BT Prime-Mover Forklift RTX35/45 Electric Stand-Up Rider Truck Master Service Manual – PDF DOWNLOAD

 BT Prime-Mover Forklift RTX35/45 Electric Stand-Up Rider Truck Master Service Manual – PDF DOWNLOAD

FILE DETAILS:

BT Prime-Mover Forklift RTX35/45 Electric Stand-Up Rider Truck Master Service Manual – PDF DOWNLOAD

Language : English,
Pages :543
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

BT Prime-Mover Forklift RTX35/45 Electric Stand-Up Rider Truck Master Service Manual – PDF DOWNLOAD

BT Prime-Mover Standard Codes 4
Worksheet standard 4
C-Code List 4
Warning Symbols 16
1 Warning Levels 16
DANGER 16
WARNING 16
CAUTION 16
NOTE! 16
Prohibitory Symbols 17
NO SMOKING 17
OPEN FLAMES PROHIBITED 17
GENERAL PROHIBITION 17
1 Ordinance Symbols 17
SAFETY SHOES 17
PROTECTIVE GLASSES 17
Safety 18
1 General Safety 18
Battery Safety 22
Static Safety 26
1 Place a static discharge wrist strap around your wrist Connect the ground lead to the wrist s 26
2 Connect the ground clamp to an unpainted, grounded surface on the truck frame 26
3 If removing or installing static-sensitive components, place them on a properly grounded stati 26
4 To transport static-sensitive components, including failed components being returned, place th 26
Welding Safety 27
Introduction, Service Manual 30
Contents, Section M 32
1 Machine Information 32
General Product Information 34
1 Truck Presentation 34
11 Truck Side Views 34
12 Open Back Compartment 35
13 Intended Truck Application 36
14 Prohibited Truck Application 36
15 Truck Data 36
16 RTX35 Dimensions 37
17 RTX45 Dimensions 38
18 Data Plate 39
Legend 39
1 Truck model number 39
2 Truck serial number 39
3 Weight less battery 39
4 Maximum battery weight 39
5 Minimum battery weight 39
6 Truck voltage DC 39
7 Battery type UL class 39
8 Battery maximum AMP hours 39
9 Hour rate 39
10 Truck type 39
11 Mast serial number 39
12 Attachment 39
13 Maximum degree rear tilt 39
14 Truck capacity 39
2 Main Components 40
1 Hydraulic valve: 40
2 Battery: 40
3 Battery connector: 40
4 Hydraulic unit: 40
5 Drive unit with brake: 40
6 Electrical steering: 40
7 Data plate: 40
8 Cover: 40
9 Pedal: 40
10 Control console: 40
11 Instrument panel (Operator Display): 40
12 Mast: 40
13 Electronics: 40
14 Control circuit fuse (F50): 40
15 Steering circuit fuse (F51): 40
16 Drive motor fuse (F1): 40
17 Pump motor fuse (F3): 41
18 Right foot pedal 41
19 Emergency stop 41
20 Lift height indicator fuse (F52): 41
21 12 volt sensor feed fuse (F53): 41
22 Display power fuse (F54): 41
23 Relay1 fuse (F55): 41
24 Fuse (AF1): 41
25 Fuse (AF2): 41
26 Auxiliary power circuit fuse (AF3): 41
Main Components of Truck 42
3 Grease Point Location 43
4 Mast Adjustment Points 44
Inch (SAE) and Metric Fasteners 46
1 Introduction 46
2 Nomenclature, Threads 47
3 Strength Identification 48
4 Conversion of Metric and English Units 55
Technical Service Data 58
MODEL 58
RTX35 (192 inch mast) 58
RTX45 (210 inch mast) 58
Series – DC 58
Series – DC 58
5 hp/3725 kw (24 volt drive motor) 625 hp/466 kw (36 volt drive motor) 16hp/119 kw (36 volt l 58
1 hour continuous 58
1 hour continuous 58
08 inch (20 mm) 58
08 inch (20 mm) 58
290 inches (74 mm) 58
290 inches (74 mm) 58
64 oz (180 grams) 58
64 oz (180 grams) 58
Vertical motor spiral-bevel output 58
Vertical motor spiral-bevel output 58
1757 58
1757 58
1 gallons (379 liters) 58
1 gallons (379 liters) 58
SAE 80W90 58
SAE 80W/90 58
ATF 58
SAE 80W90 58
SAE 80W/90 58
ATF 58
135 x 55 x 100 inches (343 x 140 x 254 mm) 59
135 x 55 x 100 inches (343 x 140 x 254 mm) 59
1600 lb battery 145” BC – 6735 (3054) 2000 lb battery 165” BC – 4315 (1959) 59
2000 lb battery 165” BC – 4750 (2156) 2400 lb battery 21” BC – 4910 (2229) 59
1600 lb battery 145” BC – 3240 (1471) 2000 lb battery 165” BC – 3430 (1557) 59
2000 lb battery 165” BC – 3780 (1716) 2400 lb battery 21” BC – 4025 (1827) 59
95 ft-lb (130 N•m) 59
95 ft-lb (130 N•m) 59
50 x 36 inches (127 x 91 mm) 59
50 x 36 inches (127 x 91 mm) 59
1600 lb battery 145” BC – 6860 (3114 2000 lb battery 165” BC – 7145 (3244) 59
2000 lb battery 165” BC – 8595 (3902) 2400 lb battery 21” BC – 8690 (3945) 59
300 Amp 400 Amp 59
Not Applicable (N/A) 425 Amp 59
24V -1400 empty-750 loaded 36V – 2100 empty-1500 loaded 59
36V – 2250 empty-1450 loaded 59
36 volt 116 HP with 20% duty cycle 59
20% on 5 minute cycles 59
08 inch (20 mm) 59
062 inch (16 mm) 59
290 inches (74 mm) 59
280 inches (72 mm) 59
64 oz (180 grams) 59
40 oz (1120 grams) 59
2450 psi (16890 kPa) 59
2450 psi (16890 kPa) 59
11 cc upper/4 cc lower 60
16 cc upper/4 cc lower 8 cc upper/4 cc lower 60
N/A 60
23 cc upper/4 cc lower 11 cc upper/4 cc lower 60
5 gallons (19 liters) 60
5 gallons (19 liters) 60
Sunoco TH 60
ATF 60
Texaco 15 60
Sunoco TH 60
ATF 60
Texaco 15 60
250 Amp 60
250 Amp 60
425 Amp 60
355 Amp 60
N/A 60
500 Amp 60
10 Amp 60
10 Amp 60
144 x 388 x 320 inches 60
(366 x 986 x 813 mm) 60
164 x 388 x 320 inches 60
(417 x 986 x 813 mm) 60
164 x 388 x 320 inches 60
(417 x 986 x 813 mm) 60
209 x 388 x 320 inches 60
(531 x 986 x 813 mm) 60
1020 Amp hours 60
1000 Amp hours 875 Amp hours 60
N/A 60
1000 Amp hours 875 Amp hours 60
145 inches (368 mm) 1600 lb (726 kg) 60
(2300 lb / 1044 kg) 60
165 inches (419 mm) 2000 lb (908 kg) 60
(2300 lb / 1044 kg) 60
165 inches (419 mm) 2000 lb (908 kg) 60
(2300 lb / 1044 kg) 60
210 inches (533 mm) 2400 lb (1089 kg) 60
(2900 lb (1317 kg) 60
60 mph (965 kph) 61
65 mph (1046 kph) 61
N/A 61
65 mph (1046 kph) 61
55 mph (885 kph) 61
60 mph (965 kph) 61
N/A 61
60 mph (965 kph) 61
57 fpm (1737 m/min) 61
80 fpm (244 m/min) 61
N/A 61
95 fpm (29 m/min) 61
34 fpm (104 m/min) 61
60 fpm (183 m/min) 61
N/A 61
60 fpm (183 m/min) 61
80 fpm (244 m/min) 61
90 fpm (275 m/min) 61
80 fpm (244 m/min) 61
95 fpm (29 m/min) 61
95 Amps 61
80 Amps 61
N/A 90 Amps 61
115 Amps 61
95 Amps 61
N/A 61
105 Amps 61
170 Amps 61
215 Amps 61
145 Amps 61
200 Amps 61
235 Amps 61
170 Amps 61
N/A 61
310 Amps 61
225 Amps 61
N/A 61
330 Amps 61
240 Amps 61
325 Amps 61
395 Amps 61
270 Amps 61
355 Amps 61
430 Amps 61
300 Amps 61
N/A 61
530 Amps 61
390 Amps 61
N/A 61
550 Amps 61
395 Amps 61
Ordering Spare Parts 62
1 Locate the fault on the truck 62
2 Identify truck model, serial number, and battery voltage 62
3 Locate the page with the exploded diagram and find the item number for the part required 62
4 Locate the item number in the table Select the column for the actual truck model and serial n 62
5 Note the part number 62
6 Call your local BT Prime-Mover Dealer and indicate the part number 62
7 If the model, serial number, or the article number cannot be found on the truck, call your loc 62
Contents, Section P 64
1 Planned Maintenance 64
Introduction, Maintenance 66
1 Safe Jacking Procedure 67
1 Lower the forks completely Remove any load 67
11 Elevate Rear of Truck 67
1 Place the jack in the designated jacking position 67
11 Elevate Either Side of Truck 67
1 Place the jack in the designated jacking position 67
2 Lubricants 68
21 Cold Storage Conditioning 68
22 Electrical Component Cold Storage Conditioning 68
Service Schedule 70
1 Planned Maintenance Schedule 70
ITEM 70
WORK REQUIRED 70
Interval in Hours 70
2 Planned Maintenance Procedures 75
21 Services Performed Daily or Every 8 Operating Hours 75
211 Battery Discharge Indicator with slow down 75
212 Hydraulic System 75
213 Frame/Sheet Metal 76
214 Wheels/Tires 76
215 Functions/Operations 76
22 Services Performed Monthly or Every 120 Operating Hours 76
221 Inspection 76
222 Transmission 76
223 Brake 76
224 Battery 77
225 Electrical Connections 77
226 Contactor Tips (NOT Sealed) 77
227 Motor Brushes 77
228 Drive Motor 77
229 Hydraulic Reservoir 78
2210 Frame Lube (“Lubrication Chart” on page79) 78
2211 Pivot Points 78
23 Services Performed Every 480 or 960 Operating Hours 79
231 Drive Motor 79
1 Dusty or sandy locations; that is cement plant, lumber or flour mills, coal dust or stone-crus 79
24 Services Performed Annually or Every 1440 Operating Hours 79
241 Inspection 79
242 Transmission 80
243 Battery 80
244 Hydraulic System 80
245 Brakes 81
246 Lift and Carriage Chains 81
Lubrication Chart 82
Interval/Running Hours 82
Lubricant 82
720 h 82
Truck Lubrication Points 82
Oil and Grease Specifications 84
1 Approved Oils and Grease 84
Specification 84
Lubricant 84
Standard and Corrosion 84
Cold Storage 84
Freezer 84
Application area 84
Continuous Operation Above 23 F (-5 C) 84
Continuous Operation To 5 F (-15 C) Intermittent Operation To -13 F (-25 C) 84
Continuous Operation To 31 F (-35 C) 84
Contents, Section S 86
1 Service Instructions 86
Troubleshooting Guidelines 88
1 General 88
1 Inspect truck for physical damage or mechanical malfunction Contactors must be free to move a 89
2 Check for ground faults from the electrical system to the frame with an ohmmeter A minimum of 89
3 Check that the battery is fully charged and connected 89
4 Operate the truck in all modes to determine the exact symptoms DO NOT forget that these syste 89
2 Electrical 90
21 Shorts to Frame Test 90
1 Turn the key switch OFF and disconnect the battery connector 91
2 To test the battery for shorts to case, connect a 12-volt test light to the battery case from 91
3 With the battery disconnected from the truck, use a digital volt/ohm/ammeter on the ampere fun 92
4 With the battery disconnected (or removed and disconnected) from the truck, use a digital ohmm 92
a To identify the cause of the short to frame, disconnect circuit components until the low resis 92
5 Reconnect the battery connector to the truck and turn the key switch ON If the battery was pr 93
6 Use a volt/ohm/ammeter on the current function meter to measure leakage current to the truck f 93
a To identify the cause of the short to frame, disconnect circuit components until the leakage c 93
7 After all components are reconnected, and a reading is less than 0001 ampere (1 mA) there is 94
3 Hydraulic 95
4 Definitions 96
Chassis 98
1 General 98
t 98
2 Top Console 99
21 Removal 99
1 Park truck on a level surface and block 99
22 Installation 99
1 Place the top console over the steering wheel and control handle 99
3 Motor Compartment Door100
31 Removal100
1 Use an Allen wrench to turn the latch screw clockwise one quarter turn100
32 Installation100
1 Set the door in place so the hinge pins are securely mounted in the panel hinge100
4 Left Side Panel (Exterior)101
41 Removal101
1 Park truck on a level surface and block101
7 Remove four bolts securing the overhead guard post Disconnect wiring harness at the post if a101
8 Pull the left side panel outward and set aside101
42 Installation102
1 Lift left side panel up to align the three studs on the panel with the holes in the frame102
5 Left Operator Compartment Panel103
51 Removal103
1 Park truck on a level surface and block103
52 Installation103
1 Slide left compartment panel into position103
6 Main Electronic Card Panel104
61 Removal104
1 Park truck on a level surface and block104
62 Installation104
1 Place slots along the lower edge of the main electronic card panel over the bottom two retaini104
7 Floor Board105
71 Removal105
1 Park truck on a level surface and block105
72 Installation105
1 Truck must be properly blocked at this time105
8 Clipboard106
81 Removal106
1 Loosen top console to gain access to the clip mounting hardware106
82 Installation106
1 Raise top console to allow reach of clipboard mounting holes from underside of the cover106
Battery Retainer Plates and Rollers108
f109
1 Battery Retainer Plates109
11 Inspection109
12 Removal109
1 While lifting the battery retainer plate upward, tilt the edge toward the mast slightly forwar109
13 Installation109
1 Position the battery retainer plate with tongued edges on the bottom and facing the operator c109
2 Battery Rollers109
21 Inspection109
22 Replacement109
Mounting Points110
1 Drive Motor110
11 Removal111
1 Park the truck on a level surface and make sure all wheels are blocked to prevent accidental m111
12 Installation112
1 Remove cap from the top of transmission112
10 Add washers and nuts to terminal posts Be sure nuts are tight using an 11/16 inch (17 mm) wr112
11 Reconnect brush wear sensor, temperature sensor, and two speed/directional sensor connections112
2 Pump Motor113
21 Removal114
1 Park the truck on a level surface and make sure all wheels are blocked to prevent accidental m114
10 Remove four bolts (4) attaching bracket to the truck frame using an 9/16 inch (13 mm) socket114
11 Loosen screws in hose clamp for hose connecting the pump to the reservoir Slide hose clamp b114
12 Disconnect brush wear indicator terminals at the back of the motor115
13 Remove motor and pump assembly from truck If a hoist is available, attach a hoist to the bra115
22 Installation115
1 Place lift pump and motor assembly with bracket onto truck frame Make sure four rubber gromme115
3 Transmission117
31 Fluid Changing Procedure118
1 Remove drain plug (item 28, page169) from drive unit and drain all the fluid118
32 Removal118
1 Park the truck on a level surface118
33 Installation119
1 Place transmission in drive tire and slide transmission, in the tire cradle, beneath the truck119
Driver Controls120
1 Handle Interface Module122
11 Removal122
1 Turn key switch OFF and disconnect battery connector122
12 Installation122
1 Position handle interface module at the contactor plate/bracket, aligning mounting holes122
2 Control Handle123
21 Removal123
1 Turn key switch OFF and disconnect battery connector123
22 Installation124
1 Insert the shaft of the control handle assembly into the support bracket (3)124
23 Recalibration124
1 Voltages at the main electronic card inputs greater than 675 volts and less than 06 volts in125
2 The center and travel limits of the travel and lift/lower potentiometers are learned Therefor125
Brake Pedal (RTX35)126
1 Pedal Removal127
1 Park truck on a flat surface127
2 Pedal Bearing Replacement128
1 To replace the bearing assemblies on the brake pedal (1), remove the brake pedal return spring128
3 Pedal Adjustment128
1 See “Adjustment Procedures for Setting Brake Switch and Brake Transducer” on page355128
Brake Pedal (RTX45)129
1 Pedal Removal130
1 Park truck on a flat surface130
2 Pedal Bearing Replacement131
1 To replace bearing assemblies on brake pedal (1), remove the brake pedal return spring (5)131
3 Pedal Adjustment131
1 See “Adjustment Procedures for Setting Brake Switch and Brake Transducer” on page355131
Internal Fittings132
1 Operator Fan132
11 Removal133
1 Turn key switch OFF and disconnect battery connector133
12 Installation133
1 Reassemble the light/fan
Pump Motor (RTX35)154
1 Component Repair155
11 Motor Disassembly155
1 Remove pump motor from truck (see page111)155
10 After the motor has been separated into all its major subassemblies, the components should be156
2 Motor Inspection157
21 External Motor157
1 Check for clean, tight terminal studs and mounting bolts157
22 Brush and Commutator158
23 Bearings160
24 Armature Electrical Check160
1 Check armature for grounded circuits by placing one test lead of a Dielectric Breakdown Tester160
25 Frame & Field Service Recommendation161
26 Assembly/Testing162
1 Press against the race that is absorbing the pressure162
Pump Motor (RTX 45)164
1 Component Repair165
11 Motor Disassembly165
1 Remove pump motor from truck (see page111)165
11 After the motor has been separated into all its major subassemblies, the components should be166
2 Motor Inspection167
Drive Motor168
1 Motor Disassembly169
1 Remove drive motor from truck (see page108)169
2 Motor Inspection170
Transmission172
1 Axle Sealing Ring174
11 Disassembly174
1 Remove transmission from the truck (see page115)174
12 Assembly175
1 Place drive axle outer bearing (23) in the transmission case (38)175
2 Leakage176
21 Top Cover176
1 Remove transmission from truck176
22 Lower Cover177
1 Drain transmission oil by removing drain plug (28) Remove washer (18) from drain plug (28)177
3 Wheel Bolt178
1 Drain transmission oil by removing drain plug (28)178
Electromagnetic Brake180
1 Removal180
1 Park the truck on a level surface and make sure all wheels are blocked to prevent accidental m180
2 Installation182
1 Be sure truck is securely blocked with key switch OFF and battery disconnected182
3 Adjustments183
1 Turn Allen head retaining screws (9) counter- clockwise to loosen one at a time, to allow adju183
4 Coil Check On Brake184
5 Electromagnetic Brake, Armature and Magnetic Coil184
51 Removal184
1 Park the truck on a level surface and make sure all wheels are blocked to prevent accidental m184
52 Installation185
1 Set armature (3) and magnetic coil (2) on the base plate (6)185
6 Brake Friction Plate185
61 Inspection185
62 Replacement185
Drive Wheel186
1 Removal186
1 Park truck on a level surface186
2 Installation187
1 Press drive tire on wheel hub This is usually done while pressing off the old tire Press hub187
3 Tire Pressing Procedure188
1 Check the inside surface of the metal insert on the new tire Remove any scaling or rust with 188
Non-Braking Caster Assembly190
1 Caster Pivot192
11 Removal192
1 Park truck on a level surface192
10 Remove mounting bolts (20192
11 Loosen nuts (5) to release spring tension192
12 Remove caster pivot (13) Inspect and replace bushings and bearings as needed192
12 Installation193
1 Install pivot block (16) closest to the battery compartment first193
10 Install main electronic card panel193
11 Test truck operation, then return to service193
2 Thrust Bearing194
21 Removal194
1 Park truck on a level surface194
22 Installation195
1 The truck must be properly blocked at this time195
3 Caster Springs196
31 Adjustment196
1 Park truck on a level surface196
32 Removal196
1 Park truck on a level surface196
33 Installation197
1 Install caster springs197
4 Caster Stops198
41 Adjustment198
1 Park truck on a level surface Turn key switch OFF and disconnect battery connector Securely 198
10 Test truck operation, then return to service198
Non-Braking Caster Wheels200
1 Removal200
1 Park truck on a level surface200
2 Installation201
1 Install Nilos ring (3) on the axle201
Braking Caster Assembly202
1 Removal204
11 Caster Brake Adjustment204
1 Park truck on a flat surface204
9 Run the cable adjustment back to the original position, full threads toward the caster assembly205
10 Remove only one caster wheel Refer to caster wheel removal, on page204205
11 Remove brake assembly from caster wheel205
12 Adjust double nuts at the brake rod up or down by tightening the brake arm Check brake at 50205
13 Lock double nuts together205
14 Reassemble and test for proper brake operation205
Braking Caster Wheel Assembly206
1 Removal207
1 Park truck on a level surface207
10 Remove brake plunger (16) and spring (15)207
2 Installation208
1 Slide spring (15) in the caster bracket (2) and install brake plunger (16)208
10 Back off locknut (6) until the caster wheel turns freely The locknut (6) and lockwasher (5) 208
11 Bend lockwasher (5) tab to secure locknut (6)208
12 Grease as needed208
13 Replace wheel cap (8)208
Tandem Load Wheels210
1 Removal211
1 Park truck on a level surface211
2 Installation212
1 Pack bearings with grease212
Single Load Wheels214
1 Removal215
1 Park truck on a level surface215
2 Installation216
1 Inspect and replace bearing (4) as needed216
Steering Wheel218
1 Removal218
1 Park truck on a level surface and block wheels218
2 Installation219
1 Place steering wheel in the mounting bracket (10)219
Steer Tach220
1 Removal220
1 Park truck on a level surface and block wheels220
2 Installation221
1 Attach steering tach (14) to the underside of mounting bracket (10) with two screws (9)221
Steering Bearing222
1 Removal223
1 Park truck on a level surface223
2 Installation223
1 Install new steer bearing (1)223
Electrical Functions224
1 General224
11 Directional/Speed Control Handle224
12 Control Handle Interface Card225
13 Main Electronic Card225
2 Start Up228
3 Steering Components232
31 Steering System232
32 Wheel Direction Sensors236
Table 1: Sensor Sequence237
4 Brake Release238
5 Travel Request, Forks First240
1 A steering sensor failure (S65, S66 or S67) (See “Wheel Direction Sensors” on page233)241
2 A drive motor over temperature condition (S60)241
3 A steer controller over temperature (internal to the main electronic card (A5)241
4 The mast is extended above free lift height (S31) (See page252 and page254)241
5 Mast switches (S31 and S45) sequence error (See page252 and page254)241
Travel Request, Forks Trailing243
6 Travel Request, Forks Trailing244
1 A steering sensor failure (S65, S66 or S67) (See “Wheel Direction Sensors” on page233)245
2 A drive motor over temperature condition (S60)245
3 A steer controller over temperature (internal to the main electronic card (A5)245
4 The mast is extended above free lift height (S31) (See page252 and page254)245
5 Mast switches (S31 and S45) sequence error (See page252 and page254)245
Plug Braking247
7 Plug Braking248
71 Directional/Speed Control Handle Method248
72 Brake Pedal Method249
8 12-Volt Power Supply252
12-Volt Power Supply252
735-Volt Power Supplies253
9 735-Volt Power Supplies254
91 735-Volt Power Supply Main Electronic Card254
92 735-Volt Power Supply Control Handle Interface Card254
Speed Limit (S31) and Mast (S45) Switches255
10 Limit Switches256
101 Truck Travel Speed Limiting256
Speed Limit (S31) and Mast (S45) Switches257
102 Mast Staging Speed Limiting258
Height Indicator259
11 Height Indicator260
12 Drive Motor Brush Wear Indicator Switches262
Drive Motor Brush Wear Indicator Switches262
13 Pump Motor Brush Wear Indicator Switches263
Pump Motor Brush Wear Indicator Switches263
14 Safety Check264
Safety Check A264
Safety Check B265
15 Shunt Power Cable266
Shunt Power Cable266
Electrical Symbols274
Electrical Schematics276
1 Circuit Diagram 1 (12)276
2 Circuit Diagram 2 (12)277
3 Circuit Diagram 3 (12)278
4 Circuit Diagram 4 (12)279
5 Circuit Diagram 5 (12)280
6 Circuit Diagram 6 (12)281
7 Circuit Diagram 7 (12)282
8 Circuit Diagram 8 (12)283
9 Circuit Diagram 9 (12)284
10 Circuit Diagram 10 (12)285
11 Circuit Diagram 11 (12)286
12 Circuit Diagram 12 (12)287
Battery288
1 Removal288
1 After the truck is stopped and the brake pedal is returned to the full up position, turn key s288
2 Installation288
1 With a fully charged and tested battery on the lifting device, position the lifting device at 288
3 Battery Maintenance289
31 Battery Inspection and Care289
1 The top of the battery becomes wet and stays wet, since the acid in the electrolyte does not e289
1 Wet covers can indicate overfilling, leaky seals at posts, or excessive gassing during charge289
32 Battery Exterior Cleaning290
33 Charging290
4 Storage291
5 Battery History Record291
Light Assemblies292
1 Overhead Guard Lights (Option)292
11 Removal292
1 Turn key switch OFF and disconnect battery connector292
12 Installation292
1 Reassemble the light/fan console assembly Be sure clip nuts are positioned over mounting hole292
2 Warning Lights (Option)293
21 Removal293
1 Turn key switch OFF and disconnect battery connector293
22 Installation293
1 Secure light assembly to the overhead guard bracket (3) with two hex head screws (1)293
3 Working Lights (Option)294
31 Removal294
1 Turn key switch OFF and disconnect battery connector294
32 Installation294
1 Secure light assembly to the overhead guard294
4 Travel/Back-up Alarm (Option)295
41 Removal295
1 Turn key switch OFF and disconnect battery connector295
42 Installation295
1 Secure the travel/back-up alarm assembly to the overhead guard bracket (3) with two hex head s295
Horn296
1 Removal296
1 Turn key switch OFF and disconnect battery connector296
2 Installation296
1 Attach the horn to the truck frame and tighten mounting bolt (2)296
Battery Connector298
1 Location298
f298
2 Inspection299
1 Turn key switch OFF and disconnect battery connector299
3 Installation299
Start/Stop Switches300
1 General300
11 Test/Inspection300
2 Key Switch (S17)300
21 Inspection300
22 Removal301
1 Turn key switch OFF and disconnect battery connector301
23 Installation301
1 Install new key switch and tighten locking nut301
3 Emergency Disconnect Switch (S21)302
31 Inspection302
32 Removal302
1 Turn key switch OFF and disconnect battery connector302
33 Installation303
1 Place switch operator down through the opening in the top console303
Mast Switch (S31)304
1 General304
11 Test/Inspection304
2 Adjustment305
1 Raise the empty carriage until the bottom of the tie bar is even with the bottom of the mast s305
10 Remove the load from forks305
11 Test the truck operation to verify normal travel speed with the mast lowered305
3 Removal306
1 Raise the empty carriage until the bottom of the tie bar is even with the bottom of the mast s306
4 Installation307
1 Install new mast switch307
Control Cable and Harness308
1 Fuses308
2 Wiring309
21 Harness309
22 Power Cables310
3 Auxiliary Power Hook-up for On-board Terminal311
Contactors312
1 General312
11 Testing Resistance312
1 Turn truck’s key switch OFF and disconnect battery connector312
12 Contactor Tip Inspection312
2 Directional Contactors313
21 Removal314
1 Turn key switch OFF and disconnect battery connector314
22 Installation314
1 Position contactor over the holes in the mounting panel Attach with screws314
3 Lift Bypass Contactor315
31 Removal316
1 Turn key switch OFF and disconnect battery connector316
32 Installation316
1 Position contactor over the holes in the mounting panel Attach with screws (3)316
4 Battery Cut-out Contactor317
41 Removal318
1 Turn key switch OFF and disconnect battery connector318
42 Installation318
1 Position contactor over the holes in the mounting panel Attach with screws (1)318
Transistor Panel (Drive)320
1 Motor Connections320
11 Connections for controls321
2 Circuit Check322
1 Jack up the rear of the truck (see “Safe Jacking Procedure” on page64)322
Transistor Panel (Pump)323
1 Motor Connections323
11 Connections for controls324
Micro Switches326
1 General326
2 Lift Limit Override Switch (S33)327
21 Removal327
1 Turn key switch OFF and disconnect battery connector327
22 Installation327
1 Place new switch in the switch cluster327
3 Optional Light and Fan Switches (S96, S97 and S99)328
31 Removal328
1 Turn key switch OFF and disconnect battery connector328
32 Installation328
1 Place new switch in the switch cluster328
Main Electronic Card330
1 Removal330
1 Turn key switch OFF and disconnect battery connector330
2 Installation330
1 Place main electronic card unit against the outside wall of the chassis Align mounting holes330
3 Connectivity to Truck331
L336
4 Display337
1 Remove main electronic card panel in the operator’s compartment337
41 Time338
1 Change the time by stepping up using SW2 or down using SW1338
5 Warning/Caution codes339
6 Error codes342
61 E102 Troubleshooting Procedures344
611 POWER CIRCUIT CHECKS (LED #3)344
1 Check the 250 amp drive fuse A blown fuse will cause this error when the truck is powered up344
1 Check for battery voltage through the main contactor (K10), with respect to battery negative, 346
612 REFERENCE CIRCUIT VALUE CHECKS (LED #4)346
1 Check the voltage at the control plug on the drive transistor regulator (A1), pin #10, wire #3346
7 Parameters347
8 Running time347
9 Programming Parameters348
1 Press SW3 on the electronic card at the same time as the key switch is turned ON348
Table 2: PARAMETER NUMBER 9349
Table 3: PARAMETER NUMBER 10350
91 Parameter 13 “Battery Type” Adjustment350
911 24 Volt Unit Adjustment353
1 Install a fully charged battery into the truck354
912 36 Volt Unit Adjustment355
1 Install a fully charged battery into the truck355
10 RV2 Adjustment Procedure357
1 Remove main electronic card panel357
11 Adjustment Procedures for Setting Brake Switch and Brake Transducer358
1 Remove main electronic card access panel (see page101)358
10 The brake switch should be adjusted so it actuates between 45 and 52 on the display when depr358
11 After making adjustments, go back into programming mode358
12 Reinstall the floor plate and the main electrical card access panel359
Switches and Sensors360
1 General360
11 Test/Inspection360
2 Platform (Right Foot) Switch (S23)360
21 Removal361
1 Turn key switch OFF and disconnect battery connector361
22 Installation361
f361
1 Install two screws (1) through switch (2) into twin nut (3) on the opposite side of the switch361
3 Staging Switch (S45)361
31 Adjustment361
1 Raise the empty carriage until the top of the staging switch is even with the top of the stagi361
32 Removal362
1 Raise empty carriage until the top of the staging switch is above the top of the staging column362
33 Installation362
1 Install switch on the mounting bracket362
4 Wheel Direction Sensor363
41 Adjustment363
1 Position drive wheel with wheel nuts facing outward363
42 Removal364
1 Turn key switch OFF and disconnect battery connector364
43 Installation364
1 Install sensor in the frame364
5 Steer Stop Proximity Sensor A and Sensor B365
51 Adjustment365
1 Position drive wheel with wheel nuts facing inward365
52 Removal366
1 Turn key switch OFF and disconnect battery connector366
53 Installation366
1 Place new sensors in the frame366
6 Drive Motor Speed/Direction Sensors367
61 Removal367
1 Turn key switch OFF and disconnect battery connector367
62 Installation368
1 Install sensor (7 or 5) in spacer (6) Be sure the style of the wire ends and location match t368
Hydraulic System370
1 Operation370
Control Handle Interface Schematic371
11 Control Handle Interface, Hydraulic Control Operation372
1 Voltages at the main electronic card (A5) inputs greater than 6615 volts and less than 0735 373
2 Voltages at the main electronic card inputs other than the stated voltages will select no func373
3 Voltages at the main electronic card inputs greater than 675 volts and less than 06 volts in373
4 The center and travel limits of the travel and lift/lower potentiometers are learned Therefor373
Supply Schematic375
12 Supply376
Lifting Schematic377
13 Lifting378
Lowering Schematic379
14 Lowering380
Low Speed Extend Schematic381
15 Low Speed Extend382
High Speed Extend Schematic383
16 High Speed Extend384
Low Speed Retract Schematic385
17 Low Speed Retract386
High Speed Retract Schematic387
18 High Speed Retract388
Right Sideshift Schematic389
19 Right Sideshift390
Left Sideshift Schematic391
110 Left Sideshift392
Fork Tilt Up Schematic393
111 Fork Tilt Up394
Fork Tilt Down Schematic395
112 Fork Tilt Down396
2 RTX35 Hydraulic Schematic399
3 RTX45 Hydraulic Schematic400
Hydraulic Fluid402
1 Hydraulic Fluid Selection402
2 Changing Hydraulic System Fluid402
1 Be sure the truck is in a clean area, away from any possible contaminating elements that could402
3 System Draining403
1 Lower the carriage fully, tilt forks down completely and retract reach mechanism fully403
9 Remove female half of diagnostic fitting and hose403
10 If it is necessary to flush the reservoir, remove reservoir403
11 Dispose of old hydraulic fluid according to local regulations for hazardous materials403
4 System Refilling404
1 If reservoir was removed for flushing, install reservoir404
5 Bleeding Hydraulic System404
1 Elevate forks 2 to 3 inches (50 to 75 mm) off the floor404
10 If truck is equipped with sideshift, shift the carriage all the way to the left and right sev405
11 Thoroughly clean up any spilled hydraulic fluid405
12 Check hydraulic reservoir level and refill as necessary405
Hydraulic Tank406
1 Removal406
1 Lower carriage fully and retract reach mechanism fully406
10 Remove hydraulic filter adapter407
2 Installation407
1 Install hydraulic filter adapter407
10 Test operate truck407
11 Turn key switch OFF and disconnect battery connector Install top console Reconnect battery 407
Hydraulic Filter and Adapter408
1 Hydraulic Filter409
11 Removal409
1 Lower carriage fully to ensure all hydraulic pressure is relieved409
12 Installation409
1 Snap filter onto blue cover (13)409
2 Hydraulic Filter Adapter410
21 Removal410
1 Turn key switch OFF and disconnect battery connector410
22 Installation410
1 Clean all parts thoroughly Clean the mating surface of hydraulic tank410
10 Reconnect battery connector410
Hydraulic Pump412
1 Removal413
2 Pump Disassembly413
1 Scribe match mark on the bodies (9, 16), covers (12, 17), and spacer (4) to insure that the du413
3 Parts Inspection416
1 Wash all parts and dry thoroughly416
4 Pump Reassembly417
1 Place the front cover (12) on a flat plate with the shaft seal bore up Install new shaft seal417
5 Testing419
1 Mount pump on truck and operate for two minutes at minimum pressure and one-quarter engine speed419
Control Valve420
1 Removal420
1 Turn key switch OFF and disconnect battery connector420
2 Installation420
1 Apply thread locking compound to three mounting bolts420
3 Repair424
31 Proportional Pre-Pressure Reducing Valve, (Items 3, 4, 4a, 4b):424
1 Remove three screws and lift off twin solenoid block (2) from valve block424
32 Valve Assembly SWR14 (Item 38)424
1 Remove two screws (36) and washers (37) The SWR14 valve will separate from lift control valve424
33 Pressure Limiting Valve Assembly (Items 17 to 28)425
1 Remove screw (19) Items 17 and 18 can remain intact Inspect seal (20) for damage and replace425
34 Setting Lift/Auxiliary Pressure Relief with a Rated Load425
1 Lift a rated load (maximum capacity listed on the specification plate plus 10%)425
35 Hydraulic Lowering Rate Adjustment426
1 Loosen sealed locknut (32) so that the adjusting screw (35) can be turned426
36 Recondition Seal Kit for Lift/ Lower Valve (Items 3, 4a, 4b, 14, 18, 20, 31, 32, 33, and 34)426
1 Refer to paragraph 31 for items 3, 4a, and 4b426
9 Loosen locknut (32) and remove adjustment screw (35) Replace locknut427
10 Remove plug (29) and replace seal (20) Screw plug in two turns427
11 Remove opposite screw (49) and replace seal (20) Install screw and tighten items 29 and 49427
12 Remove plug (29a) and replace seal (20) Screw plug in two turns427
13 Remove plug (48) and replace seal (20) Install plug and tighten items 29a and 48427
14 Remove plug (47) and replace seal (33) Install plug427
15 To replace O-rings (34), refer to Valve Assembly SWR 14427
Staging Cylinder, 3 Stage428
1 Staging Cylinder Repair429
11 Removal429
1 Park truck on a level surface and apply the brake429
12 Disassembly429
1 Remove cylinder rod (12) from cylinder tube429
13 Assembly430
1 Install new wear ring (9), seals, and rod wiper (16) in gland (14) The “lip” of the wiper mus430
14 Installation430
1 Install lifting gear, chains, hoses, and electric cables430
Freelift Cylinder, 3 Stage432
1 Freelift Cylinder Repair433
11 Removal433
1 Park truck on a level surface and apply brake433
12 Disassembly435
1 Remove bearing (12) from cylinder tube (3)435
13 Assembly435
1 Install a new bearing, seals, and rod wiper in gland The “lip” of the wiper must face outward435
14 Installation435
1 Install lifting gear, chains, hoses, and electric cables435
Reach Cylinder (RTX35)436
1 Removal437
1 Park truck on a level surface and apply brake437
2 Disassembly438
1 Before disassembly, clean the exterior of reach cylinder in a cleaning solution to remove all 438
3 Inspection439
1 Carefully clean all parts in a cleaning solution and position parts on a clean work surface439
4 Assembly440
1 Install new O-rings and rod wiper (16) in bearing assembly (17) The “lip” of the wiper must f440
5 Installation441
1 Raise reach assembly to full freelift height Install reach cylinder rear mounting pins (2) S441
Reach Cylinder (RTX45)442
1 Removal443
1 Park truck on a level surface and apply brake443
2 Disassembly444
1 Before disassembly, clean the exterior of reach cylinder in a cleaning solution to remove all 444
3 Inspection445
1 Carefully clean all parts in a cleaning solution and position them on a clean work surface445
4 Assembly446
1 Install new rod wiper (21) in bearing assembly The “lip” of the wiper must face outward446
9 Install retainer (13)446
5 Installation447
1 Raise reach assembly to full freelift height Install reach cylinder rear mounting pins (10) 447
Tilt Cylinder (RTX35)448
1 Removal449
1 Park truck on a level surface and apply the brake449
1 Before disassembly, clean the exterior of tilt cylinder (1) in a cleaning solution to remove a450
1 Carefully clean all parts in a cleaning solution and position parts on a clean work surface451
1 Install new packing and rod wipers in the bearing assembly The “lip” of the wiper must face o452
10 Install cylinder bearing (7) and bearing retainer (13)452
1 Install cylinder on reach front frame453
Tilt Cylinder (RTX45)454
1 Removal455
1 Park truck on a level surface and apply brake455
1 Before disassembly, clean the exterior of tilt cylinder (1) in a cleaning solution to remove a456
1 Carefully clean all parts in a cleaning solution and position them on a clean work surface457
1 Install new packing and rod wipers in bearing assembly The “lip” of the wiper must face outward458
10 Install cylinder bearing (8) and bearing retainer (14)458
1 Install cylinder on reach front frame459
Mast, 3 Stage (RTX35)460
1 Shimming Carriage with Mast on Truck462
1 Turn key switch OFF and disconnect battery connector Remove battery from truck462
10 Remove hoist from carriage and test operation of unit Check operation first with no load, th463
2 Three Stage Mast464
21 Removal464
1 Turn key switch OFF and disconnect battery connector Remove battery from truck464
22 Disassembly465
1 Lower mast assembly to a horizontal position before work can begin465
23 Assembly466
1 Thoroughly clean all parts and air dry466
10 Extend inner column through the intermediate column as far as it will go under normal operati467
11 Install staging lift cylinder assembly in outer column lower end467
12 Press roller bearings in lift chain sheaves Grease roller bearings, then slide inner races i467
13 Install shim washers on either side of lift chain sheaves and install in intermediate column467
14 Install a bearing in the electrical sheave Grease bearing and install spacers on either side467
15 Install electrical sheave in the proper location on intermediate column Secure sheave with o467
16 Push intermediate and outer columns together Install a cap screw in intermediate column to s467
17 Install lift chain anchors through outer column Thread a wheel nut on each anchor and secure467
18 Install lift chain on chain anchors and secure with chain pins After chain pins have been in468
19 Install freelift cylinder assembly on inner column Secure with four cap screws and nuts468
20 Connect hydraulic lines to lift cylinder468
21 Lubricate grease fittings using a standard lube gun (see “Oil and Grease Specifications” on p468
24 Installation468
1 Install mast using a hoist468
Mast, 3 Stage (RTX45)469
1 Shimming Carriage with Mast on Truck471
1 Turn key switch OFF and disconnect battery connector Remove battery from truck471
10 Remove hoist from the carriage Test operation of unit Check operation first with no load, t472
2 Three Stage Mast473
21 Removal473
1 Turn key switch OFF and disconnect battery connector Remove battery from truck473
22 Disassembly474
1 Lower mast assembly to a horizontal position before work can begin474
9 Thoroughly clean all parts474
23 Assembly475
1 Thoroughly clean all parts and air dry475
10 Extend inner column through the intermediate column as far as it will go under normal operati476
11 Install staging lift cylinder assembly in the intermediate column lower end476
12 Press roller bearings in the lift chain sheaves Grease roller bearings, then slide the inner476
13 Install shim washers on either side of the lift chain sheaves Install in the intermediate co476
14 Install a bearing in the electrical sheave Grease bearing and install spacers on either side476
15 Install electrical sheave in the proper location on the intermediate column Secure with one 476
16 Push intermediate and outer columns together Install a cap screw in the intermediate column 476
17 Install lift chain anchors through the outer column Thread a wheel nut on each anchor and se477
18 Install lift chain on the chain anchors Secure with chain pins After chain pins have been i477
19 Install freelift cylinder assembly on the inner column Secure with four cap screws and nuts477
20 Connect hydraulic lines to the lift cylinder477
21 Lubricate grease fittings using a standard lube gun (see “Oil and Grease Specifications” on p477
24 Installation477
1 Install mast using a hoist477
Lift Chain479
1 Lift Chain Adjustment479
1 Loosen locking nuts on chain anchors479
2 Lift Chain Maintenance479
3 Lift Chain Inspection479
31 Wear480
32 Rust and Corrosion480
33 Cracked Plates481
34 Protruding or Turned Pins483
35 Chain Side Wear484
36 Chain Anchors and Sheaves484
4 Lift Chain Lubrication485
5 Lift Chain Replacement487
1 All chains should be replaced if any strand has wear elongation of 3% or if any of the conditi487
Lifting Gear (Crosshead) (RTX35)488
1 Lifting Gear Repair489
11 Removal489
1 Park truck on a level surface and apply brake Turn key switch OFF and disconnect battery conn489
12 Disassembly490
1 Remove retaining ring (2) from one end of the lifting gear assembly490
13 Assembly490
1 Place hydraulic/electric sheave (8) into the sheave head490
14 Installation491
1 Place lifting gear assembly on top of freelift cylinder491
Lifting Gear (Crosshead) (RTX45)492
1 Lifting Gear Repair493
11 Removal493
1 Park truck on a level surface and apply brake Turn key switch OFF and disconnect battery conn493
12 Disassembly494
1 Remove retaining ring (2) from one end of the lifting gear assembly494
13 Assembly494
1 Place hydraulic/electric sheave (8) into the sheave head494
14 Installation494
1 Place lifting gear assembly on the top of the freelift cylinder494
Sideshifter496
1 Mounting Instructions498
11 Installation498
1 Remove lower pads (12) from sideshift assembly Grease lower pads and return to the sideshift 498
10 Mount forks in the notches on the upper bar of the sideshift carriage498
11 Install fork stop bolt (7) with washer (9, 10) into the lower bar of the sideshift carriage498
12 Sideshift the unit several times to insure there are no leaks Check sideshift unit for smoot499
2 Operation499
3 Maintenance499
31 Carriage Removal500
1 Remove fork stop bolt (7) from sideshift carriage500
32 Upper Pad Replacement500
1 Remove sideshift carriage from the truck See paragraph 31 above500
33 Lower Pad Replacement501
1 Remove fork stop bolt (7) from sideshift carriage501
10 Remove blocking spacer and lower sideshift carriage to fork carriage501
11 Lift lower hook (11), bringing plastic pad (12) in contact with underside of truck carriage 501
12 Tighten set screw (8) to 21 ft-lb (30 N•m) torque501
13 Install safety screw (28) into the hole with the set screw (8) Torque safety screw to 70 ft-502
14 Connect hydraulic fittings to the sideshift cylinder Tighten fittings to 56 ft-lb (80 N•m)502
15 Mount forks in the notches on the upper bar of sideshift carriage502
16 Install fork stop bolt (7) with washer (9, 10) into lower bar of the sideshift carriage502
17 Sideshift the unit several times to insure there are no leaks Check the sideshift unit for s502
34 Cylinder503
1 Remove sideshift carriage from truck See “Carriage Removal” on page497503
4 Troubleshooting504
41 No Sideshifting504
1 Check that input pressure is not greater than 3200 psi (22060 kPa) Average working pressure s504
42 Very Slow Sideshifting504
1 Check that input pressure is not greater than 3200 psi (22060 kPa) Average working pressure s504
43 Irregular Sideshifting505
1 Check hydraulic system to be sure there is no air Bleed hydraulic system if necessary505
Reach, Single (RTX35)506
1 Maintenance506
2 Reach Repair508
21 Removal508
1 Remove forks508
21 Disassembly508
211 Front Frame Removal508
1 Disconnect hydraulic hoses from tilt and sideshift cylinders from the input side of junction b508
212 Outer Arm Removal509
1 Remove nut (28) and washer (27)509
213 Inner Arm Removal509
1 Drive pins out of reach cylinder rod end pins509
214 Rear Frame Removal509
1 Lift rear frame (3) until all tension is removed from lift chains509
215 Reach Cylinder Removal510
1 Disconnect hydraulic hoses Plug to prevent contamination510
22 Assembly510
221 Reach Cylinder Installation510
1 Install rear frame pins510
222 Rear Frame Installation510
1 Install shims (37) and rollers (32)510
223 Inner Arm Installation511
1 Install upper end of inner arms (9) into rear frame (3)511
224 Outer Arm Installation511
1 Install rollers (32), caps (31) and screws (30) on outer arms (5 and 26)511
225 Front Frame Installation512
1 Install front frame (17) onto inner arm (9) rollers (46)512
3 Carriage Bumpers512
31 Reach Adjustment512
1 Install a 0125 inch (3 mm) shim (36) behind each reach retract bumper (35)512
10 When proper adjustment is achieved, clean rod threads and apply Loctite 242® thread locking c514
4 Fork Carriage Pivot Pins514
5 Carriage Roller Bearings514
51 Removal514
1 Remove carriage/reach514
52 Installation515
1 Install new bearing on shaft515
Reach, Single (RTX45)516
1 Maintenance516
2 Reach Repair518
1 Remove forks518
21 Disassembly518
211 Front Frame Removal518
1 Disconnect hydraulic hoses from the tilt and sideshift cylinders from the input side of the so518
212 Outer Arm Removal518
1 Remove nut (16) and lockwasher (17)518
213 Inner Arm Removal519
1 Remove screws (20) and washer (22)519
214 Rear Frame Removal519
1 Lift rear frame (31) until all tension is removed from the lift chains519
215 Reach Cylinder Removal520
1 Disconnect hydraulic hoses Plug to prevent contamination520
22 Assembly520
221 Reach Cylinder Installation520
1 Install rear frame pins (27)520
222 Rear Frame Installation520
1 Install shims (35) and rollers (36)520
223 Inner Arm Installation521
1 Install bearing (6) in inner arm (10)521
224 Outer Arm Installation521
1 Install bearing (3), bearing cap (2) and screw (1) on the arms (4 and 15)521
225 Front Frame Installation521
1 Install front frame (42) onto inner arm (10) rollers (3)521
3 Reach Carriage Wear Strip522
31 Removal522
1 Partially extend the carriage so that the end of the inner scissor arm (10) is midway down the522
32 Installation522
1 Grease and wedge the new reach wear strip (57) between bearing (3) and track522
4 Fork Carriage Pivot Pins523
5 Carriage Bumpers523
6 Carriage Roller Bearings523
61 Removal523
1 Remove carriage/reach523
62 Installation524
1 Install new bearing on shaft Apply thread locking compound to socket head cap screw (38) Fas524
Height Indication526
1 General527
2 Operation527
3 Error Code 13527
Height Indicator (RTX35)528
1 Pulse sensor529
11 Repair529
1 Unplug wiring harness at the sensing unit529
12 Cable529
121 Removal529
1 To replace cable (19), remove bolt from the bottom anchor (3) relieving spring tension529
122 Installation529
1 Install a new cable (19) on the top anchor Wrap cable once around the pulley wheel529
13 Pulley530
131 Removal530
1 To replace roller (5), remove cover (2), pulse sensor, and cable (19)530
Height Indicator (RTX45)531
1 Pulse sensor532
11 Repair532
1 Unplug wiring harness at the sensing unit532
12 Cable532
121 Removal532
1 To replace cable (19), remove bolt from the bottom anchor (3) relieving spring tension532
122 Installation532
1 Install a new cable (19) on the top anchor Wrap the cable once around the pulley wheel532
13 Pulley533
131 Removal533
1 To replace roller (5), remove cover (2), pulse sensor, and cable (19)533
Load Backrest534
1 Removal535
1 Park truck on a level surface Turn key switch OFF and disconnect battery connector Remove ba535
2 Installation535
1 Place load backrest on front fork frame535

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