings from inner
column, thoroughly clean off all outside dirt around
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1997-07-15
215
F-code
Section
C-code
PS
S7.0
Mast, 3 Stage
7110
Version no
T-code
000
395/396/397/398/399
fittings. After disconnecting hoses, immediately

cap ports on tubes and hoses to prevent
contaminates from entering the hydraulic system.
NOTE! Make note of which port the hoses are from
for easier installation.
7. Raise inner column.
inner column to one side and slipping shims
between bearings and web on column. Add shims
by hand until no more may be added.
two bearings on both top and bottom of column
and install under bearings.
10. Lower inner column down and move the
intermediate column out to expose two bottom
bearings and install shims under bearings.
two bearings on top of intermediate column and
install under bearings.
12. Raise inner column up intermediate column as far
as it will go under normal operation. Check bearing
shimming as inner column is raised. Remove
where assembler cannot move mast smoothly.
Check for excessive bearing clearance with
columns in lowered position by prying column to
one side and check with 0.030-in. shim. Maximum
13. Attach a hoist to top of both inner and intermediate
column. Read and follow the correct operating
procedures for your jack or hoist.
14. Remove cap screws which secure lift staging
cylinders from top of intermediate column. Once
columns are lifted with hoist, the lift cylinder is free
to move or fall. Secure lift cylinder in place.
intermediate column to one side and slipping shims
216
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Service Manual
1997-07-15
F-code
Section
PS
S7.0
7110
Mast, 3 Stage
Version no
000
C-code
T-code
395/396/397/398/399
between bearing and web on column. Add shims

by hand until no more may be added.
two bearings on both top and bottom of column
and install under bearings.
17. Lower intermediate column down and move the
outer column out to expose the two bottom
bearings and install shims under bearings.
18. Raise intermediate column up outer column as far
as it will go under normal operation. Check bearing
shimming as intermediate column is raised.
Remove shims as required if tight spots are
encountered where assembler cannot move mast
smoothly. Check for excessive bearing clearance
with columns in the fully lowered position by prying
column to one side and check with a 0.030-in.
shim. Maximum clearance must not exceed 0.030in.
Check for excessive bearing clearance with inner
column in fully raised position by prying column to
one side and checking with a 0.030-in. shim.
Maximum clearance must not exceed 0.030-in.
19. Push intermediate and outer columns together and
install cap screw in intermediate column to secure
lift staging cylinder and attach a hoist to top of lift
carriage into place in inner column.
20. Hoist carriage/reach up inner column to attach lift
chain anchor pins. When installing lift chains,
chains are to be free of twists and adjusted for
equal tension with adjusting nuts (wheel nut) and
locknuts (jam nuts) torqued to 200 ft-lb (271 N m).
Chains are to be centered on sheaves within 1/32
in.
21. Connect electrical cable and attachment hydraulic
hoses.
22. Remove hoist from mast and lower unit to floor.
23. Install and connect battery to unit.
24. Loosen jam nut and tighten chains equally until the
top of the rails are level in the fully lowered
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1997-07-15
217
F-code
Section
C-code
PS
S7.0
Mast, 3 Stage
7110
Version no
T-code
000
395/396/397/398/399

Carriage chains should be adjusted in the fully
lowered position. Adjust chains until the heel of the
forks are 1/2 in. (12.7 mm) off of the floor.
Retighten locknuts on chain anchors.
25. Test operation of mast and check for tight or loose
spots and reshim if found. Check operation first
with no load, then with capacity rated load.
218
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Service Manual
1997-07-15
F-code
Section
PS
S7.0
7110
Mast, 3 Stage
Version no
000
C-code
T-code
395/396/397/398/399
2. Three Stage Mast

2.1. Removal
WARNING Always make sure unit is on level
surface before work can begin.
Bolts
1. Disconnect battery and remove from unit.

2. Disconnect hydraulic supply line which is located,
then lower left corner of battery box and cap.
3. Disconnect two hydraulic supply lines located by
emergency disconnect and then cap.
4. Disconnect electric wiring harness located, by
emergency disconnect.
5. If truck is equipped with lift and or fan package,
disconnect harness located at base of OHG
support bar.
6. Connect hoist to top tie bars of mast and tighten
enough to remove all slack in chains.
7. Remove two mast bolts located in the middle of
battery box.
8. Remove two side mounting plates at pivot points
on mast.
9. Lift mast enough to clear chassis and lay mast on
floor.
Plate
Bolts
BT Products
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Service Manual
1997-07-15
219
F-code
Section
C-code
PS
S7.0
Mast, 3 Stage
7110
Version no
T-code
000
395/396/397/398/399
2.2. Installation
1. Install mast using hoist.
2. Install side mounting plates.
3. Install two bolts in middle of battery box.
4. Connect hydraulic hoses to lift cylinders.
5. Connect all electrical connectors.
6. Adjust lift chains.
Loosen jam nut and tighten chains equally until the
top of the rails are level in the fully lowered
Carriage chains should be adjusted in the fully
lowered position. Adjust chains until the heel of the
forks are 1/2 in. (12.7 mm) off of the floor.
7. Grease all chain sheaves.
8. Bleed air from cylinders.
9. Install and connect battery and test operations of
mast and unit.
220
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Service Manual
1997-07-15
F-code
Section
PS
S7.0
7110
Mast, 3 Stage
Version no
000
C-code
T-code
395/396/397/398/399
2.3. Disassembly
1. Lower mast assembly to a horizontal position
before work can begin.
2. Remove lift chain anchors, lift chain, attachment
hydraulic hoses and electrical cable from mast.
3. Remove freelift chain anchor and two cotter pins
and two cylinder anchor pin from inner column and
remove free lift cylinder assembly by pulling
straight up.
NOTE! Lift cylinder can be repaired at this time,
if needed.
4. Remove chain sheaves and cable sheaves from all
columns.
5. Remove column stops from outer column.
6. Pull inner column straight forward until it stops (hits
bearings) and then 90 degrees straight up from
intermediate column.
7. Remove cap screws from top of intermediate
column and remove staging cylinder assemblies by
pushing intermediate column forward.
NOTE! Lift cylinder can be repaired at this time,
if needed.
8. Pull intermediate column straight forward until it
stops (hits bearings) and then pull 90 degrees
straight up from outer column.
9. Remove mast bearings and shim washers from all
columns.
10. Thoroughly clean all parts.
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1997-07-15
221
F-code
Section
C-code
PS
S7.0
Mast, 3 Stage
7110
Version no
T-code
000
395/396/397/398/399
2.4. Assembly
1. Thoroughly clean all parts and air dry.
WARNING Be extremely careful when working

with solvent. Even a small explosion or
fire could cause injury or death.
WARNING Compressed air used for cleaning
MUST be reduced to less than 30
p.s.i., and then only with effective chipguarding and personal protective
equipment.
2. Install mast roller bearing on both the intermediate
and outer columns.
3. Assemble intermediate column in the outer column
and slide columns together.
the inner column to one side and slipping shims
between the bearing and web on the mast. Add
shims by hand until no more can be added.
6. Extend intermediate column through outer column
as far as it will go under normal operation. Check
bearing shimming as column is extended. Remove
where assembler cannot roll mast by hand.
Check for excessive clearance with columns in the
fully closed position by prying column to one side
and checking with a 0.030-in. shim. Maximum
columns in the fully extended position by prying
column to one side and checking with a 0.030-in.
7. Assemble inner column in the intermediate column
and slide columns together.
222
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Service Manual
1997-07-15
F-code
Section
PS
S7.0
7110
Mast, 3 Stage
Version no
000
C-code
T-code
395/396/397/398/399

the inner column to one side and slipping shims
between the bearing and web on the mast. Add
shims by hand until no more can be added.
10. Extend inner column through intermediate column
as far as it will go under normal operation. Check
bearing shimming as column is extended. Remove
where assembler cannot roll mast by hand.
Check for excessive clearance with columns in the
fully closed position by prying column to one side
and checking with a 0.060-in. shim. Maximum
columns in the fully extended position by prying
column to one side and checking with a 0.030-in.
11. Install column stops in outer column and torque to
260 ft-lb (350 Nm).
12. Install staging lift cylinder assembly in intermediate
column lower end.
13. Press roller bearings in lift chain sheaves, grease
roller bearings, and slide inner races in roller
bearings.
14. Install shim washers on either side of lift chain
sheaves and install in intermediate column. Slide
pins through sheaves and secure pins with two (2)
cap screws and lockwashers. Do this to both chain
sheave pins.
15. Install bearing in electrical sheave, grease bearing
and install spacers on either side of bearing.
16. Install electrical sheave in proper location on
intermediate column and secure with one cap
screw and lockwasher.
17. Push intermediate and outer columns together and
install cap screw in intermediate column to secure
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1997-07-15
223
F-code
Section
C-code
PS
S7.0
Mast, 3 Stage
7110
Version no
T-code
000
395/396/397/398/399
staging lift cylinder.

18. Install lift chain anchors through outer column and
thread wheel nut on anchors and secure with jam
nut.
19. 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.
20. Install freelift cylinder assembly on inner column
and secure with four cap screws and nuts.
21. Connect hydraulic lines to lift cylinder.
22. Lubricate the grease fittings with Tex. Ref. C & C
No. 880 using a standard lube gun.
224
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Service Manual
1997-07-15
F-code
Section
PS
S7.1
Version no
C-code
7210
Sideshifter
T-code
000
Sideshifter
Bolzoni Sideshifter Information

BT Products
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Service Manual
1997-07-18
225
F-code
Section
C-code
PS
S7.1
Sideshifter
7210
Version no
T-code
000
POS.
NO
226
Return
DESCRIPTION
POS.
NO
DESCRIPTION
POS.
NO
DESCRIPTION
Slide, top
Hook, lower
15
Cylinder assembly
Anchor, cylinder
Screw, set
16
Spacer, nylon
Spacer
10
Screw
17
Spacer
Fitting
11
Lockwasher
18
Seal, gland
Ring, retainer
12
Frame, sideshifter
19
Retainer, wiper
Slide, lower
13
Nut
20
Wiper, rod
Nut
14
Spacer
21
Ring, retainer
Service Manual
1997-07-18
F-code
Section
PS
S7.1
Version no
C-code
7210
Sideshifter
T-code
000
1. Mounting Instructions
1.1. Installation
1. Remove lower hooks (8) from sideshifter assembly.
2. Lift sideshifter onto the trucks carriage while holding up
the cylinder to keep the upper slides in place.
1
15
9
3. Make sure the centering lug (X) on the cylinder anchor (2)
fits completely in the center notch of the truck carriage.
4. Remount the lower hooks (8) with a minimum clearance of
1/16 in. and a maximum clearance of 1/8 in. Retighten the
bolts to 55 ft-lb.
NOTE! 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) to 42 ft-lb.
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.
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Service Manual
1997-07-18
227
F-code
Section
C-code
PS
S7.1
Sideshifter
7210
Version no
T-code
000
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.
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.
228
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Service Manual
1997-07-18
F-code
Section
PS
S7.1
Version no
C-code
7210
Sideshifter
T-code
000
15
2.1. Lower Slides

1. The original thickness of a lower slide is approximately 3/
16 in. and has a useful life of 1/2 its thickness.
2. Replace the lower slide if contamination is present or
excessive play becomes evident.
2.2. Upper Slides

1. The original thickness of upper slide (1) is approximately
1/8 in. and should be replaced if the slide is worn beyond
1/16 in. at any point on the round surface.
2. Replace the upper slides (1) if there is an unacceptable
clearance (greater then 1/8 in. 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 non-serviceable
style, with the exception of the gland O ring. It is
BT Products
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Service Manual
1997-07-18
229
F-code
Section
C-code
PS
S7.1
Sideshifter
7210
Version no
T-code
000
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.
230
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Service Manual
1997-07-18
F-code
Section
PS
S7.2
7240
Reach, Single
Version no
001
C-code
T-code
394/395
Reach, Single
1. Maintenance
The only maintenance required on the reach mechanism is
the normal Preventive Maintenance per the schedule.
BT Products
Return
Service Manual
1997-07-15
231
F-code
Section
C-code
PS
S7.2
Reach, Single
7240
Version no
T-code
001
394/395
POS.
NO
232
Return
DESCRIPTION
POS.
NO
DESCRIPTION
POS.
NO
DESCRIPTION
Nut, thin
18
Cover, valve
35
Shim
Washer
19
Manifold
36
Screw
Frame, rear
20
Frame, forward
37
Anchor, chin
Screw
21
Pin, roll
38
Shim
Arm, left
22
Pin
39
Shaft
Bushing
23
Bushing
40
Nut
Fitting, grease
24
Bar, fork
41
Clamp
Arn, inner
25
Screw
42
Screw
Manifold
assembly
26
Shaft, pivot
43
Washer
10
Screw
27
Arm, right
44
Bracket
11
Bushing
28
Washer, flat
45
Screw
12
Plug, wear
29
Nut, jam
46
Pin, yoke
13
Bearing
30
Set, bearing
47
Pin, cotter
14
Washer
31
Screw
48
Manifold
15
Clamp
32
Cap
49
Busking
16
Cover
33
Bearing
17
Screw
34
Bumper
Service Manual
1997-07-15
F-code
Section
PS
S7.2
7240
Reach, Single
Version no
001
C-code
T-code
394/395
2. Reach Repair
NOTE! The reach can be
removing from mast.
repair
without
1. Remove forks.
2. Remove load backrest.
3. Raise and block reach at height for easy repair.
4. Extend reach approximately half way and block so
it will not retract.
5. Disconnect battery.
2.1. Disassembly
2.1.1. Front Frame Removal
1. Disconnect hydraulic hoses from tilt cylinder and
sideshifter cylinder and then cap with plugs to
prevent contamination.
2. Remove nut (1) and washer (2) at the front frame
(20).
3. Pins (26) can be driven to the outside by hitting
with soft hammer.
4. Remove front frame (20) from inner arm (8) rollers
(13).
2.1.2. Outer Arm Removal
1. Remove nut (29) and washer (28).
2. Remove outside bearing (30).
3. Remove right outer arm (27).
4. Repeat steps 1 thru 3 to remove left outer arm (5).
5. Remove screws (31), caps (32), and rollers (33)
from outer arms.
2.1.3. Inner Arm Removal
1. Drive pins out of reach cylinder rod end pins.
2. Disconnect hydraulic lines from the manifold block
and plug to prevent contamination.
BT Products
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Service Manual
1997-07-15
233
F-code
Section
C-code
PS
S7.2
Reach, Single
7240
Version no
T-code
001
394/395
3. Remove pins from inner frame.

4. Remove nut (1) and washer (2) at the rear frame
(3).
5. Drive pins (39) out by hitting a with soft hammer.
6. Remove inner arms (8).
2.1.4. Rear Frame Removal
1. Lift rear frame (3) 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 electrical cable.
5 Lower rear frame.
NOTE! Connect a hoist to rear frame because it
could drop when channel is raised.
6. Raise inner mast channel.
7. Remove rear frame.
8. Remove rollers (33). Keep track of shims (35) to
each roller and roller to pin location.
9. Clean and inspect all bearing, pins, rollers,
washers and wear strips for wear.
2.1.5. Reach Cylinder Removal
WARNING Block reach to keep it from collapsing.
1. Disconnect hydraulic hoses and plug to prevent
contamination.
2. Raise reach to full freelift to remove lock pins from
rear frame.
3. Lower reach to working height and remove cylinder
tube mounting pins.
4. Repair reach cylinders as needed.
234
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Service Manual
1997-07-15
F-code
Section
PS
S7.2
7240
Reach, Single
Version no
001
C-code
T-code
394/395
2.2. Assembly
Install new bearing, rollers, and pins as needed.
2.2.1. Reach Cylinder Installation
1. Raise reach to full free lift height to install rear
frame pins.
2. Install locking pins.
3. Connect hydraulic hoses.
2.2.2. Rear Frame Installation
1. Install shims (35) and rollers (33).
NOTE! Install same number of shims as
removed for initial adjustment.
2. Lower inner mast channel onto rear frame rollers
(33).
NOTE! Adjust frame rollers so there is 0.000 in.0.030 in. side movement of rear frame at
tight part of the inner mast channel.
3. Connect hydraulic hoses.
4. Connect electrical cable.
5. Install lift chain anchors.
2.2.3. Inner Arm Installation
1. Install upper end of inner arms (8) into rear frame
(3).
2. Install new bearing in the side arms.
3. Install pins (39) into rear frame and inner arms (8).
4. Install washers (2) and nuts (1), and tighten.
Torque to 85 ft-lb (115 N m). Arms should pivot
freely with some drag.
5. Install washers (14), rollers (13), and cap (12).
6. Connect hydraulic hoses to the reach cylinder.
7. Install pins in rod end of reach cylinder.
8. Install roll pins into cylinder rod pins.
BT Products
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Service Manual
1997-07-15
235
F-code
Section
C-code
PS
S7.2
Reach, Single
7240
Version no
T-code
001
394/395
2.2.4. Outer Arm Installation

1. Install rollers (33), caps (32) and screws (31) on
arms (5 and 27).
2. Install bearing (30) in outer arms (5 and 27).
3. Install outer arms (5 and 27) on center stud of inner
arm (8).
4. Install washer (28) and nut (29), and tighten.
Torque nut to 295 ft-lb (405 Nm)
5. Check for side clearance. Arms should pivot freely
with some drag.
6. Install front frame (20).
7. Connect tilt cylinder hoses.
8. Grease all fittings on the reach.
9. Test for proper operation of reach. Install forks and
load backrest.
236
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Service Manual
1997-07-15
F-code
Section
PS
C-code
S7.3
7310
Freelift Cylinder, 3 Stage
Version no
T-code
000

POS.
NO
DESCRIPTION
POS.
NO
DESCRIPTION
Tube
10
O ring
Snap ring
11
Back-up ring
Plug
12
Gland nut
Spring
13
Wear ring
Wear ring
14
Packing
Bearing retainer
15
Wiper
Rod
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! CLEANLINESS! Perform procedures in a
clean environment. Make sure all parts are
cleaned before disassembly and kept clean
during assembly.
BT Products
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Service Manual
1997-07-15
237
F-code
Section
C-code
PS
S7.3
7310
Version no
T-code
000
1. Freelift Cylinder Repair

1.1. Removal
1. Park the truck on a level surface and apply the
brake.
2. Fully extend the cylinder to inspect the rod (19) for
gouges or pits. If gouges or pits are detected, then
the cylinder must be removed for repair.
3. Lift the carriage/reach approximately 6 inches.
Block the carriage/reach to prevent lowering.
lowering, always block both sides of the
column. Otherwise, the truck could tip over
on its side.
4. Lower cylinder so the chains, hoses, and electric
cables are loose. Disconnect the battery
5. Remove chains, hoses, and electric cables from
the crosshead.
6. Remove the crosshead from the cylinder rod.
7. Clean the exterior of the lift cylinder.
WARNING Be extremely careful when working with
solvent. Even a small explosion or fire
could cause injury or death.
be reduced to less than 30 p.s.i., and then
personal protective equipment.
238
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Service Manual
1997-07-15
F-code
PS
Section
C-code
S7.3
7310
Version no
T-code
000
1.2. Disassembly
1. Remove gland nut (12) from the cylinder tube (3).
2. Remove and discard packing, back-up ring, O ring,
rod wiper and bearing retainer from the gland nut
(12). Use care NOT to damage the inside of the
gland nut (12).
1.3. Assembly
1. Install new bearing, seals and rod wiper in the
gland. The lip of the wiper must face outward. It is
not necessary to replace wear ring (7), unless the
rod was removed for repair.
1.4. Installation
1. Install crosshead, chains, hoses and electric
cables.
2. Connect battery.
3. Test for proper operation.
BT Products
Return
Service Manual
1997-07-15
239
F-code
Section
C-code
PS
S7.3
7310
Version no
T-code
000
240
Return
Service Manual
1997-07-15
F-code
PS
Section
C-code
S7.4
7310
Staging Cylinder, 3 Stage
Version no
T-code
000
395/396/397/398/399
POS.
NO
BT Products
Return
DESCRIPTION
POS.
NO
DESCRIPTION
Screw
Ring, wear
Washer, seal
10
Piston
Cylinder tube, 1 Port
11
Ring, retainer
Cylinder tube, 2 Port
12
Rod, cylinder
Plugger assembly
13
O ring
Spring
14
Bearing
Plug
15
Seal, rod
O ring
16
Wiper
Service Manual
1997-07-15
241
F-code
Section
C-code
PS
S7.4
7310
Version no
T-code
000
395/396/397/398/399
1.1. Removal
brake.
2. Fully extend the cylinders to inspect the rod (12) for
gouges or pits. If gouges or pits are detected, then
the cylinder must be removed for repair.
3. Lift mast so inner column is raised approximately
12 inches. Securely block mast, using 4 in. x 4 in.
blocks under each side of the inner columns.

lowering, always block both sides of the
column. If both sides are not blocked,
the truck could tip over on its side.
4. Remove bolts from top end of staging cylinder

rods. Lower cylinder rods hydraulically.
5. Clean the exterior of the lift cylinder.

1.2. Disassembly
1. Remove gland nut (12) from the cylinder tube.
2. Remove and discard all seals, rod wiper (15) and
bearing (14) from the gland nut (12). Us care NOT
to damage the inside of the gland nut.
1.3. Assembly
1. Install new bearing (14), seals and rod wiper (16) in
the gland. The lip of the wiper must face outward.
It is not necessary to replace wear ring (9), unless
the cylinder was removed for rod repair.
242
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Service Manual
1997-07-15
F-code
PS
Section
C-code
S7.4
7310
Version no
000
T-code
395/396/397/398/399
1.4. Installation
1. Install crosshead, chains, hoses, and electric
cables.
2. Test for proper operation.
BT Products
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Service Manual
1997-07-15
243
F-code
Section
C-code
PS
S7.4
7310
Version no
T-code
000
395/396/397/398/399
244
Return
Service Manual
1997-07-15
F-code
Section
PS
S7.5
Version no
001
C-code
7320
Tilt Cylinder
T-code
395
Tilt Cylinder
Seal Kit Contains Items Marked with K
POS.
NO
DESCRIPTION
POS.
NO
Tilt cylinder assembly
6K
Bushing
Retainer, cylinder
4
5K
BT Products
Return
DESCRIPTION
POS.
NO
DESCRIPTION
Seal
11K
O Ring
Bearing, cylinder
12K
Ring, back-up
8K
Ring, back-up
13K
Retainer
Screw, cap
9K
O Ring
Wiper
10
Rod, cylinder
Service Manual
1997-07-16
14
Tube, cylinder
245
F-code
Section
C-code
PS
S7.5
Tilt Cylinder
7320
Version no
T-code
001
395
1. Removal
brake.
2. Raise reach approximately 12 inches and block so
reach will not lower.
3. Relieve pressure on the tilt cylinder (1).
4. Pivot carriage/reach upward and block to prevent
the carriage/reach from lowering.
5. Remove the strap (3) and cap screws (4) that
secure cylinder to carriage/reach.
6. Remove hydraulic hoses from tilt cylinder (1).
7. Remove tilt cylinder (1) from the truck.
2. Disassembly
clean environment. Make sure all parts are
cleaned before disassembly and kept
clean during assembly.
1. Before disassembly, clean exterior of the tilt

cylinder (1) in a cleaning solvent to remove all
contamination.

2. Be sure all hydraulic fluid has been removed from
the cylinder. Stroking the piston rod will help force
the fluid out.
3. Put the base end of the cylinder in a vise equipped
with soft jaws.
4. Remove the bearing retainer (13) and fastening
ring (7), from cylinder tube.
246
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Service Manual
1997-07-16
F-code
Section
PS
S7.5
Version no
001
C-code
7320
Tilt Cylinder
T-code
395
5. Remove bearing assembly, seals, rings, rod (10)

and piston seals.
6. Remove and discard all seals and rod wiper
(5,6,8,9,11, and 12).
7. Inspect mounting bushings (2) located at both ends
of the cylinder. It will not be necessary to remove
them unless they are found to be unfit for further
service.
3. Inspection
1. Carefully clean all parts in a cleaning solvent and
position them on a clean work surface

2. Check the piston 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 you do not remove
the chrome plating. Deeper damage will require
replacement of the piston 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 the cylinder tube to be
sure the threads have not been damaged.
4. Assembly
1. Install new packing and rod wipers in the bearing
assembly. The lip of the wiper must face outward.
2. Install new bearing seals, back-up ring and retainer
(13) on the bearing assembly.
BT Products
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Service Manual
1997-07-16
247
F-code
Section
C-code
PS
S7.5
Tilt Cylinder
7320
Version no
T-code
001
395
3. Install new piston seals on the piston.

4. Install piston on rod.
5. Apply clean hydraulic fluid to the piston rod
assembly. Coat the inside of the cylinder barrel and
bearing assembly with clean fluid.
6. Carefully slide bearing assembly on the piston rod.
Be sure the rod end does not cut or nick the wiper
or packing upon installation.
7. Install piston and rod into cylinder barrel. Be careful
that the piston seals are not nicked or cut on the
edge of the cylinder barrel or when sliding them
over the groove within the barrel.
8. Next, install bearing assembly into cylinder barrel.
Again, use care so the seals are not nicked or cut
upon installation.
9. Check installation by making sure the piston rod
assembly moves fairly easy within the barrel
assembly without binding.
10. Install bearing fastening ring and retainer.
5. Installation
1. Install cylinder on reach front frame.
2. Install mounting straps (3) and secure with four
cap screws (4).
3. Properly connect correct hydraulic hoses to front
and rear of tilt cylinder.
4. Remove blocking and chains.
5. Fill hydraulic reservoir with new clean oil.
6. Connect battery.
7. Operate the tilt to remove air from hydraulic hoses
and check operation of the of whole hydraulic
system.
248
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Service Manual
1997-07-16
F-code
Section
PS
S7.5
Version no
001
C-code
7320
Tilt Cylinder
T-code
395

penetrate the skin causing serious
injury.
Relieve pressure
before
disconnecting hydraulic or other lines.
Tighten all connections before applying
pressure. Keep hands and body away
from pinholes and nozzles which eject
fluids under high pressure.
8. After running the hydraulic system, check and fill

the hydraulic reservoir with more new clean oil.
BT Products
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Service Manual
1997-07-16
249
F-code
Section
C-code
PS
S7.5
Tilt Cylinder
7320
Version no
T-code
001
395
250
Return
Service Manual
1997-07-16
F-code
Section
PS
S7.6
Version no
C-code
7320
Tilt Cylinder
T-code
000
396/397
Tilt Cylinder
23
22
21 20
19
18
24
25
08
26
09
16 15 14
13
12
11
17
10
05
06
07
01
04
02
03
02
BT Products
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Service Manual
1997-07-16
251
F-code
Section
C-code
PS
S7.6
Tilt Cylinder
7320
Version no
T-code
000
396/397
Pos.
No
Description
Pos.
No
Description
Pos.
No
Description
Pos.
No
Description
01
Pin, roll
08
Bearing
15K
O ring
22K
Seal, rod
02
Washer
09
Tube, cylinder
16K
Ring, sealing
23K
Wiper, rod
03
Bearing
10
Retainer
17K
O ring
24
Rod, cylinder
04
Pin
11
Nut
18K
O ring
25
Nut
05
Pin
12
Washer, flat
19K
Ring, sealing
26
Clevis
06
Pin, roll
13K
Ring, guide
20
Bearing
Kit, seal
07
Cylinder assy.
14
Piston
21K
Ring, guide
1. Removal
brake.
2. Raise reach approximately 12 inches and block so
reach will not lower.
3. Relieve pressure on the tilt cylinder.
4. Pivot carriage/reach upward and block to prevent
the carriage/reach from lowering.
5. Remove hydraulic hoses from tilt cylinder and mark
their position.
6. Remove roll pin (06) and top mounting pin (05) and
remove tilt cylinder from truck.
7. Repeat on other side of truck as needed.
252
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Service Manual
1997-07-16
F-code
Section
PS
S7.6
Version no
000
C-code
7320
Tilt Cylinder
T-code
396/397
2. Disassembly
clean environment. Make sure all parts
are cleaned before disassembly and kept
1. Before disassembly, clean exterior of the tilt

cylinder in a cleaning solvent to remove all
contamination.

the fluid out.
with soft jaws.
4. If needed, the roller bearing (03) at base of cylinder
rod can be removed at this time. Remove a roll pin
(01) and slide a mounting pin (04) from the clevis
(26).
5. Remove the gland retainer (10) and fastening ring
(20) by rotating the gland with a spanner wrench
from cylinder tube (09).
6. Remove gland assembly, seals, rings, rod and
piston, and piston seals.
7. Remove and discard all seals and rod wiper.
8. Inspect mounting bushings (08) located at the base
end of the cylinder tube (09). It will not be
necessary to remove them unless they are found to
be unfit for further service.
BT Products
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Service Manual
1997-07-16
253
F-code
Section
C-code
PS
S7.6
Tilt Cylinder
7320
Version no
T-code
000
396/397
3. Inspection
position them on a clean work surface

2. Check the 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 you do not remove the
chrome plating. Deeper damage will require
replacement of piston rod assembly. Make sure the
threads on the rod are free of damage.
replacement.
4. Check threaded section of the cylinder tube (09) to
be sure the threads have not been damaged.
4. Assembly
1. Install new packing and rod wiper in the gland
2. Install new gland seals, back-up ring and O ring on
the gland assembly
3. Install new piston seals on the piston.
4. Install piston on rod (24).
5. Install nut (11) on cylinder rod (24). Torque cylinder
piston nut to 40 ft-lb (54 Nm).
assembly. Coat the inside of the cylinder tube (9)
and gland assembly with clean fluid.
6. Carefully slide the gland assembly onto piston
254
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Service Manual
1997-07-16
F-code
Section
PS
S7.6
Version no
000
C-code
7320
Tilt Cylinder
T-code
396/397
cylinder rod (24). Be sure the rod end does not cut
or nick the wiper or packing upon installation.
7. Install piston and rod into cylinder tube (09). Be
careful that the piston seals are not nicked or cut
on the edge of the cylinder tube or when sliding
them over the groove within the tube.
8. Next, install gland assembly into cylinder tube (09).
upon installation.
assembly moves fairly easy within the tube
10. Install gland bearing (20) and retainer (10).
11. The roller bearing and clevis assembly can be
installed at this time if removed earlier.
BT Products
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Service Manual
1997-07-16
255
F-code
Section
C-code
PS
S7.6
Tilt Cylinder
7320
Version no
T-code
000
396/397
5. Installation
1. Install tilt cylinder on carriage/reach front frame.
Secure with mounting pin (05) with roll pin (06).
3. Properly connect correct hydraulic hoses to top
and bottom of tilt cylinder.
6. Connect battery.
7. Operate the tilt to remove air from hydraulic hoses
and check operation of the of whole hydraulic
system.

penetrate the skin causing serious
injury.
Relieve pressure
before
disconnecting hydraulic or other lines.
Tighten all connections before applying
pressure. Keep hands and body away
from pinholes and nozzles which eject
fluids under high pressure.
256
Return
Service Manual
1997-07-16
F-code
Section
PS
S7.7
7330
Reach Cylinder
Version no
C-code
T-code
001
Reach Cylinder
Seal Kit Contains Items Marked with K

POS.
NO
DESCRIPTION
POS.
NO
Right reach cylinder
10K
Seal
Left reach cylinder
11K
Wiper
Pin, roll
12
Rod, cylinder
Pin, clevis
13
Nut
Pin, clevis
14
Clevis
23
Right tube cylinder
6K
Back-up ring
15
Spacer (2 stage mast only)
24
Left tube cylinder
7K
O ring
16K
O Ring
25
Bearing
Bearing
17K
Ring, back-up
Kit, seal
Ring, guide
18K
O Ring
8
9K
BT Products
Return
DESCRIPTION
Service Manual
POS.
NO
19
20K
1997-09-30
DESCRIPTION
Piston
Ring, guide
21
Nut, lock
22K
Retainer
257
F-code
Section
C-code
PS
S7.7
Reach Cylinder
7330
Version no
T-code
001
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 the front and rear mounting pins and
remove reach cylinder from the truck.
7. To remove rear mounting pins, reach must be
raised to full freelift.
258
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Service Manual
1997-09-30
F-code
Section
PS
S7.7
7330
Reach Cylinder
Version no
C-code
T-code
001
2. Disassembly
clean environment. Make sure all parts
are cleaned before disassembly and kept
1. Before disassembly, clean exterior of the reach
cylinder in a cleaning solvent to remove all
contamination.
the fluid out.
with soft jaws.
4. Remove the bearing retainer (22) and bearing (8)
by rotating the bearing with a spanner wrench from
cylinder tube (23 or 24).
5. Remove bearing assembly, seals, rings, rod (12)
and piston (19) with spacer and piston seals.
6. Remove and discard all seals and rod wiper (11).
7. Inspect mounting bushings (25) located at base
end of the cylinders. It will not be necessary to
remove them unless they are found to be unfit for
further service.
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Service Manual
1997-09-30
259
F-code
Section
C-code
PS
S7.7
Reach Cylinder
7330
Version no
T-code
001
3. Inspection
position them on a clean work surface.
2. Check the piston rod 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 you do not remove the chrome plating.
Deeper damage will require replacement of the
piston rod assembly. Make sure the threads on the
rod are free of damage.
replacement.
4. Check threaded section of the cylinder tube to be
sure the threads have not been damaged.
260
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Service Manual
1997-09-30
F-code
Section
PS
S7.7
7330
Reach Cylinder
Version no
C-code
T-code
001
4. Assembly
1. Install new O rings and rod wiper in the bearing
2. Install new bearing seals, back-up ring (17), and
bearing (8) on the bearing assembly.
3. Install new piston seals on the piston (19).
4. Install piston (19) on rod.
5. Install nut (21) on cylinder rod (12). Torque reach
cylinder piston nut to 40 ft-lb (Nm).
assembly. Coat the inside of the cylinder tube and
bearing assembly with clean fluid.
7. Carefully slide the spacer (if used) and bearing
assembly onto the cylinder rod. Be sure the rod
end does not cut or nick the wiper or packing upon
installation.
7. Install piston (19) and cylinder rod (12) into cylinder
tube (23 or 24). Be careful that the piston seals are
not nicked or cut on the edge of the cylinder tube or
when sliding them over the groove within the tube.
8. Next, install bearing assembly into cylinder tube.
upon installation.
assembly moves smoothly within the tube
10. Install bearing (8) and retainer (22).
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1997-09-30
261
F-code
Section
C-code
PS
S7.7
Reach Cylinder
7330
Version no
T-code
001
5. Installation
1. Raise reach to full freelift height and install reach
cylinder and front and rear mounting pins. Secure
mounting pins with roll pins.
2. Connect correct hydraulic hoses to reach cylinders.
5. Connect battery.
6. Operate the reach to remove air from hydraulic
hoses and check operation of the of whole
hydraulic system.
CAUTION DO NOT use your hands to check for

penetrate the skin causing serious injury.
Relieve pressure before disconnecting
hydraulic or other lines. Tighten all
connections before applying pressure.
Keep hands and body away from pinholes
and nozzles which eject fluids under high
pressure.
262
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Service Manual
1997-09-30
F-code
Section
PS
S9.0
9310
Height Indicator
Version no
C-code
T-code
000
395/396/397/398/399
Height Indicator
13
17
18
14
10
1
16
11
12
15
19
9
7
8
2
Wiring
Harness
4
POS.
NO
BT Products
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DESCRIPTION
POS.
NO
DESCRIPTION
POS.
NO
DESCRIPTION
Support
Ring, locking
15
Device, sensing
Cover
Bearing
16
Screw
Anchor, bottom
10
Washer
17
Nut
Spring
11
Screw
18
Screw
Roller
12
Arm
19
Cable
Bearing
13
Screw
Ring, snap
14
Setscrew
Service Manual
1997-07-15
263
F-code
Section
C-code
PS
S9.0
Height Indicator
9310
Version no
T-code
000
395/396/397/398/399
1. Pulse sensor
1.1. Repair
1. Unplug wiring connector from assembly.
2. Remove screws (16) and remove cover (2).
3. To replace pulse sensor (15), loosen setscrew (14)
and remove pulse sensor.
4. Remove screws (13) and remove arm (12).
Reverse procedure to reinstall.
1.2. Cable
1.2.1. Removal
1. To replace cable (19), remove bolt from bottom
anchor (3) relieving spring tension.
2. Remove spring (4) and anchor (3) from cable (19).
3. Remove cable (19) from top anchor, and remove
from pulley.
1.2.2. Installation
1. Install new cable (19) on top anchor. Wrap cable
once around pulley wheel.
2. Attach spring (14) and bottom anchor (3) to cable
(19).
3. Stretch cable (19) tight and reinstall bottom anchor
bolt.
1.3. Pulley
1.3.1. Removal
1. To replace pulley wheel (5), remove cover (2),
pulse sensor, and cable (19).
2. Remove screw (11) and remove pulley wheel.
3. Remove bearing (9), retaining rings, (7 and 8) and
bearing (6).
4. Reverse procedure to reinstall.
264
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Service Manual
1997-07-15
F-code
Section
C-code
PS
S9.1
9390
Height Indication & Preset Height
Version no
000
T-code
395/396/397/398/399

01
02
POS.
NO
BT Products
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Service Manual
DESCRIPTION
01
Indicator, lift height
02
Range of lift preseletion
1997-07-15
265
F-code
Section
C-code
PS
S9.1
9390
Version no
T-code
000
395/396/397/398/399
1. General
A height indicator is fitted to trucks with high lifting heights
which show the current position of the forks within the staging
zone.
The character window (01) shows the fork height, based on
information from the sensing device (pulse sensor) (15)
mounted on mast.
2. Operation
The measurement in the staging zone starts when the
reference switch (S45) is activated and sends a signal to the
electronic card (A5). The pulse sensor (15) send pulses to
(A5) which starts by indicating the preprogrammed free lift
height on the display (02). 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 the forks are
moved up or down.
266
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1997-07-15
F-code
Section
C-code
PS
S9.1
9390
Version no
000
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.
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1997-07-15
267
F-code
Section
C-code
PS
S9.1
9390
Version no
T-code
000
395/396/397/398/399
4. Display
The diagram shows the rear of the display for preset height.
Table describes the contactors terminal number where I
stands for input and O stands for output.
Contactor Terminal Number

Terminal
Number
Connection
Function
TX (+), transmits data
RX (+), receives data
+48V
TX (-), transmits data
Minus
RX (+), receives data
268
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1997-07-15
F-code
Section
C-code
PS
S9.1
9390
Version no
000
T-code
395/396/397/398/399
5. Description of the display symbols.

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 that the
operator has a load on the forks
when starting.
Push-button to access
programming routines.
Display for indicating height
levels and error codes.
BT Products
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Service Manual
1997-07-15
269
F-code
Section
C-code
PS
S9.1
9390
Version no
T-code
000
395/396/397/398/399
6. Programming
Press the button PROG briefly to enter the programming
mode. The LED in the button comes on and the display
shows PL00 when programming routines have been started.
You can program new lifting heights, modify programmed
values, or remove programmed values.
6.1. Programming a Level

Programming of lift heights can only take place within the
staging zone, above initial lift.
NOTE: Forks not horizontal.
The load can slide off the forks or catch on
the rack. When the load is left or collected,
the forks should always be positioned
horizontally.
6.1.1. Collection Level

1. Press the PROG button briefly. State the required
level (e.g., 1+5=level 15). The numbers are shown
on the display.
2. Lift the forks to the required level and press the
button COLLECT. The LED flashes.
6.1.2. Leaving Level
1. Pick-up the load and wait three seconds. Lift the
forks just enough so that the pallet can be removed
from the rack. Ensure that there is sufficient space
for safe handling.
2. Now press the LEAVE button, both LEDs for
collecting and leaving will start to flash.
3. Press the PROG button until both the LEDs go out
and the display indicates PL00, storing information.
4. Repeat from the first point to program more levels.
5. Press STOP to return to the display mode.
270
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F-code
Section
C-code
PS
S9.1
9390
Version no
000
T-code
395/396/397/398/399
6.2. Erasing Programmed Levels

1. Lower the forks to the free lift zone when
programmed lifting heights are to be erased.
2. Enter the programming mode and state the
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 the forks are raised/lowered to required level without a
load and the other with a load.
6.2.2. Collecting a Load
1. State the required height level using buttons 0-9,
(e.g., 1+2=level 12). The display will show LE12.
2. Raise/lower the forks until they are automatically
stopped by the 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 the forks stop and the COLLECT LED
comes ON, the forks can be maneuvered in under
the load.
horizontally.
4. Lift the forks until they are automatically stopped by
the electronics and the LED leave comes ON.
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271
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Section
C-code
PS
S9.1
9390
Version no
T-code
000
395/396/397/398/399
5. Move the load from the rack. When the 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 the required height level using buttons 0-9,
(e.g., 5=level 05). The display will show LE05.
3. Raise/lower the forks until they are automatically
stopped by the 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 the forks stop and the LEAVE LED comes
ON, the forks can be maneuvered out from under
the load.
horizontally.
5. Lower the forks until they are automatically

stopped by the electronics and the COLLECT LED
comes ON.
6. Remove the forks from the rack. When the work
cycle has been completed, the LEDs will go OUT.
272
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1997-07-15
F-code
Section
C-code
PS
S9.1
9390
Version no
000
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 the 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 the factory
settings. These can be changed to any of the min/
max. values shown in the, Parameters table.
NOTE: If a value outside the min/max. range is
programmed in, this will be replaced by the
max/min. factory setting.
4. Press the STOP button to complete programming.
P1
Select the measurement unit (meters or inches) you wish to
use. Press the PROG button to save the unit you selected.
The display shows P_.
P2
If the distance between lifting heights is equal on all levels,
you can make a common program:
1. State parameter 2 and press the LOAD button.
The display shows P 00 and you now 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.
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1997-07-15
273
F-code
Section
C-code
PS
S9.1
9390
Version no
T-code
000
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 the numerical keys. The permitted
max/min. 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 the
numerical keys.
3. Press the PROG button to save the new values.
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 max/min. 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 min. distance.
Enter the new value using the numerical keys,
(e.g., 030=30 mm). The permitted max/min. values
are shown in the Parameters table.
274
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F-code
Section
C-code
PS
S9.1
9390
Version no
000
T-code
395/396/397/398/399
2. Press the Load button. The display shows the

previously programmed value for the max distance.
(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.
(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_.
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1997-07-15
275
F-code
Section
C-code
PS
S9.1
9390
Version no
T-code
000
395/396/397/398/399
Parameter Table
Parameter
number
Max/min.
value
P1
001
002
Factory
setting
Unit
Function
m-10 mm
inch-10ths of
an inch
Measurement unit
P2
Programming of several levels at

equal collect/leave distances.
1-69
0-999
0-255
0-999
P3
10s of mm
10 mm
10 mm
% of maximum
speed
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
0-255
0-255
276
Return
Number of levels.
Distance first collect height.
Distance collect-leave.
Distance between leave levels.
050
030
10 mm
10 mm
Service Manual
Braking distance before stop:

Lower
Lift
1997-07-15
F-code
Section
C-code
PS
S9.1
9390
Version no
000
Position
T-code
395/396/397/398/399
Function
Leave level
Collect level
Staging zone
H2
Free lifting zone
C
P3
P9
P7
A
P5
B
P3 P5
P9
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H2
Service Manual
1997-07-15
277
F-code
Section
C-code
PS
S9.1
9390
Version no
T-code
000
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 the truck computer.
Four lines light up when started. This indicates that no

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

was active when the truck was started, e.g., the forks were
over the free lift zone. If the points still flash, the preset
mast height could be set to 0; or when the forks are
lowered, there can be a fault in the wiring; or the reference
height switch can be faulty.
278
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1997-07-15
F-code
Section
C-code
PS
S9.1
9390
Version no
000
BT Products
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Service Manual
1997-07-15
T-code
395/396/397/398/399
279
BT Prime-Mover, Inc., 3305 N. Highway 38, Muscatine, Iowa 52761-8800 U.S.A

Tel (319) 262-7700 Fax (319) 262-7600
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306756-000 1998 - April PDF

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Service Manual

RRX35/45, RDX30, RSX40/50

WARNING Read and observe all warnings on this unit

Date: April 20, 1998

Drive Gear / Transmission

Brake / Wheel System

Hydraulic / Pneumatic System

Operating Function-lifting Mast / Cylinders

Peripheral / Installation Equipment

Inch (SAE) and Metric Fasteners ................................................................

Technical Service Data ................................................................................ 37

Brake Pedal ...................................................................................................

Drive Motor ...................................................................................................

Drive Motor ...................................................................................................

Caster Brake Assembly ............................................................................... 89

Drive Wheel ................................................................................................... 97

Tandem Load Wheels ................................................................................. 111

Caster Wheels .............................................................................................

Steering Arm / Wheel / Lever .....................................................................

Steering Bearing ......................................................................................... 127

Transistor Regulator ................................................................................... 167

Pump Motor .................................................................................................

Hydraulic System ........................................................................................ 199

Mast, 3 Stage ............................................................................................... 213

Tilt Cylinder .................................................................................................

Reach Cylinder ............................................................................................

Height Indicator ........................................................................................... 263

OPEN FLAMES PROHIBITED

Introduction, Service Manual

GENERAL PRODUCT INFORMATION

TECHNICAL SERVICE DATA

ORDERING SPARE PARTS

General Product Information

1.1. Intended Application of the Trucks

1.2. Forbidden Application of the Truck

As a towing tractor for trailers.

To tow other trucks.

To drive on gravel or grass.

1.3. Truck Data

Operating speed without load, mph

Operating speed with load, mph

Lifting capacity rated load, lb

Service weight without battery, lb

The trucks lifting capacity, lifting height, and weight can be

1.4. RRX35 Dimensions

1.5. RRX45 Dimensions

1.6. RDX30 Dimensions

1.7. RSX40 Dimensions

1.8. RSX50 Dimensions

1.9. Data Plate

Truck model number

14 Control circuit fuse:

Main Components of Truck

3. Grease Point Location

4. Mast Adjustment Points

Inch (SAE) and Metric Fasteners

1/2 x 13 UNC x 1-1/2

WARNING When fasteners must be replaced the new

Table 1. Bolt and Screw Designations

Strength Levels: Property Classes

* Markings Not Required

Hex Head Bolts