Professional Documents
Culture Documents
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F-code
Section
C-code
T-code
000
= 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 Prime-Mover Inc.
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C-Code
Chassis
0000
Drive Motor
1000
2000
3000
Steering System
4000
Electrical System
5000
6000
7000
8000
Options / Attachments
9000
Service Manual
2001-03-15
F-code
Section
C-code
T-code
000
Return
Service Manual
2001-03-15
Table of Contents
BT Prime-Mover Standard Codes ................................................................ 1
Warning Symbols ......................................................................................... 13
Warning Levels ......................................................................................... 13
Prohibitory Symbols .................................................................................... 14
Ordinance Symbols .................................................................................. 14
Safety ............................................................................................................ 15
General Safety .......................................................................................... 15
Battery Safety ............................................................................................... 19
Static Safety .................................................................................................. 23
Welding Safety ............................................................................................. 24
Introduction, Service Manual ...................................................................... 27
Contents, Section M ..................................................................................... 29
Machine Information ................................................................................. 29
General Product Information ......................................................................
Truck Presentation ....................................................................................
Main Components .....................................................................................
Grease Point Location ..............................................................................
Mast Adjustment Points ............................................................................
31
31
37
40
41
43
43
44
45
52
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Table of Contents
Service Schedule ......................................................................................... 67
Planned Maintenance Schedule ............................................................... 67
Planned Maintenance Procedures ............................................................ 72
Lubrication Chart ......................................................................................... 79
Oil and Grease Specifications .................................................................... 81
Approved Oils and Grease ....................................................................... 81
Contents, Section S ..................................................................................... 83
Service Instructions .................................................................................. 83
Troubleshooting Guidelines .......................................................................
General .....................................................................................................
Electrical ...................................................................................................
Hydraulic ...................................................................................................
Definitions .................................................................................................
85
85
87
92
93
Chassis ......................................................................................................... 95
General ..................................................................................................... 95
Top Console ............................................................................................. 96
Motor Compartment Door ......................................................................... 97
Left Side Panel (Exterior) .......................................................................... 98
Left Operator Compartment Panel ........................................................... 100
Main Electronic Card Panel ..................................................................... 101
Floor Board .............................................................................................. 102
Clipboard ................................................................................................. 103
Battery Retainer Plates and Rollers .......................................................... 105
Battery Retainer Plates ............................................................................ 106
Battery Rollers ......................................................................................... 106
Mounting Points ..........................................................................................
Drive Motor ..............................................................................................
Pump Motor .............................................................................................
Transmission ...........................................................................................
107
107
110
114
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123
124
125
125
Table of Contents
Brake Pedal (RTX45) ...................................................................................
Pedal Removal ........................................................................................
Pedal Bearing Replacement ....................................................................
Pedal Adjustment .....................................................................................
126
127
128
128
137
137
138
139
143
143
143
144
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Wheel Bolt ............................................................................................... 175
Electromagnetic Brake ...............................................................................
Removal ...................................................................................................
Installation ................................................................................................
Adjustments .............................................................................................
Coil Check On Brake ...............................................................................
Electromagnetic Brake, Armature and Magnetic Coil ..............................
Brake Friction Plate .................................................................................
177
177
179
180
181
181
182
183
183
184
185
187
189
191
193
195
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Removal ................................................................................................... 217
Installation ................................................................................................ 218
Steering Bearing ......................................................................................... 219
Removal ................................................................................................... 220
Installation ................................................................................................ 220
Electrical Functions ....................................................................................
General ....................................................................................................
Start Up ....................................................................................................
Steering Components ..............................................................................
Brake Release .........................................................................................
Travel Request, Forks First .....................................................................
Travel Request, Forks Trailing .................................................................
Plug Braking ............................................................................................
12-Volt Power Supply ..............................................................................
7.35-Volt Power Supplies ........................................................................
Limit Switches ..........................................................................................
Height Indicator ........................................................................................
Drive Motor Brush Wear Indicator Switches ............................................
Pump Motor Brush Wear Indicator Switches ...........................................
Safety Check ...........................................................................................
Shunt Power Cable ..................................................................................
221
221
225
229
235
237
241
245
249
251
253
257
259
260
261
263
273
273
274
275
276
277
278
279
280
281
282
283
284
Battery ..........................................................................................................
Removal ...................................................................................................
Installation ................................................................................................
Battery Maintenance ................................................................................
Storage ....................................................................................................
285
285
285
286
288
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Table of Contents
Battery History Record ............................................................................. 288
Light Assemblies ........................................................................................
Overhead Guard Lights (Option) .............................................................
Warning Lights (Option) ...........................................................................
Working Lights (Option) ...........................................................................
Travel/Back-up Alarm (Option) ................................................................
289
289
290
291
292
295
295
296
296
297
297
297
299
301
301
302
303
304
305
305
306
308
Contactors ...................................................................................................
General ....................................................................................................
Directional Contactors .............................................................................
Lift Bypass Contactor ...............................................................................
Battery Cut-out Contactor ........................................................................
309
309
310
312
314
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Motor Connections ................................................................................... 320
Micro Switches ............................................................................................
General ....................................................................................................
Lift Limit Override Switch (S33) ...............................................................
Optional Light and Fan Switches (S96, S97 and S99) ............................
323
323
324
325
327
327
327
328
334
336
339
344
344
345
354
357
357
357
358
360
362
364
367
367
396
397
399
399
399
400
401
401
355
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Table of Contents
Hydraulic Filter and Adapter ..................................................................... 405
Hydraulic Filter ......................................................................................... 406
Hydraulic Filter Adapter .......................................................................... 407
Hydraulic Pump ..........................................................................................
Removal ...................................................................................................
Pump Disassembly ..................................................................................
Parts Inspection .......................................................................................
Pump Reassembly ...................................................................................
Testing .....................................................................................................
409
410
410
413
414
416
417
417
417
421
433
434
435
436
437
438
439
440
441
442
443
444
445
446
447
448
449
450
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10
Table of Contents
Disassembly ............................................................................................
Inspection ................................................................................................
Assembly .................................................................................................
Installation ................................................................................................
453
454
455
456
476
476
476
476
482
484
493
495
496
496
501
503
503
505
509
511
511
513
513
515
519
520
520
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11
Table of Contents
Carriage Roller Bearings ......................................................................... 520
Height Indication .........................................................................................
General ....................................................................................................
Operation .................................................................................................
Error Code 13 ..........................................................................................
523
524
524
524
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12
F-code
Section
C-code
PS
Warning Symbols
Version no
T-code
001
Warning Symbols
Always follow the warnings given in this Instruction Manual
and on the truck to avoid accidents and incidents from
occurring.
1. Warning Levels
Warning texts are given in four levels and provide information
on the risks, describe the consequences, and instruct how to
avoid accidents.
DANGER
Warns that an accident will occur if the instructions are not
followed.
The consequences are serious personal injury or possibly
death, and/or extremely large material damage.
WARNING
Warns that an accident can occur if the instructions are not
followed.
The consequences are serious personal injury or possibly
death, and/or large material damage.
CAUTION
Warns that an accident can occur if the instructions are not
followed.
The consequences are personal injury and/or material
damage.
NOTE!
Marks the risk of an accident or breakdown if the
instructions are not followed.
BT Prime-Mover Inc.
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Service Manual
2001-03-15
13
F-code
Section
C-code
PS
Prohibitory Symbols
Version no
T-code
001
Prohibitory Symbols
NO SMOKING
If smoking occurs in situations where a restriction against
smoking is stated, a serious accident can occur.
GENERAL PROHIBITION
If the prohibition is ignored, a serious accident can occur.
1. Ordinance Symbols
SAFETY SHOES
When the directive for safety shoes is given, safety shoes
shall always be worn to avoid personal injury.
PROTECTIVE GLASSES
When the directive for protective glasses is given,
protective glasses shall always be worn to avoid personal
injury.
14
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Service Manual
2001-03-15
F-code
Section
C-code
PS
Safety
Version no
T-code
001
Safety
1. General Safety
Do NOT operate or work on this truck unless trained,
qualified, and authorized to do so and have read the
Operators Manual.
BT Prime-Mover Inc.
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Service Manual
2001-03-15
15
F-code
Section
C-code
PS
Safety
Version no
T-code
001
16
Return
Service Manual
lubrication,
maintenance,
and
2001-03-15
F-code
Section
C-code
PS
Safety
Version no
T-code
001
BT
BT Prime-Mover Inc.
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Service Manual
2001-03-15
17
F-code
Section
C-code
PS
Safety
Version no
T-code
001
18
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Service Manual
2001-03-15
F-code
Section
C-code
PS
Battery Safety
Version no
T-code
001
Battery Safety
WARNING As a battery is being charged, an
explosive gas mixture forms within and
around each cell. If the area is not properly
ventilated, this explosive gas can remain
in or around the battery for several hours
after charging. Be sure there are no open
flames or sparks in the charging area. An
open flame or spark can ignite this gas,
resulting in serious damage or injury.
WARNING Battery electrolyte is a solution of sulfuric
acid and water. Battery acid causes burns.
Should any electrolyte come in contact
with your clothing or skin, flush the area
immediately with cold water. Should the
solution get on your face or in your eyes,
flush the area with cold water and get
medical help immediately.
Read, understand, and follow procedures, recommendations
and specifications in the battery and battery charger
manufacturers manuals.
BT Prime-Mover Inc.
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2001-03-15
19
F-code
Section
C-code
PS
Battery Safety
Version no
T-code
001
Turn the key switch off before disconnecting the battery from
the truck at the battery connector. Do NOT break live circuits
at the battery terminals. A spark often occurs at the point
where a live circuit is broken.
20
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Service Manual
2001-03-15
F-code
Section
C-code
PS
Battery Safety
Version no
T-code
001
Keep filler plugs firmly in place at all times except when the
electrolyte level is checked, when water is added to the cells,
or when the specific gravity is checked.
Make sure vent holes in filler plugs are open to allow gas to
escape from the cells.
Vent Hole
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2001-03-15
21
F-code
Section
C-code
PS
Battery Safety
Version no
T-code
001
22
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Service Manual
2001-03-15
F-code
Section
C-code
PS
Static Safety
Version no
T-code
001
Static Safety
Electronic circuit board and devices used on this truck can be
damaged by the discharge of static electricity, called
electrostatic discharge.
Static charges can accumulate from normal operation of the
truck as well as movement or contact between nonconductive materials such as, plastic bags, synthetic clothing,
synthetic soles on shoes, styrofoam coffee cups, etc.
Accumulated static can be discharged through human skin to
a circuit board or component by touching the parts. Static
discharge is also possible through the air when a charged
object is placed close to another surface at a different
electrical potential. Static discharge can occur without
your seeing or feeling it.
Whenever working on or near static-sensitive electronics,
always use static discharge precautions.
1. Place a static discharge wrist strap around your wrist.
Connect the ground lead to the wrist strap connector.
2. Connect the ground clamp to an unpainted, grounded
surface on the truck frame.
3. If removing or installing static-sensitive components,
place them on a properly grounded static mat.
4. To transport static-sensitive components, including failed
components being returned, place the components in an
antistatic bag or box.
The wrist strap and associated accessories should be tested
monthly. A wrist strap that is not working properly will not alert
that it is bad.
BT Prime-Mover Inc.
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2001-03-15
23
F-code
Section
C-code
PS
Welding Safety
Version no
T-code
001
Welding Safety
WARNING Flame cutting or welding on powder coat
painted surfaces may produce potentially
harmful fumes, smoke and vapors. Prior to
performing flame cutting or welding
operations, it is recommended that the
coating be removed in the vicinity where
the operation(s) will be performed.
WARNING Coating removal may be by mechanical
methods, chemical methods or a
combination of methods. Flame cutting
and/or welding operations should be
carried out only in well ventilated areas
using local exhaust if necessary.
Before working on this truck, make sure that:
Fire protection equipment is nearby.
Know where the nearest eyewash station is.
24
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Service Manual
2001-03-15
F-code
Section
C-code
PS
Welding Safety
Version no
T-code
001
BT Prime-Mover Inc.
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2001-03-15
25
F-code
Section
C-code
PS
Welding Safety
Version no
T-code
001
26
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Service Manual
2001-03-15
F-code
Section
C-code
M
Introduction, Service Manual
Version no
001
T-code
RTX35/RTX45
BT Prime-Mover Inc.
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SUBJECT
MACHINE INFORMATION
PLANNED MAINTENANCE
SERVICE INSTRUCTIONS
OPTIONS
Service Manual
2001-03-15
27
F-code
Section
C-code
M
Introduction, Service Manual
Version no
T-code
001
RTX35/RTX45
28
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Service Manual
2001-03-15
F-code
Section
C-code
M
Contents, Section M
Version no
T-code
001
Contents, Section M
1. Machine Information
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M1.0
M2.0
M3.0
Service Manual
2001-03-15
29
F-code
Section
C-code
M
Contents, Section M
Version no
T-code
001
30
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Service Manual
2001-03-15
F-code
Section
C-code
M1.0
General Product Information
Version no
000
T-code
RTX35/RTX45
1+01/2
Left Side
Rear
Forward
Right Side
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2001-03-15
31
F-code
Section
C-code
M1.0
General Product Information
Version no
T-code
000
RTX35/RTX45
+1
1/2
0
Open
back
compartment
32
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Service Manual
2001-03-15
F-code
Section
C-code
M1.0
General Product Information
Version no
T-code
000
RTX35/RTX45
To transport/lift passengers.
Truck data
Lifting capacity rated load
Lift height
RTX35
RTX45
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Service Manual
2001-03-15
33
F-code
Section
C-code
M1.0
General Product Information
Version no
T-code
000
RTX35/RTX45
5.5 (139)
16.0 (406) 32.0 (812)
to
to
30 (762), 36 (914), 42 (1066),
50.0 (1270)
29.5 (749)
1.75 (44) x 4.0 (101) Forks
40.5
31.0
(1028) (787)
48 (1219)
5.5 (139)
70.2 (1783)
B
5.7 (144)
A
43.5 (1104)
23.0 (584)
C
48.0 (1219)
95.0
(2413)
+4
11.75
(298)
Step
Height
3.0
(76)
OALH
-3
2.0
(50)
Battery
Roller 7.0 (177)
Height
14.4
(265)
9.1
(231)
55.45
(1408)
Free Lift
5.0 (127)
34
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Service Manual
2001-03-15
F-code
Section
C-code
M1.0
General Product Information
Version no
000
T-code
RTX35/RTX45
40.5 31.0
1028) (787)
5.5 (139)
74.6
(1894)
B
7.7 (195)
A
46.0 (1168)
95.0
(2413)
22.0 (558)
C
48.0
(1219)
+4
11.75
(298)
Step
Height
OALH
-3
3.0
(76)
2.0
(50)
Battery
Roller 7.0 (177)
Height
16.4
(416)
5.0
(127)
60.0
(1524)
9.1
(231)
Free Lift
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2001-03-15
35
F-code
Section
C-code
M1.0
General Product Information
Version no
T-code
000
RTX35/RTX45
Model
1
Battery Wt.
Maximum (Lbs.)
Battery Wt.
Minimum (Lbs.)
Use UL Class
Battery Type
6
Type
14
Hour Rate
Attachment
10
Inches
B
Truck Wt.
Less Batt. (Lbs.)
DC Voltage
Cap. (Lbs.)
11
12
Max
Back Tilt
13
B
BT Prime-Mover, Inc.
Muscatine, IA 52761
310574-000
Legend
1
2
3
4
5
6
7
8
9
10
11
12
13
14
36
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Service Manual
2001-03-15
F-code
Section
C-code
M1.0
General Product Information
Version no
000
T-code
RTX35/RTX45
2. Main Components
1
Hydraulic valve:
The valves are located to provide easy access.
Battery:
24/36V with different capacities and weights.
Battery connector:
The truck is connected to the battery through the battery connector.
When charging the battery, do not connect the battery charger to the
battery connector at the truck chassis.
Hydraulic unit:
Pump motor and pump are an integrated unit.
Electrical steering:
A servo steer motor drives a gear ring enabling the drive unit to be
rotated through 180 degrees (90 degrees in either direction).
Data plate:
See Data Plate on page 36.
Cover:
Removable to provide access for servicing.
Pedal:
Brake pedal.
10 Control console:
The operator controls are located either on the console cover or on
the control handle. The steering wheel, instrument panel, and
switches (key switch, emergency stop, and light/fan cluster) are on
the console cover. The hydraulic functions (lift, reach, and auxiliary),
horn, and travel speed and direction are controlled through the control
handle. The orientation of the controls permit operation in a 45 degree
or side stance configuration.
11 Instrument panel (Operator Display):
Provides information on the trucks running hours, time display, error
codes, parking brake, and battery status.
12 Mast:
The mast is a clear view model.
13 Electronics:
The electronics are in a protected compartment.
14 Control circuit fuse (F50):
10A, BT part number 25275-12
15 Steering circuit fuse (F51):
30A, BT part number 25275-13
16 Drive motor fuse (F1):
250A, BT part number 305656-000
BT Prime-Mover Inc.
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2001-03-15
37
F-code
Section
C-code
M1.0
General Product Information
Version no
T-code
000
RTX35/RTX45
38
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Service Manual
2001-03-15
F-code
Section
C-code
M1.0
General Product Information
Version no
T-code
000
RTX35/RTX45
12
19
11
16
17
10
8
1+ 01/2
5
4
6
7
9
18
13
14
15
20
21
22
23
24
25
26
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2001-03-15
39
F-code
Section
C-code
M1.0
General Product Information
Version no
T-code
000
RTX35/RTX45
1+ 01/2
40
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Service Manual
2001-03-15
F-code
Section
C-code
M1.0
General Product Information
Version no
000
T-code
RTX35/RTX45
+1 1
0/2
BT Prime-Mover Inc.
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2001-03-15
41
F-code
Section
C-code
M1.0
General Product Information
Version no
T-code
000
RTX35/RTX45
42
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Service Manual
2001-03-15
F-code
Section
C-code
M1.1
Inch (SAE) and Metric Fasteners
Version no
T-code
001
10
10
1. Introduction
Threaded fasteners such as bolts, nuts, cap screws, and
studs are made to specifications that describe the mechanical
strength and hardness of the fastener. A fastener used in a
design application is selected in accordance with its
specifications. Fasteners that are similar cannot be used as
direct replacements.
Service persons must use replacement fasteners that have
the same specifications as the original. Fasteners made to
each specification have identification marks for that
specification. This specification is commonly called grade
for SAE standards and property for metric standards. This
section describes the identification of some common
fasteners.
The metric system used is described as SI (International
System of Units, also called SI in all languages). The SI
system of measurement is described in ISO Standard 1000,
1973.
BT Prime-Mover Inc.
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2001-03-15
43
F-code
Section
C-code
M1.1
Inch (SAE) and Metric Fasteners
Version no
T-code
001
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
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
44
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A = THREAD SIZE
B = PITCH
C = LENGTH
2001-03-15
F-code
Section
C-code
M1.1
Inch (SAE) and Metric Fasteners
Version no
T-code
001
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
than 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.
When fasteners must be replaced, new
CAUTION fasteners must be of same strength or
greater than original fasteners. The new
fasteners must also be the correct size.
NOTE! Identification marks are according to bolt
strength. The higher the number, or increase
in number of marks, indicates increased bolt
strength.
BT Prime-Mover Inc.
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2001-03-15
45
F-code
Section
C-code
M1.1
Inch (SAE) and Metric Fasteners
Version no
T-code
001
Types of
Fasteners
Inch Fasteners
Metric Fasteners
5.2
4.6*
4.8*
5.8*
8.8
4.6
4.8
5.8
8.8
9.8
10.9
12.9
9.8
10.9
12.9
Markings
for size
M5 and
Larger
Hex Head
Flange Screws
Same As Above
5
12 Point
Flange Screws
Markings Not Required
8.8
12.9
8.8
12.9
4.8*
9.8
4.8
9.8
SEMS
46
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Service Manual
2001-03-15
F-code
Section
C-code
M1.1
Inch (SAE) and Metric Fasteners
Version no
T-code
001
Types of
Fasteners
Metric Fasteners
Inch Fasteners
4.6*
5.2*
8*
5.8*
4.8
4.6
5*
4.8*
8.8
5.8
9.8
10.9
9.8
10.9
8.8
12.9
Markings
for size
M5 and
Larger
12.9
8.1
or
Studs
Hex Nuts
BT Prime-Mover Inc.
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10
12
10
12
10
12
8
or
or
10
12
10
12
10
12
10
12
Service Manual
2001-03-15
47
F-code
Section
C-code
M1.1
Inch (SAE) and Metric Fasteners
Version no
T-code
001
Types of
Fasteners
Inch Fasteners
Strength Levels: SAE Grades
Metric Fasteners
Strength Levels: Property Classes
10
10
or
All Metal Prevailing Torque
Nuts
G
9
10
or
All Metal Prevailing Torque
Flange Nuts
10
or
48
Return
Service Manual
2001-03-15
F-code
Section
C-code
M1.1
Inch (SAE) and Metric Fasteners
Version no
T-code
001
Types of
Fasteners
Metric Fasteners
Inch Fasteners
10
10
or
or
or
10
10
or
BT Prime-Mover Inc.
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Service Manual
2001-03-15
49
F-code
Section
C-code
M1.1
Inch (SAE) and Metric Fasteners
Version no
T-code
001
Property, Class
8.8*
Property, Class
10.9**
Property, Class
12.9***
Nm
in-lbs
Nm
in-lbs
Nm
in-lbs
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
50
Return
Service Manual
2001-03-15
F-code
Section
C-code
M1.1
Inch (SAE) and Metric Fasteners
Version no
T-code
001
6 ft-lb (8 Nm)
BT Prime-Mover Inc.
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Torque Specification
Service Manual
2001-03-15
51
F-code
Section
C-code
M1.1
Inch (SAE) and Metric Fasteners
Version no
T-code
001
By
To Get
Multiply
By
To Get
inches
6.451
centimeters (cm)
centimeters
0.155
inches (in)
feet
0.093
meters (m)
meters
10.764
feet (ft)
LINEAR
Multiply
By
To Get
Multiply
By
To Get
inches
25.4
millimeters(mm)
millimeter
0.039
inches (in.)
feet
0.305
meters (m)
meter
3.280
feet (ft)
yards
0.914
meters (m)
meter
1.094
yards (yd)
miles
1.609
kilometers (km)
kilometer
0.621
miles (mi)
MASS
Multiply
By
To Get
Multiply
By
To Get
ounces (oz)
28.49
grams (g)
grams
0.035
ounces (oz)
pounds (lb)
0.454
kilograms (kg)
kilograms
2.205
pounds (lb)
907.18
kilograms (kg)
kilograms
0.001
0.907
metric ton
1.102
POWER
Multiply
By
To Get
Multiply
By
To Get
horsepower
0.746
kilowatts (kW)
kilowatts
1.34
horsepower
(hp)
PRESSURE
52
Multiply
By
To Get
Multiply
By
To Get
pounds/in
6.895
kilopascal (kPa)
kilopascals
0.145
pounds/in
(psi)
pounds/in
0.007
megapascal (MPa)
megapascals
145.04
pounds/in
(psi)
Return
Service Manual
2001-03-15
F-code
Section
C-code
M1.1
Inch (SAE) and Metric Fasteners
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
8.851
inch pounds
in-lbs
feet pound
1.356
0.738
foot pounds
ft-lb
VELOCITY
Multiply
By
To Get
Multiply
By
To Get
miles/hour
1.609
kilometer/hour
(km/h)
kilometer/hour
0.621
miles/hour
(mph)
VOLUME
Multiply
By
To Get
Multiply
By
To Get
inches
16.387
centimeters (cm)
centimeters
0.061
inches (in)
inches
0.016
liters
liters
61.024
inches (in)
quarts, U.S.
0.946
liters
liters
1.057
quarts, U.S.
(qt)
quarts, U.S.
0.83
quarts, Imp.
1.205
quarts, U.S.
(qt)
gallons, U.S.
3.785
liters
liters
0.264
gallons, U.S.
(gal)
gallons, U.S.
0.83
gallons, Imp.
1.205
gallons, U.S.
(gal)
ounces
29.57
milliliters (ml)
milliliters
0.034
ounces (oz)
BT Prime-Mover Inc.
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Service Manual
2001-03-15
53
F-code
Section
C-code
M1.1
Inch (SAE) and Metric Fasteners
Version no
T-code
001
54
Return
Service Manual
2001-03-15
F-code
PS
Section
C-code
M2.0
Technical Service Data
Version no
T-code
000
RTX35/RTX45
MODEL
RTX35
(192 inch mast)
RTX45
(210 inch mast)
Series - DC
Series - DC
DRIVE MOTOR
Type
Power
Duty factory
1 hour continuous
1 hour continuous
Minimum commutator
diameter
Vertical motor
spiral-bevel output
Vertical motor
spiral-bevel output
Gear ratio
17.57
17.57
Oil volume
SAE 80W90
SAE 80W/90
ATF
SAE 80W90
SAE 80W/90
ATF
TRANSMISSION/GEAR
Type
Normal temperature
Above 23 F (-5 C)
Below 23 F (-5 C)
Below 5 F (-15 C)
BT Prime-Mover Inc.
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Service Manual
2001-03-15
55
F-code
Section
C-code
PS
M2.0
Technical Service Data
Version no
T-code
000
RTX35/RTX45
MODEL
RTX35
(192 inch mast)
RTX45
(210 inch mast)
Drive wheel
1600 lb battery
14.5 BC - 6735 (3054)
2000 lb battery
16.5 BC - 4315 (1959)
2000 lb battery
16.5 BC - 4750 (2156)
2400 lb battery
21 BC - 4910 (2229)
1600 lb battery
14.5 BC - 3240 (1471)
2000 lb battery
16.5 BC - 3430 (1557)
2000 lb battery
16.5 BC - 3780 (1716)
2400 lb battery
21 BC - 4025 (1827)
95 ft-lb
(130 Nm)
95 ft-lb
(130 Nm)
1600 lb battery
14.5 BC - 6860 (3114
2000 lb battery
16.5 BC - 7145 (3244)
2000 lb battery
16.5 BC - 8595 (3902)
2400 lb battery
21 BC - 8690 (3945)
300 Amp
400 Amp
WHEELS
HYDRAULIC UNIT
Power (upper staging lift
reading with worn-in motor)
24 volt
36 volt
Revolutions/minute at work
pressure
Duty factor
20% on
5 minute cycles
Minimum commutator
diameter
40 oz (1120 grams)
56
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Service Manual
2001-03-15
F-code
Section
PS
C-code
M2.0
Technical Service Data
Version no
000
T-code
RTX35/RTX45
MODEL
RTX35
(192 inch mast)
RTX45
(210 inch mast)
11 cc upper/4 cc lower
16 cc upper/4 cc lower
8 cc upper/4 cc lower
N/A
23 cc upper/4 cc lower
11 cc upper/4 cc lower
5 gallons
(19 liters)
5 gallons
(19 liters)
Sunoco TH
ATF
Texaco 15
Sunoco TH
ATF
Texaco 15
250 Amp
250 Amp
425 Amp
355 Amp
N/A
500 Amp
10 Amp
10 Amp
N/A
1000 Amp hours
875 Amp hours
Pump displacement
24 volt
E
EE
Tank volume
Normal temperature
Above 23 F (-5 C)
Below 23 F (-5 C)
Below 5 F (-15 C)
FUSES
Drive motor circuit
Pump motor circuit
24 volt
36 volt
Control circuit
BATTERIES
Dimension W x L x H
BT Prime-Mover Inc.
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Service Manual
2001-03-15
57
F-code
Section
C-code
PS
M2.0
Technical Service Data
Version no
T-code
000
RTX35/RTX45
MODEL
RTX35
(192 inch mast)
RTX45
(210 inch mast)
N/A
6.5 mph (10.46 kph)
N/A
6.0 mph (9.65 kph)
24 volt
36 volt
N/A
95 fpm (29 m/min.)
24 volt
36 volt
N/A
60 fpm (18.3 m/min.)
24 volt
36 volt
95 Amps
80 Amps
N/A
90 Amps
24 volt
36 volt
115 Amps
95 Amps
N/A
105 Amps
DRIVING SPEEDS
LIFTING/LOWERING TIME
Lift without load
CURRENT READINGS
Driving without load
58
Return
Freelift
170 Amps
215 Amps
145 Amps
Staging
200 Amps
235 Amps
170 Amps
Freelift
N/A
310 Amps
225 Amps
Staging
N/A
330 Amps
240 Amps
Freelift
325 Amps
395 Amps
270 Amps
Staging
355 Amps
430 Amps
300 Amps
Freelift
N/A
530 Amps
390 Amps
Staging
N/A
550 Amps
395 Amps
Service Manual
2001-03-15
F-code
PS
Version no
Section
C-code
M3.0
Ordering Spare Parts
T-code
000
BT Prime-Mover Inc.
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Service Manual
2001-03-15
59
F-code
Section
C-code
PS
M3.0
Ordering Spare Parts
Version no
T-code
000
60
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Service Manual
2001-03-15
F-code
PS
Version no
Section
C-code
P
Contents, Section P
T-code
001
Contents, Section P
1. Planned Maintenance
BT Prime-Mover Inc.
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P1.0
INTRODUCTION, MAINTENANCE
P2.0
SERVICE SCHEDULE
P3.0
LUBRICATION CHART
P4.0
Service Manual
2001-03-15
61
F-code
Section
C-code
PS
P
Contents, Section P
Version no
T-code
001
62
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Service Manual
2001-03-15
F-code
PS
Section
C-code
P1.0
Introduction, Maintenance
Version no
T-code
000
Introduction, Maintenance
A
regularly
scheduled
recommended to enable:
maintenance
program
is
BT Prime-Mover Inc.
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Service Manual
2001-03-15
63
F-code
Section
C-code
PS
P1.0
Introduction, Maintenance
Version no
T-code
000
64
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Service Manual
2001-03-15
F-code
PS
Section
C-code
P1.0
Introduction, Maintenance
Version no
T-code
000
2. Lubricants
2.1. Cold Storage Conditioning
BT Prime-Mover reach trucks are recommended to operate
in temperatures between 32 F (0 C) and 115 F (46 C) in
their standard design. Cold storage conditioning is available
for continuous operation in -5 F (-15 C) temperatures or for
in and out applications to -13 F (-25 C). A freezer
conditioning package is available for applications with
continuous operation to -31 F (-35 C).
If the truck is to be used in a cold storage application, it will be
equipped with cold storage components and cold storage
fluids in the hydraulic tank and the drive unit when delivered
from the factory.
BT Prime-Mover Inc.
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Service Manual
2001-03-15
65
F-code
Section
C-code
PS
P1.0
Introduction, Maintenance
Version no
T-code
000
66
Return
Service Manual
2001-03-15
F-code
Section
PS
P2.0
Service Schedule
Version no
C-code
T-code
001
RTX35/RTX45
Service Schedule
1. Planned Maintenance Schedule
ITEM
0000
0000.1
0000.2
0000.3
0000.4
0000.5
0640
0640.1
0640.2
0640.3
1700
1700.1
1700.2
1700.3
1700.4
1700.5
1700.6
1700.7
2550
2550.1
3300
3300.1
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
Replace any unreadable or
damaged decals.
Operator Controls
Check that the travel direction/
speed control is operational
Check that the horn button is
operational
Check that the lift pot and
auxiliary buttons are operational
Motors
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
Blow carbon, copper, and plastic
particle accumulations from the
motor using compressed air.
Check electrical armature (See
Armature Electrical Check on
page 157.)
Drive Gear
Check for oil leakage
Brake
Clean dust and debris
BT Prime-Mover Inc.
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Service Manual
8
1d
30
1w
120
1m
240
2m
360
3m
720
6m
1440
12 m
4320
36 m
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
2001-03-15
67
F-code
Section
C-code
PS
P2.0
Service Schedule
Version no
T-code
001
RTX35/RTX45
ITEM
3300.2
3300.3
3300.4
3500
3500.1
3500.2
3500.3
3500.4
4100
4100.1
4100.2
5110
5110.1
5110.2
5110.3
5110.4
5200
5200.1
5300
5300.1
5300.2
5300.3
5300.4
5300.5
5400
5400.1
5400.2
68
Return
WORK REQUIRED
Interval in Hours
Interval in Days/Weeks/Months
Check brake shoes for wear
Check correct clearance of
electrical brake and brake shoes
Check brake operation
Wheels
Remove all string, wrapping and
debris
Check all wheels for wear
Grease load wheel bearings
Grease caster and caster
wheels
Steering Wheel
Check fasteners
Check ease of steering
Battery
Electrolyte level, 0.5 inch (13 mm)
above cell plates
All connections: battery and
battery and charger plugs
All cell and link covers intact
Check battery specific gravity
Instrument Panel
Check battery indicator and hour
meter for correct operation
Electrical Control System
Check key switch
Check brake micro switch
Check control wiring harness for
proper routing
Examine negative cable and
wires from battery to the main
electronic card (A5).
Check that the red emergency
stop switch is operational
Electrical Panel
Cleaning and mounting to
chassis
Tightening of connections
8
1d
30
1w
120
1m
240
2m
360
3m
720
6m
1440
12 m
X
4320
36 m
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Service Manual
X
X
2001-03-15
F-code
Section
PS
P2.0
Service Schedule
Version no
T-code
001
ITEM
5400.3
5400.4
5400.5
5400.6
5710
5710.1
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
7200
7200.1
7200.2
7200.3
RTX35/RTX45
WORK REQUIRED
Interval in Hours
Interval in Days/Weeks/Months
Check contactor tips
Check contactor tips for free
movements
Check all cable insulation for
damage
Check power safety control
system on the transistor regulator
(refer to page 319).
Electronic Card
Check for connections in harness
connectors
Hydraulic System
Check hoses and connections
for leakage
Check hoses for wear and
damage
Check oil tank for cracks, leaks
and mounting
Check correct oil level
Change hydraulic oil and filter
Mast
Check for damage and cracks
Retighten mast mounting bolts
Check clearance of the rollers
Check lateral play of inner section
Check for wear on lift chains and
chain rollers
Check adjustment of lift chains
Clean & lube lift chains
Clean & lube mast rails
Lube chain sheaves
Sideshifter
Check torque of lower hook
mounting bolts
Inspect hydraulic hoses for wear
Inspect cylinder and fittings for
wear or leaks
BT Prime-Mover Inc.
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C-code
Service Manual
8
1d
30
1w
120
1m
240
2m
360
3m
720
6m
X
X
1440
12 m
4320
36 m
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
2001-03-15
69
F-code
Section
C-code
PS
P2.0
Service Schedule
Version no
T-code
001
RTX35/RTX45
ITEM
7200.4
7200.5
7200.6
7200.7
7310
7310.1
7310.2
7400.
7400.1
7400.2
7400.3
7400.4
7400.5
7400.6
7400.7
70
Return
WORK REQUIRED
Interval in Hours
Interval in Days/Weeks/Months
Grease lower hook where pads
slide
Check thickness of upper pads
Check thickness of lower pads
Replace upper and lower pads
Lift Cylinder
Check for leakage
Check mounting
Lifting Device
Check clearance of fork carriage
Check fork carriage for
damage and cracks
Check forks for wear and cracks
Check reach attachment for
damage and cracks
Check reach attachment for
proper reach stoke and timing.
Check reach attachment for
damaged retract bumpers
Lube all grease fittings on reach
attachment
8
1d
Service Manual
30
1w
120
1m
X
240
2m
360
3m
X
720
6m
1440
12 m
4320
36 m
X
X
X
X
X
X
X
X
X
X
X
X
2001-03-15
F-code
Section
PS
P2.0
Service Schedule
Version no
C-code
T-code
001
RTX35/RTX45
7310
7100
0640
0840
6000
5200
5400
4100
5300
1700
7200
1+ 01/2
5710
7400
3300
2550
5100
3500
0000
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Service Manual
2001-03-15
71
F-code
Section
C-code
PS
P2.0
Service Schedule
Version no
T-code
001
RTX35/RTX45
1/2
Discharged battery
72
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Service Manual
2001-03-15
F-code
Section
PS
P2.0
Service Schedule
Version no
001
C-code
T-code
RTX35/RTX45
BT Prime-Mover Inc.
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2001-03-15
73
F-code
Section
C-code
PS
P2.0
Service Schedule
Version no
T-code
001
RTX35/RTX45
2.2.4. Battery
Contact your battery dealer for specific instructions on care
and maintenance of the battery.
An average battery will have a specific gravity of 1.170 at the
80% discharged level. However, there are many different
batteries on the market. Only the battery manufacturer can
accurately determine the fully charged and 80% charged
levels. Contact the battery manufacturer for this information.
2.2.5. Electrical Connections
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 0.0625 inch (1.6 mm) 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 (206 kPa),
and then only with effective chip-guarding
and personal protective equipment worn.
74
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Service Manual
2001-03-15
F-code
Section
PS
P2.0
Service Schedule
Version no
001
C-code
T-code
RTX35/RTX45
BT Prime-Mover Inc.
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Service Manual
2001-03-15
75
F-code
Section
C-code
PS
P2.0
Service Schedule
Version no
T-code
001
RTX35/RTX45
76
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Service Manual
2001-03-15
F-code
Section
PS
P2.0
Service Schedule
Version no
001
C-code
T-code
RTX35/RTX45
2.4.2. Transmission
The transmission fluid should be drained once a year. The
drain port is located on the lower portion of the side cover
opposite the drive tire. Remove the bolt to drain the
transmission fluid. Flush the transmission case. Pour clean
solution 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. Stop flushing when the
solution runs clean. Allow the solution to drain well before
replacing the drain plug bolt. Replace the drain plug bolt.
Refill the transmission with the proper clean oil before
operating the truck.
2.4.3. Battery
At approximately 1500 hours, contact an authorized battery
dealer to determine the overall condition of the battery.
Determine if the battery needs to be washed down. This can
only be done by properly equipped and trained personnel.
2.4.4. Hydraulic System
The hydraulic system should be drained, flushed and refilled,
and the pressure relief valve setting should be checked and
adjusted. This will maintain proper lubrication properties
within the system.
WARNING Before siphoning oil from reservoir, make
certain siphon is clean.
To drain the reservoir, remove the reservoir filter assembly.
Siphon oil from the reservoir and purge the oil out of hydraulic
system. Fill the reservoir with proper clean oil. Operate the
raise and lower function several times to purge air from
system. Check the oil level. Put a rated truck capacity load on
the forks and adjust pressure relief valve, if necessary, so
that truck will lift a rated load.
BT Prime-Mover Inc.
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Service Manual
2001-03-15
77
F-code
Section
C-code
PS
P2.0
Service Schedule
Version no
T-code
001
RTX35/RTX45
2.4.5. Brakes
Follow procedures for brake removal before inspecting.
Remove the brake assembly and inspect the friction disc for
wear. The friction disc should be replaced once thickness is
0.25 inch (6 mm) or less. The armature and magnetic coil
should be adjusted if machine will not meet stopping and
holding specifications. The air gap should not exceed 0.014
inch (0.36 mm) and should remain within 0.003 inch (0.076
mm) throughout the circumference.
2.4.6. Lift and Carriage Chains.
Lift and carriage chains should be checked every 720 hours.
A chain gauge should be used to check stretch of the links.
To adjust inner rails, loosen jam nut and tighten chains
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 with the forks
level. Adjust chains until the top of the forks are 2.0 inches
(50.8 mm) off of the floor.
78
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Service Manual
2001-03-15
F-code
Section
PS
P3.0
Lubrication Chart
Version no
C-code
T-code
000
RTX35/RTX45
Lubrication Chart
Interval/Running Hours
Pos. No.
Service Point
1
2
3
4
5
6
360 h
Wheel bearings
Mast beam
Lifting chains
Hydraulic system
Steering bearings
Drive gear
720 h
1440 h
L
L
L
C
C
L= Lubrication
C = Check
O
L
O
Lubricant
(See Approved
Oils and Grease
on page 81.)
A
A
D
B
A
C
O = Oil change
2
3
+
1/21 0
5
1
1
Truck Lubrication Points
BT Prime-Mover Inc.
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Service Manual
2001-03-15
79
F-code
Section
C-code
PS
P3.0
Lubrication Chart
Version no
T-code
000
RTX35/RTX45
80
Return
Service Manual
2001-03-15
F-code
Section
C-code
PS
P4.0
Oil and Grease Specifications
Version no
T-code
000
RTX35/RTX45
Lubricant
Standard and
Corrosion
Continuous
Operation
Above
23 F (-5 C)
Cold Storage
Freezer
Continuous Operation
To 5 F (-15 C)
Intermittent Operation
To -13 F (-25 C)
Continuous
Operation
To
31 F (-35 C)
Application
area
Bearings and
bushings
Hydraulic
system
Grease
Mystik JT-6
Mystik JT-6
Mobiltemp
SHC 32
Hydraulic oil
Sunoco TH
ATF
Texaco 15
SAE 80
SAE 80
ATF
Gears
# 10 W 40
# 10 W 40
# 10 W 40
Chains
Mast rails,
Reach,
Sideshift
Mast rails,
Reach,
Sideshift
Transmission
oil
Motor Oil
Grease
Molykote
200025 *
Molykote 200025
Molykote
200025
Grease
49670-00 *
49670-00
49670-00
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2001-03-15
81
F-code
Section
C-code
PS
P4.0
Oil and Grease Specifications
Version no
T-code
000
RTX35/RTX45
B
+
1/21 0
C
A
A
82
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Service Manual
2001-03-15
F-code
PS
Section
C-code
S
Contents, Section S
Version no
T-code
000
Contents, Section S
1. Service Instructions
NO
FUNCTION GROUP
C-CODE
TROUBLESHOOTING GUIDELINES
0
CHASSIS
0000
MOTORS
1000
2000
3000
STEERING SYSTEM
4000
5000
6000
LIFTING MAST
7000
PERIPHERAL / INSTALLATION
EQUIPMENT
8000
OPTIONS / ATTACHMENTS
9000
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2001-03-15
83
F-code
Section
C-code
PS
S
Contents, Section S
Version no
T-code
000
84
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Service Manual
2001-03-15
F-code
Section
C-code
PS
S0.0
Troubleshooting Guidelines
Version no
000
T-code
RTX35/RTX45
Troubleshooting Guidelines
1. General
Troubleshooting can be broken down into two sections: (1)
mechanical and (2) electrical circuits. Electrical circuits can
be further broken down into control circuit and power circuit.
Many hours of troubleshooting time can be saved by knowing
the exact operational symptoms. If the proper switch operates
for the chosen direction and speed, the problem can be found
in the controller or the power circuit of that function.
Voltage tests are made with the negative lead of the
voltmeter connected to battery negative if the negative lead is
connected to a negative terminal on the electrical panel. First,
verify the negative connection to the battery by touching the
positive meter lead to the positive battery post. The battery
voltage must be at least 25.2 volts for a 24 volt system. If the
battery voltage is below 22 volts (no load), the controller may
not operate properly. The battery voltage must be at least
37.8 volts for a 36 volt system. If the battery voltage is below
33 volts (no load), the controller may not operate properly.
Charge the battery before starting the troubleshooting
procedures.
When testing voltage, the positive side of any component
refers to the terminal on that component that is closest
electrically to the battery positive terminal. The negative
side of any component refers to the terminal on that
component that is farthest electrically from the battery
positive terminal. It is possible, and in many cases desirable,
to measure battery voltage on the negative side of a
component.
Rear direction refers to travel in the direction of the truck
with the forks trailing. Forward direction refers to travel with
the forks first.
After the final test is completed, the truck should be repaired
and operating properly. If it is not, then verify test results and
possibly re-evaluate the failure symptoms. If the truck is still
not repaired, then call your local authorized BT Prime-Mover
Dealer for assistance.
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2001-03-15
85
F-code
Section
C-code
PS
S0.0
Troubleshooting Guidelines
Version no
T-code
000
RTX35/RTX45
86
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Service Manual
2001-03-15
F-code
Section
C-code
PS
S0.0
Troubleshooting Guidelines
Version no
000
T-code
RTX35/RTX45
2. Electrical
Many problems are caused by a faulty or dirty battery. Make
sure the battery is clean. Check the electrolyte level and state
of charge.
CAUTION Be sure to block the truck whenever a
troubleshooting procedure requires turning
key switch (S17) ON. This will avoid
accidents caused by unexpected truck
travel.
CAUTION Unless otherwise directed, disconnect the
battery connector when checking electrical
circuits or components with an ohmmeter.
Electrical current can damage the
ohmmeter.
For error code listings see pages 336 and 340. For
programming parameters see page 345. Visually inspect all
wiring and electrical components for the following:
Loose connections or connectors
Loose or broken terminals
Damaged terminals, blocks, or strips
Broken wiring and shorted conditions (especially those that
are close to metal edges or surfaces)
Proper connections from the main electronics card (A5) to
and from the battery
Use an ohmmeter to check for wiring continuity.
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2001-03-15
87
F-code
Section
C-code
PS
S0.0
Troubleshooting Guidelines
Version no
T-code
000
RTX35/RTX45
Return
Service Manual
2001-03-15
F-code
Section
C-code
PS
S0.0
Troubleshooting Guidelines
Version no
000
T-code
RTX35/RTX45
Return
Service Manual
2001-03-15
89
F-code
Section
C-code
PS
S0.0
Troubleshooting Guidelines
Version no
T-code
000
RTX35/RTX45
90
Return
Motors
Heat sinks
Power cables
Power circuit components
Control circuit components
Service Manual
2001-03-15
F-code
Section
C-code
PS
S0.0
Troubleshooting Guidelines
Version no
000
T-code
RTX35/RTX45
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91
F-code
Section
C-code
PS
S0.0
Troubleshooting Guidelines
Version no
T-code
000
RTX35/RTX45
3. Hydraulic
NOTE! Proper care and cleanliness should be
observed when servicing the truck to ensure
that the oil does not become contaminated
with dirt or other foreign material.
Contaminants drawn into the pump may
cause the pump to stick, score, or fail.
If the hydraulic pump assembly does not operate properly,
preliminary checks should be made of the following: For error
code listings see pages 336 and 340. For programming
parameters see page 345.
Proper oil level
All electrical connections tight
Battery fully charged
CAUTION After elevating or reaching the carriage for
troubleshooting, be sure to use blocks to
secure the carriage.
Use extreme care when blocking the mast
for any reason. Never remove a block when
it is supporting the mast.
Lower the carriage fully and retract the reach mechanism
fully.
If the truck is equipped with tilt, set the forks level, not tilted
either up or down.
If the truck is equipped with sideshift, center the forks
horizontally.
When checking voltage at solenoids, make sure hydraulic
lines and components are fully installed.
Whenever possible, keep the key switch OFF and the
battery connector disconnected.
92
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Service Manual
2001-03-15
F-code
Section
C-code
PS
S0.0
Troubleshooting Guidelines
Version no
000
T-code
RTX35/RTX45
4. Definitions
Auxiliary Function. A hydraulic function other than lift/lower.
The truck includes: reach/retract; tilt; and sideshift. Some
auxiliary functions, or aux functions are optional features on
the truck.
Continuity. A continuous and uninterrupted path between
two or more locations in an electrical circuit, typically having a
resistance of less than 1 ohm.
Brake Pedal Switch. The switch in the truck that must be
closed to allow reach truck operation. It is activated by the
operator stepping on the foot pedal thus engaging the brake
pedal. Travel is prohibited when the brake is applied.
High Speed Travel Limit. A reduced speed initiated when
the truck is driven while the carriage is elevated above a
certain mast height. This is a safety feature that limits the
speed of travel with an elevated mast and helps prevent
unstable load conditions.
Mast Assembly. The elevating section of the truck, which
bolts to the chassis section adjacent to the battery. The mast
assembly consists of column sections, carriage assembly, lift
cylinders, lift chains, etc.
Mast Switch. A switch on the mast that is actuated when the
carriage is above a certain height on the mast. It is used to
activate the speed limit feature to limit travel speed when the
carriage is elevated.
Open Circuit. A lack of a continuous path between two or
more electrical connections. Generally, when such a circuit is
tested, it will have a resistance greater than ten megohms.
Overtemperature (Power Amplifier). Overtemperature
of
the motor power amplifier is from 185o F (85o C) and above.
At overtemperature the drive current limit is linearly
decreased from full set current down to zero. Plug current is
not reduced to provide full vehicle braking under all thermal
conditions.
Pulse Width Modulation. Pulse Width Modulation (PWM),
also called chopping, controls the speed of the motor by
switching the battery voltage to the motor on and off very
quickly.
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2001-03-15
93
F-code
Section
C-code
PS
S0.0
Troubleshooting Guidelines
Version no
T-code
000
RTX35/RTX45
94
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Service Manual
2001-03-15
F-code
Section
PS
S0.1
Version no
001
C-code
0340
Chassis
T-code
RTX35/RTX45
Chassis
1. General
t
Contactor
Plate/Bracket
Floor
Board
Motor
Compartment
Door
Left Operator
Compartment
Panel
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Main
Electronic
Card Access
Panel
Service Manual
2001-03-15
95
F-code
Section
C-code
PS
Chassis
S0.1
0340
Version no
T-code
001
RTX35/RTX45
2. Top Console
The top console is a one piece unit. It covers the motor
compartment, the drive and pump transistor regulators, and
contactors. The operator display, key switch, emergency
disconnect switch, and optional push-button switches are
mounted in the top console.
2.1. Removal
1. Park truck on a level surface and block.
2. Turn keyswitch OFF and disconnect the battery
connector.
3. Remove hardware securing the top console to the
frame.
4. Lift the cover up enough to disconnect the wiring
harness connections to the key switch, emergency
disconnect switch, optional push-button switches,
and the operator display.
5. Lift the top console off the steering wheel and
control handle, removing it from the truck.
2.2. Installation
1. Place the top console over the steering wheel and
control handle.
2. Attach the harness connections to the operator
display, the key switch, the emergency disconnect
switch, and the optional push-button switches.
3. Align the bolt holes in the cover with the ones in the
frame.
4. Secure cover to the frame.
5. Reconnect battery connector.
6. Return truck to service.
96
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Service Manual
2001-03-15
F-code
Section
PS
S0.1
Version no
001
C-code
0340
Chassis
T-code
RTX35/RTX45
3.2. Installation
1. Set the door in place so the hinge pins are securely
mounted in the panel hinge.
CAUTION Do not force the Allen head screw past one
quarter turn or the latch can become loose.
2. Close the door. Tighten the latch screw count.
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97
F-code
Section
C-code
PS
Chassis
S0.1
0340
Version no
T-code
001
RTX35/RTX45
4.1. Removal
1. Park truck on a level surface and block.
2. Turn keyswitch OFF and disconnect the battery
connector.
3. Remove top console (see page 96).
4. Remove motor compartment door (see page 97).
5. Remove three flanged nuts using a 0.59 inch (15
mm) socket. Two are located under the control
console by the hydraulic tank. The third flanged nut
can be accessed through the left side of the battery
box or by removal of the operators compartment
left side panel.
6. Remove 0.511 inch (13 mm) bolt at the rear of the
panel, located by drive motor.
7.
98
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Service Manual
2001-03-15
F-code
Section
PS
S0.1
Version no
001
C-code
0340
Chassis
T-code
RTX35/RTX45
4.2. Installation
1. Lift left side panel up to align the three studs on the
panel with the holes in the frame.
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2001-03-15
99
F-code
Section
C-code
PS
Chassis
S0.1
0340
Version no
T-code
001
RTX35/RTX45
5.2. Installation
1. Slide left compartment panel into position.
2. Install bolt at the top of the panel.
3. Tighten bolt near the brake pedal.
100
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Service Manual
2001-03-15
F-code
Section
PS
S0.1
Version no
001
C-code
0340
Chassis
T-code
RTX35/RTX45
6.1. Removal
1. Park truck on a level surface and block.
2. Turn keyswitch OFF and disconnect the battery
connector.
3. Remove two Allen head screws at the top of the
main electronic card panel.
4. Loosen two lower Allen head screws if access to
the main electronic card is required. If the operator
compartment floor is to be removed, remove the
two screws at the bottom of the main electronic
card panel.
5. Tilt panel in, toward the operator compartment. Lift
the main electronic card panel out and set to the
side.
6.2. Installation
1. Place slots along the lower edge of the main
electronic card panel over the bottom two retaining
screws.
2. Install two top screws, then tighten the two lower
screws.
3. Reconnect battery connector and return truck to
service.
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2001-03-15
101
F-code
Section
C-code
PS
Chassis
S0.1
0340
Version no
T-code
001
RTX35/RTX45
7. Floor Board
7.1. Removal
1. Park truck on a level surface and block.
2. Turn keyswitch OFF and disconnect battery
connector.
3. Remove main electronic card panel.
7.2. Installation
1. Truck must be properly blocked at this time.
2. Reconnect wires to the right foot switch. Push
down on the left (brake) pedal with one hand and
install the floor board by pushing down and pivoting
the plate away from the motor compartment.
Release brake pedal as the floor board pivots
down.
3. Install main electronic card panel.
102
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2001-03-15
F-code
Section
PS
S0.1
Version no
001
C-code
0340
Chassis
T-code
RTX35/RTX45
8. Clipboard
The clipboard is located on the top console near the steering
wheel.
+
1 1/2
0
8.1. Removal
1. Loosen top console to gain access to the clip
mounting hardware.
2. Remove screw, small flat washer, compression
spring, and large flat washer from each clip shaft.
Clip
Large
Flat
Washer
8.2. Installation
1. Raise top console to allow reach of clipboard
mounting holes from underside of the cover.
Compression
Spring
Small Flat
Washer
Screw (2)
Small Flat
Washer (2)
4. Secure both screws into the clip. Torque to 31 inlbs (3.5 Nm).
Compression
Spring (2)
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Large Flat
Washer (2)
Service Manual
2001-03-15
103
F-code
Section
C-code
PS
Chassis
S0.1
0340
Version no
T-code
001
RTX35/RTX45
104
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Service Manual
2001-03-15
F-code
Section
C-code
PS
S0.2
0391
Battery Retainer Plates and Rollers
Version no
001
T-code
RTX35/RTX45
3
1
2
1
4
Item No.
Description
Bearing
Roller, battery
Shaft, battery
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2001-03-15
105
F-code
Section
C-code
PS
S0.2
0391
Battery Retainer Plates and Rollers
Version no
T-code
001
RTX35/RTX45
f
Battery
Rollers
Battery
Retainer
Plate
1.1. Inspection
Inspect the battery retainer plates for bending or cracks.
Replace if necessary.
1.2. Removal
1. While lifting the battery retainer plate upward, tilt
the edge toward the mast slightly forward to
disengage the tongue on the operator
compartment end of the battery retainer plate.
2. Continue lifting until the battery retainer plate is
clear of the truck, then set aside.
1.3. Installation
1. Position the battery retainer plate with tongued
edges on the bottom and facing the operator
compartment.
2. The edge toward the operator compartment should
be tilted in so that the tongue engages with the slot
in the back of the battery compartment.
3. Carefully lower the battery retainer plate into
position. Move the plate forward and backward
until proper engagement is noted.
2. Battery Rollers
2.1. Inspection
Inspect the battery rollers to ensure they can turn freely.
Clean off electrolyte using a solution of 1 pound (0.45 kg) of
baking soda added to 0.5 gallon (3.7 liters) of hot water.
2.2. Replacement
Lift the damaged roller from its slot and replace with a new
one.
106
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Service Manual
2001-03-15
F-code
Section
PS
S0.3
0451
Mounting Points
Version no
001
C-code
T-code
RTX35/RTX45
Mounting Points
1. Drive Motor
28
27
26
25
24
23
22
21
19
20
18
17
16
Item No.
BT Prime-Mover Inc.
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Description
Item No.
Description
16
Stop, steering
23
Sleeve
17
Screw, cap
24
O-ring
18
Screw, cap
25
Screw, cap
19
Ring, retainer
26
20
Ring, retainer
27
Brake assembly
21
Bearing
28
Sensor assembly
22
Ring, seal
Service Manual
2001-03-15
107
F-code
Section
C-code
PS
S0.3
Mounting Points
0451
Version no
T-code
001
RTX35/RTX45
1.1. Removal
WARNING There is no brake on truck when drive motor
is removed from transmission assembly.
Block all wheels to prevent truck from
rolling.
1. Park the truck on a level surface and make sure all
wheels are blocked to prevent accidental
movement.
2. Turn key switch OFF and disconnect battery
connector.
3. Remove top console, motor compartment door,
and left side panel to allow access to drive motor.
4. Remove four power cables. An 11/16 inch (17 mm)
wrench is required to loosen terminal nuts for the
field and armature connections. Note cable
numbers and terminal locations for use in
reassembly.
5. Disconnect the drive motor brush sensor, two
speed/directional sensors, temperature sensor,
and brake assembly connectors.
6. Using an 9/16 inch (13 mm) socket, remove the six
drive motor mounting bolts (25). A 24 inch (609
mm) extension is helpful to access the two bolts
behind the drive motor.
7. Attach a lifting tool to lift the drive motor. (Using two
eye bolts screwed into the top of the brake
assembly (two empty holes used for the brake
manual release screws), attach a piece of chain
(about 20 inches (508 mm) long) with a S hook at
each end to each of the eye bolts.)
8. Attach a hoist to the lifting tool attached to the top
of the brake assembly.
9. Gently lift the drive motor out of the transmission.
(It may be necessary to rock the drive motor gently
to loosen it from the transmission.)
10. Cap top of the transmission
contamination of transmission fluid.
108
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to
prevent
2001-03-15
F-code
Section
PS
S0.3
0451
Mounting Points
Version no
001
C-code
T-code
RTX35/RTX45
1.2. Installation
1. Remove cap from the top of transmission.
2. Lower drive motor straight down onto transmission.
The drive motor terminals and brush motor sensor
should be facing out.
3. Remove chain, S hooks, and eye bolts from brake
assembly.
4. Apply Loctite 242 to drive motor mounting bolts.
A magnet may be handy to help start the back bolt
or to retrieve a bolt if dropped behind the drive
motor.
5. Using an 9/16 inch (13 mm) socket tighten drive
motor mounting bolts (25).
6. Be sure to draw motor down evenly to allow the
gear on the motor shaft to properly mesh with the
transmission.
7. Attach brake electrical connection (R3).
8. Attach brush wear indicator connections.
9. Install drive motor power cables to terminal posts.
10. Add washers and nuts to terminal posts. Be sure
nuts are tight using an 11/16 inch (17 mm) wrench
for the armature and field connections.
11. Reconnect brush wear sensor, temperature
sensor, and two speed/directional sensor
connections.
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109
F-code
Section
C-code
PS
S0.3
Mounting Points
0451
Version no
T-code
001
RTX35/RTX45
2. Pump Motor
1
2
3
4
5
6
Item
No.
Description
Item
No.
Description
Item
No.
Description
Washer, flat
Screw
Screw
Shock, mount
110
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Service Manual
2001-03-15
F-code
Section
PS
S0.3
0451
Mounting Points
Version no
001
C-code
T-code
RTX35/RTX45
2.1. Removal
WARNING Block all wheels to prevent truck from
rolling.
Suction (Supply)
Hose To Pump
Motor
Bracket
Mounting
Bolts
Pump
Motor
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111
F-code
Section
C-code
PS
S0.3
Mounting Points
0451
Version no
T-code
001
RTX35/RTX45
2.2. Installation
1. Place lift pump and motor assembly with bracket
onto truck frame. Make sure four rubber grommet
shock mounts (6) are in the bracket mounting
holes.
2. Align suction hose flange with reservoir hose. Slide
reservoir hose onto flange as the pump and motor
assembly is installed into the truck. Install hose
clamp at the flange. Be sure clamp is tightened to
prevent leakage. If a leak is found later, the drive
motor will have to be removed to access the
clamps.
Align
Hose
112
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2001-03-15
F-code
Section
PS
S0.3
0451
Mounting Points
Version no
001
C-code
T-code
RTX35/RTX45
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113
F-code
Section
C-code
PS
S0.3
Mounting Points
0451
Version no
T-code
001
RTX35/RTX45
3. Transmission
18
17
16
15
14
13
12
10
11
Item
No.
114
Description
Item
No.
Description
Item
No.
Description
Plate, stop
11
15
Screw, EE
Plate, target
12
Cap, plug
16
Stop, steering
Transmission
assembly
13
Gasket, EE
17
Screw, cap
10
Drive wheel
assembly
14
Plate, EE
18
Screw, cap
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Service Manual
2001-03-15
F-code
Section
PS
S0.3
0451
Mounting Points
Version no
001
C-code
T-code
RTX35/RTX45
3.2. Removal
1. Park the truck on a level surface.
2. Turn key switch OFF and disconnect battery
connector.
3. Jack the rear of truck (see Safe Jacking
Procedure on page 64).
4. Drain transmission fluid. See paragraph 3.1 above.
5. Remove drive tire. See Removal on page 183.
6. Place drive tire face down on the floor. Slide it
under the transmission to act as a cradle to keep
the transmission upright when it is unbolted from
truck frame. There should be an 1 inch (25.4 mm)
gap between the tire and the transmission before
the transmission is unbolted.
7. Using an 3/4 inch (19 mm) socket remove six bolts
(18) that secure the transmission to truck frame.
Remove drive motor before removing the
transmission (see page 108).
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Service Manual
2001-03-15
115
F-code
Section
C-code
PS
S0.3
Mounting Points
0451
Version no
T-code
001
RTX35/RTX45
3.3. Installation
1. Place transmission in drive tire and slide
transmission, in the tire cradle, beneath the truck.
Using a hoist, lower the truck frame onto the
transmission. Be careful not to pinch hands
between the transmission and the truck frame.
2. Line grease fittings up with the indentations in the
frame.
3. The half-moon shaped piece mounted to the top
surface of the transmission should be toward the
left so that the sensors will read the wheel position
correctly.
4. Guide the transmission, with one hand through the
hole in the truck frame, while lowering the frame
onto the transmission. Install drive motor (see
page 109).
5. Clean and apply Loctite 242 to the transmission
mounting bolts (18). Using a 3/4 inch (19 mm)
wrench to help get the bolts started straight.
6. The transmission will draw tight to the truck frame
mounting surface as the bolts are tightened.
Transmission mounting bolts (18) should be
torqued to 90 ft-lbs (122 Nm).
7. Add transmission fluid. (See Fluid Changing
Procedure on page 115.)
8. Install drive wheel. Lubricate wheel nut. Secure
drive wheel with wheel nut. Torque wheel nut to 65
ft-lb (88 Nm).
9. Lower truck and remove blocks.
10. Reconnect battery connector.
116
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Service Manual
2001-03-15
F-code
Section
PS
S0.4
0640
Driver Controls
Version no
C-code
T-code
001
RTX35/RTX45
Driver Controls
16
15
9
10
3
4
11
14
12
13
31
6
7
18
28
7
27
19
18
22
29
20
30
26 25 24 23
BT Prime-Mover Inc.
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2001-03-15
21
117
F-code
Section
C-code
PS
S0.4
Driver Controls
0640
Version no
T-code
001
RTX35/RTX45
Item
No.
118
Return
Item
No.
Description
Description
Handle, control
17
Button, auxiliary
18
19
20
Shaft
Screw
21
Bearing
Screw
22
Screw
Screw
23
Spring
Screw, set
24
Screw, set
Screw, set
25
Spacer
10
Knob, left
26
Potentiometer
11
Spring
27
Tie, wire
12
Bracket
28
Housing, connector
13
Potentiometer
29
Pin, connector
14
30
Cable assembly
15
Actuator, button
31
16
Spring
Service Manual
2001-03-15
F-code
Section
PS
S0.4
0640
Driver Controls
Version no
001
C-code
T-code
RTX35/RTX45
1.1. Removal
1. Turn key switch OFF and disconnect battery
connector.
2. Remove top console (see page 96).
3. Disconnect wiring harnesses to the control handle
and main electronic card.
4. Remove two thread forming screws securing the
interface module to the bracket.
5. Remove interface module from truck.
1.2. Installation
1. Position handle interface module at the contactor
plate/bracket, aligning mounting holes.
2. Install two thread forming screws to secure module
to bracket.
Screw
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2001-03-15
119
F-code
Section
C-code
PS
S0.4
Driver Controls
0640
Version no
T-code
001
RTX35/RTX45
2. Control Handle
The control handle is the operators means of controlling
travel, lift/lower, and auxiliary functions. The control handle
assembly is located in the middle of the top console, to the
right of the steering wheel.
Lift/lower
Knob
Item
No.
Allen head
screw
Keep 14 of
cable off of the
control handle
straight
Description
Item
No.
Description
Handle, control
Screw
Pin, dowel
Plate, keeper
Support, travel
Module, interface
Screw, set
Screw
2.1. Removal
5
6
2
4
7
CAUTION Be sure to observe proper precautions
against electrostatic discharge (see Static
Safety on page 23).
3. Unplug control handle wiring harness from the
handle interface module (7).
4. Cut any tie-straps that secure the wiring harness.
5. Loosen Allen head screw (4) that secures the
control handle assembly to its support travel
bracket (3).
6. Slide the control handle assembly to the left, out of
its support bracket.
120
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Service Manual
2001-03-15
F-code
Section
PS
S0.4
0640
Driver Controls
Version no
001
C-code
T-code
RTX35/RTX45
2.2. Installation
1. Insert the shaft of the control handle assembly into
the support bracket (3).
2. Apply thread-locking compound to the threads of
the Allen head screw (4).
3. Hold the control handle in place.
4. Align the hole in the shaft with the set screw hole.
Torque the set screw to 30 ft-lb (42 Nm).
CAUTION To ensure long handle cable life, proper
wire routing is necessary. Make sure 14
inches (355 mm) of the cable off of the
control handle is kept straight.
5. Route the control handle wiring harness up and
plug it into the Handle Interface Module (7).
6. Secure the control handle wiring harness in place
with tie-straps. Ensure the cable extends out of the
handle as straight as possible to avoid kinking.
7. Reinstall top console.
8. Reconnect battery connector and turn key switch
ON.
2.3. Recalibration
Recalibration of the control handle is necessary whenever
error codes 30, 38 or 33 appear on the operator display.
To clear error code 30 (Control Handle Calibration Error
1): Key OFF the truck. Press and hold SW1 on the main
electronic card. Key ON truck until truck powers-up and the
display turns on. Release SW1 to prepare the main electronic
card for calibration of the control handle.
To clear error code 38 (Accelerator Pot Span Calibration
Error): With both foot pedals released, move the control
handle forward and backward the full range of travel until the
code 38 disappears. This calibrates the handle travel and
limit positions.
BT Prime-Mover Inc.
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2001-03-15
121
F-code
Section
C-code
PS
S0.4
Driver Controls
0640
Version no
T-code
001
RTX35/RTX45
Control
Handle
Function
Control
Handle
Interface
Card
Input Pin
Travel
Notes:
HM210
Control Handle
Interface Card
Approximate Input
Voltage (measured
with respect to HM213)
Min. 0.6V Rev
Nom. 1.4V
Max. 2.2V Fwd
Control Handle
Interface Card
Output Pin
(measured with
respect to HM110)
HM105
Control Handle
Interface Card
Nominal Output
Voltage
Min. 0.6V Rev
Nom. 1.4V
Max. 2.2V Fwd
Wire #
50
Main Electronic
Card (A5) Input
Pin (measured
with respect to
510)
505
Main
Electronic
Card (A5)
Nominal Input
Voltage
Min. 0.6V Rev
Nom. 1.4V
Max. 2.2V Fwd
1.
Voltages at the main electronic card inputs greater than 6.75 volts and less than 0.6 volts indicate shorted or
open signal wires for travel and lift/lower.
2.
The center and travel limits of the travel and lift/lower potentiometers are learned. Therefore, the voltages listed
are a rough approximation.
122
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Service Manual
2001-03-15
F-code
Section
PS
C-code
S0.5
0642
Brake Pedal (RTX35)
Version no
T-code
000
RTX35/RTX45
2
1
2
5
8
4
3
8
9
13
14
10
11
Item
No.
Description
Item
No.
Pedal, brake
Bumper
11
Screw
Bearing, flanged
Plate
12
Mat, pedal
Bumper
Screw
13
Nut, twin
Bracket, brake
Screw
14
Switch, brake
Spring, return
10
Potentiometer
15
Screw
BT Prime-Mover, Inc.
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15
Service Manual
Description
2001-03-15
Item
No.
Description
123
F-code
Section
PS
S0.5
Brake Pedal (RTX35)
Version no
T-code
000
RTX35/RTX45
C-code
0642
1. Pedal Removal
1. Park truck on a flat surface.
2. Disconnect battery at the battery connector. Check
to make sure the battery retainer plates are in
place.
3. Jack the rear of the truck (see Safe Jacking
Procedure on page 64).
4. Remove the main electronics card panel (see
page 101).
124
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Service Manual
2001-03-15
F-code
PS
Version no
000
Section
C-code
S0.5
0642
Brake Pedal (RTX35)
T-code
RTX35/RTX45
3. Pedal Adjustment
1. See Adjustment Procedures for Setting Brake
Switch and Brake Transducer on page 355.
2. When replacing bumper (6), it should be threaded
down until the stop makes contact with bracket (4).
BT Prime-Mover, Inc.
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Service Manual
2001-03-15
125
F-code
Section
PS
S0.5
Brake Pedal (RTX45)
Version no
T-code
000
RTX35/RTX45
C-code
0642
6
2
1
17
16
5
4
3
8
13
14
7
10
11
15
126
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Service Manual
2001-03-15
F-code
PS
Version no
000
C-code
S0.5
0642
Brake Pedal (RTX45)
T-code
RTX35/RTX45
Item
No.
Description
Item
No.
Pedal, brake
Plate
13
Nut, twin
Bearing, flanged
Screw
14
Switch, brake
Bumper
Screw
15
Screw
Bracket, brake
10
Potentiometer
16
Cable, brake
Spring, return
11
Screw
17
Bumper
12
Mat, pedal
Description
Item
No.
Section
Description
1. Pedal Removal
1. Park truck on a flat surface.
2. Disconnect battery at the battery connector. Check
to make sure battery retainer plates are in place.
3. Jack the rear of the truck (see Safe Jacking
Procedure on page 64).
4. Remove the main electronics card panel (see
page 101).
BT Prime-Mover, Inc.
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2001-03-15
127
F-code
Section
PS
S0.5
Brake Pedal (RTX45)
Version no
T-code
000
RTX35/RTX45
C-code
0642
3. Pedal Adjustment
1. See Adjustment Procedures for Setting Brake
Switch and Brake Transducer on page 355.
2. When replacing the bumper (6), it should be
threaded down until the stop makes contact with
the bracket (4).
128
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Service Manual
2001-03-15
F-code
Section
PS
S0.6
0681
Internal Fittings
Version no
001
C-code
T-code
RTX35/RTX45
Internal Fittings
1. Operator Fan
The operator fan/overhead light is located in the compartment
on the left side of the overhead guard. The operator fan/
overhead light is an option, therefore, it may not be on your
particular truck. There are separate switches for the operator
fan and the overhead light. These switches are located to the
right of the key switch on the top console.
1
2
3
3
4
13
14
6
7
8
12
11
10
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2001-03-15
129
F-code
Section
C-code
PS
S0.6
Internal Fittings
0681
Version no
T-code
001
RTX35/RTX45
Item
No.
Description
Item
No.
Description
Screw
Nut
Screw
Screw
Nut, clip
10
Console
Bracket, hanger
11
Louver
Plate, filler
12
Shroud
Washer, flat
13
Tie, wire
Lockwasher
14
Fan motor
1.1. Removal
1. Turn key switch OFF and disconnect battery
connector.
2. From the top of the overhead guard, remove four
screws (1) securing the light/fan assembly.
3. Lower the light/fan assembly enough to disconnect
it from the harness.
4. Remove the light/fan assembly from the truck.
5. Repair or replacement of the fan is achieved by
removing the four screws (9) in the sides of the
light/fan console assembly to detach the hanger
bracket (4) from the top of the console (10).
1.2. Installation
1. Reassemble the light/fan console assembly. Be
sure the clip nuts (3) are positioned over the
mounting holes for attachment to the overhead
guard.
2. Reconnect the harness connections.
3. Install the mounting screws (1) through the top of
the overhead guard to secure the assembly.
4. Reconnect battery connector.
5. Test the operation of the light assembly, then
return truck to service.
130
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Service Manual
2001-03-15
F-code
Section
PS
S0.7
Version no
001
C-code
0811
Guards
T-code
RTX35/RTX45
Guards
4
1. Overhead Guard
Item
No.
3
5
Description
Overhead guard
Bolt
Screw, cap
Nut
BT Prime-Mover Inc.
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2001-03-15
131
F-code
Section
C-code
PS
Guards
S0.7
0811
Version no
T-code
001
RTX35/RTX45
132
Return
Service Manual
2001-03-15
F-code
Section
PS
S0.8
Version no
001
C-code
0851
Decals
T-code
RTX35/RTX45
Decals
Remove and replace any decals that are damaged. Replace
any missing decals. Remove a damaged decal by using a
sharp edge to peel the decal from the surface. Use caution
not to scratch or damage the paint on the truck when
removing the decal.
Using the required cleaning solution, thoroughly clean the
surface of the truck before applying a new decal. Allow the
surface to completely dry, be sure that there is no residue.
Touch up the paint in the area of the decal, as required.
BT Prime-Mover Inc.
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2001-03-15
133
F-code
Section
C-code
PS
Decals
S0.8
0851
Version no
T-code
001
RTX35/RTX45
12
KEEP HANDS CLEAR
11
10
+1/21
0
8
7
Model
Serial Number
Cap. (Lbs.)
TruckBatt.
Wt. (Lbs.)
Less
DC Volt age
UseULType
Class
Battery
BInches C
C
B
BTPrime-Mover, Inc.
Muscatine, IA 52761
5
3
4
134
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Service Manual
2001-03-15
F-code
Section
PS
S0.8
Version no
001
Item
No.
BT Prime-Mover Inc.
Return
Description
Item
No.
T-code
RTX35/RTX45
Description
Decal, WARNING
Decal, RTX45
Decal, WARNING
Decal, RTX35
Box, Manual
10
Plate, UL
11
Decal WARNING
Plate, Data
12
Service Manual
2001-03-15
C-code
0851
Decals
135
F-code
Section
C-code
PS
Decals
S0.8
0851
Version no
T-code
001
RTX35/RTX45
136
Return
Service Manual
2001-03-15
F-code
Section
PS
S1.0
1730
Steering Motor
Version no
001
C-code
T-code
RTX35/RTX45
Steering Motor
The steering motor is located in the lower right section of the
motor compartment, nearest the motor compartment door. It
is to the right of the drive motor and beneath the control
valve.
1. Removal
WARNING Block all wheels to prevent truck from
rolling.
1. Park truck on a level surface. Block truck to
prevent accidental movement.
2. Turn key switch OFF and disconnect battery
connector.
3. Remove motor compartment door to access the
steering motor (see page 97).
4. Disconnect steering motor from the main electrical
harness.
5. Use an 13/64 inch (5 mm) Allen wrench to remove
four bolts securing the steering motor to the truck
frame. The rubber gasket should remain on each
bolt.
Spacer
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2001-03-15
137
F-code
Section
C-code
PS
S1.0
Steering Motor
1730
Version no
T-code
001
RTX35/RTX45
2. Installation
1. Make sure the rubber spacer and two O-rings are
on the end of the steering motor.
2. Apply a little grease so the motor will slide into the
frame without cutting the O-rings.
3. Apply black graphite grease to the gear to help
prevent excessive wear.
4. Place the electrical connectors toward the lift
motor. Insert the steering motor into the truck
frame.
5. Apply Loctite 242 to the mounting bolt threads.
Install the four bolts with rubber grommets. Using
an 0.203 inch (5 mm) Allen wrench torque to 35 inlbs (3.95 Nm).
6. Reconnect the electrical harness connections.
7. Install the motor compartment door.
8. Remove blocks from truck. Reconnect the battery
connector.
9. Test truck for proper operation.
10. Return truck to service.
138
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Service Manual
2001-03-15
F-code
Section
PS
S1.0
1730
Steering Motor
Version no
001
C-code
T-code
RTX35/RTX45
3.2. Installation
1. Slide steering gear onto the steering motor shaft.
2. Install mounting bolt in the steering gear.
3. Torque gear mounting bolt to 88 in-lbs (10 Nm).
4. Return steering motor to the truck following the
installation procedure on page 138.
BT Prime-Mover Inc.
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2001-03-15
139
F-code
Section
C-code
PS
S1.0
Steering Motor
1730
Version no
T-code
001
RTX35/RTX45
140
Return
Service Manual
2001-03-15
F-code
Section
PS
S1.1
Version no
001
C-code
1740
Fan Motor
T-code
RTX35/RTX45
Fan Motor
The main fan motor in the truck cools the upper electrical
compartment. An optional operator cooling fan is also
available.
1.1. Removal
1. Turn key switch OFF and disconnect battery
connector.
2. Remove top console (see page 96).
3. Disconnect electrical connections from the fan to
the main wiring harness.
4. Remove four nuts (1) from upper electrical
compartment side.
5. Remove four screws (2) from the mast side of the
truck compartment.
6. Remove the fan assembly from truck.
1
1.2. Installation
1. Install fan assembly by inserting four screws (2)
through the truck frame from the mast side.
2. Install four nuts (1) from the electrical compartment
side.
3. Connect electrical connections to the main wiring
harness.
4. Install top console.
5. Reconnect battery and return truck to service.
BT Prime-Mover Inc.
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2001-03-15
141
F-code
Section
C-code
PS
Fan Motor
S1.1
1740
Version no
T-code
001
RTX35/RTX45
2. Operator Fan
The operator fan is located in the compartment with the
overhead light on the left side of the overhead guard. The
operator fan/overhead light is an option, therefore, it may not
be on your particular truck. To service the operator fan, see
Internal Fittings on page 129.
142
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Service Manual
2001-03-15
F-code
Section
C-code
PS
S1.2
1700
Motor Maintenance Schedule/Troubleshooting
Version no
000
T-code
RTX35/RTX45
Motor Maintenance
Schedule/Troubleshooting
1. General Information
A routine maintenance schedule with recorded findings is the
best way to reduce costly shut-downs and repair of
equipment during operating hours. The goal of any
maintenance program, long-life and trouble-free operations is
related to the time spent making inspections and correcting
minor problems as they occur. The drive motor and pump
motor are both equipped with brush sensors. When brushes
are in need of replacement, a warning code C-17 will show on
the dash display.
2. Operating Conditions
Operating environment of reach truck motors varies
widely: The following recommendations should be applied as
actual conditions dictate.
Normal Service:
Severe Service:
Extreme Service:
yChemical Processing
yFreezer operation
yProcessing plants (poultry, meat)
BT Prime-Mover Inc.
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2001-03-15
143
F-code
Section
C-code
PS
S1.2
1700
Motor Maintenance Schedule/Troubleshooting
Version no
T-code
000
RTX35/RTX45
3. Troubleshooting
When a motor has trouble in operation, a reasonable decision
has to be made as to the proper corrective course of action. A
review of the many troubleshooting guides has been
conducted and have been reduced to a few which seem to be
the most effective Symptom/Cause relationships and listed
on tables 1 and 2.
144
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Table 1
Table 2
Service Manual
2001-03-15
F-code
Section
C-code
PS
S1.2
1700
Motor Maintenance Schedule/Troubleshooting
Version no
000
T-code
RTX35/RTX45
Immediate Causes
Primary Faults
Sparking
1-2-3-43-44-45-46-49-59-60
7-12-31-33
7-12-30-32
7-12-30-32
8-9-11
6-14-15-16-17-18-19-20-21-28
29
25-27-28-29-38-39-40-41-42
7-13-23-34
51-52
See Chattering or Noisy Brushes
55-57-59
50
Overcommutation
Undercommutation
Too rapid reversal of current
7-12-31-33
7-12-30-32
7-12-30-32
Glowing
Embedded copper
Severe sparking
Imperfect contact with
commutator
Wrong brush grade
11-14-15-16-51-52
54-58
Embedded copper
Faulty machine adjustment
Severe load condition
Bad service condition
Wrong brush grade
2-3
43-46-47-48-49
59-61
Flashover at Brushes
Machine condition
Bad load condition
Lack of attention
14-35
38-39-41-53
5-11
Chattering or Noisy
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2001-03-15
145
F-code
Section
C-code
PS
S1.2
1700
Motor Maintenance Schedule/Troubleshooting
Version no
T-code
000
RTX35/RTX45
Immediate Causes
Primary Faults
1-2-3-4-17
5-44-60
Eccentric Surface
1-19-22-52
Sparking
17
Sparking
Copper or foreign material in
brush face
Glowing
2-25
2-3-43-44-45-46-47-48-49-59-61
Sparking
Flashover
2-3-7-12-30-31-32-33
5-11-14-35-38-39-41-53
Sparking
25-37
Sparking
7-12-30-57-60
Flat Spot
Sparking
Flashover
Lack of attention
19-23-25-41-53
5-11-14-35-38-39-41-53
1-5-11
Discoloration of Surface
High temperature
Atmospheric condition
Wrong brush grade
Embedded copper
Bad service condition
Wrong brush grade
Rapid Commutator
Wear with Blackened Surface
Burning
Severe sparking
2-3-11-14
See Sparking
Rapid Commutator
Wear with Bright Surface
Copper Dragging
43-45-47-49
61
39-52-58-59
146
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Service Manual
2001-03-15
F-code
Section
C-code
PS
S1.2
1700
Motor Maintenance Schedule/Troubleshooting
Version no
000
T-code
RTX35/RTX45
Immediate Causes
Primary Faults
Heating in Windings
38-41-42-53
18-19-20-21-27-28-29
8-19-22-25-27-28-29-37
38-41-42
7-8-9-12-20-33-45-57
10-11-36-43-45-49-58-59
See specific surface fault in
evidence
6-24
56
38-41-42
7-10-11-12-26
See Sparking
See Streaking or Threading of
Surface
See Copper in Brush Face
57-58-59-61-62
Heating at Commutator
Heating at Brushes
BT Prime-Mover Inc.
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2001-03-15
7-13-23-24
147
F-code
Section
C-code
PS
S1.2
1700
Motor Maintenance Schedule/Troubleshooting
Version no
T-code
000
RTX35/RTX45
2.
High mica
3.
Feather-edge mica
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
148
Return
14.
15.
16.
17.
Commutator loose
18.
19.
20.
21.
22.
Dynamic unbalance
23.
2001-03-15
F-code
Section
C-code
PS
S1.2
1700
Motor Maintenance Schedule/Troubleshooting
Version no
000
T-code
RTX35/RTX45
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
BT Prime-Mover Inc.
Return
38.
Overload
39.
40.
41.
Plugging
42.
Dynamic braking
43.
44.
Contaminated atmosphere
45.
Contact poisons
46.
47.
2001-03-15
149
F-code
Section
C-code
PS
S1.2
1700
Motor Maintenance Schedule/Troubleshooting
Version no
T-code
000
RTX35/RTX45
49.
50.
Silicone contamination
Disturbing External Condition
150
Return
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
Service Manual
2001-03-15
F-code
Section
PS
C-code
S1.3
1750
Pump Motor (RTX35)
Version no
T-code
000
RTX35
18
8
13
17
16
11
9
10
14
ROTATION
Item
No.
C.C.W.C.E.
Motor assembly
10
Holder, brush
11
Lead assembly
12
Bearing
13
Washer, wave
14
Spring, brush
15
Bearing
16
Hardware, fan
Brush
17
Shroud, fan
Spring
18
Hardware, shroud
Counterclockwise
when viewed from
commutator end.
BT Prime-Mover Inc.
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15
12
Description
Service Manual
2001-03-15
Item
No.
Description
151
F-code
Section
PS
S1.3
Pump Motor (RTX35)
Version no
T-code
000
RTX35
C-code
1750
1. Component Repair
1.1. Motor Disassembly
1. Remove pump motor from truck (see page 111).
2. Use a brush hook to reach into the motor and lift
the brush springs (9). Pull the brushes (8) out of
the brush holders. Either position brushes outside
the motor or remove brush retaining screws, and
remove brushes (8) from the motor.
3. Scribe or center punch locating marks in the end
head and frame. Although locating marks are not
always necessary, they can save time when the
motor does not have locating pins.
4. Remove commutator end head retaining screws.
Most motors have a slip fit bearing at the
commutator end, and end head can be removed
with very little trouble.
5. Remove drive end head retaining screws if
necessary. Some of the smaller pump motors
retain the drive end head with the motor through
bolts. Separate armature (3) and drive end head
(5) as an assembly from the frame and field coil
assembly.
6. Separate armature (3) from the drive end head (5),
by pressing the armature out of the drive end
bearing. Remove bearing with a puller, protecting
the end of the armature shaft with a nut or a thick
flat washer.
CAUTION Use caution and DO NOT damage
armature during removal. If shaft, coupling,
or spline is damaged when removing the
drive end head, the armature or the drive
spline must usually be replaced.
7. Separate bearing (6) from end head (4). On larger
motors, the bearing is retained with a snap ring.
Remove the snap ring. Press the bearing out of the
end head.
152
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2001-03-15
F-code
PS
Version no
000
Section
C-code
S1.3
1750
Pump Motor (RTX35)
T-code
RTX35
BT Prime-Mover Inc.
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2001-03-15
153
F-code
Section
PS
S1.3
Pump Motor (RTX35)
Version no
T-code
000
RTX35
C-code
1750
2. Motor Inspection
A good planned maintenance program will save many hours
of future down time on a piece of equipment. Maintenance
schedules should consist of periodic routine inspections of
motors, battery and wiring circuitry.
154
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Service Manual
2001-03-15
F-code
Section
PS
C-code
S1.3
1750
Pump Motor (RTX35)
Version no
T-code
000
RTX35
segments
GOOD UNDERCUT
0.04 inch deep
mica
segments mica
segments
BAD UNDERCUT
Brushes should be inspected for uneven wear and signs of
overheating such as discolored brush shunts and brush
springs. See Table 1. Unsatisfactory Brush Performance on
BT Prime-Mover Inc.
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Service Manual
2001-03-15
155
F-code
Section
PS
S1.3
Pump Motor (RTX35)
Version no
T-code
000
RTX35
C-code
1750
page 145. Check the brush holders for physical damage and
make sure they are not loose on the end head or the brush
holder plate. Check the brush springs for correct alignment on
the brush. A brush spring that does not apply equal pressure
on the center of the brush will cause the brush to wear
unevenly. Check for correct clearance and freedom of brush
movement in the holder. If any of the brushes are worn to the
point that replacement is necessary, the complete brush set
should be replaced. Do not replace just one or two brushes.
When brush service is required on the motor, lift brush spring
over holding bracket before removing brush. See drawing
below:
156
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Service Manual
2001-03-15
F-code
PS
Version no
000
Section
C-code
S1.3
1750
Pump Motor (RTX35)
T-code
RTX35
2.3. Bearings
After the motor has been disassembled, it is recommended
that new bearings are installed. Bearings may have been
damaged during removal. Although the bearings may appear
and feel good, the bearing races could be brinelled and fail
within a relatively short period of service.
BT Prime-Mover Inc.
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Service Manual
2001-03-15
157
F-code
Section
PS
S1.3
Pump Motor (RTX35)
Version no
T-code
000
RTX35
C-code
1750
158
Return
Service Manual
2001-03-15
F-code
PS
Version no
000
Section
C-code
S1.3
1750
Pump Motor (RTX35)
T-code
RTX35
2.6. Assembly/Testing
Refer to the following drawing whenever a bearing is installed
into an end head or shaft.
Press Ram
Bearings
Inner Race
End Head
Armature
Shaft
Snap Ring
BT Prime-Mover Inc.
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Service Manual
2001-03-15
159
F-code
Section
PS
S1.3
Pump Motor (RTX35)
Version no
T-code
000
RTX35
160
Return
C-code
1750
Service Manual
2001-03-15
F-code
PS
Section
C-code
S1.4
1750
Pump Motor (RTX 45)
Version no
T-code
000
RTX45
1
6
15
12
11
14
10
8
9
13
Item
No.
Description
Item
No.
Description
ROTATION
1
Ring, retainer
C.C.W.C.E.
Bearing
10
Counterclockwise
when viewed from
commutator end.
11
Bearing
Fan
12
Washer, wave
13
14
Brush
15
Spring, brush
BT Prime-Mover Inc.
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2001-03-15
161
F-code
Section
PS
S1.4
Pump Motor (RTX 45)
Version no
T-code
000
RTX45
C-code
1750
1. Component Repair
1.1. Motor Disassembly
1. Remove pump motor from truck (see page 111).
2. Remove cover band (14) from the commutator end
of the motor.
3. Use a brush hook to reach into the motor and lift
the brush springs (8). 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.
4. 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.
5. 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.
6. 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 (3) as an assembly from the frame and field
coil assembly.
162
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2001-03-15
F-code
PS
Version no
000
Section
C-code
S1.4
1750
Pump Motor (RTX 45)
T-code
RTX45
BT Prime-Mover Inc.
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2001-03-15
163
F-code
Section
PS
S1.4
Pump Motor (RTX 45)
Version no
T-code
000
RTX45
C-code
1750
2. Motor Inspection
See Motor Inspection on page 154.
164
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Service Manual
2001-03-15
F-code
Section
PS
S1.5
Version no
C-code
1760
Drive Motor
T-code
000
RTX35/RTX45
Drive Motor
5
3
1
4
2
10
6
12
11
9
8
13
Item
No.
Description
Item
No
Description
Item
No
Description
Brush
10
Key
Spring, brush
11
Ring, retainer
12
Bearing
Fan
13
BT Prime-Mover Inc.
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2001-03-15
165
F-code
Section
C-code
PS
S1.5
Drive Motor
1760
Version no
T-code
000
RTX35/RTX45
1. Motor Disassembly
1. Remove drive motor from truck (see page 108).
2. For EE motors, remove the head band from the
commutator end of the motor.
3. Use a brush hook to reach into the motor and lift
the brush springs (7). Pull the brushes (6) 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.
4. 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.
5. Remove the commutator end head retaining
screws. Most motors have a slip fit bearing (12) at
the commutator end, and the end head can be
removed with very little trouble.
6. Remove the drive end head retaining screws, if
necessary. Separate the armature (3) and drive
end head (5) as an assembly from the frame and
field coil assembly.
CAUTION Use caution and DO NOT damage the
armature during removal. If the shaft,
coupling, or spline is damaged when
removing the drive end head, the armature
or the drive spline usually must be
replaced.
7. Separate the armature (3) from the drive end head
(5), by pressing the armature out of the drive end
bearing.
8. Remove retainer (11) from the commutator end
head (13). Press bearing (12) out of the
commutator end head.
9. After the motor has been separated into all its
major subassemblies, the components should be
cleaned and inspected for wear or damage.
166
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Service Manual
2001-03-15
F-code
Section
PS
S1.5
Version no
000
C-code
1760
Drive Motor
T-code
RTX35/RTX45
2. Motor Inspection
See Motor Inspection on page 154.
BT Prime-Mover Inc.
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Service Manual
2001-03-15
167
F-code
Section
C-code
PS
S1.5
Drive Motor
1760
Version no
T-code
000
RTX35/RTX45
168
Return
Service Manual
2001-03-15
F-code
Section
PS
S2.0
2550
Transmission.
Version no
C-code
T-code
000
RTX35/RTX45
Transmission.
Before disassembly of parts, thoroughly clean the outside of
the assembly with cleaning solution or other non-corrosive
cleaning fluid and air dry parts
31
30
8
10
29
40
9
39
11
12
38
35
41
32
13
24
20
14
19
17
33
36
16
15
37
22
21
26
27
18
23
25
BT Prime-Mover Inc.
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34
Service Manual
2001-03-15
28
169
F-code
Section
C-code
PS
S2.0
Transmission.
2550
Version no
T-code
000
RTX35/RTX45
Item
No.
170
Return
Item
No.
Description
Description
Transmission assembly
22
Screw
Gear, ring
23
Bearing
24
Washer
25
Spacer
26
Ring, sealing
27
Ring, locking
28
Plug, drain
Gear, wheel
29
Gear, wheel
30
10
Nut
31
11
Bearing
32
Screw
12
Kit, shim
33
Gear, bevel
13
Kit, shim
34
Screw
14
Bearing
35
Plug, fill
15
O-ring
36
Keeper
16
Screw
37
Cover
17
Axle
38
Case
18
Washer, copper
39
Bearing
19
Bearing
40
Screw
20
Kit, shim
41
O-ring
21
Cover ring
Service Manual
2001-03-15
F-code
Section
PS
S2.0
2550
Transmission.
Version no
C-code
T-code
000
RTX35/RTX45
1.1. Disassembly
1. Remove transmission
page 115).
from
the
truck
(see
BT Prime-Mover Inc.
Return
Service Manual
2001-03-15
from
axle
(17)
or
171
F-code
Section
C-code
PS
S2.0
Transmission.
2550
Version no
T-code
000
RTX35/RTX45
1.2. Assembly
1. Place drive axle outer bearing (23) in the
transmission case (38).
.
NOTE! Use care when pressing the new seal ring into
place so the seal is seated correctly in the
gear housing.
2. Press new seal ring (26) into transmission case
(38).
3. Press drive axle (17) into the transmission case.
Be sure the spacer (25) is aligned with the axle
(17) and that the splines on the drive axle (17) are
aligned with the splines in the bevel gear (33).
4. Place keeper washer (36) onto the drive axle end
and install new bolts (16). Use Loctite 242 on
bolts (16). Torque axle bolts (16) to 81 ft-lb (110
Nm).
5. Install a new O-ring (15) on the lower cover (37).
Install lower cover (37). Lubricate new bolts (34).
Secure lower cover (37) with new bolts (34).
Torque bolts (34) to 18 ft-lb (25 Nm). Make sure
O-ring (15) is not damaged during installation.
6. Install a new copper washer (18) on drain plug
(28). Install drain plug (28) in the transmission. Fill
transmission with oil (see Approved Oils and
Grease on page 81). Install fill level plug (35) in
the transmission case.
7. Install transmission on truck (see page 116).
172
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Service Manual
2001-03-15
F-code
Section
PS
S2.0
2550
Transmission.
Version no
000
C-code
T-code
RTX35/RTX45
2. Leakage
When there is leakage from the transmission top cover,
proceed as follows:
BT Prime-Mover Inc.
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2001-03-15
173
F-code
Section
C-code
PS
S2.0
Transmission.
2550
Version no
T-code
000
RTX35/RTX45
174
Return
Service Manual
2001-03-15
F-code
Section
PS
S2.0
2550
Transmission.
Version no
000
C-code
T-code
RTX35/RTX45
3. Wheel Bolt
1. Drain transmission oil by removing drain plug (28).
2. Remove transmission from truck.
3. Remove drive axle from the transmission case.
4. Press or knock out the damaged bolt from the drive
axle rim.
NOTE! Always install a new drive axle seal during
assembly.
5. Smooth away any burring around the bolt hole.
Press or knock new bolt into place.
6. Install drive axle into the transmission case (see
page 172).
7. Install transmission on truck.
BT Prime-Mover Inc.
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2001-03-15
175
F-code
Section
C-code
PS
S2.0
Transmission.
2550
Version no
T-code
000
RTX35/RTX45
176
Return
Service Manual
2001-03-15
F-code
Section
PS
C-code
S3.0
3371
Electromagnetic Brake
Version no
T-code
001
RTX35/RTX45
Electromagnetic Brake
13
11
Item
No.
10
2
7
4
12
5
Description
Brake assembly
Coil
Armature
Hub
Plate, friction
Plate, mounting
Spacer, Adjustable
Spring
10
Washer
11
12
Screw
13
Spacer
1. Removal
WARNING Block all wheels to prevent truck from
rolling.
1. Park the truck on a level surface and make sure all
wheels are blocked to prevent accidental
movement.
BT Prime-Mover Inc.
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2001-03-15
177
F-code
Section
C-code
PS
S3.0
3371
Electromagnetic Brake
Version no
T-code
001
RTX35/RTX45
178
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Service Manual
2001-03-15
F-code
PS
Version no
001
Section
C-code
S3.0
3371
Electromagnetic Brake
T-code
RTX35/RTX45
2. Installation
WARNING Block all wheels to prevent truck from
rolling.
1. Be sure truck is securely blocked with key switch
OFF and battery disconnected.
WARNING The magnetic coil (2) and armature (3) are
under pressure. DO NOT remove the
retaining screws (9) without the manual
release screws (11) securely in place.
WARNING The two manual release screws (11) must
be fully tightened before removing the
three brake retaining screws (9). Screws
(11) are used as a tool for braking. Size of
screw is 8 mm x 1.25 thread x 37.5 mm.
Refer to Section 3000 of the Parts Book
for part number of screw (11).
2. Fully tighten two manual release screws (11) .
3. Remove three retaining screws (9) which hold
brake parts and set aside, ensuring all parts are
clean and dry. Avoid moving the adjustable
spacers (7) if possible, thus maintaining correct
axial air gap when reassembled. The mounting
plate is secured to drive motor with retaining screw
(9).
4. Secure brake hub (4) to motor shaft. It should not
interfere with mounting plate (6).
5. Slide friction plate (5) onto the hub spline and up to
the mounting plate (6).
6. Place armature (3) and coil (2) of the brake over
the mounting plate (6) and line up screws (9).
Carefully secure in place.
7. Once brake is fully secured in position, remove
manual release screws (11) and set aside.
8. Check air gap and adjust if necessary. For
adjustment procedures see Adjustments on
page 180.
BT Prime-Mover Inc.
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Service Manual
2001-03-15
179
F-code
Section
C-code
PS
S3.0
3371
Electromagnetic Brake
Version no
T-code
001
RTX35/RTX45
3. Adjustments
NOTE! Do not remove retaining screws (9).
Adjustment is carried out by using a 9/16 inch
(14 mm) open end wrench and a 1/4 inch (6
mm) socket key.
1. Turn Allen head retaining screws (9) counterclockwise to loosen one at a time, to allow
adjustment of threaded spacers (7).
2. Using a 9/16 inch (14 mm) wrench, the brass nut
on the threaded spacers (7) can now be threaded
in or out of the magnet. This changes the relative
position of the armature and end plate, thus
changing the air gap.
Turn the brass nut to the left (clockwise) to
increase the air gap. Turn the brass nut to the right
(counter-clockwise) to decrease the air gap.
NOTE! Be sure to tighten the Allen head retaining
screw (9) before checking the air gap. The
gap should be checked on each side of the
brass nut to assure consistency in the setting.
3. The air gap should be set to 0.008 inch to 0.014
inch (0.20 to 0.36 mm) and be within 0.003 inch
(0.08 mm) throughout the entire circumference.
180
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Service Manual
2001-03-15
F-code
PS
Section
C-code
S3.0
3371
Electromagnetic Brake
Version no
001
T-code
RTX35/RTX45
BT Prime-Mover Inc.
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Service Manual
2001-03-15
181
F-code
Section
C-code
PS
S3.0
3371
Electromagnetic Brake
Version no
T-code
001
RTX35/RTX45
5.2. Installation
NOTE! Make certain brake friction plate (5) and
armature (3) are clean and free of fluid.
1. Set armature (3) and magnetic coil (2) on the base
plate (6).
2. Align and tighten three brake retaining screws (9).
3. Remove two manual release screws (11) and
electrically connect the brake.
4. Set the air gap to 0.008 inch to 0.014 inch (0.20 to
0.36 mm) and be within 0.003 inch (0.08 mm)
throughout the entire circumference.
5. To test operation of the brake, connect battery, turn
key switch ON, and depress brake pedal. This will
allow the truck to operate.
6.2. Replacement
If the brake friction plate needs replaced, remove and install
new plate.
182
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Service Manual
2001-03-15
F-code
Section
PS
S3.1
Version no
C-code
3531
Drive Wheel
T-code
000
RTX35/RTX45
Drive Wheel
3
4
Item
No.
Description
Item
No.
Description
Tire
Nut
Wheel, drive
Washer, spherical
1. Removal
NOTE! Replace drive wheel when traction problems
develop.
1. Park truck on a level surface.
2. Turn key switch to OFF and disconnect battery at
the battery connector. Check to make sure battery
retainer plates are in place.
3. Jack the rear of the truck (see Safe Jacking
Procedure on page 64).
4. Remove seven wheel retaining nuts (3) and
spherical washers (4). Pull tire (1) and drive wheel
(2) from the transmission drive axle hub.
BT Prime-Mover Inc.
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2001-03-15
183
F-code
Section
C-code
PS
S3.1
Drive Wheel
3531
Version no
T-code
000
RTX35/RTX45
2. Installation
1. Press drive tire on wheel hub. This is usually done
while pressing off the old tire. Press hub to the
center of the tire (1).
2. Install drive tire assembly on the transmission axle
hub. Torque drive tire retaining nuts to 95 ft-lb (130
Nm).
184
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Service Manual
2001-03-15
F-code
Section
PS
S3.1
Version no
000
C-code
3531
Drive Wheel
T-code
RTX35/RTX45
New Tire
Worn Tire
Circular Ram
Press Table
BT Prime-Mover Inc.
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Service Manual
2001-03-15
185
F-code
Section
C-code
PS
S3.1
Drive Wheel
3531
Version no
T-code
000
RTX35/RTX45
186
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Service Manual
2001-03-15
F-code
Section
C-code
PS
S3.2
3541
Non-Braking Caster Assembly
Version no
001
T-code
RTX35
3
6
4
7
8
9
17
10
11
12
19
20
18
13
14
17
15
16
BT Prime-Mover, Inc.
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2001-03-15
187
F-code
Section
C-code
PS
S3.2
3541
Non-Braking Caster Assembly
Version no
T-code
001
RTX35
Item
No.
188
Return
Description
Item
No.
Description
Item
No.
Description
Locknut
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
Service Manual
2001-03-15
F-code
Section
C-code
PS
S3.2
3541
Non-Braking Caster Assembly
Version no
001
T-code
RTX35
1. Caster Pivot
1.1. Removal
1. Park truck on a level surface.
2. Turn key switch OFF and disconnect battery
connector. Check to make sure the battery retainer
plates are in place.
3. Jack the rear of the truck (see Safe Jacking
Procedure on page 64).
4. Remove main electronic card panel. See Main
Electronic Card Panel on page 101.
5. Remove floor board.
WARNING Secure caster pivot before removing
mounting bolts (20). Serious injury could
occur if failure to comply with this
requirement.
6. Turn and secure transmission to access the
mounting bolts (20).
NOTE! For models with a brake on the caster wheels,
the cable linkage must be disconnected
before removal of the brake pedal.
7. Bend lockwasher (2) tab down and remove locknut
(1).
8. Remove Nilos ring (3) and bearing (4).
9. Remove caster assembly.
10. Remove mounting bolts (20
11. Loosen nuts (5) to release spring tension.
12. Remove caster pivot (13). Inspect and replace
bushings and bearings as needed.
BT Prime-Mover, Inc.
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2001-03-15
189
F-code
Section
C-code
PS
S3.2
3541
Non-Braking Caster Assembly
Version no
T-code
001
RTX35
1.2. Installation
1. Install pivot block (16) closest to the battery
compartment first.
2. Install rear pivot block (16) on caster pivot (13).
3. Maneuver caster pivot (13) in place between the
frame.
4. Install caster assembly in the caster pivot (13).
NOTE! Make certain Nilos ring and lockwasher are in
the correct position.
5. Tighten locknut (1) while turning the caster wheel
assembly until tight, then back off 1/4 turn.
6. Bend the tab on lockwasher (2) up to secure the
locknut (1).
7. Install brake pedal.
NOTE! For models with a brake on the caster wheels,
the cable linkage must be installed.
8. Set spring tension and stops. See Caster Springs
on page 193.
9. Install floor board.
10. Install main electronic card panel.
11. Test truck operation, then return to service.
190
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Service Manual
2001-03-15
F-code
Section
C-code
PS
S3.2
3541
Non-Braking Caster Assembly
Version no
001
T-code
RTX35
2. Thrust Bearing
2.1. Removal
1. Park truck on a level surface.
2. Turn key switch OFF and disconnect battery
connector. Check to make sure the battery retainer
plates are in place.
3. Jack the rear of the truck.
4. Remove main electronic card panel.
5. Remove floor board.
NOTE! For models with brakes on the caster wheels,
remove the brake arm.
6. Bend the tab down on the lockwasher (2).
7. Remove locknut (1), lockwasher (2) and Nilos ring
(3).
8. Inspect and replace bearings as needed.
BT Prime-Mover, Inc.
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Service Manual
2001-03-15
191
F-code
Section
C-code
PS
S3.2
3541
Non-Braking Caster Assembly
Version no
T-code
001
RTX35
2.2. Installation
1. The truck must be properly blocked at this time.
2. Install the race (4) in the caster pivot and the thrust
bearing (14) on the caster assembly.
3. Install caster assembly in the caster pivot (13).
4. Install bearing (4), Nilos ring (3), lockwasher (2)
and locknut (1).
5. Tighten locknut (1) while turning the caster wheel
assembly until tight, then back off 1/4 turn.
6. Bend the lockwasher tab (2) up to secure the
locknut (1).
NOTE! For models with brakes on the caster wheels,
install the brake arm.
7. Test caster operation.
192
Return
Service Manual
2001-03-15
F-code
Section
C-code
PS
S3.2
3541
Non-Braking Caster Assembly
Version no
001
T-code
RTX35
3. Caster Springs
3.1. Adjustment
1. Park truck on a level surface.
5.375-5.50 inches
battery
3.2. Removal
New Free Length
is 7 inches (178 mm)
BT Prime-Mover, Inc.
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Service Manual
2001-03-15
193
F-code
Section
C-code
PS
S3.2
3541
Non-Braking Caster Assembly
Version no
T-code
001
RTX35
3.3. Installation
5
11
5.375-5.50 inches
9
10
12
192 inches
(4877 mm)
210 inches
(5334 mm)
240 inches
(6096 mm)
270 inches
(6858 mm)
0.375 inch
(9.53 mm)
0.375 inch
(9.53 mm)
0.375 inch
(9.53 mm)
N/A
0.375 inch
(9.53 mm)
0.375 inch
(9.53 mm)
0.375 inch
(9.53 mm)
N/A
0.375 inch
(9.53 mm)
0.375 inch
(9.53 mm)
0.375 inch
(9.53 mm)
N/A
0.375 inch
(9.53 mm)
0.375 inch
(9.53 mm)
0.375 inch
(9.53 mm)
N/A
194
Return
Service Manual
2001-03-15
F-code
Section
C-code
PS
S3.2
3541
Non-Braking Caster Assembly
Version no
001
T-code
RTX35
4. Caster Stops
4.1. Adjustment
5.375-5.50
inches
11
12
BT Prime-Mover, Inc.
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Service Manual
2001-03-15
195
F-code
Section
C-code
PS
S3.2
3541
Non-Braking Caster Assembly
Version no
T-code
001
RTX35
196
Return
Service Manual
2001-03-15
F-code
Section
C-code
PS
S3.3
3542
Non-Braking Caster Wheels
Version no
T-code
000
RTX35
2
1
3
4
4
Item
No.
Description
Item
No.
Description
Wheel, caster
Lockwasher
Bracket, caster
Locknut
Ring, Nilos
Fitting, grease
Bearing
Cap, wheel
1. Removal
NOTE! Replace caster wheel when caster spring can
no longer be adjusted. (See Caster Springs
on page 193.)
1. Park truck on a level surface.
2. Turn key switch to OFF and disconnect battery at
the battery connector. Check to make sure the
battery retainer plates are in place.
3. Jack the rear of truck (see Safe Jacking
Procedure on page 64).
4. Remove wheel cap (8).
5. Bend lockwasher (5) tab down and remove locknut
(6).
BT Prime-Mover Inc.
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Service Manual
2001-03-15
197
F-code
Section
C-code
PS
S3.3
3542
Non-Braking Caster Wheels
Version no
T-code
000
RTX35
2. Installation
1. Install Nilos ring (3) on the axle.
2. Install caster wheel assembly.
3. Install Nilos ring (3), lockwasher (5) and locknut
(6).
4. While turning the caster wheel, tighten locknut (6)
until the wheel becomes tight.
5. Back off locknut (6) until the caster wheel turns
freely. The locknut (6) and lockwasher (5) tab
should be aligned.
6. Bend lockwasher (5) tab to secure locknut (6).
7. Grease as needed.
8. Replace wheel cap (8).
198
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Service Manual
2001-03-15
F-code
PS
Version no
001
Section
C-code
S3.4
3543
Braking Caster Assembly
T-code
RTX45
2
3
5
4
25
26
23
24
23
7
9
17
21
22
10
11
12
20
19
13
18
14
16
BT Prime-Mover Inc.
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15
17
Service Manual
2001-03-15
199
F-code
Section
C-code
PS
S3.4
3543
Braking Caster Assembly
Version no
T-code
001
RTX45
Item
No.
200
Return
Description
Item
No.
Description
Item
No.
Description
Locknut
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
Service Manual
2001-03-15
F-code
PS
Section
C-code
S3.4
3543
Braking Caster Assembly
Version no
001
T-code
RTX45
1. Removal
NOTE! For models with a brake on the caster wheels.
electronic
card
panel
(see
Adjuster nuts
BT Prime-Mover Inc.
Return
Service Manual
2001-03-15
201
F-code
Section
C-code
PS
S3.4
3543
Braking Caster Assembly
Version no
T-code
001
RTX45
9.
Rod
Spring
Adjusting
nuts
202
Return
Service Manual
2001-03-15
F-code
Section
C-code
PS
S3.5
3544
Braking Caster Wheel Assembly
Version no
T-code
000
RTX45
15
13
9
14
2
11
10
13
12
9
10
11
1
4
4
3
5
Item
No.
Description
Item
No.
Description
Item
No.
Description
Wheel, caster
Fitting, grease
13
Washer
Bracket, caster
Cap, wheel
14
Pivot, brake
Ring, Nilos
Ring, E
15
Spring
Bearing
10
Brake assembly
16
Plunger, brake
Lockwasher
11
Screw, cap
Locknut
12
Nut
BT Prime-Mover Inc.
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Service Manual
2001-03-15
203
F-code
Section
C-code
PS
S3.5
3544
Braking Caster Wheel Assembly
Version no
T-code
000
RTX45
1. Removal
NOTE! Replace caster wheel when caster spring can
no longer be adjusted. (See Caster Brake
Adjustment on page 201.)
1. Park truck on a level surface.
2. Turn key switch to OFF and disconnect battery at
the battery connector. Check to make sure the
battery retainer plates are in place.
3. Jack the rear of truck (see Safe Jacking
Procedure on page 64).
4. Remove wheel cap (8).
5. Bend down lockwasher (5) tab and remove locknut
(6).
6. Remove caster wheel assembly.
7. Inspect and replace the race and bearing (4) as
needed.
8. Remove E-ring (9) and cap screws (11) if brake
assembly is to be replaced, otherwise replace
brake shoes.
9. Remove nuts (12), washer (13), and slide brake
plunger (16) up to remove brake pivot (14) and
other washer (13).
10. Remove brake plunger (16) and spring (15).
204
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Service Manual
2001-03-15
F-code
Section
C-code
PS
S3.5
3544
Braking Caster Wheel Assembly
Version no
000
T-code
RTX45
2. Installation
1. Slide spring (15) in the caster bracket (2) and
install brake plunger (16).
2. Install washer (13) on the brake plunger (16). Then
slide the brake pivot (14) on the brake plunger (16),
against the washer (13).
3. Install a second washer (13) on the brake plunger
against the brake pivot (14). Secure assembly
together with a nut (12). Install a second nut (12) to
lock the first nut in place.
4. Install brake assembly (10) with cap screws (11).
5. Move brake pivot (14) around to install an E-ring
(9) on both brake assemblies (10).
6. Install Nilos ring (3) on the axle.
7. Install caster wheel assembly.
8. Install Nilos ring (3), lockwasher (5), and locknut
(6).
9. While turning caster wheel, tighten locknut (6) until
the wheel becomes tight.
10. Back off locknut (6) until the caster wheel turns
freely. The locknut (6) and lockwasher (5) tab
should be aligned.
11. Bend lockwasher (5) tab to secure locknut (6).
12. Grease as needed.
13. Replace wheel cap (8).
BT Prime-Mover Inc.
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Service Manual
2001-03-15
205
F-code
Section
C-code
PS
S3.5
3544
Braking Caster Wheel Assembly
Version no
T-code
000
RTX45
206
Return
Service Manual
2001-03-15
F-code
Section
PS
C-code
S3.6
3551
Tandem Load Wheels
Version no
T-code
000
RTX35/RTX45
11
3
4
10
5
6
7
8
9
8
7
6
Item
No.
BT Prime-Mover Inc.
Return
Description
Item
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
2001-03-15
207
F-code
Section
PS
S3.6
Tandem Load Wheels
Version no
T-code
000
RTX35/RTX45
C-code
3551
1. Removal
NOTE! Replace load wheels when traction problems
develop.
1. Park truck on a level surface.
2. Lower the carriage fully
3. Turn key switch to OFF. Disconnect the battery at
the battery connector. Check to make sure the
battery retainer plates are in place.
WARNING Block all wheels to prevent truck from
rolling.
4. Hoist truck so the load wheels are approximately 2
inches (50.8 mm) off the floor and securely block.
5. Remove retainer ring (4) from the axles.
6. Use a piece of rod or a punch to tap the axle (1)
back out through the wheels. Remove rocker plate
(3). Remove two washers (6 and 7) on each side of
the wheel (9). The axle is welded into the rocker
plate. Remove the load wheel (9) from the toe box
(2).
7. Inspect bearings (8).
208
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Service Manual
2001-03-15
F-code
PS
Section
C-code
S3.6
3551
Tandem Load Wheels
Version no
000
T-code
RTX35/RTX45
2. Installation
1. Pack bearings with grease.
2. Install bearings (8) in the load wheel (9).
WARNING Install bearing shield and 10 gauge
washer (6) properly.
3. Install load wheel assembly in the toe box (2).
NOTE! Place a block behind the axle (1) to hold it in
place while assembling the rocker plate and
snap rings.
4. Install axle (1), washers (6 and 7) and rocker plate
(3).
5. Install retainer rings (4) to axle (1).
6. Grease as needed.
7. Remove blocking and lower truck to the floor.
8. Reconnect battery connector.
9. Test operate truck.
10. Return truck to service.
BT Prime-Mover Inc.
Return
Service Manual
2001-03-15
209
F-code
Section
PS
S3.6
Tandem Load Wheels
Version no
T-code
000
RTX35/RTX45
210
Return
C-code
3551
Service Manual
2001-03-15
F-code
PS
Section
C-code
S3.7
3555
Single Load Wheels
Version no
T-code
000
RTX35/RTX45
11
4
3
7
9
Item No.
BT Prime-Mover Inc.
Return
Description
Item No.
Description
Washer, 10 gauge
Fitting, grease
Washer, 18 gauge
Nut
Bearing
10
Bolt, shoulder
Tire, load
11
Wheel
Service Manual
2001-03-15
211
F-code
Section
PS
S3.7
Single Load Wheels
Version no
T-code
000
RTX35/RTX45
C-code
3555
1. Removal
NOTE! Replace load wheels when traction problems
develop.
1. Park truck on a level surface.
2. Lower carriage fully. Turn key switch to OFF.
Disconnect the battery at battery connector. Check
to make sure the battery retainer plates are in
place.
WARNING Block all wheels to prevent truck from
rolling.
3. Hoist truck so the load wheels are approximately 2
inches (50.8 mm) off the floor, and securely block.
4. Remove toe box retaining nuts (9) and bolts (10).
5. Remove axle nut (9).
6. Remove right toe box (1) and load wheel (6).
7. Grease as needed.
8. Press load tire (5) from wheel (6).
9. Inspect bearings and replace if necessary.
WARNING Be sure to install the bearing shield and 10
gauge washer (2) properly.
212
Return
Service Manual
2001-03-15
F-code
PS
Section
C-code
S3.7
3555
Single Load Wheels
Version no
000
T-code
RTX35/RTX45
2. Installation
1. Inspect and replace bearing (4) as needed.
2. Press new load tire (5) on wheel (6).
3. Install load wheel assembly (11) on toe box axle.
4. Install right toe box (1).
5. Install axle nut (9).
6. Install toe box assembly on the support arm. Apply
Loctite 242 to nuts (9) and bolts (10).
7. Remove blocking and lower truck to the floor.
8. Reconnect battery connector.
9. Test the operation of the load wheel and truck.
Return truck to service.
BT Prime-Mover Inc.
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Service Manual
2001-03-15
213
F-code
Section
PS
S3.7
Single Load Wheels
Version no
T-code
000
RTX35/RTX45
214
Return
C-code
3555
Service Manual
2001-03-15
F-code
Section
PS
S4.0
4110
Steering Wheel
Version no
T-code
001
Spring
RTX35/RTX45
Steering Wheel
E-Clip
Item
No.
Set screw
Coupler
C-code
1
2
3
Description
Item
No.
Description
Cap, spinner
10
Bracket
Nut
11
Spring
Washer
12
Ring, retainer
Spinner
13
Coupler
Wheel, steering
14
Tachometer
Spacer, steering
15
Screw
Bushing, flat
16
Washer, flat
Bushing, flanged
17
Support, steering
Screw
18
Screw
1. Removal
4
5
6
18
17
11
8
9
7
12
16
10
15
13
14
BT Prime-Mover Inc.
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Service Manual
2001-03-15
215
F-code
Section
C-code
PS
S4.0
Steering Wheel
4110
Version no
T-code
001
RTX35/RTX45
2. Installation
1. Place steering wheel in the mounting bracket (10).
2. Lift up on the spring (11) and install E-clip (12).
3. Apply Loctite 242 to setscrew. Tighten set screw
in the coupler (13) to 5 in-lbs (0.56 Nm).
4. Check steering wheel for ease of operation.
5. Test the operation of steering wheel and truck.
6. Replace top console.
7. Remove blocks and return truck to service.
216
Return
Service Manual
2001-03-15
F-code
Section
PS
S4.0
Version no
T-code
001
Spring
E-Clip
C-code
4110
Steer Tach
RTX35/RTX45
Steer Tach
The steer tach is attached to a bracket beneath the steering
wheel.
Item
No.
Set screw
Coupler
1
2
3
Description
Item
No.
Description
Cap, spinner
10
Bracket
Nut
11
Spring
Washer
12
Ring, retainer
Spinner
13
Coupler
Wheel, steering
14
Tachometer
Spacer, steering
15
Screw
Bushing, flat
16
Washer, flat
Bushing, flanged
17
Support, steering
Screw
18
Screw
1. Removal
5
6
18
17
11
7
12
8
9
16
10
15
13
14
BT Prime-Mover Inc.
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Service Manual
2001-03-15
217
F-code
Section
C-code
PS
S4.0
Steer Tach
4110
Version no
T-code
001
RTX35/RTX45
2. Installation
1. Attach steering tach (14) to the underside of
mounting bracket (10) with two screws (9).
2. Attach flexible coupler (13) to the tach shaft.
3. Lift up on spring (11) to install E-clip (12).
4. Apply Loctite 242 to setscrew. Tighten set screw
in the coupler (13) to 5 in-lbs (0.56 Nm).
5. Reconnect the electrical harness.
6. Test to see that the steering functions properly.
7. Install top console (see page 96).
8. Remove blocks and return truck to service.
218
Return
Service Manual
2001-03-15
F-code
Section
PS
S4.1
4181
Steering Bearing
Version no
000
C-code
T-code
RTX35/RTX45
Steering Bearing
1
2
Item
No.
BT Prime-Mover Inc.
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Service Manual
Description
Bearing
Screw
Transmission assembly
2001-03-15
219
F-code
Section
C-code
PS
S4.1
Steering Bearing
4181
Version no
T-code
000
RTX35/RTX45
1. Removal
NOTE! The transmission and drive motor must be
removed from the truck to access the steering
bearing. (To remove drive motor see
page 108. and page 115 for removal of
transmission.)
1. Park truck on a level surface.
2. Turn key switch to OFF and disconnect the battery
at battery connector. Check to make sure the
battery retainer plates are in place.
3. Jack the rear of truck (see Safe Jacking
Procedure on page 64).
4. Remove the motor compartment door and left side
panel to access the motor compartment. (See
page 97 and page 98.)
5. Disconnect all electrical connections on the drive
motor and brake assembly.
6. Remove drive motor.
7. Remove transmission.
8. Remove mounting ring.
9. Remove fifteen bolts (11) retaining the steering
bearing (1).
2. Installation
1. Install new steer bearing (1).
2. Install
transmission
mounting
plate
and
transmission in the truck. Torque the six mounting
bolts to 90 ft-lb (122 Nm).
3. Install drive motor.
4. Connect all electrical connections.
5. Refill transmission as needed.
6. Test the steering and truck operation.
220
Return
Service Manual
2001-03-15
F-code
PS
Version no
001
Section
C-code
S5.0
5000
Electrical Functions
T-code
RTX35/RTX45
Electrical Functions
1. General
The braking, steering, and travel control systems on the
reach truck are electrically controlled and monitored. The lift/
lower and auxiliary function systems are electrically controlled
and hydraulically operated. See Electrical Schematics on
page 273 and Hydraulic System on page 367.
The control system of the reach truck consists of the following
components: control handle; control handle interface card;
main electronic card containing steer control; drive motor
transistor regulator; pump motor transistor regulator; steering
components; and brake. An operator instrument panel
displaying actual time, hourmeter/error code, parking brake
indicator, right foot switch indicator, and parameter set mode.
For a listing of error codes see pages 336 and 340. For a
listing of parameters see page 345. For information on the
fuses and their location see page 305.
+
1 1/2
0
BT Prime-Mover Inc.
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Service Manual
2001-03-15
221
F-code
Section
PS
S5.0
Electrical Functions
Version no
T-code
001
RTX35/RTX45
C-code
5000
222
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Service Manual
2001-03-15
F-code
PS
Version no
001
Section
C-code
S5.0
5000
Electrical Functions
T-code
RTX35/RTX45
BT Prime-Mover Inc.
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Service Manual
2001-03-15
223
F-code
Section
C-code
PS
S5.0
Electrical Functions
5000
Version no
T-code
001
RTX35/RTX45
K10
K10
A1
3
A2
M1
F55
ARMATURE
B7
2
A1
15
ACC
RELAY
B+
A5
44
F1
S21
101
34
902
40
FIELD
1
K11
K13
M1
K11
K13
8
M
1
805
64
Y1
803
51
K11
802
52
K13
22
F51
F50
808
36V only
501
S48
43 111
A71
25
S108
21
S21
24
S17
49 102
22
809
901
Legend
ELECTRIC POSITIVE
ELECTRIC NEGATIVE
LED OFF ( Not lit)
LED input (lit)
LED output (lit)
224
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Service Manual
2001-03-15
F-code
PS
Version no
001
Section
C-code
S5.0
5000
Electrical Functions
T-code
RTX35/RTX45
2. Start Up
With the battery connected to the reach truck, wire #1
connects battery voltage to the battery terminal of the main
contactor (K10), the control fuse (F50), the steer servo fuse
(F51), and the accessory fuse (F55). Control fuse F50 and
wire #21 connect voltage to the main electronic card (A5)
connector pin 808 (and connector pin 501 for 36V trucks), the
positive terminal of one section of the emergency disconnect
(S21) switch, and the control handle interface card. Steer
servo fuse (F51) and wire #25 connect battery positive to the
main electronic card (A5) connector pin 901 (steer servo).
Accessory fuse (F55) and wire #15 connect battery voltage to
the accessories relay(s). The main electronic card (A5), steer
servo, and control handle interface card are powered when
the battery is connected. Wire #40 is battery negative.
BT Prime-Mover Inc.
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Service Manual
2001-03-15
225
F-code
Section
C-code
PS
S5.0
Electrical Functions
5000
Version no
T-code
001
RTX35/RTX45
A2
K10
F3
K10
B+
A1
3
A2
M1
F55
B+
ARMATURE
2
FIELD
K11
B7
A1
15
ACC
RELAY
A5
44
F1
S21
101
34
902
40
K13
M1
1
K11
K13
8
M
1
805
64
Y1
803
51
K11
802
52
K13
22
F51
F50
808
36V only
501
S48
43 111
A71
25
S108
21
S21
24
S17
49 102
22
809
901
Legend
ELECTRIC POSITIVE
ELECTRIC NEGATIVE
LED OFF ( Not lit)
LED input (lit)
LED output (lit)
226
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Service Manual
2001-03-15
F-code
PS
Version no
001
Section
C-code
S5.0
5000
Electrical Functions
T-code
RTX35/RTX45
BT Prime-Mover Inc.
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Service Manual
2001-03-15
227
F-code
Section
C-code
PS
S5.0
Electrical Functions
5000
Version no
T-code
001
RTX35/RTX45
A5
40
902 (0V)
F51
25
1
60
M6
901
Tx+ 303
A6
Rx+
Tx- 304
Rx-
903 +
M
61
904 -
62
503 IN U1
G
63
502 IN +
Steering Components
Legend
ELECTRIC POSITIVE
ELECTRIC NEGATIVE
LED OFF ( Not lit)
LED input (lit)
LED output (lit)
228
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Service Manual
2001-03-15
F-code
PS
Version no
001
Section
C-code
S5.0
5000
Electrical Functions
T-code
RTX35/RTX45
3. Steering Components
3.1. Steering System
The steering system is electrically controlled. The input is a
tachometer (DC generator (U1) connected to the steering
wheel. The faster the steering wheel is turned, the higher the
voltage produced by the tachometer (U1). The direction of
tachometer (U1) rotation determines the polarity of the signal.
The tachometer (U1) is connected to the main electronic card
(A5) by wire #62 to input 503 (-) and by wire #63 to input 502
(+). The master processor on the main electronic card (A5)
processes the tachometer signal and communicates the
result to the steer slave processor. The steer slave processor
controls the steer chopper to obtain the appropriate output
voltage and polarity to drive the steer motor (M6). The steer
motor is connected to the main electronic card (A5) through
wire #60 output 903 (+) and wire #61 output 904 (-). Current
through the main electronic card (A5) connector pins 903 (+)
and 904 (-) determine the steer motor direction. Electrical
power for the steer motor is supplied through wire #1 to fuse
(F51) and through wire #25 to the main electronic card (A5) at
connector pin 901. The negative is wire #40 connected to the
main electronic card (A5) connector pin 902.
The main electronic card (A5) monitors the steer system. If a
fault is sensed in the steer tachometer, steer controller, steer
motor, or wiring, an error code will appear on the Operator
Display (A6) indicating the steering problem.
Three parameters can be modified to adjust the steering for
custom control. Parameter 1 adjusts speed sensitive steering
(reduced steering sensitivity at high speed). Parameter 2
adjusts steering sensitivity (tachometer response). Parameter
11 adjusts steer direction (forks trailing or forks first).
Turning the steering wheel clockwise directs B- current to the
steer motor through a series of steps:
The steer tachometer determines the rate and direction of
steer wheel rotations.
Turning the steer tachometer clockwise sends 0 to +2.9
volts (depending upon the rate of rotation of the steering
wheel) to the main electronic card (A5) at input 502 with
respect to connector pin 503.
BT Prime-Mover Inc.
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2001-03-15
229
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S5.0
Electrical Functions
Version no
T-code
001
RTX35/RTX45
C-code
5000
The main electronic card (A5) interprets the input from the
steer tachometer (depending upon the sensitivity setting
selected) and instructs the steer motor to rotate clockwise
(direction parameter 11 set to forward) by supplying Bvoltage through wire #60 from output 903 to the steer
motor with respect to wire #61, connector pin 904.
The drive wheel steers in a counter-clockwise direction
turning the forks of a moving, forks leading truck to the
right.
Turning the steering wheel counter-clockwise directs B+
current to the steer motor through a series of steps:
The steer tachometer determines the rate and direction of
steer wheel rotations.
Turning the steer tachometer counter-clockwise sends 0 to
-2.9 volts (depending upon the rate of rotation of the
steering wheel) to the main electronic card (A5) at input
502 with respect to connector pin 503.
The main electronic card (A5) interprets the input from the
steer tachometer (depending upon the sensitivity setting
selected) and instructs the steer motor to rotate
counterclockwise (direction parameter 11 set to forward)
by supplying B+ voltage through wire #60 from output 903
to the steer motor with respect to wire #61, connector pin
904.
The drive wheel steers in a clockwise direction turning the
forks of a moving, forks leading truck to the left.
230
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2001-03-15
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Version no
001
Section
C-code
S5.0
5000
Electrical Functions
T-code
RTX35/RTX45
BT Prime-Mover Inc.
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2001-03-15
231
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PS
S5.0
Electrical Functions
5000
Version no
T-code
001
RTX35/RTX45
A5
F53
67
810 12V +
31
811 -
32
58
S66
59
S67
22
57
S65
204
STEERING STOP A
203
STEERING STOP B
202
STEER WHEEL POSITION
40
40
902 (0V)
Legend
ELECTRIC POSITIVE
ELECTRIC NEGATIVE
LED OFF ( Not lit)
LED input (lit)
LED output (lit)
232
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2001-03-15
F-code
PS
Version no
001
Section
C-code
S5.0
5000
Electrical Functions
T-code
RTX35/RTX45
BT Prime-Mover Inc.
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2001-03-15
233
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Section
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PS
S5.0
Electrical Functions
Version no
T-code
001
RTX35/RTX45
5000
S66
Steering
Stop A
A5 input 204
Wire #58
S67
Steering
Stop B
A5 input 203
Wire #59
ON
OFF
OFF
ON
ON
OFF
OFF
ON
OFF
OFF
ON
ON
ON
OFF
OFF
ON
OFF
ON
OFF
OFF
ON
At Steering Stop
OFF
ON
ON
234
Return
Failure Error
OFF
OFF
OFF
Failure Error
ON
ON
ON
Service Manual
2001-03-15
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Section
PS
C-code
S5.0
5000
Electrical Functions
Version no
T-code
001
RTX35/RTX45
4. Brake Release
Brake release occurs when the brake pedal is fully
depressed. The emergency switch (S21) ON, key switch
(S17) ON and the brake pedal fully depressed (down) causes
the brake switch (S48) to open removing the input to the main
electronic card (A5) terminal 111 (wire #43). The brake
potentiometer (R3) output goes to a higher voltage than when
the brake pedal is released (up). The main electronic card
(A5) senses the increase in voltage at terminal 511 (wire
#65). The main electronic card (A5) responds by turning on
output 805 (wire #64) sending current to the magnetic brake
coil (Y1). The energizing of the brake coil (Y1) causes the
brake pressure plate to move from the brake friction plate,
releasing the brake and allowing the truck to travel.
Legend
ELECTRIC POSITIVE
ELECTRIC NEGATIVE
LED OFF ( Not lit)
LED input (lit)
LED output (lit)
K10
K10
A5
A1
44
F1
3
A2
M1
B+
ARMATURE
B-
S21
7
2
A1
K13
8
22
40
29 504 +7.35V
50 505 +3.65V
K13
M1
K11
902
FIELD
K11
101
34
30 510 0V
M
1
805
65
R3
64
Y01
51
K11
52
K13
511
803
F50
802
808
36V only
S48
43
21
S108
S21
24
S17
49
22
501
111
102
809
Brake Release
BT Prime-Mover Inc.
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2001-03-15
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S5.0
Electrical Functions
5000
Version no
T-code
001
RTX35/RTX45
K10
K10
A1
F1
A2
M1
A1
FIELD
M1
K11
B7
10
ARMATURE
2
K11
B+
44
K13
11
6
34
36
22
37
35
M
1
902
40
611
609 -
A71
HM104
HM105
29 504 +7.35V
50 505 +3.65V
HM110
30 510 0V
HM111
64
Y1
51
K11
52
K13
805
R1
Blue/white stripe
HM215
Orange/black stripe
F50
101
610
K13
8
A5
S21
R3
65 511
803
802
HM210
Red/white stripe
HM213
808
36V only
S48
43
21
S108
S21
24
S17
501
111
49
102
22 809
S60
39
104
Legend
ELECTRIC POSITIVE
ELECTRIC NEGATIVE
LED OFF ( Not lit)
LED input (lit)
LED output (lit)
236
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2001-03-15
F-code
PS
Version no
001
Section
C-code
S5.0
5000
Electrical Functions
T-code
RTX35/RTX45
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2001-03-15
237
F-code
Section
C-code
PS
S5.0
Electrical Functions
Version no
T-code
001
RTX35/RTX45
5000
A5
238
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Version no
001
Section
C-code
S5.0
5000
Electrical Functions
T-code
RTX35/RTX45
displayed and the control handle has been calibrated for truck
operation. If control handle calibration was not successful the
same or other codes may be displayed. Other codes could be
caused by incorrect calibrating procedure, a bad control
handle, a failed control handle interface card, a failed control
module (A5) or wiring.
The relationship between the drive transistor (A1) regulator
speed request voltage and travel potentiometer (R1) is an
approximate relationship and include the following:
The travel speed request voltage range is 0 to 5 volts. The
travel potentiometer (RI) voltage is approximately 0.6 to
2.2 volts with the center at approximately 1.4 volts.
Moving the control handle away from the operator causes
voltage to increase from 1.4 to 2.2 volts. For every 0.16
volt increase of the travel potentiometer (R1), the speed
request will increase approximately 1 volt.
The speed request voltage is from the main electronic card
(A5) terminal 610 through wire #36 to the drive transistor
(A1) regulator pin 10.
Wire #35, connecting the drive transistor (A1) regulator pin
6 and the main electronic card (A5) pin 609, is the common
reference for the speed request/current limit voltages.
BT Prime-Mover Inc.
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2001-03-15
239
F-code
Section
C-code
PS
S5.0
Electrical Functions
5000
Version no
T-code
001
RTX35/RTX45
K10
K10
A1
44
F1
3
A2
M1
B+
ARMATURE
2
A1
FIELD
K11
M1
K11
B10
K13
11
6
34
22
101
610
37
M
1
902
40
611
609 -
A71
HM104
35
HM105
29 504 +7.35V
50 505 +3.65V
HM110
30 510 0V
HM111
64
Y1
51
K11
52
K13
805
R1
Blue/white stripe
HM215
Orange/black stripe
F50
S21
36
K13
8
A5
R3
65
511
803
HM210
Red/white stripe
HM213
802
808
36V only
S48
43
21
S108
S21
24
501
111
49
102
22 809
S17
S60
104
39
Legend
ELECTRIC POSITIVE
ELECTRIC NEGATIVE
LED OFF ( Not lit)
LED input (lit)
LED output (lit)
240
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2001-03-15
F-code
PS
Version no
001
Section
C-code
S5.0
5000
Electrical Functions
T-code
RTX35/RTX45
Return
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2001-03-15
241
F-code
Section
PS
S5.0
Electrical Functions
Version no
T-code
001
RTX35/RTX45
C-code
5000
Return
Service Manual
2001-03-15
F-code
PS
Version no
001
Section
C-code
S5.0
5000
Electrical Functions
T-code
RTX35/RTX45
BT Prime-Mover Inc.
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Service Manual
2001-03-15
243
F-code
Section
C-code
PS
S5.0
Electrical Functions
5000
Version no
T-code
001
RTX35/RTX45
K10
K10
A1
3
A2
M1
B+
K11
FIELD
M1
K13
11
37
M
1
609 611
A71
29
HM104
50
HM105
1
30
HM110
R1
22
40
610
35
6
8
902
103
36
10
K13
K11
101
34
38
2
A1
S21
B7
ARMATURE
A5
44
F1
504 +7.35V
505 +3.65V
510 0V
HM111
Blue/white stripe
Orange/black stripe
Red/white stripe
HM210
Y1
51
K11
52
K13
805
R3
HM215
64
511
65
803
802
HM213
F50
810 +
811 -
22
808
36V only
S48
21
S108
S21
24
S17
S
125
501
43
49
111
102
23
105
809
22
S
64
56
201
Plug Braking
Legend
ELECTRIC POSITIVE
ELECTRIC NEGATIVE
LED OFF ( Not lit)
LED input (lit)
LED output (lit)
244
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2001-03-15
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PS
Version no
001
Section
C-code
S5.0
5000
Electrical Functions
T-code
RTX35/RTX45
7. Plug Braking
CAUTION Releasing the brake pedal while on an
incline will cause the truck to move.
There are two methods of plug braking available on the reach
truck. The one is using the directional/speed control handle
and is detailed first. The second method is accomplished
through raising the brake pedal and is detailed second.
Return
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2001-03-15
245
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S5.0
Electrical Functions
Version no
T-code
001
RTX35/RTX45
C-code
5000
246
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Service Manual
2001-03-15
F-code
PS
Version no
001
Section
C-code
S5.0
5000
Electrical Functions
T-code
RTX35/RTX45
BT Prime-Mover Inc.
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2001-03-15
247
F-code
Section
PS
S5.0
Electrical Functions
Version no
T-code
001
RTX35/RTX45
C-code
5000
248
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2001-03-15
F-code
Section
PS
C-code
S5.0
5000
Electrical Functions
Version no
T-code
001
RTX35/RTX45
A5
32
31 S125
105
32
31
S64
S66
ELECTRIC NEGATIVE
67
56
810+
201
204
S67
203
U10
205
206
Legend
ELECTRIC POSITIVE
F53
811-
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F-code
Section
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PS
S5.0
Electrical Functions
5000
Version no
T-code
001
RTX35/RTX45
CONTROL
HANDLE
S55 S56
S212 S211
S52 S51
S18
A5
A71
HM214 +7.35V
HM104
29
50
HM105
R11
HM208 +7.35V
HM106
HM211
HM110
82
30
504 +7.35V
505 +1.4V
506 +1.65V
510 0V
HM111
HM215 +7.35V
R1
R3
HM210
511
21
HM213
F50
1
Legend
250
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2001-03-15
F-code
PS
Version no
001
Section
C-code
S5.0
5000
Electrical Functions
T-code
RTX35/RTX45
BT Prime-Mover Inc.
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2001-03-15
251
F-code
Section
C-code
PS
S5.0
Electrical Functions
5000
Version no
T-code
001
RTX35/RTX45
A5
22 40
S31
79
HM104
29
50
HM105
30
HM110
R1
504 + 7.35V
A1
505
510 0V
610
35
10
201
107
S64
56
Legend
ELECTRIC POSITIVE
ELECTRIC NEGATIVE
LED OFF ( Not lit)
LED input (lit)
LED output (lit)
252
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2001-03-15
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PS
Version no
001
Section
C-code
S5.0
5000
Electrical Functions
T-code
RTX35/RTX45
BT Prime-Mover Inc.
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F-code
Section
C-code
PS
S5.0
Electrical Functions
5000
Version no
T-code
001
RTX35/RTX45
S45
A5
22 40
106
S31
207
107
79
22 40
88
40
Y10
A2
804
10
75
702
Legend
ELECTRIC POSITIVE
ELECTRIC NEGATIVE
LED OFF ( Not lit)
LED input (lit)
LED output (lit)
254
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2001-03-15
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PS
Version no
001
Section
C-code
S5.0
5000
Electrical Functions
T-code
RTX35/RTX45
BT Prime-Mover Inc.
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2001-03-15
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F-code
Section
C-code
PS
S5.0
Electrical Functions
5000
Version no
T-code
001
RTX35/RTX45
A8
A5
F52
22
3+
+5
4 0V
-2
125
126
40
S45
106
405 +
402 -
207
F53
810
31
U10
+
98
205
99
206
B
32
811
Legend
Height Indicator
ELECTRIC POSITIVE
ELECTRIC NEGATIVE
LED OFF ( Not lit)
LED input (lit)
LED output (lit)
256
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2001-03-15
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PS
Version no
001
Section
C-code
S5.0
5000
Electrical Functions
T-code
RTX35/RTX45
Return
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2001-03-15
257
F-code
Section
PS
S5.0
Electrical Functions
Version no
T-code
001
RTX35/RTX45
C-code
5000
258
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F-code
Section
PS
C-code
S5.0
5000
Electrical Functions
Version no
T-code
001
RTX35/RTX45
K10
K10
A5
A1
F1
44
3
SA2
B+
B-
S21
101
34
M1
ARMATURE
2
SA1
902
40
FIELD
K11
K13
M1
K11
K13
8
M
41
803 51
K11
52
K13
208
Legend
802
ELECTRIC POSITIVE
42
209
ELECTRIC NEGATIVE
LED OFF ( Not lit)
LED input (lit)
LED output (lit)
BT Prime-Mover Inc.
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2001-03-15
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Section
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PS
S5.0
Electrical Functions
5000
Version no
T-code
001
RTX35/RTX45
A2
14
F3
9
ARMATURE
M3
SA2
B+
B-
40
FIELD
M3
10
SA1
A5
77
210
Legend
ELECTRIC POSITIVE
78
ELECTRIC NEGATIVE
211
260
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2001-03-15
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Section
PS
C-code
S5.0
5000
Electrical Functions
Version no
T-code
001
RTX35/RTX45
K10
K10
A1
3
A2
M1
B+
ARMATURE
2
K11
FIELD
B7
A1
A5
44
F1
S21
34
101
902
40
K13
M1
K11
K13
8
Legend
Safety Check A
ELECTRIC POSITIVE
ELECTRIC NEGATIVE
LED OFF ( Not lit)
LED input (lit)
LED output (lit)
BT Prime-Mover Inc.
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F-code
Section
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PS
S5.0
Electrical Functions
5000
Version no
T-code
001
RTX35/RTX45
K10
K10
A1
3
A2
B+
ARMATURE
M1
2
K11
FIELD
B7
A1
A5
44
F1
S21
34
101
902
40
K13
M1
K11
K13
8
Legend
Safety Check B
ELECTRIC POSITIVE
ELECTRIC NEGATIVE
LED OFF ( Not lit)
LED input (lit)
LED output (lit)
262
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F-code
PS
Section
C-code
S5.0
5000
Electrical Functions
Version no
T-code
001
RTX35/RTX45
Shunt Wire
+
1
40
A5
606
607
608
Legend
ELECTRIC POSITIVE
606 -(+)
607 -(-)
608 +
ELECTRIC NEGATIVE
LED OFF ( Not lit)
LED input (lit)
LED output (lit)
BT Prime-Mover Inc.
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2001-03-15
263
F-code
Section
C-code
PS
S5.0
Electrical Functions
Version no
T-code
001
RTX35/RTX45
5000
List of Symbols
264
Return
Symbol
Designation
Function
Remark
A1
Drive Motor
A2
Pump Motor
A5
Electronic card
Main Card
A6
Electronic card
Display
A7
Electronic card
Height Preset
A8
Electronic card
Height Indication
A71
Electronic card
BT
Battery
E1
Light
Overhead Guard
E3
Light
Work
E4
Light
Work
E21
Heater
A1/A2
E22
Heater
Handle
E23
Heater
Handle
E24
Heater
E25
Heater
E26
Heater
A5
F1
Fuse
Drive Motor
250 Amp
F3
Fuse
Pump Motor
24V-425A
36V-355A (RTX35)
36V-500A (RTX45)
F50
Fuse
Control Circuit
10 Amp
F51
Fuse
Steering Motor
30 Amp
F52
Fuse
1/4 Amp
F53
Fuse
12 V. Sensor Feed
1/4 Amp
24/36 Volt
Service Manual
2001-03-15
F-code
PS
Section
C-code
S5.0
5000
Electrical Functions
Version no
001
T-code
RTX35/RTX45
List of Symbols
Symbol
BT Prime-Mover Inc.
Function
Remark
F54
Fuse
Display Power
1/4 Amp
F55
Fuse
Relay 1
10 Amp
F81
Fuse
10 Amp
F82
Fuse
10 Amp
F83
Fuse
2 Amp
H1
Horn
Alarm
H2
Flashing light
Light
option
H3
Traction
Alarm
option
K10
Contactor
Main Contactor
K11
Contactor
Forks leading
K13
Contactor
Forks Trailing
K34
Contactor
Bypass Lift
RTX45 only
K101
Relay
36 volt only
K102
Relay
Flashing Light
36 volt only
K103
Relay
A1/A2
36 volt only
K104
Relay
A5 Heater
36 volt only
K105
Relay
36 volt only
M1
Motor
Drive Motor
M3
Motor
Pump Motor
M6
Motor
Steering Motor
M12
Fan
Electronics
Potentiometer
Travel
R1
Return
Designation
Service Manual
2001-03-15
265
F-code
Section
C-code
PS
S5.0
Electrical Functions
Version no
T-code
001
RTX35/RTX45
5000
List of Symbols
Symbol
266
Return
Designation
Function
Remark
R3
Potentiometer
Brake
R11
Potentiometer
Lift/lower
R20
Resistor
Plug-in Module
Not used
R21
Resistor
Output Load
Not used
R22
Resistor
Output Load
S17
Switch
Key
S18
Switch
Horn
S21
Switch
Emergency stop
S31
Switch
Speed Limit
S33
Switch
S45
Inductive sensor
Carriage Sensor
S48
Switch
S51
Switch
Sideshift Left
S52
Switch
Sideshift Right
S55
Switch
Reach Extend
S56
Switch
Reach Retract
S60
Thermostat
Drive Temperature
S64
Inductive sensor
Drive Speed
S65
Inductive sensor
S66
Inductive sensor
Steer Stop A
S67
Inductive sensor
Steer Stop B
S96
Switch
Fan
Push Button
S97
Switch
Work Light
Push Button
S99
Switch
Light
Push Button
S108
Switch
Right Foot
S111
Switch
A1 & A2 Thermostat
S112
Switch
Push Button
2001-03-15
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PS
Version no
001
Section
C-code
S5.0
5000
Electrical Functions
T-code
RTX35/RTX45
List of Symbols
Symbol
BT Prime-Mover Inc.
Function
Remark
S113
Switch
A5 Thermostat
S125
Inductive sensor
Drive Direction
S211
Switch
Tilt Up
S212
Switch
Tilt Down
SA1
Switch
SA2
Switch
U1
Tachometer
Steering
U10
Pulse sensor
Height Counter
V101
Zener diode
Voltage Regulator
Return
Designation
Battery Connector
X101
Connector
Y1
Brake coil
Parking Brake
Y10
Valve
Lift/Lower
Y10/2
Valve
Lift Of Forks
Y10/3
Valve
Y11
Valve
Y12
Valve
Direction A
Y13
Valve
Direction B
Y14
Valve
Reach Out
Y15
Valve
Reach In
Y16
Valve
Sideshift
Y17
Valve
Tilt
Service Manual
2001-03-15
267
F-code
Section
C-code
PS
S5.0
Electrical Functions
Version no
T-code
001
RTX35/RTX45
5000
U1
+
1 1/2
0
S18
R11
S55, S56
K11
A2
A1
K13
2
3
K10
K34
Y14
+1
01/2
Y15
Y17
Y16
268
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Service Manual
2001-03-15
F-code
Section
PS
C-code
S5.0
5000
Electrical Functions
Version no
T-code
001
RTX35/RTX45
Y12
S18
M3
Y11
Y13
1+01/2
Y1
M1
S64
M6
F50
F51
A5
S48
BT Prime-Mover Inc.
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Service Manual
R3
2001-03-15
269
F-code
Section
PS
S5.0
Electrical Functions
Version no
T-code
001
RTX35/RTX45
270
Return
C-code
5000
Service Manual
2001-03-15
F-code
PS
Version no
000
Section
C-code
S5.1
5000
Electrical Symbols
T-code
RTX35/RTX45
Electrical Symbols
Electrical Symbols
Symbol
BT Prime-Mover Inc.
Return
Symbol
Description
Battery
Brake (coil)
Contactor
Diode
Emergency stop
Fuse
Horn
Inductive sensor
(normally closed)
Inductive sensor
(normally open)
Key switch
Magnet switch
(normally closed)
Magnet switch
(normally open)
Motor
Potentiometer
A1
Description
A2
Service Manual
2001-03-15
271
F-code
Section
C-code
PS
S5.1
Electrical Symbols
5000
Version no
T-code
000
RTX35/RTX45
Electrical Symbols
Symbol
Description
Push button switch
(normally closed)
Symbol
Description
Push button switch
(normally open)
Resistor
Switch
Switch
(normally closed)
Switch
(normally open)
Valve
272
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Service Manual
2001-03-15
F-code
PS
Section
C-code
S5.2
5000
Electrical Schematics
Version no
001
T-code
RTX35/RTX45
Electrical Schematics
Legend
Sh. = Sheet or page of Diagram
First number = Previous page wire was found.
Second number = Next page wire is found.
BT Prime-Mover Inc.
Return
Service Manual
2001-03-22
273
F-code
Section
PS
S5.2
Electrical Schematics
Version no
T-code
001
RTX35/RTX45
C-code
5000
Legend
Sh. = Sheet or page of Diagram
First number = Previous page wire was found.
Second number = Next page wire is found.
274
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Service Manual
2001-03-22
F-code
PS
Section
C-code
S5.2
5000
Electrical Schematics
Version no
001
T-code
RTX35/RTX45
Legend
Sh. = Sheet or page of Diagram
First number = Previous page wire was found.
Second number = Next page wire is found.
BT Prime-Mover Inc.
Return
Service Manual
2001-03-22
275
F-code
Section
PS
S5.2
Electrical Schematics
Version no
T-code
001
RTX35/RTX45
C-code
5000
Legend
Sh. = Sheet or page of Diagram
First number = Previous page wire was found.
Second number = Next page wire is found.
276
Return
Service Manual
2001-03-22
F-code
PS
Section
C-code
S5.2
5000
Electrical Schematics
Version no
001
T-code
RTX35/RTX45
Legend
Sh. = Sheet or page of Diagram
First number = Previous page wire was found.
Second number = Next page wire is found.
BT Prime-Mover Inc.
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Service Manual
2001-03-22
277
F-code
Section
PS
S5.2
Electrical Schematics
Version no
T-code
001
RTX35/RTX45
C-code
5000
Legend
Sh. = Sheet or page of Diagram
First number = Previous page wire was found.
Second number = Next page wire is found.
278
Return
Service Manual
2001-03-22
F-code
PS
Section
C-code
S5.2
5000
Electrical Schematics
Version no
001
T-code
RTX35/RTX45
Legend
Sh. = Sheet or page of Diagram
First number = Previous page wire was found.
Second number = Next page wire is found.
BT Prime-Mover Inc.
Return
Service Manual
2001-03-22
279
F-code
Section
PS
S5.2
Electrical Schematics
Version no
T-code
001
RTX35/RTX45
C-code
5000
Legend
Sh. = Sheet or page of Diagram
First number = Previous page wire was found.
Second number = Next page wire is found.
280
Return
Service Manual
2001-03-22
F-code
PS
Section
C-code
S5.2
5000
Electrical Schematics
Version no
001
T-code
RTX35/RTX45
Legend
Sh. = Sheet or page of Diagram
First number = Previous page wire was found.
Second number = Next page wire is found.
BT Prime-Mover Inc.
Return
Service Manual
2001-03-22
281
F-code
Section
PS
S5.2
Electrical Schematics
Version no
T-code
001
RTX35/RTX45
C-code
5000
Legend
Sh. = Sheet or page of Diagram
First number = Previous page wire was found.
Second number = Next page wire is found.
282
Return
Service Manual
2001-03-22
F-code
PS
Version no
001
Section
C-code
S5.2
5000
Electrical Schematics
T-code
RTX35/RTX45
Legend
Sh. = Sheet or page of Diagram
First number = Previous page wire was found.
Second number = Next page wire is found.
BT Prime-Mover Inc.
Return
Service Manual
2001-03-22
283
F-code
Section
PS
S5.2
Electrical Schematics
Version no
T-code
001
RTX35/RTX45
C-code
5000
Legend
Sh. = Sheet or page of Diagram
First number = Previous page wire was found.
Second number = Next page wire is found.
284
Return
Service Manual
2001-03-22
F-code
Section
PS
S5.3
Version no
001
C-code
5110
Battery
T-code
RTX35/RTX45
Battery
Battery
Connector
1. Removal
1. After the truck is stopped and the brake pedal is
returned to the full up position, turn key switch to
the OFF position.
Battery
Roller
Battery
Retainer
Plate
2. Installation
1. With a fully charged and tested battery on the lifting
device, position the lifting device at the truck
according to the manufacturers recommendations.
2. Position the battery in the compartment. Be sure
the battery has no more than 0.50 inch (13 mm) of
free play movement in the battery compartment.
3. Install battery retainer plate (see page 106).
4. Move lifting device from the area.
5. Reconnect battery connector, turn key switch ON,
and test the operation of truck.
BT Prime-Mover Inc.
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Service Manual
2001-03-15
285
F-code
Section
C-code
PS
Battery
S5.3
5110
Version no
T-code
001
RTX35/RTX45
3. Battery Maintenance
The following information does not supercede or replace
information supplied by the battery and battery charger
manufacturer. Read, understand, and follow the procedures
in the manual supplied with the battery and battery charger.
Notify your supervisor if there are any concerns or questions
regarding battery safety or procedures.
286
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Service Manual
2001-03-15
F-code
Section
PS
S5.3
Version no
001
C-code
5110
Battery
T-code
RTX35/RTX45
3.3. Charging
OSHA regulations require that battery charging installations
be located in areas designated for that specific purpose. Such
areas must provide for flushing and neutralizing spilled
electrolyte, for fire protection, for protecting charging
equipment from damage by reach trucks and for adequate
ventilation of fumes from gassing batteries.
To charge a battery, direct current is passed through the
battery cells in the direction opposite that of discharge.
Charging time is 5% to 20% longer than discharge time.
BT Prime-Mover Inc.
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2001-03-15
287
F-code
Section
C-code
PS
Battery
S5.3
5110
Version no
T-code
001
RTX35/RTX45
4. Storage
Before storing the battery, make sure the electrolyte is at the
proper level in all the cells, filler plugs are tight, and battery is
fully charged. Store battery in a clean, cool, dry location away
from radiators and other sources of heat. Check the
electrolyte level and specific gravity every 30 days during
storage. Whenever the specific gravity is less than 1.230,
charge the battery.
288
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Service Manual
2001-03-15
F-code
Section
PS
S5.4
5121
Light Assemblies
Version no
001
C-code
T-code
RTX35/RTX45
Light Assemblies
Description
Light, dome
Bezel, light
Tie, wire
1.1. Removal
1. Turn key switch OFF and disconnect battery
connector.
2. From the top of the overhead guard, remove four
screws securing the light/fan assembly.
3. Lower the light/fan assembly enough to disconnect
it from the harness.
4. Remove light/fan assembly from truck.
5. Repair or replacement of the light is achieved by
removing four screws in the sides of the light/fan
console assembly to detach the hanger bracket
from the top of console.
1.2. Installation
1. Reassemble the light/fan console assembly. Be
sure clip nuts are positioned over mounting holes
for attachment to the overhead guard.
2. Reconnect harness connections.
3. Install mounting screws through the top of
overhead guard to secure the assembly.
BT Prime-Mover Inc.
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Service Manual
2001-03-15
289
F-code
Section
C-code
PS
S5.4
Light Assemblies
5121
Version no
T-code
001
RTX35/RTX45
1
2
The warning lights are strobe lights. The color of the lights are
by customer request. Warning lights are mounted at the back
of the overhead guard, to the right of the back post.
Item
No.
3
Description
Item
No.
Description
Screw, slotted
Alarm, travel
Light
Screw
Bracket, mounting
2.1. Removal
1. Turn key switch OFF and disconnect battery
connector.
2. Disconnect electrical connection at the warning
light.
3. Remove two hex head screws (1) securing light
assembly (2) to the overhead guard bracket (3).
4. Replace light bulb or light assembly as required.
2.2. Installation
1. Secure light assembly to the overhead guard
bracket (3) with two hex head screws (1).
2. Reconnect wiring harness.
3. Reconnect battery connector.
4. Test the operation of warning lights, then return
truck to service.
290
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Service Manual
2001-03-15
F-code
Section
PS
S5.4
5121
Light Assemblies
Version no
001
C-code
T-code
RTX35/RTX45
3.1. Removal
1. Turn key switch OFF and disconnect battery
connector.
2. Disconnect electrical connection at the working
light.
3. Remove screws securing light assembly to the
overhead guard.
4. Replace light bulb or light assembly as required.
3.2. Installation
1. Secure light assembly to the overhead guard.
2. Reconnect wiring harness.
3. Reconnect battery connector.
4. Test the operation of the working lights, then return
truck to service.
BT Prime-Mover Inc.
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Service Manual
2001-03-15
291
F-code
Section
C-code
PS
S5.4
Light Assemblies
Version no
T-code
001
RTX35/RTX45
5121
1
2
5
Item
No.
4
Description
Item
No.
Description
Screw, slotted
Alarm, travel
Light
Screw
Bracket, mounting
4.1. Removal
1. Turn key switch OFF and disconnect battery
connector.
2. Disconnect electrical connection at the travel/backup alarm.
3. Remove two hex head screws (5) securing the
travel/back-up alarm (4) to the overhead guard
bracket (3).
4. Replace alarm assembly as required.
4.2. Installation
1. Secure the travel/back-up alarm assembly to the
overhead guard bracket (3) with two hex head
screws (5).
2. Reconnect wiring harness.
3. Reconnect battery connector.
4. Test the operation of the alarm, then return truck to
service.
292
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Service Manual
2001-03-15
F-code
Section
PS
S5.5
Version no
001
C-code
5160
Horn
T-code
RTX35/RTX45
Horn
NOTE! The horn can only be sounded with the key
switch in the ON position.
2
1. Removal
1. Turn key switch OFF and disconnect battery
connector.
2. Installation
1. Attach the horn to the truck frame and tighten
mounting bolt (2).
2. Attach the three wires.
3. Reconnect battery connector and test operation.
4. Close motor compartment door.
BT Prime-Mover Inc.
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Service Manual
2001-03-15
293
F-code
Section
C-code
PS
Horn
S5.5
5160
Version no
T-code
001
RTX35/RTX45
294
Return
Service Manual
2001-03-15
F-code
PS
Version no
001
Section
C-code
S5.6
5192
Battery Connector
T-code
RTX35/RTX45
Battery Connector
2
1
4
Item No.
Battery
Connector
Description
Connector, SB-350
Cap screw
Cable, Negative
Cable, Positive
1. Location
The battery connector is located on the right side of the truck,
above the battery.
f
BT Prime-Mover Inc.
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Service Manual
2001-03-15
295
F-code
Section
PS
S5.6
Battery Connector
Version no
T-code
001
RTX35/RTX45
C-code
5192
2. Inspection
1. Turn key switch OFF and disconnect battery
connector.
2. Check battery connector for damaged cables.
3. Check to see if battery cables are pulling out of the
connector.
4. Check cables at the battery terminals. Connections
should be tight, with no corrosion.
5. Look inside the connector. Check internal contacts
for damage, dirt, or corrosion. DO NOT use a
metal object to clean the connector.
3. Installation
The cables to either half of the connector have a lip on their
forward end. This lip snaps over a spring-loaded retainer
which is part of the connector. To remove a cable from the
connector, push retainer down while pulling the battery cable
towards the rear and out of the connector.
296
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Service Manual
2001-03-15
F-code
PS
Version no
001
Section
C-code
S5.7
5311
Start/Stop Switches
T-code
RTX35/RTX45
Start/Stop Switches
1. General
Refer to the electrical schematic to identify the electrical
circuit location of the switch (see Circuit Diagrams on
page 273 through page 284).
1.1. Test/Inspection
Examine the switch for signs of arcing, overheating,
discoloration, cracking, or other physical damage. Replace
switch if such damage is present.
To test a switch, isolate it from the electrical circuit. Remove
all the connections from the switch, making sure all wires are
labeled and identified for reconnection.
Use an ohmmeter set to a low resistance scale to measure
the resistance across the switch. In a closed position, the
switch should be less than 1 ohm. In an open position, the
switch should show a resistance greater than 10 megohms.
Key Switch
+
1
1/ 2
2.1. Inspection
With the battery plugged in and key switch in the ON position,
battery voltage B+ should be present on both terminals of the
switch. Test the key switch with an ohmmeter after removing
it from the electrical system. In the OFF position, the
ohmmeter should read greater than 10 megohms, and in the
BT Prime-Mover Inc.
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2001-03-15
297
F-code
Section
PS
S5.7
Start/Stop Switches
Version no
T-code
001
RTX35/RTX45
C-code
5311
2.2. Removal
1. Turn key switch OFF and disconnect battery
connector.
2. Remove top console (see page 96).
3. Disconnect wires from the bottom of the key
switch.
4. Remove mounting nut from the stem of the key
switch.
5. Remove key switch.
2.3. Installation
1. Install new key switch and tighten locking nut.
2. Connect wires to the terminals.
3. Reconnect battery connector and check operation.
4. Turn key switch OFF and disconnect battery
connector.
5. Install top console.
6. Reconnect battery connector.
298
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Service Manual
2001-03-15
F-code
PS
Version no
001
Section
C-code
S5.7
5311
Start/Stop Switches
T-code
RTX35/RTX45
Emergency Stop
Switch
+
1
1/
3.1. Inspection
With the battery plugged in and the emergency disconnect
switch OUT, in the ON position, battery voltage B+ should be
present on both terminals of the switch. Test the emergency
disconnect switch with an ohmmeter after removing it from
the electrical system. In the OFF position, the ohmmeter
should read greater than 10 megohms, and in the ON
position, the ohmmeter should read less than 1 ohm. If not,
replace the switch.
3.2. Removal
1. Turn key switch OFF and disconnect battery
connector.
2. Remove top console (see page 96).
3. Disconnect electrical harness from the base of the
emergency disconnect switch.
4. Use a small phillips head screwdriver to loosen two
screws in the backside of the top console.
5. Press two halves of the emergency disconnect
switch together and turn counterclockwise to
disconnect the switch body from the top console.
6. Finish removing two screws.
7. Repair or replace as necessary.
BT Prime-Mover Inc.
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2001-03-15
299
F-code
Section
PS
S5.7
Start/Stop Switches
Version no
T-code
001
RTX35/RTX45
C-code
5311
3.3. Installation
1. Place switch operator down through the opening in
the top console.
2. Attach switch body to the operator from the
backside of the top console.
3. Turn the halves clockwise to engage the latches.
4. Secure the base of the emergency disconnect
switch to the back of the top console with two
screws.
5. Reconnect electrical harness to the base of the
emergency disconnect switch.
6. Install top console.
7. Reconnect battery connector.
8. Test truck operation, then return to service.
300
Return
Service Manual
2001-03-15
F-code
Section
PS
C-code
S5.8
5332
Mast Switch (S31)
Version no
T-code
001
RTX35/RTX45
1. General
Refer to the electrical schematic to identify the electrical
circuit location of the switch (see Circuit Diagrams on
page 273 through page 284).
1.1. Test/Inspection
Examine the switch for signs of arcing, overheating,
discoloration, cracking, or other physical damage. Replace
switch if such damage is present.
+01/21
High Speed
Travel Limit
Switch
BT Prime-Mover Inc.
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Description
Bracket, switch
Sensor
2001-03-15
301
F-code
Section
PS
S5.8
Mast Switch (S31)
Version no
T-code
001
RTX35/RTX45
C-code
5332
2. Adjustment
1. Raise the empty carriage until the bottom of the tie
bar is even with the bottom of the mast switch.
2. Secure the carriage with blocks and a hoist to
prevent any movement.
3. Loosen jam nut securing the mast switch to the
mast.
4. Making sure the mast channel are pushed
completely to the rear, adjust the switch to 0.187
inch (4.76 mm). Allowable tolerance is +0.0625
inch (1.59 mm) and -0 mm.
5. Tighten jam nut.
6. Check the clearance with jam nut tightened.
7. Remove blocks and hoist.
8. Place a maximum capacity load on the forks. Verify
that the tie bar does not contact the switch under
normal working conditions.
9. Adjust the clearance as necessary to achieve
proper clearance when fully loaded.
10. Remove the load from forks.
11. Test the truck operation to verify normal travel
speed with the mast lowered.
302
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Service Manual
2001-03-15
F-code
PS
Version no
001
Section
C-code
S5.8
5332
Mast Switch (S31)
T-code
RTX35/RTX45
3. Removal
1. Raise the empty carriage until the bottom of the tie
bar is even with the bottom of the mast switch.
2. Secure the carriage with blocks and a hoist to
prevent any movement.
3. Turn key switch OFF and disconnect battery
connector.
4. Disconnect switch from the harness.
5. Loosen jam nut securing the mast switch to the
mast.
6. Remove mast switch from the mast.
BT Prime-Mover Inc.
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Service Manual
2001-03-15
303
F-code
Section
PS
S5.8
Mast Switch (S31)
Version no
T-code
001
RTX35/RTX45
C-code
5332
4. Installation
1. Install new mast switch.
2. Tighten jam nut to secure the switch.
3. Attach wiring harness.
4. Reconnect battery connector.
5. Adjust switch following the procedure on page 302.
6. Return truck to service.
304
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Service Manual
2001-03-15
F-code
PS
Section
Version no
T-code
001
C-code
S5.9
5391
Control Cable and Harness
RTX35/RTX45
F83
F82
F81
F55
F54
F53
Fuse
No.
Amp
F52
F1
250
F3
425
355
500
F50
10
Control Circuit
F51
30
Steer Circuit
F52
1/4
F53
1/4
F54
1/4
F55
10
Relay1
F81
10
F82
10
F83
Auxiliary Power
F50
F51
Function
BB+
F1
F3
BT Prime-Mover Inc.
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2001-03-15
305
F-code
Section
C-code
PS
S5.9
5391
Control Cable and Harness
Version no
T-code
001
RTX35/RTX45
2. Wiring
2.1. Harness
Whenever working on the truck, use care around the wiring
harnesses.
Do not pull on wires.
Carefully mate and unmate all connectors.
Do not pry apart connectors with unspecified tools.
Examine and maintain any added materials used to dress
or protect the wire. This includes spiral wrap, brackets,
cable ties, fasteners, flexible conduit, etc.
Check harness wires for abrasions, scrapes, nicks in the
wire, damage from overheating or burns, or other general
insulation damage.
Replace terminations with exposed wire visible at the
connectors. Damaged terminations, exposed wires, or
damaged connectors can cause operational failure of the
truck.
During troubleshooting and repairs, it is sometimes
necessary to unmate a connector, move a harness, cut a
cable tie, or remove the wire from a bracket. Note carefully
the location of the wire and all protective or securing
attachments before moving the harness.
After repair, return or replace all protective and/or securing
hardware to its original condition. Protective materials are
necessary to provide reliable performance of the interconnect
system.
NOTE! It is normal to find unused connectors for
uninstalled options that have had heat shrink
applied over them and have been strapped to
the harness.
There should be a wire marker at each termination. If the
marker is missing or unreadable, remark the wire to allow
easier identification.
306
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Service Manual
2001-03-15
F-code
PS
Section
C-code
S5.9
5391
Control Cable and Harness
Version no
001
T-code
RTX35/RTX45
BT Prime-Mover Inc.
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2001-03-15
307
F-code
Section
C-code
PS
S5.9
5391
Control Cable and Harness
Version no
T-code
001
RTX35/RTX45
+01/21
Item No.
2
1
308
Return
Description
Fitting, wire
Lockwasher
Screw
Terminal
Service Manual
2001-03-15
F-code
Section
PS
S5.10
Version no
001
C-code
5441
Contactors
T-code
RTX35/RTX45
Contactors
1. General
1.1. Testing Resistance
Visually inspect the contactor for any signs of burning or
physical damage.
1. Turn trucks key switch OFF and disconnect
battery connector.
2. Disconnect two wires from the base of the
contactor.
3. Connect one lead of the ohmmeter to the one wire
from the contactor. Connect the other lead to the
other wire from the contactor.
4. The reading should be between 20 and 40 ohms. If
it is not, replace the contactor.
before
inspecting
or
servicing
BT Prime-Mover Inc.
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2001-03-15
309
F-code
Section
C-code
PS
S5.10
Contactors
5441
Version no
T-code
001
RTX35/RTX45
2. Directional Contactors
4
3
310
Return
Item
No.
Description
Item
No.
Contactor assembly
Base
Screw
Kit, service
Contactor
Service Manual
Description
2001-03-15
F-code
Section
PS
S5.10
Version no
001
C-code
5441
Contactors
T-code
RTX35/RTX45
2.1. Removal
1. Turn key switch OFF and disconnect battery
connector.
2. Remove top console (see page 96).
3. Disconnect cables by removing hex nuts. Identify
cables and their location. Label, if necessary, for
proper installation.
4. Remove contactor coil wires by pulling the wire
connector. Note their locations and label if
necessary.
5. Remove two screws (2) holding the contactor to
the mounting panel.
6. Remove contactor from the contactor panel.
2.2. Installation
1. Position contactor over the holes in the mounting
panel. Attach with screws.
2. Attach coil wires by sliding the connector onto the
appropriate spade terminal.
3. Attach cables to the appropriate lugs and tighten
securely.
4. Reconnect battery connector.
5. Turn key switch ON and test truck operation.
6. Turn key switch OFF, disconnect
connector, and install the top console.
battery
BT Prime-Mover Inc.
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Service Manual
2001-03-15
311
F-code
Section
C-code
PS
S5.10
Contactors
5441
Version no
T-code
001
RTX35/RTX45
Item No.
312
Return
Description
Contactor
Kit, service
Screw
Service Manual
2001-03-15
F-code
Section
PS
S5.10
Version no
001
C-code
5441
Contactors
T-code
RTX35/RTX45
3.1. Removal
1. Turn key switch OFF and disconnect battery
connector.
2. Remove top console (see page 96).
3. Disconnect cables by removing hex nuts. Identify
cables and their location. Label, if necessary, for
proper installation.
4. Remove contactor coil wires by pulling the wire
connector. Note their locations and label if
necessary.
5. Remove two screws (3) holding the contactor to
the mounting panel.
6. Remove contactor from contactor panel.
3.2. Installation
1. Position contactor over the holes in the mounting
panel. Attach with screws (3).
2. Attach coil wires by sliding the connector onto the
appropriate spade terminal.
3. Attach cables to the appropriate lugs and tighten
securely.
4. Reconnect battery connector.
5. Turn key switch ON and test truck operation.
6. Turn key switch OFF, disconnect
connector, and install top console.
battery
BT Prime-Mover Inc.
Return
Service Manual
2001-03-15
313
F-code
Section
C-code
PS
S5.10
Contactors
5441
Version no
T-code
001
RTX35/RTX45
2
3
Item No.
314
Return
Description
Screw
Contactor
Cover, bridge
Kit, service
Service Manual
2001-03-15
F-code
Section
PS
S5.10
Version no
001
C-code
5441
Contactors
T-code
RTX35/RTX45
4.1. Removal
1. Turn key switch OFF and disconnect battery
connector.
2. Remove top console (see page 96).
3. Disconnect cables by removing hex nuts. Identify
cables and their location. Label, if necessary, for
proper installation.
4. Remove contactor coil wires by pulling the wire
connector. Note their locations and label if
necessary.
5. Remove two screws (1) holding contactor to the
mounting panel.
6. Remove contactor from the contactor panel.
4.2. Installation
1. Position contactor over the holes in the mounting
panel. Attach with screws (1).
2. Attach coil wires by sliding the connector onto the
appropriate spade terminal.
3. Attach cables to the appropriate lugs and tighten
securely.
4. Reconnect battery connector.
5. Turn key switch ON and test truck operation.
6. Turn key switch OFF, disconnect
connector, and install the top console.
battery
BT Prime-Mover Inc.
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Service Manual
2001-03-15
315
F-code
Section
PS
S5.10
Contactors
Version no
T-code
001
RTX35/RTX45
316
Return
C-code
5441
Service Manual
2001-03-15
F-code
PS
Section
C-code
S5.11
5461
Transistor Panel (Drive)
Version no
T-code
001
RTX35/RTX45
3
4
Item
No.
Description
Item
No.
Nut
Screw
Screw
Lockwasher
Screw
Description
1. Motor Connections
The drive transistor regulator has four connections for power
cables, described in the table below.
Terminal
Number
B-
Battery minus
B+
Battery plus
BT Prime-Mover Inc.
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Function
Service Manual
2001-03-15
317
F-code
Section
C-code
PS
S5.11
5461
Transistor Panel (Drive)
Version no
T-code
001
RTX35/RTX45
Color
Green
Supply voltage
Yellow
Upper/lower temperature
Red
Red
Terminal
Number
Connection
Safety test
7 1
318
Return
Function
Function
7
8
9
1
3
4
10
11
Not connected
Logic OV
Logic OV
Common differential
Safety circuit
Braking indication
Voltage output
10
Speed command
11
Service Manual
2001-03-15
F-code
PS
Version no
001
Section
C-code
S5.11
5461
Transistor Panel (Drive)
T-code
RTX35/RTX45
2. Circuit Check.
This check applies to reach trucks equipped with a transistor
regulator type.
1. Jack up the rear of the truck (see Safe Jacking
Procedure on page 64).
2. Remove console cover (see page 96).
3. Turn key switch so that the main electronic card is
ON.
Battery
negative
71
7
8
9
10
11
1
2
3
4
5
6
BT Prime-Mover Inc.
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Service Manual
2001-03-15
319
F-code
Section
C-code
PS
S5.11
5461
Transistor Panel (Pump)
Version no
T-code
001
RTX35/RTX45
3
4
Item
No.
Description
Item
No.
Nut
Screw
Screw
Lockwasher
Screw
Description
1. Motor Connections
The pump transistor regulator has three connections for
power cables, described in the table below.
Terminal
Number
B-
Battery minus
B+
Battery plus
320
Return
Function
Service Manual
2001-03-15
F-code
PS
Section
C-code
S5.11
5461
Transistor Panel (Pump)
Version no
T-code
001
RTX35/RTX45
Color
Green
Supply voltage
Yellow
Upper/lower temperature
Red
Red
Terminal
Number
Connection
Function
Function
7 1
7
8
9
10
11
1
2
3
4
Current value
Voltage value
5
6
Not connected
5
6
Logic OV
I
BT Prime-Mover Inc.
Return
Common differential
Not connected
Temperature value
Voltage output
10
Speed command
11
Service Manual
2001-03-15
321
F-code
Section
C-code
PS
S5.11
5461
Transistor Panel (Pump)
Version no
T-code
001
RTX35/RTX45
322
Return
Service Manual
2001-03-15
F-code
Section
PS
S5.12
5511
Micro Switches
Version no
001
C-code
T-code
RTX35/RTX45
Micro Switches
1. General
Refer to the electrical schematic to identify the electrical
circuit location of the switch (see Circuit Diagrams on
page 273 through page 284). Examine the switch for signs of
arcing, overheating, discoloration, cracking, or other physical
damage. Replace switch if such damage is present.
To test a switch, isolate it from the electrical circuit. Remove
all the connections from the switch, making sure all wires are
labeled and identified for reconnection. Use an ohmmeter set
to a low resistance scale to measure the resistance across
the switch. In a closed position, the switch should be less
than 1 ohm. In an open position, the switch should show a
resistance greater than 10 megohms.
BT Prime-Mover Inc.
Return
Service Manual
2001-03-15
323
F-code
Section
PS
S5.12
Micro Switches
Version no
T-code
001
RTX35/RTX45
C-code
5511
Lift Limit
Override
Switch
2.1. Removal
1. Turn key switch OFF and disconnect battery
connector.
2. Loosen top console to allow access to the wiring
harness connection at the switch cluster.
3. Pull two wires off the tabs on the back of the
switch.
4. Unscrew nut securing the switch in the switch
cluster.
5. Lift switch from the switch cluster.
2.2. Installation
1. Place new switch in the switch cluster.
2. Secure switch with nut.
3. Attach two wires to the tabs on the back of the
switch.
4. Secure top console to the truck.
5. Reconnect battery connector.
6. Check the operation of the truck, then return truck
to service.
324
Return
Service Manual
2001-03-15
F-code
Section
PS
S5.12
5511
Micro Switches
Version no
001
Working
Light
Switch
C-code
T-code
RTX35/RTX45
Operator
Fan
Switch
Overhead
Light
Switch
3.1. Removal
1. Turn key switch OFF and disconnect battery
connector.
2. Loosen the top console to allow access to wiring
harness connection at the switch cluster.
3. Pull two wires off the tabs on the back of the
switch.
4. Unscrew nut securing the switch in the switch
cluster.
5. Lift switch from the switch cluster.
3.2. Installation
1. Place new switch in the switch cluster.
2. Secure switch with the nut.
3. Attach two wires to the tabs on the back of the
switch.
4. Secure top console to truck.
5. Reconnect battery connector.
6. Check operation of truck, then return truck to
service.
BT Prime-Mover Inc.
Return
Service Manual
2001-03-15
325
F-code
Section
PS
S5.12
Micro Switches
Version no
T-code
001
RTX35/RTX45
326
Return
C-code
5511
Service Manual
2001-03-15
F-code
PS
Section
C-code
S5.13
5711
Main Electronic Card
Version no
001
T-code
RTX35/RTX45
1. Removal
1. Turn key switch OFF and disconnect battery
connector.
2. Remove main
page 101).
electronic
card
panel
(see
2. Installation
1. Place main electronic card unit against the outside
wall of the chassis. Align mounting holes.
2. Secure main electronic card to truck frame with
four Allen head screws.
3. Reconnect all electrical cables to main electronic
card.
4. Install main electronic card panel.
5. Reconnect battery connector.
6. Perform RV2
page 354).
adjustment
procedure
(see
BT Prime-Mover Inc.
Return
Service Manual
2001-03-15
327
F-code
Section
C-code
PS
S5.13
Main Electronic Card
Version no
T-code
001
RTX35/RTX45
5711
36 Volt Resistor
24 Volt Jumper
101
to
111
201
to
211
301
to
304
401
to
405
501
to
511
601
to
611
701
to
710
801
to
811
901
to
904
Terminal Locations
I=Input, green LED; O=Output, red LED
3. Connectivity to Truck
The main electronic card is connected to the trucks circuitry
by nine connectors. To remove connectors one through eight,
depress the connectors latch and unplug the connector. To
install the connectors, push the connectors together until the
latch snaps into position. To remove connector nine, grasp
the connector (do not grasp the wires) and, with a slight
rotational wiggling action, unplug the connector. To install,
push the connector onto the pins making sure all of the pins
are captured by the connector.
328
Return
Service Manual
2001-03-15
F-code
Section
PS
C-code
S5.13
5711
Main Electronic Card
Version no
T-code
001
RTX35/RTX45
BT Prime-Mover Inc.
Return
Terminal
Number
LED
No.
Connection
101
102
103
104
105
106
107
111
101
102
103
104
105
106
107
111
I
I
I
I
I
I
I
I
LED No.
Color
Function
TX
Green
Service Manual
Function
Traction power amplifier - OK
Right foot switch
Plug braking
Drive, temperature sense
Drive direction
Lift limit override
Speed reduction
Brake switch
2001-03-15
329
F-code
Section
C-code
PS
S5.13
Main Electronic Card
5711
Version no
T-code
001
RTX35/RTX45
Terminal
Number
LED
No.
Connection
201
202
203
204
205
206
207
208
209
210
211
201
202
203
204
205
206
207
208
209
210
211
I
I
I
I
I
I
I
I
I
I
I
Terminal
Number
330
Function
Display power +
Display power TX positive display
TX negative display
Connection
402
405
Return
Drive measuring
Connection
301
302
303
304
Terminal
Number
Function
Function
TX negative height unit
TX positive height unit
Service Manual
2001-03-15
F-code
Section
PS
Version no
T-code
001
Terminal
Number
501
502
503
504
505
506
507
508
509
510
511
BT Prime-Mover Inc.
Return
LED No.
Connection
501
I
I
I
O
I
I
I
I
I
C-code
S5.13
5711
Main Electronic Card
RTX35/RTX45
Function
24/36 volt select
Steering/tach +
Steering/tach Positive 7.35 volts
Speed request value
Lift/lower
Reach/retract
Tilt
Sideshift
Zero voltage
Terminal
Number
Connection
601
602
603
604
606
607
608
609
610
611
I
I
I
I
I
I
I
O
O
O
Service Manual
Function
Negative for 602-604
Lift regulator temperature
Lift regulator voltage
Lift regulator current
Battery indicator current +
Battery indicator current Battery indicator +
Speed/current reference Speed request value +
Current limit +
2001-03-15
331
F-code
Section
C-code
PS
S5.13
Main Electronic Card
Version no
T-code
001
RTX35/RTX45
5711
Terminal
Number
701
702
703
704
705
706
707
708
709
710
711
332
Return
LED
No.
704
705
706
707
708
709
710
711
Connection
O
O
O
O
O
O
O
O
O
O
O
Function
Negative for 702-703
Lift regulator speed request value +
Lift regulator current limit +
Fork lift
Direction A
Direction B
Reach out
Reach in (Retract)
Sideshift
Tilt
Pedal sense
Terminal
Number
LED
No.
Connection
801
802
803
804
805
806
807
808
809
810
811
801
802
803
804
805
O
O
O
O
O
I
O
+24/36 volt
Function
Service Manual
2001-03-15
F-code
PS
Section
Version no
T-code
001
Terminal
Number
Connection
901
902
903
904
I
I
O
O
LED
Color
POWER
STEER PWR
STEER OK
Green
Green
Green
C-code
S5.13
5711
Main Electronic Card
RTX35/RTX45
Function
+24/36 volt steer motor
Zero voltage
+ steer motor
- steer motor
Function
Indication, all voltage is fed to the electronic card
Voltage feed to control electronics
Steering OK
Switch
SW 1
SW 2
SW 3
Function
Switch to program parameters and error codes
Switch to program parameters and error codes
Switch to program parameters and error codes
Potentiometer
RV2
BT Prime-Mover Inc.
Return
Function
Adjustment of lowering speed
Service Manual
2001-03-15
333
F-code
Section
C-code
PS
S5.13
Main Electronic Card
Version no
T-code
001
RTX35/RTX45
SW1
SW2
5711
4. Display
SW3
ANTY
SW3
SW2
SW1
111
107
109
105
101
103
205
204
202
207
209
303
301
RV1
403
RV2
401
305
304
404
405
501
505
503
If only the colon (A) displays when the key switch is turned to
the ON position, the truck must be serviced.
+
1
1/2
H G F E D
334
Return
Service Manual
2001-03-15
F-code
PS
Version no
001
SW1
SW2
Section
C-code
S5.13
5711
Main Electronic Card
T-code
RTX35/RTX45
4.1. Time
SW3
ANTY
SW3
SW2
SW1
105
101
103
107
109
205
204
202
207
209
301
303
RV1
305
304
RV2
403
401
405
404
Function
501
Value
505
503
Hours
Minutes
09=9h
35=35 min.
+
1
1/2
H G F E D
BT Prime-Mover Inc.
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Service Manual
2001-03-15
335
F-code
Section
C-code
PS
S5.13
Main Electronic Card
Version no
T-code
001
RTX35/RTX45
5711
5. Warning/Caution codes
Character
Error
Warning/
Caution
1
1/2
H G F E D
Error
No.
336
5
10
11
13
14
16
17
18
19
20
21
22
23
24
Return
Comment
Parameter 14 set incorrectly
Steer chopper high temperature current limit
Height counter error
Forks are above free height at power-on with Special
Height Parameter set greater than zero (a height counter
is installed)
Worn pump motor brush
Worn drive motor brush
Control module internal error
Service Manual
2001-03-15
F-code
PS
Section
C-code
S5.13
5711
Main Electronic Card
Version no
001
T-code
RTX35/RTX45
Error
No.
Comment
25
27
28
30
31
32
33
35
36
37
38
40
Travel Error
45
52
53
54
55
56
57
58
59
60
61
63
O Lift Error
O Tilt Error
O Direction A Error
O Direction B Error
O Sideshift Error
O Hydraulic Dump Error
O Alarm Out Error
O Reach In Error
O Reach Out Error
O Lower Prop Error
O Forward Contactor Error
BT Prime-Mover Inc.
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Service Manual
2001-03-15
337
F-code
Section
C-code
PS
S5.13
Main Electronic Card
Version no
T-code
001
RTX35/RTX45
Error
No.
338
5711
64
80
89
90
91
92
93
Return
Comment
Shorted or opened backward contactor output
Shorted or opened steer limit sensor(s). One or more of
the drive wheel steering limit control sensors are not
correctly signalling the control module. A minimum of
one sensor and control module input LED should be on
during the allowed steering rotational distance of the
drive wheel. If all three sensors are on or if all three
sensors are off, error code 80 will be displayed.
Lift potentiometer end value(s) exceeded the maximum
limits
Shorted or opened lift potentiometer input
Shorted or opened tilt request input
Shorted or opened reach request input
Shorted or opened sideshift request input
Service Manual
2001-03-15
F-code
PS
Version no
001
Section
C-code
S5.13
5711
Main Electronic Card
T-code
RTX35/RTX45
6. Error codes
Character
Error
Error
+
1
1/2
H G F E D
BT Prime-Mover Inc.
Return
Service Manual
2001-03-15
339
F-code
Section
C-code
PS
S5.13
Main Electronic Card
Version no
T-code
001
RTX35/RTX45
Error
No.
340
5711
100
101
102
104
105
106
110
111
112
113
114
115
116
117
120
121
122
123
124
125
126
127
130
131
132
133
140
Return
Comment
Pump chopper over or under temperature
Drive chopper internal error (see page 341)
Accelerator potentiometer zero or maximum travel
memory value error. Control handle calibration required
(see page 121). Lift/lower may also be in error and
disabled.
Shorted or opened accelerator potentiometer input.
Accelerator potentiometer end point value(s) exceeded
the maximum limit.
Potentiometer/pushbutton supply voltage failure
Pedal/parking brake potentiometer adjustment or failure
Pedal/parking brake switch adjustment or failure
Shorted or open parking brake output
Speed and direction sensor failure
Drive motor speed sensor failure
Drive motor direction sensor failure
Drive chopper reversing signal failure
Control module internal error
Steer chopper error
Steer chopper high temperature limit
Service Manual
2001-03-15
F-code
PS
Version no
001
Section
C-code
S5.13
5711
Main Electronic Card
T-code
RTX35/RTX45
Green
Yellow
LED3
Red
LED4
Red
BT Prime-Mover Inc.
Return
Service Manual
2001-03-15
341
F-code
Section
PS
S5.13
Main Electronic Card
Version no
T-code
001
RTX35/RTX45
C-code
5711
342
Return
Service Manual
2001-03-15
F-code
PS
Version no
001
Section
C-code
S5.13
5711
Main Electronic Card
T-code
RTX35/RTX45
Return
Service Manual
2001-03-15
343
F-code
Section
C-code
PS
S5.13
Main Electronic Card
Version no
T-code
001
RTX35/RTX45
5711
SW1
SW2
7. Parameters
SW3
ANTY
SW3
SW2
SW1
111
107
109
105
101
103
8. Running time
205
204
202
211
207
209
301
303
Character
Time
RV1
305
304
Key time
RV2
403
401
404
501
505
503
344
Return
Service Manual
2001-03-15
F-code
PS
Version no
001
Section
C-code
S5.13
5711
Main Electronic Card
T-code
RTX35/RTX45
9. Programming Parameters
+
1
1/2
Parameter
Name
Value
Range
Default
Inc
Values
Comment
1-6
(1)
1-Least sensitivity
5-Most sensitivity
6-Test curve
0-3
(0)
0-Least sensitivity
2-Most sensitivity
10-100%
100
% of maximum speed
10-50%
(40)
% of maximum speed
Accel Par
10-100%
(50)
% of maximum acceleration
Acceleration reduction.
10-100%
(80)
Decel Par
50-100%
(70)
% of maximum deceleration
Deceleration reduction
parameter.
Not Used
(0)
0-531 in.
(0)
10
60-177 in.
(90)
11
0-1
(1)
0-Backward (Eur.)
1-Forward (US)
Steer direction
BT Prime-Mover Inc.
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Service Manual
2001-03-15
Special height
345
F-code
Section
C-code
PS
S5.13
Main Electronic Card
5711
Version no
T-code
001
RTX35/RTX45
Programming Parameters
No.
Parameter
Name
Value
Range
Default
Inc
Values
Comment
12
1-4
(2)
Displayed timer
13
Battery Par
1-30
(15)
1-Shallow discharge
29-Deep discharge (not a
permanent parameter)
30-Force BDI to full charge
battery indication (not a
permanent parameter
value.)
14
0-3
(0)
15
Alarm Options
Par
0-2
(0)
0-None
1-Travel Alarm
2-Backup Alarm
16
0-3
(0)
17
Clock Year
0-99
(0)
18
Clock Day
0-31
(0)
Clock Day
19
Clock Month
0-12
(0)
Clock Month
20
Clock Hour
0-24
(0)
21
Clock Minute
0-59
(0)
Clock Year
346
Return
Service Manual
RTX35
RTX45
0
CUSTOMER VALUE (IN.)
RANGE 0 - 531
MAST HEIGHT (INCH)
See Table 3
2001-03-15
F-code
PS
Version no
001
Section
C-code
S5.13
5711
Main Electronic Card
T-code
RTX35/RTX45
BT Prime-Mover Inc.
Return
Service Manual
2001-03-15
347
F-code
Section
PS
S5.13
Main Electronic Card
Version no
T-code
001
RTX35/RTX45
C-code
5711
348
Return
Service Manual
2001-03-15
F-code
PS
Section
C-code
S5.13
5711
Main Electronic Card
Version no
T-code
001
RTX35/RTX45
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
2.09
1.94
1.87
2.03
1.88
1.81
1.96
1.81
1.74
1.89
1.73
1.66
1.81
1.66
1.57
BT Prime-Mover Inc.
Return
Battery Exceeds
Full Discharge
1.59
1.74
1.52
NOT
VALID
1.67
Force Reset
1.53
Force Reset
Service Manual
2001-03-15
Force Reset
349
F-code
Section
PS
S5.13
Main Electronic Card
Version no
T-code
001
RTX35/RTX45
C-code
5711
Color
10 min.
Green
9 max.
Green
9 min.
Green
8 max.
Green
8 min.
Green
7 max.
Green
7 min.
Green
6 max.
Green
6 min.
Green
5 max.
Green
5 min.
Green
4 max.
Yellow
4 min.
Yellow
3 max.
Yellow
3 min.
Yellow
2 max.
Red
2 min.
Red
1 max.
Red
1 min.
Red
Open Circuit Voltage
Discharge Level
350
Return
25.00
24.83
24.65
24.48
24.30
24.13
23.95
23.78
23.60
23.43
23.25
23.08
22.90
22.73
22.55
22.38
22.20
22.03
21.85
1.85 volts
Service Manual
25.00
24.86
24.73
24.59
24.45
24.31
24.18
24.04
23.90
23.76
23.63
23.49
23.35
23.21
23.08
22.94
22.80
22.66
22.53
1.9 volts
25.00
24.90
24.80
24.70
24.60
24.50
24.40
24.30
24.20
24.10
24.00
23.90
23.80
23.70
23.60
23.50
23.40
23.30
23.20
1.95 volts
Open Cell
Voltage
25.00
24.94
24.88
24.81
24.75
24.69
24.63
24.56
24.50
24.44
24.38
24.31
24.25
24.19
24.13
24.06
24.00
23.94
23.88
2.0 volts
2001-03-15
F-code
PS
Version no
001
Section
C-code
S5.13
5711
Main Electronic Card
T-code
RTX35/RTX45
BT Prime-Mover Inc.
Return
Service Manual
2001-03-15
351
F-code
Section
PS
S5.13
Main Electronic Card
Version no
T-code
001
RTX35/RTX45
C-code
5711
Color
10 min.
Green
9 max.
Green
9 min.
Green
8 max.
Green
8 min.
Green
7 max.
Green
7 min.
Green
6 max.
Green
6 min.
Green
5 max.
Green
5 min.
Green
4 max.
Yellow
4 min.
Yellow
3 max.
Yellow
3 min.
Yellow
2 max.
Red
2 min.
Red
1 max.
Red
1 min.
Red
Open Circuit Voltage
Discharge Level
Open Cell Open Cell Open Cell Open Cell Open Cell
Voltage
Voltage
Voltage
Voltage
Voltage
37.5
37.18
36.86
36.54
36.23
35.91
35.59
35.27
34.95
34.63
34.31
33.99
33.68
33.36
33.04
32.72
32.4
32.08
31.76
1.8 Volts
37.5
37.24
36.98
36.71
36.45
36.19
35.93
35.68
35.4
35.14
34.88
34.61
34.35
34.09
33.83
33.56
33.3
33.04
32.77
1.85 Volts
37.5
37.29
37.09
36.88
36.68
36.47
36.26
36.06
35.85
35.64
35.44
35.23
35.03
34.82
34.61
34.41
34.2
33.99
33.79
1.9 Volts
37.5
37.35
37.2
37.05
36.9
36.75
36.6
36.45
36.3
36.15
36
35.85
35.7
35.55
35.4
35.25
35.1
34.95
34.8
1.95 Volts
37.5
37.41
37.31
37.22
37.13
37.03
36.94
36.84
36.75
36.68
36.56
36.47
36.38
36.28
36.19
36.09
36
35.91
35.81
2.0 Volts
352
Return
Service Manual
2001-03-15
F-code
PS
Version no
001
Section
C-code
S5.13
5711
Main Electronic Card
T-code
RTX35/RTX45
BT Prime-Mover Inc.
Return
Service Manual
2001-03-15
353
F-code
Section
PS
S5.13
Main Electronic Card
Version no
T-code
001
RTX35/RTX45
C-code
5711
354
Return
Service Manual
2001-03-15
F-code
PS
Version no
001
Section
C-code
S5.13
5711
Main Electronic Card
T-code
RTX35/RTX45
Refer
to
Set parameter 12 at 4
Set parameter 17 at 50
Return
Service Manual
go
back
into
Set parameter 12 at 2.
Set parameter 17 to the current year.
2001-03-15
355
F-code
Section
PS
S5.13
Main Electronic Card
Version no
T-code
001
RTX35/RTX45
C-code
5711
12. Reinstall the floor plate and the main electrical card
access panel.
356
Return
Service Manual
2001-03-15
F-code
PS
Section
C-code
S5.14
5751
Switches and Sensors
Version no
T-code
001
RTX35/RTX45
1.1. Test/Inspection
Examine the switch for signs of arcing, overheating,
discoloration, cracking, or other physical damage. Replace
switch if such damage is present.
To test a switch, isolate it from the electrical circuit. Do this by
removing all the connections from the switch, making sure all
wires are labeled and identified for reconnection.
+
1
Item No.
1/2
Description
BT Prime-Mover Inc.
Return
Service Manual
Screw, machine
Nut, twin
2001-03-15
357
F-code
Section
C-code
PS
S5.14
5751
Switches and Sensors
Version no
T-code
001
RTX35/RTX45
2.1. Removal
1. Turn key switch OFF and disconnect battery
connector.
2. Remove floor board (see page 102).
3. Remove two screws (1) securing switch (2) to twin
nut (3) at switch bracket.
2.2. Installation
f
3.1. Adjustment
1. Raise the empty carriage until the top of the
staging switch is even with the top of the staging
column.
2. Secure carriage with blocks and a hoist to prevent
any movement.
3. Loosen switch mounting bracket screws.
358
Return
Service Manual
2001-03-15
F-code
PS
Section
C-code
S5.14
5751
Switches and Sensors
Version no
001
T-code
RTX35/RTX45
3.2. Removal
1. Raise empty carriage until the top of the staging
switch is above the top of the staging column.
2. Secure carriage with blocks and a hoist to prevent
any movement.
3. Turn key switch OFF and disconnect battery
connector.
4. Disconnect switch from wiring harness.
5. Remove switch mounting bracket screws.
3.3. Installation
1. Install switch on the mounting bracket.
2. Tighten switch mounting bracket screws.
3. Connect switch to wiring harness.
4. Reconnect battery connector.
5. Adjust switch following the procedure on page 358.
6. Return truck to service.
BT Prime-Mover Inc.
Return
Service Manual
2001-03-15
359
F-code
Section
C-code
PS
S5.14
5751
Switches and Sensors
Version no
T-code
001
RTX35/RTX45
4.1. Adjustment
CAUTION Adjustment of sensor with wheel nuts
facing inward will result in shearing of
sensor when the drive wheel is rotated.
1. Position drive wheel with wheel nuts facing
outward.
2. Turn key switch OFF and disconnect battery
connector.
3. Remove top console, motor compartment door,
and left side panel to allow access to drive unit.
4. Loosen jam nut securing the sensor to the frame.
5. Turn wheel direction sensor by hand in a clockwise
direction until it contacts the drive unit housing.
6. Back sensor out by turning
counterclockwise 1-1/4 turns.
the
sensor
360
Return
Service Manual
2001-03-15
F-code
PS
Section
C-code
S5.14
5751
Switches and Sensors
Version no
001
T-code
RTX35/RTX45
4.2. Removal
1. Turn key switch OFF and disconnect battery
connector.
2. Disconnect sensor at the main wiring harness.
3. Loosen jam nut securing the sensor to the frame.
4. Turn sensor counterclockwise to remove it from the
frame.
4.3. Installation
1. Install sensor in the frame.
2. Tighten by hand in a clockwise direction until it just
contacts the drive unit housing.
3. Set the proper sensor distance by turning the
sensor counterclockwise 1-1/4 turns.
4. Tighten jam nut securing the sensor to the frame.
5. Reconnect sensor electrical connection to the main
wiring harness.
6. Reconnect battery connector.
7. Return truck to service.
BT Prime-Mover Inc.
Return
Service Manual
2001-03-15
361
F-code
Section
C-code
PS
S5.14
5751
Switches and Sensors
Version no
T-code
001
RTX35/RTX45
S66
5.1. Adjustment
CAUTION Adjustment of sensors with wheel nuts
facing outward will result in shearing of
sensors when the drive wheel is rotated.
1. Position drive wheel with wheel nuts facing inward.
2. Turn key switch OFF and disconnect battery
connector.
3. Remove top console, motor compartment door,
and left side panel to allow access to drive unit.
STEER
STOP
SENSORS
TURN DRIVE
WHEEL
INWARD 90o
362
Return
Service Manual
2001-03-15
F-code
PS
Section
C-code
S5.14
5751
Switches and Sensors
Version no
001
T-code
RTX35/RTX45
5.2. Removal
1. Turn key switch OFF and disconnect battery
connector.
2. Disconnect sensors from wiring harness.
3. Remove jam nuts securing the sensors to the
frame.
4. Remove sensors from truck.
5.3. Installation
1. Place new sensors in the frame.
NOTE! Do not overtighten jam nuts. Overtightening
can cause damage to the sensors.
2. Secure sensors to frame with jam nuts.
3. Reconnect wiring harness.
4. Adjust sensors
page 362.
following
the
procedure
on
BT Prime-Mover Inc.
Return
Service Manual
2001-03-15
363
F-code
Section
C-code
PS
S5.14
5751
Switches and Sensors
Version no
T-code
001
RTX35/RTX45
Description
Item
No.
Description
Screw
Sensor, speed
(male plug) S64
Nut, sensor
Housing, sensor
Spacer, brake
sensor
Sensor, direction
(female plug) S125
Screw, cap
6.1. Removal
1
2
4
7
6
364
Return
Service Manual
2001-03-15
F-code
PS
Section
Version no
001
T-code
RTX35/RTX45
6.2. Installation
3
7
6
C-code
S5.14
5751
Switches and Sensors
BT Prime-Mover Inc.
Return
Service Manual
2001-03-15
365
F-code
Section
C-code
PS
S5.14
5751
Switches and Sensors
Version no
T-code
001
RTX35/RTX45
366
Return
Service Manual
2001-03-15
F-code
Section
PS
S6.0
6000
Hydraulic System
Version no
000
C-code
T-code
RTX35/RTX45
Hydraulic System
WARNING DO NOT use your hands to check for
hydraulic leakage. Use a piece of
cardboard or paper to search for leaks.
Escaping fluid under pressure can
penetrate the skin causing serious injury.
Relieve pressure before disconnecting
hydraulic or other lines. Tighten all
connections before applying pressure.
Keep hands and body away from pinholes
and nozzles which eject fluids under high
pressure.
1. Operation
See RTX35 Hydraulic Schematic on page 396 or RTX45
Hydraulic Schematic on page 397. For a listing of error
codes see pages page 336 and 340. For a listing of
parameters see page 345. For information on the fuses and
their location see page 305.
BT Prime-Mover Inc.
Return
Service Manual
2001-03-15
367
F-code
Section
C-code
PS
S6.0
Hydraulic System
6000
Version no
T-code
000
RTX35/RTX45
A71
HM214
A5
S55 EXTEND
HM201
83
507
HM107
S56 RETRACT
HM202
S211 TILT UP
HM203
HM109
84
508
HM204
S51 SIDESHIFT LEFT
HM205
85
509
HM108
50
HM210
HM105
HM211
HM106
505
82
506
368
Return
Service Manual
2001-03-15
F-code
Section
PS
S6.0
6000
Hydraulic System
Version no
000
C-code
T-code
RTX35/RTX45
BT Prime-Mover Inc.
Return
Service Manual
2001-03-15
369
F-code
Section
C-code
PS
S6.0
Hydraulic System
6000
Version no
T-code
000
RTX35/RTX45
Control
Handle
Function
Selected
Control
Handle
Interface
Card
Input Pin
Control Handle
Interface Card
Approximate Input
Voltage (measured
with respect to HM213)
Control Handle
Interface Card
Output Pin
(measured with
respect to HM110)
Control Handle
Interface Card
Nominal Output
Voltage
Wire #
Main Electronic
Card (A5) Input
Pin (measured
with respect to
510)
Main
Electronic
Card (A5)
Nominal Input
Voltage
No Reach
Function
Selected
HM201 and
HM202
0V (both inputs)
HM107
Min. 1.103V
Nom. 1.470V
Max 1.873V
83
507
Min. 1.103V
Nom. 1.470V
Max 1.873V
Reach
Low
Speed
HM201
7.35V
HM107
Min. 2.573V
Nom. 2.940V
Max. 3.307V
83
507
Min. 2.573V
Nom. 2.940V
Max. 3.307V
Reach
High
Speed
HM201 and
HM202
HM107
Min. 5.513V
Nom. 5.880V
Max. 6.247V
83
507
Min. 5.513V
Nom. 5.880V
Max. 6.247V
Retract
Low
Speed
HM202
7.35V
HM107
Min. 4.043V
Nom. 4.410V
Max. 4.777V
83
507
Min. 4.043V
Nom. 4.410V
Max. 4.777V
Retract
High
Speed
HM202 and
HM201
HM107
Min. 5.513V
Nom. 5.880V
Max. 6.247V
83
507
Min. 5.513V
Nom. 5.880V
Max. 6.247V
No Tilt
Function
Selected
HM203 and
HM204
0V (both inputs)
HM109
Min. 1.103V
Nom. 1.470V
Max 1.873V
84
508
Min. 1.103V
Nom. 1.470V
Max 1.873V
Tilt Up
HM203
7.35V
HM109
Min. 2.573V
Nom. 2.940V
Max. 3.307V
84
508
Min. 2.573V
Nom. 2.940V
Max. 3.307V
Tilt Down
HM204
7.35V
HM109
Min. 4.043V
Nom. 4.410V
Max. 4.777V
84
508
Min. 4.043V
Nom. 4.410V
Max. 4.777V
No Sideshift
Function
Selected
HM205 and
HM206
0V (both inputs)
HM108
Min. 1.103V
Nom. 1.470V
Max 1.873V
85
509
Min. 1.103V
Nom. 1.470V
Max 1.873V
Sideshift
Left
HM205
7.35V
HM108
Min. 2.573V
Nom. 2.940V
Max. 3.307V
85
509
Min. 2.573V
Nom. 2.940V
Max. 3.307V
Sideshift
Right
HM206
7.35V
HM108
Min. 4.043V
Nom. 4.410V
Max. 4.777V
85
509
Min. 4.043V
Nom. 4.410V
Max. 4.777V
Travel
HM210
HM105
50
505
Lift/Lower
HM211
HM106
82
506
Notes:
370
Return
1.
Voltages at the main electronic card (A5) inputs greater than 6.615 volts and less than 0.735 volts indicate
shorted or open signal wires for reach, tilt, and sideshift.
2.
Voltages at the main electronic card inputs other than the stated voltages will select no function for reach, tilt,
and sideshift.
3.
Voltages at the main electronic card inputs greater than 6.75 volts and less than 0.6 volts indicate shorted or
open signal wires for travel and lift/lower.
4.
The center and travel limits of the travel and lift/lower potentiometers are learned. Therefore, the voltages listed
are a rough approximation.
Service Manual
2001-03-15
F-code
Section
PS
S6.0
6000
Hydraulic System
Version no
000
C-code
T-code
RTX35/RTX45
BT Prime-Mover Inc.
Return
Service Manual
2001-03-15
371
F-code
Section
C-code
PS
S6.0
Hydraulic System
6000
Version no
T-code
000
RTX35/RTX45
CONTROL
HANDLE
S55
R11
S56
S212
S52
S211
S51
S18
A71
A5
HANDLE
INTERFACE
MODULE
701
74
6
(-)
40
B-
702
703
75
76
10
11
A2
To
Y 10/2
B+
From
Y10/3
M
Relief
Valve
M3
(+)
10
P1
Pressure Auxiliary
Return Auxiliary
P2
Y11 Dump Valve
Filter
Tank
Supply Schematic
LEGEND
PRESSURE OIL
RETURN OIL
ELECTRIC POSITIVE
ELECTRIC NEGATIVE
372
Return
Service Manual
2001-03-15
F-code
Section
PS
S6.0
6000
Hydraulic System
Version no
000
C-code
T-code
RTX35/RTX45
1.2. Supply
A voltage from lift (R11), reach (S55/S56), sideshift (S51/
S52), or tilt (S211/S212) on the control handle to the control
handle interface card to the main electronic card (A5) initiates
a pump request to the pump transistor regulator (A2). The
electronic card (A5) turns on speed request output 702 (wire
#75) to a level proportional to the control handle request. This
signal is sent to the pump transistor regulator (A2) input pin
10. A current limit signal is also sent from the main electronic
card (A5) output 703 (wire #76) to the pump transistor
regulator (A2) input pin 11 limiting the current from the pump
transistor regulator (A2) to the motor. Both speed request and
current limit signals range from 0 volts to approximately 4.5
volts and are measured with respect to main electronic card
(A5) output 701 (wire #74). The pump transistor regulator
sends the amplified signal to the pump motor (M3)
commanding pumping.
Hydraulic functions can be performed by using the brake
pedal, the right foot pedal, or both. By depressing the right
foot pedal and releasing the brake pedal setting the parking
brake, hydraulic functions can be performed with the truck
parked in position.
Oil is pumped by a two-section pump from the hydraulic tank
into the hydraulic system. The small section of the pump is
used for the auxiliary functions. Appropriate solenoids are
activated opening valves and the auxiliary functions are
performed. The combination of the oil from both sections
through the Y11 dump valve is used for lifting. If the pressure
in the system increases to the preset value of the relief valve,
it will open directing oil back to the hydraulic tank. The
lowering function is powered by gravity and proportionally
controlled. Returned oil is filtered at the hydraulic tank.
BT Prime-Mover Inc.
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Service Manual
2001-03-15
373
F-code
Section
C-code
PS
S6.0
Hydraulic System
6000
Version no
T-code
000
RTX35/RTX45
3
11
11
R11
1
A71
HM211
HANDLE
INTERFACE
MODULE
HM106
82
A5
804
88
704
89
506
Y10/2
711
Y10/3
(-)
40
R
Y11
P2
P1
Lifting Schematic
LEGEND
PRESSURE OIL
RETURN OIL
ELECTRIC POSITIVE
ELECTRIC NEGATIVE
374
Return
Service Manual
2001-03-15
F-code
Section
PS
S6.0
6000
Hydraulic System
Version no
000
C-code
T-code
RTX35/RTX45
1.3. Lifting
With the key switch ON and brake pedal and/or right foot
switch depressed, rotating the lift/lower control lever upward
on the control handle causes R11 to output a voltage less
than when in the neutral position. The control handle interface
card senses this decrease in voltage at terminal HM211 and
notifies the main electronic card (A5) input 506 (wire #82).
The main electronic card (A5) responds by enabling voltage
to the dump valve coil (Y11) and the lift valve coil (Y10/2).
The lift speed can be infinitely varied to the maximum lift
speed.
Oil is fed from the pump to the lift valve (Y10) and from the
valve to the free lift and main lift cylinders. The free lift
cylinder, having less weight on it, will lift first. After the free lift
cylinder has reached full extension, the main lift cylinders will
begin to lift. If the pressure in the system increases to the
relief valves preset value, oil flows back to the hydraulic tank.
BT Prime-Mover Inc.
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2001-03-15
375
F-code
Section
C-code
PS
S6.0
Hydraulic System
6000
Version no
T-code
000
RTX35/RTX45
11
11
R11
A71
HM211
HANDLE
INTERFACE
MODULE
A5
804
HM106
88
506
704
89
Y10/2
Y10/3
(-)
40
R
Lowering Schematic
LEGEND
PRESSURE OIL
RETURN OIL
ELECTRIC POSITIVE
ELECTRIC NEGATIVE
376
Return
Service Manual
2001-03-15
F-code
Section
PS
S6.0
6000
Hydraulic System
Version no
000
C-code
T-code
RTX35/RTX45
1.4. Lowering
With the key switch ON and brake pedal and/or right foot
switch depressed, rotating the lift/lower control lever
downward on the control handle causes R11 to output a
voltage greater than when in the neutral position. The control
handle interface card senses this increase in voltage at
terminal HM211 and notifies the main electronic (A5) card
input 506 (wire #82). The main electronic (A5) card enables
voltage to the proportional lower solenoid coil (Y10/3). The
lowering speed is regulated by the proportional lowering
valve (Y10/3) in direct proportion to the voltage from (R11).
Proportional lower solenoid coil (Y10/3) is normally closed.
Oil flows from the cylinders through the valve, returning to the
hydraulic tank. A reach, tilt, or sideshift function can be
performed while lowering.
BT Prime-Mover Inc.
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Service Manual
2001-03-15
377
F-code
Section
C-code
PS
S6.0
Hydraulic System
6000
Version no
T-code
000
RTX35/RTX45
S55
EXTEND
BUTTON
Y14
A71
Y15
HM201
HM214
A5
HANDLE
INTERFACE
MODULE
707
HM107
83
507
708
706
705
(-)
92
93
91
90
40
Y12
Y13
378
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Service Manual
2001-03-15
F-code
Section
PS
S6.0
6000
Hydraulic System
Version no
000
C-code
T-code
RTX35/RTX45
BT Prime-Mover Inc.
Return
Service Manual
2001-03-15
379
F-code
Section
C-code
PS
S6.0
Hydraulic System
6000
Version no
T-code
000
RTX35/RTX45
S55
EXTEND
BUTTON
S56
RETRACT
BUTTON
Y14
A71
HM201
Y15
HM202
HM214
A5
HANDLE
INTERFACE
MODULE
707
HM107
83
507
708
706
705
(-)
92
93
91
90
40
Y12
Y13
380
Return
Service Manual
2001-03-15
F-code
Section
PS
S6.0
6000
Hydraulic System
Version no
000
C-code
T-code
RTX35/RTX45
BT Prime-Mover Inc.
Return
Service Manual
2001-03-15
381
F-code
Section
C-code
PS
S6.0
Hydraulic System
6000
Version no
T-code
000
RTX35/RTX45
S56
RETRACT
BUTTON
Y14
A71
Y15
HM202
HM214
A5
HANDLE
INTERFACE
MODULE
707
HM107
83
507
708
706
705
(-)
92
93
91
90
40
Y12
Y13
382
Return
Service Manual
2001-03-15
F-code
Section
PS
S6.0
6000
Hydraulic System
Version no
000
C-code
T-code
RTX35/RTX45
BT Prime-Mover Inc.
Return
Service Manual
2001-03-15
383
F-code
Section
C-code
PS
S6.0
Hydraulic System
6000
Version no
T-code
000
RTX35/RTX45
S55
EXTEND
BUTTON
S56
RETRACT
BUTTON
A71
Y14
Y15
HM202 HM201
HM214
A5
HANDLE
INTERFACE
MODULE
707
HM107
83
507
708
706
705
92
93
91
90
40
Y12
Y13
384
Return
Service Manual
2001-03-15
F-code
Section
PS
S6.0
6000
Hydraulic System
Version no
000
C-code
T-code
RTX35/RTX45
BT Prime-Mover Inc.
Return
Service Manual
2001-03-15
385
F-code
Section
C-code
PS
S6.0
Hydraulic System
6000
Version no
T-code
000
RTX35/RTX45
S52
SIDESHIFT
RIGHT
BUTTON
Y16
A71
HM206
HM214
HANDLE
INTERFACE
MODULE
A5
HM108
85
509
709
706
95
91
90
705
(-)
40
Y12
Y13
386
Return
Service Manual
2001-03-15
F-code
Section
PS
S6.0
6000
Hydraulic System
Version no
000
C-code
T-code
RTX35/RTX45
BT Prime-Mover Inc.
Return
Service Manual
2001-03-15
387
F-code
Section
C-code
PS
S6.0
Hydraulic System
6000
Version no
T-code
000
RTX35/RTX45
S51
SIDESHIFT
LEFT
BUTTON
Y16
A71
HM205
HM214
HANDLE
INTERFACE
MODULE
A5
85
HM108
709
706
705
(-)
95
509
40
91
90
Y12
Y13
388
Return
Service Manual
2001-03-15
F-code
Section
PS
S6.0
6000
Hydraulic System
Version no
000
C-code
T-code
RTX35/RTX45
BT Prime-Mover Inc.
Return
Service Manual
2001-03-15
389
F-code
Section
C-code
PS
S6.0
Hydraulic System
6000
Version no
T-code
000
RTX35/RTX45
S211
TILT UP
BUTTON
Y17
A71
HM203
HM214
HANDLE
INTERFACE
MODULE
A5
94
84
HM109
710
508
91
706
90
705
(-)
40
Y12
Y13
390
Return
Service Manual
2001-03-15
F-code
Section
PS
S6.0
6000
Hydraulic System
Version no
000
C-code
T-code
RTX35/RTX45
BT Prime-Mover Inc.
Return
Service Manual
2001-03-15
391
F-code
Section
C-code
PS
S6.0
Hydraulic System
6000
Version no
T-code
000
RTX35/RTX45
S212
TILT DOWN
BUTTON
Y17
A71
HM204
HM214
HANDLE
INTERFACE
MODULE
A5
94
84
HM109
710
508
706
705
(-)
40
91
90
Y13
Y12
392
Return
Service Manual
2001-03-15
F-code
Section
PS
S6.0
6000
Hydraulic System
Version no
000
C-code
T-code
RTX35/RTX45
BT Prime-Mover Inc.
Return
Service Manual
2001-03-15
393
F-code
Section
C-code
PS
S6.0
Hydraulic System
6000
Version no
T-code
000
RTX35/RTX45
List of Symbols
Symbol
Designation
Function
1-2
Cylinder
Staging
Cylinder
Free lift
Cylinder
Reach/retract
Cylinder
Tilt
Cylinder
Sideshift
11
Valve
13
Valve
14
Valve
Relief
A2
Pump Motor
A5
Electronic card
Main Card
A71
Electronic card
Filter
Main filter
M3
Motor
Pump motor
Pump
Hydraulic pump
R1
Potentiometer
Travel
R11
Potentiometer
Lift/lower
S51
Switch
Sideshift Left
S52
Switch
Sideshift Right
S55
Switch
Reach Extend
394
Return
Service Manual
Remarks
2001-03-15
F-code
Section
PS
S6.0
6000
Hydraulic System
Version no
000
C-code
T-code
RTX35/RTX45
List of Symbols
Symbol
Designation
Function
S56
Switch
Reach Retract
S211
Switch
Tilt Up
S212
Switch
Tilt Down
Y10/2
Valve
Lift of Forks
Y10/3
Valve
Y10
Valve
Lift/lower
Y11
Valve
Y12
Valve
Direction A
Y13
Valve
Direction B
Y14
Valve
Reach out
Y15
Valve
Reach in
Y16
Valve
Sideshift
Y17
Valve
Tilt
BT Prime-Mover Inc.
Return
Service Manual
2001-03-15
Remarks
395
F-code
Section
C-code
PS
S6.0
Hydraulic System
6000
Version no
T-code
000
RTX35/RTX45
FREELIFT
VALVE
FREELIFT
CYLINDER
STAGING
CYLINDER
STAGING
CYLINDER
STAGING
VALVE
Y10
Y10
Y13
Y12
RELIEF
VALVE
M
P
R
Y11
F
P6
6A
6B
2A
2B
P3
3A
3B
P5
5A
5B
P2
Y16
SIDESHIFT CYLINDER
TILT CYLINDER
Y17
P4
P1
300 PSI
Y14
Y15
396
Return
REACH CYLINDER
P1
P4
Service Manual
REACH CYLINDER
2001-03-15
F-code
Section
PS
S6.0
6000
Hydraulic System
Version no
C-code
T-code
000
RTX35/RTX45
FREELIFT
CYLINDER
STAGING
CYLINDER
STAGING
CYLINDER
STAGING
VALVE
Y10
Y10
RELIEF
VALVE
Y13
Y12
P
R
Y11
F
C2
C1
C3
C1
C2
C4
Y15
Y17
S1
Y16
CV
300 PSI
REACH CYLINDERS
BT Prime-Mover Inc.
Return
Service Manual
2001-03-15
TILT CYLINDER
SIDESHIFT CYLINDER
397
F-code
Section
PS
S6.0
Hydraulic System
Version no
T-code
000
RTX35/RTX45
398
Return
C-code
6000
Service Manual
2001-03-15
F-code
Section
PS
S6.1
6112
Hydraulic Fluid
Version no
000
C-code
T-code
RTX35/RTX45
Hydraulic Fluid
1. Hydraulic Fluid Selection
Before adding or changing hydraulic fluid, determine the
environment and usage of the truck. To make the proper oil/
lubricant selection see Oil and Grease Specifications on
page 81.
BT Prime-Mover Inc.
Return
Service Manual
2001-03-15
399
F-code
Section
C-code
PS
S6.1
Hydraulic Fluid
6112
Version no
T-code
000
RTX35/RTX45
3. System Draining
1. Lower the carriage fully, tilt forks down completely
and retract reach mechanism fully.
2. Turn key switch OFF and disconnect battery
connector.
3. Remove top console and open motor compartment
door.
4. Use female half of the diagnostic fitting (24 inch
hose) and direct the hydraulic fluid into a waste
container with a capacity greater than 5 gallons (19
liters).
5. Reconnect battery connector and turn key switch
ON.
6. Operate lift until air in the system is heard.
7. Turn key switch OFF and disconnect battery
connector.
8. Remove drainage tube and replace diagnostic
fitting.
9.
400
Return
Service Manual
2001-03-15
F-code
Section
PS
S6.1
6112
Hydraulic Fluid
Version no
000
C-code
T-code
RTX35/RTX45
4. System Refilling
1. If reservoir was removed for flushing, install
reservoir.
2. Install hydraulic filter.
3. Fill hydraulic reservoir through breather cap/fill
hole. Be sure to use the proper grade of fluid. The
reservoir holds 5 gallons (19 liters) of fluid.
4. Reconnect battery connector and turn key switch
ON.
5. Bleed hydraulic system. See paragraph 5 below.
6. Install top console and secure motor compartment
door.
BT Prime-Mover Inc.
Return
Service Manual
2001-03-15
401
F-code
Section
C-code
PS
S6.1
Hydraulic Fluid
6112
Version no
T-code
000
RTX35/RTX45
402
Return
Service Manual
2001-03-15
F-code
Section
PS
S6.1
6112
Hydraulic Tank
Version no
C-code
T-code
000
RTX35/RTX45
Hydraulic Tank
1
Item
No.
Description
1. Removal
1. Lower carriage fully and retract reach mechanism
fully.
2. Remove top console. See Top Console on
page 96.
3. Drain hydraulic system. See Hydraulic Fluid on
page 399.
4. Turn key switch OFF and disconnect battery
connector.
5. Remove drive motor and brake assembly.
6. Remove lift pump and motor.
BT Prime-Mover Inc.
Return
Service Manual
2001-03-15
403
F-code
Section
C-code
PS
S6.1
Hydraulic Tank
6112
Version no
T-code
000
RTX35/RTX45
2. Installation
1. Install hydraulic filter adapter.
2. Install hydraulic filter.
3. Angle mast end of reservoir down and push
forward to the frame. Let the chassis end of the
reservoir drop straight down at this point.
4. Install lift pump and motor assembly.
5. Connect hoses to reservoir.
6. Fill hydraulic reservoir.
7. Install drive motor and brake assembly.
8. Reconnect battery connector.
9. Bleed hydraulic system. See Bleeding Hydraulic
System on page 401.
10. Test operate truck.
11. Turn key switch OFF and disconnect battery
connector. Install top console. Reconnect battery
connector.
404
Return
Service Manual
2001-03-15
F-code
Section
C-code
PS
S6.2
6131
Hydraulic Filter and Adapter
Version no
T-code
001
RTX35/RTX45
13
11
8
1, 2
3, 4
5, 6
12
10
Item
No.
BT Prime-Mover Inc.
Return
Description
Item
No.
Description
Screw
O-ring
Washer
Ring
Screw
10
Element, filter
Washer
11
U-gasket
Plate
12
Gasket, tank
Gasket
13
Cap, filter
Filter assembly
Service Manual
2001-03-15
405
F-code
Section
C-code
PS
S6.2
6131
Hydraulic Filter and Adapter
Version no
T-code
001
RTX35/RTX45
1. Hydraulic Filter
1.1. Removal
NOTE! It is recommended that the hydraulic fluid be
drained from the hydraulic tank prior to
replacing the filter.
1. Lower carriage fully to ensure all hydraulic
pressure is relieved.
2. Turn key switch OFF and disconnect battery
connector.
3. Remove top console (see page 96).
4. Remove blue cover (13) on the filter adapter collar.
5. Remove filter attached to the bottom of the blue
cover by pulling straight down to snap it out of the
latch.
1.2. Installation
1. Snap filter onto blue cover (13).
2. Install cap and filter assembly in hydraulic tank.
3. Test operate truck.
4. Check hydraulic fluid level and refill as needed.
5. Replace top console.
6. Reconnect battery connector.
7. Return to service.
406
Return
Service Manual
2001-03-15
F-code
Section
C-code
PS
S6.2
6131
Hydraulic Filter and Adapter
Version no
001
T-code
RTX35/RTX45
2.2. Installation
1. Clean all parts thoroughly. Clean the mating
surface of hydraulic tank.
2. Align collar mounting holes with the hydraulic tank
holes. Torque four mounting screws to 44.4 inch lb
(50 Nm).
3. Install cap and filter.
4. Check fill level fluid in the hydraulic tank.
5. Reconnect battery connector.
6. Bleed hydraulic system. See Bleeding Hydraulic
System on page 401.
7. Test operate truck.
8. Turn key switch OFF and disconnect battery
connector.
9. Install top console.
10. Reconnect battery connector.
BT Prime-Mover Inc.
Return
Service Manual
2001-03-15
407
F-code
Section
C-code
PS
S6.2
6131
Hydraulic Filter and Adapter
Version no
T-code
001
RTX35/RTX45
408
Return
Service Manual
2001-03-15
F-code
Section
PS
S6.3
6141
Hydraulic Pump
Version no
C-code
T-code
000
RTX35/RTX45
Hydraulic Pump
3
4
5
3
6
7
8
9
5
10
8
7
6
19
5
6
18
12
11
7
8
17
13
14
8
7
6
16
5
15
2
1
BT Prime-Mover Inc.
Return
Service Manual
2001-03-15
409
F-code
Section
C-code
PS
S6.3
Hydraulic Pump
6141
Version no
T-code
000
RTX35/RTX45
Item No.
Description
Item No.
Description
Screw
11
Gear, driven
Pump Assembly
12
Flange, mounting
O-ring
13
Seal, shaft
Spacer
14
Gear, drive
Pin, dowel
15
Gear, driven
Seal, back-up
16
Body
Seal, plate
17
End, cap
Bearing
18
Washer
Body
19
Screw
10
Gear, drive
1. Removal
Remove hydraulic pump from pump motor. (See Removal
on page 111.)
2. Pump Disassembly
CAUTION Overhaul pump only in a clean, dust-free
location, using clean tools and equipment.
Dirt or grit will damage the highly machined
surfaces and will result in leakage or
premature failure of the pump.
1. Scribe match mark on the bodies (9, 16), covers
(12, 17), and spacer (4) to insure that the dual
pump will be reassembled in the same manner. If
the bodies or covers are replaced during overhaul,
scribe a match mark on the replaced part.
2. Thoroughly clean outside of dual pump and air dry.
3. Secure unit in vise (use light clamping pressure on
the ears of the front cover) with shaft end down.
Remove capscrews (19) and washers (18).
410
Return
Service Manual
2001-03-15
F-code
Section
PS
S6.3
6141
Hydraulic Pump
Version no
000
C-code
T-code
RTX35/RTX45
Outlet
Side
(Discharge
Pressure)
Inlet
Side
(Suction)
BT Prime-Mover Inc.
Return
Service Manual
2001-03-15
411
F-code
Section
C-code
PS
S6.3
Hydraulic Pump
6141
Version no
T-code
000
RTX35/RTX45
11. Dowel pins (5) and the front static seal (3) may
remain with either the body (9) or front cover (13).
Remove and discard front static seal (3).
12. Invert body (9) and lift out front bearing block (8).
CAUTION Care should be taken not to damage
(gouge) the shaft seal bore because this
will result in shaft seal leakage.
13. Invert front cover (12) with shaft seal up. Remove
shaft seal (4) by prying it out with a large
screwdriver.
412
Return
Service Manual
2001-03-15
F-code
Section
PS
S6.3
6141
Hydraulic Pump
Version no
C-code
T-code
000
RTX35/RTX45
3. Parts Inspection
1. Wash all parts and dry thoroughly.
NOTE! A somewhat heavier wear pattern is normal
on the low pressure (inlet) side of the bearing
blocks (8). There should be no heavy scoring
on this area.
2. Inspect front and rear bearing blocks (8). Replace if
scoring or uneven wear is observed.
3. Remove anti extrusion seal (6) and pressure
loading seal (7) from each bearing block and
discard.
4. Inspect bushings in each bearing block (8).
Replace bearing block if bushings are heavily
scored or burned.
5. Inspect gear journals and faces. If faces or journals
are scored or worn, replace pump.
6. Inspect bodies for wear and scoring. If gear contact
wear on low pressure side (inlet) exceeds 0.005
(0.127 mm) depth, replace pump. If the body is
usable, lightly wipe and remove burrs with suitable
de-burring tool.
8
7
6
BT Prime-Mover Inc.
Return
Service Manual
2001-03-15
413
F-code
Section
C-code
PS
S6.3
Hydraulic Pump
6141
Version no
T-code
000
RTX35/RTX45
4. Pump Reassembly
1. Place the front cover (12) on a flat plate with the
shaft seal bore up. Install new shaft seal (13).
Press seal until it is 0.157 inch (4.0 mm) below
front surface. Pack the area between the double lip
of the seal with Lubriplate or equivalent grease.
Face
of Pilot
Diameter
Arbor
press
0.15
(4.0 mm)
Seal
Pressing
Tool
Front
Cover
(12)
Shaft
Seal (13)
Shaft Seal
Drive Shaft
Installation
Tool (Bullet)
Lubricate
414
Return
Service Manual
2001-03-15
F-code
Section
PS
S6.3
6141
Hydraulic Pump
Version no
000
C-code
T-code
RTX35/RTX45
Outlet
Side
(Discharge
Pressure)
Inlet
Side
(Suction)
BT Prime-Mover Inc.
Return
Service Manual
2001-03-15
415
F-code
Section
C-code
PS
S6.3
Hydraulic Pump
6141
Version no
T-code
000
RTX35/RTX45
5. Testing
1. Mount pump on truck and operate for two minutes
at minimum pressure and one-quarter engine
speed.
2. Increase discharge pressure to relief setting with
control valve. Hold for five seconds and release.
Continue cycle for two minutes.
3. Repeat step 2 for three minutes at one-half pump
speed.
4. Repeat step 2 for three minutes at full pump speed.
5. With truck at idle speed, check pump and hydraulic
system for leaks. No shaft seal leakage sufficient to
form a drop is permissible. No external leakage is
permissible.
416
Return
Service Manual
2001-03-15
F-code
Section
PS
S6.4
6211
Control Valve
Version no
000
To
Mast
Y12 DIRA
Y13 DIRB
C-code
T-code
RTX35/RTX45
Control Valve
1. Removal
1. Turn key switch OFF and disconnect battery
connector.
2. Remove top console.
3. Remove motor compartment rear door.
To
Reservoir
To Aux.
Functions
To
Pump
2. Installation
1. Apply thread locking compound to three mounting
bolts.
2. Tighten using a 1/2 inch (13 mm) socket.
3. Attach hoses to control valve in the following order:
- Control valve to reservoir
- Return hose to mast 1-1/8 inch (28.58 mm)
- Control valve to lift pump 1-1/8 inch (28.58
mm)
BT Prime-Mover Inc.
Return
Service Manual
2001-03-15
417
F-code
Section
C-code
PS
S6.4
Control Valve
6211
Version no
T-code
000
RTX35/RTX45
To
Mast
Y12 DIRA
Y13 DIRB
To
Reservoir
To Aux.
Functions
To
Pump
418
Return
Service Manual
2001-03-15
F-code
Section
PS
S6.4
6211
Control Valve
Version no
000
C-code
T-code
RTX35/RTX45
Control Valve
Solenoid Mounting Screws
17
2
18
3
4
20
4a
21
4b
13
19
22
14
15
38
23
16
29a
29
Valve Block
36
24
25
26
27
28
20
37
39
40
34
41
46
31
30
45
42
43
33
33
47
20
47
44
49
32
39
20
48
35
BT Prime-Mover Inc.
Return
Service Manual
2001-03-15
419
F-code
Section
C-code
PS
S6.4
Control Valve
6211
Version no
T-code
000
RTX35/RTX45
Item
No.
Description
Item
No.
Description
Description
Valve assembly,
control
Plug
O-ring
O-ring
13
Screw **
4a
O-ring
Insert
15
Spring **
4b
Seal
4a
O-ring
16
Insert, dampener **
14
USIT-ring
4b
Seal
29
Plug **
18
Nut
29a
Plug **
20
Seal
30
Screw **
31
Seal
17
Screw
35
Screw, adjusting
32
Nut
18
Nut
36
33
Seal
19
Screw
37
Washer, flat
34
O-ring
20
Ring, seal
38
Valve assembly,
manifold
21
Disc
39
Coil
22
Spring
40
Valve, check
23
Guide spring
41
24
Piston
42
Body
25
Spring
43
Valve, check
26
Spring
44
27
Sleeve
45
Spring **
28
Ball
46
Ball, check **
47
Plug **
48
Plug **
49
Plug **
420
Return
Seal Kit
(Contains items below)
Item
No.
Proportional Pre-Pressure
Relief Valve Kit
(Contains items below)
DBV Kit
(Contains items below)
** Items 13, 15, 16, 29, 29a, 30, 45, 46, 47, 48, and 49 are
shown for reference only. They are not serviceable individually.
Service Manual
2001-03-15
F-code
Section
PS
S6.4
6211
Control Valve
Version no
000
C-code
T-code
RTX35/RTX45
3. Repair
WARNING When disassembling, replacing piece
parts, and resealing, it is advisable that the
valve assembly be removed from the
truck. The mast carriage must be fully
lowered. Hot oil under pressure may be
present. Some spillage of hydraulic oil will
occur. Perform any procedures in a clean
environment. Make sure all parts are
cleaned before disassembly and kept
clean during assembly.
BT Prime-Mover Inc.
Return
Service Manual
2001-03-15
421
F-code
Section
C-code
PS
S6.4
Control Valve
6211
Version no
T-code
000
RTX35/RTX45
422
Return
Service Manual
2001-03-15
F-code
Section
PS
S6.4
6211
Control Valve
Version no
000
C-code
T-code
RTX35/RTX45
that
to
the
increase
insert
or
BT Prime-Mover Inc.
Return
Service Manual
2001-03-15
423
F-code
Section
C-code
PS
S6.4
Control Valve
6211
Version no
T-code
000
RTX35/RTX45
424
Return
Service Manual
2001-03-15
F-code
PS
Section
C-code
S6.5
6610
Staging Cylinder, 3 Stage
Version no
T-code
000
RTX35/RTX45
3
1
2
4
9
10
11
12
13
16
15
14
Item No.
BT Prime-Mover Inc.
Return
Description
Item No.
Description
Screw
Ring, wear
Washer, seal
10
Piston
11
Ring, retainer
12
Rod, cylinder
Plugger assembly
13
O-ring
Spring
14
Bearing
Plug
15
Seal, rod
O-ring
16
Wiper
Service Manual
2001-03-15
425
F-code
Section
C-code
PS
S6.5
6610
Staging Cylinder, 3 Stage
Version no
T-code
000
RTX35/RTX45
1.2. Disassembly
1. Remove cylinder rod (12) from cylinder tube.
2. Remove and discard all seals, rod wiper (16), rod
seal (15), and wear ring (9) from bearing (14). Use
care NOT to damage the inside of the bearing.
426
Return
Service Manual
2001-03-15
F-code
PS
Section
C-code
S6.5
6610
Staging Cylinder, 3 Stage
Version no
000
T-code
RTX35/RTX45
1.3. Assembly
1. Install new wear ring (9), seals, and rod wiper (16)
in gland (14). The lip of the wiper must face
outward. It is not necessary to replace wear ring
(9), unless cylinder was removed for rod repair.
1.4. Installation
1. Install lifting gear, chains, hoses, and electric
cables.
2. Test for proper operation.
BT Prime-Mover Inc.
Return
Service Manual
2001-03-15
427
F-code
Section
C-code
PS
S6.5
6610
Staging Cylinder, 3 Stage
Version no
T-code
000
RTX35/RTX45
428
Return
Service Manual
2001-03-15
F-code
PS
Section
C-code
S6.6
6620
Freelift Cylinder, 3 Stage
Version no
T-code
000
RTX35/RTX45
3
15
8
14
13
7
12
6
11
5
10
4
Seal Kit Contains Items Marked with K
Item
No.
Screw
10K
O-ring
Tube cylinder
11K
Back-up ring
Ring, retainer
12
Plunger assembly
13K
Ring, guide
Spring
14K
Seal
Ring, guide
15K
Wiper
Service Manual
Piston
2001-03-15
Description
Washer, seal
BT Prime-Mover Inc.
Item
No.
7K
Return
Description
Rod cylinder
Bearing
Kit, seal
429
F-code
Section
C-code
PS
S6.6
6620
Freelift Cylinder, 3 Stage
Version no
T-code
000
RTX35/RTX45
430
Return
Service Manual
2001-03-15
F-code
PS
Section
C-code
S6.6
6620
Freelift Cylinder, 3 Stage
Version no
000
T-code
RTX35/RTX45
BT Prime-Mover Inc.
Return
Service Manual
2001-03-15
431
F-code
Section
C-code
PS
S6.6
6620
Freelift Cylinder, 3 Stage
Version no
T-code
000
RTX35/RTX45
1.2. Disassembly
1. Remove bearing (12) from cylinder tube (3).
2. Remove and discard packing, back-up ring, O-ring,
rod wiper, and bearing retainer from bearing (12).
Use care NOT to damage inside of bearing (12).
1.3. Assembly
1. Install a new bearing, seals, and rod wiper in 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 lifting gear, chains, hoses, and electric
cables.
2. Connect battery.
3. Test for proper operation.
432
Return
Service Manual
2001-03-15
F-code
PS
C-code
S6.7
6650
Reach Cylinder (RTX35)
Version no
001
Section
T-code
RTX35/RTX45
K
6
23
7
8
22
10
11
12
20
19
18 17
16
15
13
14
21
5
1
4
3
Forks Direction
BT Prime-Mover Inc.
Return
Service Manual
2001-03-15
433
F-code
Section
C-code
PS
S6.7
6650
Reach Cylinder (RTX35)
Version no
T-code
001
RTX35/RTX45
Item
No.
Item
No.
Description
Description
Pin, roll
9K
Ring, guide
Pin, clevis
10K
Pin, clevis
Item
No.
Description
17
Bearing
Ring, sealing
18K
Seal rod
11K
O-Ring
19K
Ring, guide
12
Rod assembly
20K
Ring, back-up
13
Nut
21K
Seal, rod
14
Screw, set
22
O-Ring
15
Yoke, cylinder
23
Grease Fitting
Wiper
Kit, seal
8K
Retainer
16K
1. Removal
1. Park truck on a level surface and apply brake.
2. Extend reach about 1/2 to 3/4 of total reach.
3. Block and chain reach mechanism to prevent
movement of reach mechanism.
4. Relieve pressure on reach cylinders.
5. Remove hoses from reach cylinder.
6. Remove front cylinder mounting pins (3).
7. Raise reach assembly above full freelift. Remove
rear cylinder mounting pins (2).
8. Remove reach cylinder from truck.
434
Return
Service Manual
2001-03-15
F-code
PS
Section
C-code
S6.7
6650
Reach Cylinder (RTX35)
Version no
001
T-code
RTX35/RTX45
2. Disassembly
NOTE! Perform procedures in a clean environment.
Make sure all parts are cleaned before
disassembly and kept clean during assembly.
1. Before disassembly, clean the exterior of reach
cylinder in a cleaning solution to remove all
contamination.
WARNING Compressed air used for cleaning MUST
be reduced to less than 30 psi (206 kPa),
and then only with effective chip-guarding
and personal protective equipment.
2. Be sure all hydraulic fluid has been removed from
cylinder. Stroking piston rod will help force fluid out.
3. Put base end of cylinder in a vise equipped with
soft jaws.
4. Remove bearing retainer (8) and bearing (22) by
rotating bearing from cylinder tube (6 or 7) with a
spanner wrench.
5. Remove rod assembly (12).
6. Remove and discard all seals and rod wiper (16).
7. Inspect mounting bearings (22) located at the base
end of cylinders. It will not be necessary to remove
bearings unless they are found to be unfit for
further service.
BT Prime-Mover Inc.
Return
Service Manual
2001-03-15
435
F-code
Section
C-code
PS
S6.7
6650
Reach Cylinder (RTX35)
Version no
T-code
001
RTX35/RTX45
3. Inspection
WARNING Compressed air used for cleaning MUST
be reduced to less than 30 psi (206 kPa),
and then only with effective chip-guarding
and personal protective equipment.
1. Carefully clean all parts in a cleaning solution and
position parts on a clean work surface.
2. Check rod assembly (12) for damage. Look for
gouges, scratches, corrosion, or evidence of
unusual wear. Minor surface damage can be
repaired by the use of fine abrasion cloth or
stoning. Be extremely careful not to remove
chrome plating. Deeper damage will require
replacement of piston rod assembly (12). Make
sure threads on rod are free of damage.
3. Check cylinder bore for any damage. Parts with
deep gouges or pitted surfaces will require
replacement.
436
Return
Service Manual
2001-03-15
F-code
PS
Version no
001
Section
C-code
S6.7
6650
Reach Cylinder (RTX35)
T-code
RTX35/RTX45
4. Assembly
1. Install new O-rings and rod wiper (16) in bearing
assembly (17). The lip of the wiper must face
outward.
2. Install new bearing seals (18 & 19), back-up ring
(20), and O-rings (21) on bearing (17).
3. If necessary, replace rod assembly (12) with new.
Install rod assembly (12).
4. Apply clean hydraulic fluid to piston rod assembly.
Coat the inside of cylinder tube and bearing
assembly with clean fluid.
5. Carefully slide bearing assembly (17) onto cylinder
rod assembly (12). Be sure rod end does not cut or
nick wiper or packing upon installation.
6. Install bearing assembly into cylinder tube. Use
care so the seals are not nicked or cut upon
installation.
7. Check installation by making sure piston rod
assembly moves smoothly within tube assembly
without binding.
8. Install retainer (8).
BT Prime-Mover Inc.
Return
Service Manual
2001-03-15
437
F-code
Section
C-code
PS
S6.7
6650
Reach Cylinder (RTX35)
Version no
T-code
001
RTX35/RTX45
5. Installation
1. Raise reach assembly to full freelift height. Install
reach cylinder rear mounting pins (2). Secure
mounting pins with roll pins.
2. Lower reach assembly. Install reach cylinder front
mounting pins (3). Secure mounting pins with roll
pins.
3. Connect correct hydraulic hoses to reach cylinders.
4. Remove blocking and chains.
5. Fill hydraulic tank with new clean oil.
6. Connect battery.
7. Operate reach to remove air from hydraulic hoses.
Check operation of the whole hydraulic system.
CAUTION DO NOT use your hands to check for
hydraulic leakage. Use a piece of
cardboard or paper to search for leaks.
Escaping fluid under pressure can
penetrate the skin causing serious injury.
Relieve pressure before disconnecting
hydraulic or other lines. Tighten all
connections before applying pressure.
Keep hands and body away from pinholes
and nozzles which eject fluids under high
pressure.
8. After running the hydraulic system, check and fill
the hydraulic tank with new clean oil.
438
Return
Service Manual
2001-03-15
F-code
PS
Section
C-code
S6.7
6650
Reach Cylinder (RTX45)
Version no
T-code
001
RTX35/RTX45
11
12
28
13
14
27
15
16
17
25
24
23
22
21
20
18
19
26
5
6
7
10
3
2
5
4
8
7
6
Forks Direction
BT Prime-Mover Inc.
Return
Service Manual
2001-03-15
439
F-code
Section
C-code
PS
S6.7
6650
Reach Cylinder (RTX45)
Version no
T-code
001
RTX35/RTX45
Item
No.
Item
No.
Description
Description
Item
No.
Description
Spacer
11
21K Wiper
12
13K Retainer
Screw
Lockwasher
Washer, flat
16K O-ring
26K O-Ring
Pin, cotter
17
Rod assembly
27
Bearing
Pin
18
Nut
28
Fitting, grease
Spacer
19
Screw, set
Kit, Seal
10
Pin
20
Yoke, cylinder
22
Bearing
1. Removal
1. Park truck on a level surface and apply brake.
2. Extend reach about 1/2 to 3/4 of total reach.
3. Block and chain reach mechanism to prevent
movement of reach mechanism.
4. Relieve pressure on reach cylinders.
5. Remove hoses from reach cylinder.
6. Remove screws (4), washers (5 and 6) and cotter
pins (7) securing front cylinder mounting pins in
position. Remove front cylinder mounting pins (8).
7. Raise reach assembly above full freelift. Remove
screws (4), washers (5 and 6) and cotter pins (7)
securing rear cylinder mounting pins in position.
Remove rear cylinder mounting pins (10).
8. Remove reach cylinder from truck.
440
Return
Service Manual
2001-03-15
F-code
PS
Section
C-code
S6.7
6650
Reach Cylinder (RTX45)
Version no
001
T-code
RTX35/RTX45
2. Disassembly
NOTE! Perform procedures in a clean environment.
Make sure all parts are cleaned before
disassembly and kept clean during assembly.
1. Before disassembly, clean the exterior of reach
cylinder in a cleaning solution to remove all
contamination.
WARNING Compressed air used for cleaning MUST
be reduced to less than 30 psi (206 kPa),
and then only with effective chip-guarding
and personal protective equipment.
2. Be sure all hydraulic fluid has been removed from
the cylinder. Stroking piston rod will help force fluid
out.
3. Put base end of cylinder in a vise equipped with
soft jaws.
4. Remove bearing retainer (13) and bearing (22) by
rotating bearing from cylinder tube (11 or 12) with a
spanner wrench.
5. Remove rod assembly (17).
6. Remove and discard all seals and rod wiper (21).
7. Inspect mounting bearings (27) located at the base
end of cylinders. It will not be necessary to remove
bearings unless they are found to be unfit for
further service.
BT Prime-Mover Inc.
Return
Service Manual
2001-03-15
441
F-code
Section
C-code
PS
S6.7
6650
Reach Cylinder (RTX45)
Version no
T-code
001
RTX35/RTX45
3. Inspection
WARNING Compressed air used for cleaning MUST
be reduced to less than 30 psi (206 kPa),
and then only with effective chip-guarding
and personal protective equipment.
1. Carefully clean all parts in a cleaning solution and
position them on a clean work surface.
2. Check rod assembly (17) 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 to not remove
chrome plating. Deeper damage will require
replacement of piston rod assembly. Make sure
threads on rod are free of damage.
3. Check cylinder bore for any damage. Parts with
deep gouges or pitted surfaces will require
replacement.
442
Return
Service Manual
2001-03-15
F-code
PS
Version no
001
Section
C-code
S6.7
6650
Reach Cylinder (RTX45)
T-code
RTX35/RTX45
4. Assembly
1. Install new rod wiper (21) in bearing assembly. The
lip of the wiper must face outward.
2. Install new bearing seals (23 & 24), back-up ring
(25), and O-rings (26) on bearing assembly.
3. If necessary, replace rod assembly (17) with new.
Install rod assembly (17).
4. Apply clean hydraulic fluid to piston rod assembly.
Coat the inside of cylinder tube and bearing
assembly with clean fluid.
5. Carefully slide bearing assembly (22) onto cylinder
rod assembly (17). Be sure rod end does not cut or
nick wiper or packing upon installation.
6. Install piston and cylinder rod assembly into
cylinder tube (11 or 12). Be careful that piston
seals are not nicked or cut on the edge of cylinder
tube or when sliding them over the groove within
the tube.
7. Install bearing assembly into cylinder tube. Use
care so seals are not nicked or cut upon
installation.
8. Check installation by making sure piston rod
assembly moves smoothly within tube assembly
without binding.
9.
BT Prime-Mover Inc.
Return
Service Manual
2001-03-15
443
F-code
Section
C-code
PS
S6.7
6650
Reach Cylinder (RTX45)
Version no
T-code
001
RTX35/RTX45
5. Installation
1. Raise reach assembly to full freelift height. Install
reach cylinder rear mounting pins (10). Secure
mounting pins in position with cotter pins (7),
washers (5 and 6) and screws (4).
2. Lower reach assembly. Install reach cylinder front
mounting pins (8). Secure mounting pins in
position with cotter pins (7), washers (5 and 6) and
screws (4).
3. Connect correct hydraulic hoses to reach cylinders.
4. Remove blocking and chains.
5. Fill hydraulic tank with new clean oil.
6. Connect battery.
7. Operate reach to remove air from hydraulic hoses.
Check operation of the whole hydraulic system.
CAUTION DO NOT use your hands to check for
hydraulic leakage. Use a piece of
cardboard or paper to search for leaks.
Escaping fluid under pressure can
penetrate the skin causing serious injury.
Relieve pressure before disconnecting
hydraulic or other lines. Tighten all
connections before applying pressure.
Keep hands and body away from pinholes
and nozzles which eject fluids under high
pressure.
8. After running the hydraulic system, check and fill
hydraulic tank with new clean oil.
444
Return
Service Manual
2001-03-15
F-code
Section
PS
C-code
S6.8
6660
Tilt Cylinder (RTX35)
Version no
T-code
001
RTX35/RTX45
7
5
12
10
1
2
3
4
BT Prime-Mover, Inc.
Return
Item
No.
Description
Item
No.
Seal
11
O-ring
Bushing
Bearing, cylinder
12
Ring, back-up
Retainer, cylinder
Ring, back-up
13
Retainer
Screw, cap
O-ring
14
Tube, cylinder
Wiper
10
Rod, cylinder
Service Manual
Description
2001-03-15
Item
No.
Description
445
F-code
Section
PS
S6.8
Tilt Cylinder (RTX35)
Version no
T-code
001
RTX35/RTX45
C-code
6660
1. Removal
1. Park truck on a level surface and apply the brake.
2. Raise reach approximately 12 inches (305 mm)
and block so reach will not lower.
3. Relieve pressure on tilt cylinder (1).
4. Pivot carriage/reach upward and block to prevent
the fork frame from lowering.
5. Remove strap (3) and cap screws (4) that secure
the cylinder to the fork frame.
6. Remove hydraulic hoses from tilt cylinder (1).
7. Remove tilt cylinder (1) from truck.
446
Return
Service Manual
2001-03-15
F-code
PS
Version no
001
Section
C-code
S6.8
6660
Tilt Cylinder (RTX35)
T-code
RTX35/RTX45
2. Disassembly
WARNING Compressed air used for cleaning MUST
be reduced to less than 30 psi (206 kPa),
and then only with effective chip-guarding
and personal protective equipment.
NOTE! Perform procedures in a clean environment.
Make sure all parts are cleaned before
disassembly and kept clean during assembly.
1. Before disassembly, clean the exterior of tilt
cylinder (1) in a cleaning solution to remove all
contamination.
2. Be sure all hydraulic fluid has been removed from
the cylinder. Stroking the piston rod will help force
the fluid out.
3. Put the base end of the cylinder in a vise equipped
with soft jaws.
4. Remove bearing retainer (13) and cylinder bearing
(7) from the cylinder tube.
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
bushings unless they are found to be unfit for
further service.
BT Prime-Mover, Inc.
Return
Service Manual
2001-03-15
447
F-code
Section
PS
S6.8
Tilt Cylinder (RTX35)
Version no
T-code
001
RTX35/RTX45
C-code
6660
3. Inspection
WARNING Compressed air used for cleaning MUST
be reduced to less than 30 psi (206 kPa),
and then only with effective chip-guarding
and personal protective equipment.
1. Carefully clean all parts in a cleaning solution and
position parts on a clean work surface.
2. Check 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 not to remove the
chrome plating. Deeper damage will require
replacement of the piston rod assembly.
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.
448
Return
Service Manual
2001-03-15
F-code
PS
Version no
001
Section
C-code
S6.8
6660
Tilt Cylinder (RTX35)
T-code
RTX35/RTX45
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.
3. Install new piston seals on the piston.
4. Install piston on the rod.
5. Apply clean hydraulic fluid to piston rod assembly.
Coat the inside of cylinder barrel and bearing
assembly with clean fluid.
6. Carefully slide bearing assembly on piston rod. Be
sure rod end does not cut or nick wiper or packing
upon installation.
7. Install piston and rod into cylinder barrel. Be careful
that 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. Install bearing assembly into cylinder barrel. Use
care so seals are not nicked or cut upon
installation.
9. Check installation by making sure piston rod
assembly moves fairly easy within barrel assembly
without binding.
10. Install cylinder bearing (7) and bearing retainer
(13).
BT Prime-Mover, Inc.
Return
Service Manual
2001-03-15
449
F-code
Section
PS
S6.8
Tilt Cylinder (RTX35)
Version no
T-code
001
RTX35/RTX45
C-code
6660
5. Installation
1. Install cylinder on reach front frame.
2. Install mounting straps (3). Secure with four cap
screws (4).
3. Properly connect correct hydraulic hoses to the
front and rear of tilt cylinder.
4. Remove blocking and chains.
5. Fill hydraulic tank with new clean oil.
6. Connect battery.
WARNING DO NOT use your hands to check for
hydraulic leakage. Use a piece of
cardboard or paper to search for leaks.
Escaping fluid under pressure can
penetrate the skin causing serious injury.
Relieve pressure before disconnecting
hydraulic or other lines. Tighten all
connections before applying pressure.
Keep hands and body away from pinholes
and nozzles which eject fluids under high
pressure.
7. Operate tilt to remove air from hydraulic hoses and
check operation of the whole hydraulic system.
8. After running the hydraulic system, check and fill
the hydraulic tank with new clean oil.
450
Return
Service Manual
2001-03-15
F-code
Section
PS
C-code
S6.8
6660
Tilt Cylinder (RTX45)
Version no
T-code
001
RTX35/RTX45
15
13
12
9
8
6
11
10
5
4
2
3
BT Prime-Mover, Inc.
Return
Item
No.
Description
Item
No.
Wiper
11
Rod, cylinder
Bushing
Seal
12
O-ring
Retainer, cylinder
Bearing, cylinder
13
Ring, back-up
Lockwasher
Ring, back-up
14
Retainer
Screw, cap
10
O-ring
15
Tube, cylinder
Service Manual
Description
2001-03-15
Item
No.
Description
451
F-code
Section
PS
S6.8
Tilt Cylinder (RTX45)
Version no
T-code
001
RTX35/RTX45
C-code
6660
1. Removal
1. Park truck on a level surface and apply brake.
2. Raise reach approximately 12 inches (305 mm)
and block so reach will not lower.
3. Relieve pressure on tilt cylinder (1).
4. Pivot carriage/reach upward and block to prevent
carriage/reach from lowering.
5. Remove cylinder retainers (3), lockwashers (4),
and cap screws (5) that secure cylinder to carriage/
reach.
6. Remove hydraulic hoses from tilt cylinder (1).
7. Remove tilt cylinder (1) from truck.
452
Return
Service Manual
2001-03-15
F-code
PS
Version no
001
Section
C-code
S6.8
6660
Tilt Cylinder (RTX45)
T-code
RTX35/RTX45
2. Disassembly
WARNING Compressed air used for cleaning MUST
be reduced to less than 30 psi (206 kPa),
and then only with effective chip-guarding
and personal protective equipment.
NOTE! Perform procedures in a clean environment.
Make sure all parts are cleaned before
disassembly and kept clean during assembly.
1. Before disassembly, clean the exterior of tilt
cylinder (1) in a cleaning solution to remove all
contamination.
2. Be sure all hydraulic fluid has been removed from
cylinder. Stroking piston rod will help force fluid out.
3. Put base end of cylinder in a vise equipped with
soft jaws.
4. Remove bearing retainer (14) and cylinder bearing
(8) from cylinder tube.
5. Remove bearing assembly, seals, rings, rod (11),
and piston seals.
6. Remove and discard all seals and rod wiper (6, 7,
9, 10, 12, and 13).
7. Inspect mounting bushings (2) located at both ends
of cylinder. It will not be necessary to remove them
unless they are found to be unfit for further service.
BT Prime-Mover, Inc.
Return
Service Manual
2001-03-15
453
F-code
Section
PS
S6.8
Tilt Cylinder (RTX45)
Version no
T-code
001
RTX35/RTX45
C-code
6660
3. Inspection
WARNING Compressed air used for cleaning MUST
be reduced to less than 30 psi (206 kPa),
and then only with effective chip-guarding
and personal protective equipment.
1. Carefully clean all parts in a cleaning solution and
position them on a clean work surface.
2. Check piston rod (11) 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 to not remove the
chrome plating. Deeper damage will require
replacement of piston rod assembly.
3. Check cylinder bore for any damage. Parts with
deep gouges or pitted surfaces will require
replacement.
4. Check threaded section of cylinder tube to be sure
threads have not been damaged.
454
Return
Service Manual
2001-03-15
F-code
PS
Version no
001
Section
C-code
S6.8
6660
Tilt Cylinder (RTX45)
T-code
RTX35/RTX45
4. Assembly
1. Install new packing and rod wipers in bearing
assembly. The lip of the wiper must face outward.
2. Install new bearing seals and back-up ring on
bearing assembly.
3. Install new piston seals on piston.
4. Install piston on rod.
5. Apply clean hydraulic fluid to piston rod assembly.
Coat the inside of cylinder barrel and bearing
assembly with clean fluid.
6. Carefully slide bearing assembly on piston rod. Be
sure rod end does not cut or nick wiper or packing
upon installation.
7. Install piston and rod into cylinder barrel. Be careful
that piston seals are not nicked or cut on the edge
of cylinder barrel or when sliding them over the
groove within the barrel.
8. Install bearing assembly into cylinder barrel. Use
care so seals are not nicked or cut upon
installation.
9. Check installation by making sure piston rod
assembly moves fairly easy within the barrel
assembly without binding.
10. Install cylinder bearing (8) and bearing retainer
(14).
BT Prime-Mover, Inc.
Return
Service Manual
2001-03-15
455
F-code
Section
PS
S6.8
Tilt Cylinder (RTX45)
Version no
T-code
001
RTX35/RTX45
C-code
6660
5. Installation
1. Install cylinder on reach front frame.
2. Install cylinder retainers (3). Secure with four
lockwashers (4) and cap screws (5).
3. Properly connect correct hydraulic hoses to the
front and rear of tilt cylinder.
4. Remove blocking and chains.
5. Fill hydraulic tank with new clean oil.
6. Connect battery.
WARNING DO NOT use your hands to check for
hydraulic leakage. Use a piece of
cardboard or paper to search for leaks.
Escaping fluid under pressure can
penetrate the skin causing serious injury.
Relieve pressure before disconnecting
hydraulic or other lines. Tighten all
connections before applying pressure.
Keep hands and body away from pinholes
and nozzles which eject fluids under high
pressure.
7. Operate tilt to remove air from hydraulic hoses and
check operation of the whole hydraulic system.
8. After running the hydraulic system, check and fill
hydraulic tank with new clean oil.
456
Return
Service Manual
2001-03-15
F-code
PS
Section
C-code
S7.0
7110
Mast, 3 Stage (RTX35)
Version no
T-code
000
RTX35/RTX45
32
34
5
34
35
28
29
30
31
28
3
4
10
3
1
7
4
11
22
14
12
13
15
3
26
14
21
20
15
23
18
5
38
36
16
37 36
17
40
25
24
BT Prime-Mover Inc.
Return
17 19
Service Manual
2001-03-15
39
457
F-code
Section
PS
S7.0
Mast, 3 Stage (RTX35)
Version no
T-code
000
RTX35/RTX45
Item
No.
458
C-code
7110
Description
Item
No.
Description
Item
No.
Description
Anchor, chain
15
Nut, jam
29
Sheave, chain
16
Line, hydraulic
30
Bearing, roller
Pin, cotter
17
Screw, cap
31
Race, inner
Pin, chain
18
Column, Intermediate
32
Lockwasher
Shim
19
Bracket
33
Screw, cap
Bearing
20
Screw, cap
34
Fitting, grease
Staging cylinder
assembly
21
Lockwasher
35
Shaft
22
Sheave
36
Spacer
Column, inner
23
Screw, cap
37
Sheave, hose
10
24
Washer, flat
38
Screw, cap
11
Freelift cylinder
assembly
25
Screw, cap
39
Shaft, sheave
12
Pin, anchor
26
Column, outer
40
Sheave, hydraulic,
and electrical
13
Pin, cotter
27
Shaft
14
Nut
28
Washer, shim
Return
Service Manual
2001-03-15
F-code
PS
Version no
000
Section
C-code
S7.0
7110
Mast, 3 Stage (RTX35)
T-code
RTX35/RTX45
Return
Service Manual
2001-03-15
459
F-code
Section
PS
S7.0
Mast, 3 Stage (RTX35)
Version no
T-code
000
RTX35/RTX45
C-code
7110
460
Return
Service Manual
2001-03-15
F-code
PS
Version no
000
Section
C-code
S7.0
7110
Mast, 3 Stage (RTX35)
T-code
RTX35/RTX45
1+ 01/2
Plate
BT Prime-Mover Inc.
Return
Service Manual
2001-03-15
461
F-code
Section
PS
S7.0
Mast, 3 Stage (RTX35)
Version no
T-code
000
RTX35/RTX45
C-code
7110
2.2. Disassembly
1. Lower mast assembly to a horizontal position
before work can begin.
2. Remove lift chain anchors, lift chain, attachment
hydraulic hoses, and electrical cable from the
mast.
3. Remove freelift chain anchor, two cotter pins, and
two cylinder anchor pins from inner column. Pull
straight up to remove freelift cylinder assembly.
NOTE! Lift cylinder can be repaired at this time, if
needed.
4. Remove chain sheaves and cable sheaves from all
columns.
5. Pull inner column straight forward until it stops (hits
bearings) and then 90 degrees straight up from
intermediate column.
6. Remove cap screws from the top of intermediate
column. Remove staging cylinder assemblies by
pushing intermediate column forward.
NOTE! Lift cylinder can be repaired at this time, if
needed.
7. Pull intermediate column straight forward until it
stops (hits bearings) and then pull 90 degrees
straight up from the outer column.
8. Remove mast bearings and shim washers from all
columns.
9. Thoroughly clean all parts.
462
Return
Service Manual
2001-03-15
F-code
PS
Version no
000
Section
C-code
S7.0
7110
Mast, 3 Stage (RTX35)
T-code
RTX35/RTX45
2.3. Assembly
WARNING Compressed air used for cleaning MUST
be reduced to less than 30 psi (206 kPa),
and then only with effective chip-guarding
and personal protective equipment.
1. Thoroughly clean all parts and air dry.
2. Install mast roller bearing on both intermediate and
outer columns.
3. Assemble intermediate column in outer column.
Slide columns together.
4. Determine amount of shims required. Pry inner
column to one side and slip shims between bearing
and web on mast. Add shims by hand until no more
can be added.
5. Divide shims as equally as possible between the
two bearings. Install shims under the bearings.
6. Extend intermediate column through the outer
column as far as it will go under normal operation.
Check bearing shimming as column is extended.
Remove shims as required if tight spots are
encountered where an assembler cannot roll the
mast by hand.
Check for excessive clearance with columns in
fully closed position. Pry column to one side and
check with a 0.030 inch (0.76 mm) shim. Maximum
clearance must not exceed 0.030 inch (0.76 mm).
Check for excessive bearing clearance with
columns in the fully extended position. Pry column
to one side and check with a 0.030 inch (0.76 mm)
shim. Maximum clearance must not exceed 0.030
inch (0.76 mm).
7. Assemble inner column in intermediate column.
Slide columns together.
8. Determine amount of shims required. Pry inner
column to one side and slip shims between bearing
and web on the mast. Add shims by hand until no
more can be added.
BT Prime-Mover Inc.
Return
Service Manual
2001-03-15
463
F-code
Section
PS
S7.0
Mast, 3 Stage (RTX35)
Version no
T-code
000
RTX35/RTX45
C-code
7110
Return
Service Manual
2001-03-15
F-code
PS
Section
C-code
S7.0
7110
Mast, 3 Stage (RTX35)
Version no
000
T-code
RTX35/RTX45
2.4. Installation
1. Install mast using a hoist.
2. Install side mounting plates. Torque mounting plate
bolts to 85 ft-lb (115 Nm).
3. Install two bolts in middle of the battery box.
Torque to 400 ft-lb (543 Nm).
4. Install two bolts at the base of overhead guard
post. Torque to 25 ft-lb (34 Nm).
5. Connect hydraulic hoses to lift cylinders.
6. Hydraulically lift up inner column enough to install
reach carriage assembly.
7. Connect all electrical connectors.
8. Adjust lift chains.
Loosen jam nut and tighten staging chains equally
until the top of the rails are level in the fully lowered
position. Retighten jam nut and torque.
Freelift chains should be adjusted in the fully
lowered position. Adjust chains until the top of forks
are 2.0 inches (50 mm) off the floor.
9. Grease all chain sheaves.
10. Bleed any air from cylinders.
11. Install and connect battery. Test operations of mast
and unit.
BT Prime-Mover Inc.
Return
Service Manual
2001-03-15
465
F-code
Section
C-code
PS
S7.0
Mast, 3 Stage (RTX45)
7110
Version no
T-code
000
RTX35/RTX45
29
24
25
30
8
26
27
31
24
9
4
10
6
3
1
4
11
18
12
13
14
37
15
19
14
15
22
38
17
4
16
23
5
6
6
20
32
33
32
21
35
34
466
Return
36
Service Manual
2001-03-15
F-code
PS
Version no
000
Item
No.
Description
Item
No.
Description
Item
No.
Section
T-code
RTX35/RTX45
Description
Anchor, chain
14
Nut
27
Race, inner
15
Nut, jam
28
Lockwasher
Pin, cotter
16
Line, hydraulic
29
Screw, cap
Pin, chain
17
Screw, cap
30
Fitting, grease
Shim
18
Column, Intermediate
31
Shaft
Bearing
19
Bracket
32
Spacer
Staging cylinder
assembly
20
Screw, cap
33
Sheave, hose
21
Shaft, sheave
34
Screw, cap
Column, inner
22
Column, outer
35
Washer, shim
10
23
Screw, cap
36
Sheave, hydraulic,
and electrical
11
Freelift cylinder
assembly
24
Washer, shim
37
Manifold
12
Pin, anchor
25
Sheave, chain
38
Screw
13
Pin, cotter
26
Bearing, roller
BT Prime-Mover Inc.
Return
Service Manual
2001-03-15
C-code
S7.0
7110
Mast, 3 Stage (RTX45)
467
F-code
Section
PS
S7.0
Mast, 3 Stage (RTX45)
Version no
T-code
000
RTX35/RTX45
C-code
7110
Return
Service Manual
2001-03-15
F-code
PS
Version no
000
Section
C-code
S7.0
7110
Mast, 3 Stage (RTX45)
T-code
RTX35/RTX45
BT Prime-Mover Inc.
Return
Service Manual
2001-03-15
469
F-code
Section
C-code
PS
S7.0
Mast, 3 Stage (RTX45)
Version no
T-code
000
RTX35/RTX45
7110
+
01/21 -
Plate
Bolts
470
Return
2001-03-15
F-code
PS
Version no
000
Section
C-code
S7.0
7110
Mast, 3 Stage (RTX45)
T-code
RTX35/RTX45
2.2. Disassembly
1. Lower mast assembly to a horizontal position
before work can begin.
2. Remove lift chain anchors, lift chain, attachment
hydraulic hoses, and electrical cable from mast.
3. Remove freelift chain anchor, two cotter pins, and
two cylinder anchor pins from inner column.
Remove freelift cylinder assembly by pulling
straight up.
NOTE! Lift cylinder can be repaired at this time, if
needed.
4. Remove chain sheaves and cable sheaves from all
columns.
5. Pull inner column straight forward until it stops (hits
bearings) and then 90 degrees straight up from
intermediate column.
6. Remove cap screws from the top of intermediate
column. Remove staging cylinder assemblies by
pushing the intermediate column forward.
NOTE! Lift cylinder can be repaired at this time, if
needed.
7. Pull intermediate column straight forward until it
stops (hits bearings) and then pull 90 degrees
straight up from the outer column.
8. Remove mast bearings and shim washers from all
columns.
9.
BT Prime-Mover Inc.
Return
Service Manual
2001-03-15
471
F-code
Section
PS
S7.0
Mast, 3 Stage (RTX45)
Version no
T-code
000
RTX35/RTX45
C-code
7110
2.3. Assembly
WARNING Compressed air used for cleaning MUST
be reduced to less than 30 psi (206 kPa),
and then only with effective chip-guarding
and personal protective equipment.
1. Thoroughly clean all parts and air dry.
2. Install mast roller bearing on both the intermediate
and outer columns.
3. Assemble intermediate column
column. Slide columns together.
in the outer
472
Return
Service Manual
2001-03-15
F-code
PS
Version no
000
Section
C-code
S7.0
7110
Mast, 3 Stage (RTX45)
T-code
RTX35/RTX45
Return
Service Manual
2001-03-15
473
F-code
Section
PS
S7.0
Mast, 3 Stage (RTX45)
Version no
T-code
000
RTX35/RTX45
C-code
7110
2.4. Installation
1. Install mast using a hoist.
2. Install side mounting plates. Torque mounting plate
bolts to 85 ft-lb (115 Nm).
3. Install two bolts in the middle of the battery box.
Torque to 400 ft-lb (543 Nm).
4. Install two bolts at base of overhead guard post.
Torque to 25 ft-lb (34 Nm).
5. Connect hydraulic hoses to lift cylinders.
6. Hydraulically lift up inner column enough to install
reach carriage assembly.
7. Connect all electrical connectors.
8. Adjust lift chains.
Loosen jam nut and tighten chains equally until top
of rails are level in the fully lowered position.
Retighten jam nut and torque.
Carriage chains should be adjusted in the fully
lowered position. Adjust chains until the top of forks
are 2.0 inch (50 mm) off the floor.
9. Grease all chain sheaves.
10. Bleed any air from the cylinders.
474
Return
Service Manual
2001-03-15
F-code
PS
Version no
000
Section
C-code
S7.0
7110
Mast, 3 Stage (RTX45)
T-code
RTX35/RTX45
BT Prime-Mover Inc.
Return
Service Manual
2001-03-15
475
F-code
Section
C-code
PS
Lift Chain
S7.0
7110
Version no
T-code
000
RTX35/RTX45
Lift Chain
Lift chains are very important components of the truck. The
chain system on the mast was designed for efficient, reliable
transmission of lifting force from the hydraulic cylinder to the
forks. Safe, uninterrupted use of the truck depends on proper
care and maintenance of lift chains.
After 100 hours of truck operation, lift chains should be
inspected and lubricated. When operating in unfamiliar
corrosive environment, inspect chains every 50 hours.
476
Return
Service Manual
2001-03-15
F-code
Section
PS
S7.0
Version no
000
C-code
7110
Lift Chain
T-code
RTX35/RTX45
3.1. Wear
As the chain flexes on and off the sheaves, the joints
gradually wear. The stretch a chain develops in service is
due to material being worn off the pin on the outside diameter
and the pitch hole inside diameter on the inside plates.
Chain
Wear
Scale
New Chain
Stretched
Chain
Stress-corrosion Cracking
BT Prime-Mover Inc.
Return
Service Manual
2001-03-15
477
F-code
Section
C-code
PS
Lift Chain
S7.0
7110
Version no
T-code
000
RTX35/RTX45
lift chains on the truck if the plates are cracked. Lubricate the
chains when reinstalled on the truck.
478
Return
Service Manual
2001-03-15
F-code
Section
PS
S7.0
Version no
000
C-code
7110
Lift Chain
T-code
RTX35/RTX45
BT Prime-Mover Inc.
Return
Service Manual
Rusty joints
2001-03-15
479
F-code
Section
C-code
PS
Lift Chain
S7.0
7110
Version no
T-code
000
RTX35/RTX45
480
Return
Service Manual
2001-03-15
F-code
Section
PS
S7.0
Version no
000
C-code
7110
Lift Chain
T-code
RTX35/RTX45
Protruding Pins
MA0633.ill
MA0000.ill
Turned Pins
Return
Service Manual
2001-03-15
481
F-code
Section
C-code
PS
Lift Chain
S7.0
7110
Version no
T-code
000
RTX35/RTX45
Prevent corrosion
482
Return
Service Manual
2001-03-15
F-code
Section
PS
S7.0
Version no
000
C-code
7110
Lift Chain
T-code
RTX35/RTX45
Lubricate
Lubricate
BT Prime-Mover Inc.
Return
Service Manual
2001-03-15
483
F-code
Section
C-code
PS
Lift Chain
S7.0
7110
Version no
T-code
000
RTX35/RTX45
484
Return
Service Manual
2001-03-15
F-code
Section
C-code
PS
S7.1
7170
Lifting Gear (Crosshead) (RTX35)
Version no
T-code
000
RTX35/RTX45
3
7
9
3
10
6
5
4
3
2
1
Freelift Cylinder
Item
No.
BT Prime-Mover Inc.
Return
Description
Item
No.
Description
Fitting, grease
Sheave, chain
Ring, retainer
Head, sheave
Shim
Race
Shaft
Bearing, roller
10
Screw, set
Service Manual
2001-03-15
485
F-code
Section
C-code
PS
S7.1
7170
Lifting Gear (Crosshead) (RTX35)
Version no
T-code
000
RTX35/RTX45
486
Return
Service Manual
2001-03-15
F-code
Section
C-code
PS
S7.1
7170
Lifting Gear (Crosshead) (RTX35)
Version no
000
T-code
RTX35/RTX45
1.2. Disassembly
1. Remove retaining ring (2) from one end of the
lifting gear assembly.
2. Slide shim (3), bearing roller and race (5 and 4),
chain sheave (6) and the second shim (3) off the
shaft (9).
3. Repeat steps 1 and 2 for the opposite side.
4. Loosen set screw (10) in the side of the sheave
head (7).
5. Remove shaft (9) from sheave head (7) releasing
the hydraulic/electric sheave (8).
1.3. Assembly
1. Place hydraulic/electric sheave (8) into the sheave
head.
2. Lube sheave head. Insert shaft (9) into sheave
head (7), through the hydraulic/electric sheave (8).
3. Secure shaft in position with a set screw (10).
4. Install one shim (3), one chain sheave with bearing
assembly (6, 5, 4), a second shim (3), and a
retaining ring (2) on shaft (9).
5. Repeat step 4 for the opposite side.
6. Install a grease fitting (1) in each end of the shaft
(9).
BT Prime-Mover Inc.
Return
Service Manual
2001-03-15
487
F-code
Section
C-code
PS
S7.1
7170
Lifting Gear (Crosshead) (RTX35)
Version no
T-code
000
RTX35/RTX45
1.4. Installation
1. Place lifting gear assembly on top of freelift
cylinder.
2. Tighten set screw (10) in the base of sheave head
(7) to secure the lifting gear to the cylinder.
3. Grease chain sheaves. Install chains, hoses, and
electric cables.
4. Connect battery.
5. Remove blocking and test for proper operation.
488
Return
Service Manual
2001-03-15
F-code
Section
C-code
PS
S7.1
7170
Lifting Gear (Crosshead) (RTX45)
Version no
T-code
000
RTX35/RTX45
8
7
9
3
10
6
5
4
3
2
1
Freelift Cylinder
Item
No.
BT Prime-Mover Inc.
Return
Description
Item
No.
Description
Fitting, grease
Sheave, chain
Ring, retainer
Head, sheave
Shim
Race
Shaft
Bearing, roller
10
Screw, set
Service Manual
2001-03-15
489
F-code
Section
C-code
PS
S7.1
7170
Lifting Gear (Crosshead) (RTX45)
Version no
T-code
000
RTX35/RTX45
490
Return
Service Manual
2001-03-15
F-code
Section
C-code
PS
S7.1
7170
Lifting Gear (Crosshead) (RTX45)
Version no
000
T-code
RTX35/RTX45
1.2. Disassembly
1. Remove retaining ring (2) from one end of the
lifting gear assembly.
2. Slide shim (3), bearing roller and race (5 and 4),
chain sheave (6) and the second shim (3) off shaft
(9).
3. Repeat steps 1 and 2 for the opposite side.
4. Loosen set screw (10) in the side of sheave head
(7).
5. Remove shaft (9) from sheave head (7) releasing
the hydraulic/electric sheave (8).
1.3. Assembly
1. Place hydraulic/electric sheave (8) into the sheave
head.
2. Lube sheave head. Insert shaft (9) into the sheave
head (7), through the hydraulic/electric sheave (8).
3. Secure shaft in position with a set screw (10).
4. Install one shim (3), one chain sheave with bearing
assembly (6, 5, 4), a second shim (3), and a
retaining ring (2) on the shaft (9).
5. Repeat step 4 for the opposite side.
6. Install a grease fitting (1) in each end of the shaft
(9).
1.4. Installation
1. Place lifting gear assembly on the top of the freelift
cylinder.
2. Tighten set screw (10) in the base of the sheave
head (7) to secure the lifting gear to the cylinder.
3. Grease chain sheaves. Install chains, hoses, and
electric cables.
BT Prime-Mover Inc.
Return
Service Manual
2001-03-15
491
F-code
Section
C-code
PS
S7.1
7170
Lifting Gear (Crosshead) (RTX45)
Version no
T-code
000
RTX35/RTX45
4. Connect battery.
5. Remove blocking and test for proper operation.
492
Return
Service Manual
2001-03-15
F-code
Section
PS
S7.2
Version no
C-code
7211
Sideshifter
T-code
000
RTX35/RTX45
Sideshifter
1
2
25
24
21
23
22 20
19
18 17
16
26
15
14
29
3
X
7
28
10
27
13
11
12
BT Prime-Mover Inc.
Return
Service Manual
2001-03-15
493
F-code
Section
C-code
PS
S7.2
Sideshifter
7211
Version no
T-code
000
RTX35/RTX45
Item
No.
494
Return
Description
Item
No.
Description
Item
No.
Description
Screw
11
Hook, lower
21
Bracket
12
Pad, lower
22
Support
13
23
Seal
Pad, upper
14
Cap, right
24
Seal
Frame
15
Body, cylinder
25
Rod
16
Seal
26
Cylinder
Bolt, stop
17
Piston
27
Washer
18
O-ring
28
Screw
19
Ring
29
Restrictor, flow
10
20
Bushing
Service Manual
2001-03-15
F-code
Section
PS
S7.2
Version no
000
C-code
7211
Sideshifter
T-code
RTX35/RTX45
1. Mounting Instructions
1.1. Installation
NOTE! Clean the fork carriage and inspect to be sure
it is free of damage or grooves before
installing the sideshift carriage. Apply grease
to the fork carriage frame where the lower
pads slide.
1. Remove lower pads (12) from sideshift assembly.
Grease lower pads and return to the sideshift unit.
2. Lift sideshift unit onto the trucks carriage using a
lifting device with a minimum capacity of 1000 lbs
(454 kg).
3. Make sure centering lug (X) on cylinder support (3)
fits completely in the center notch of the truck
carriage.
4. Remove cylinder retaining caps (21).
5. Loosen two lower hook securing bolts (6). Lift lower
hook (11), bringing the plastic pad (12) in contact
with the underside of the truck carriage. Torque
securing bolts (6) to 65 ft-lb (90 Nm).
6. Remove safety screw (28) located between the
lower hook mounting bolts (6).
7. Tighten set screw (8) to 21 ft-lb (30 Nm) torque.
8. Install safety screw (28) into the hole with the set
screw (8). Torque safety screw to 70 ft-lb (100
Nm).
9. Connect hydraulic fittings to the sideshift cylinder.
Tighten fittings to 56 ft-lb (80 Nm).
10. Mount forks in the notches on the upper bar of the
sideshift carriage.
11. Install fork stop bolt (7) with washer (9, 10) into the
lower bar of the sideshift carriage.
BT Prime-Mover Inc.
Return
Service Manual
2001-03-15
495
F-code
Section
C-code
PS
S7.2
Sideshifter
7211
Version no
T-code
000
RTX35/RTX45
2. Operation
Always operate the truck controls in a smooth manner.
Sudden movements of the sideshift at high lifts can
compromise the stability of the truck, as well as cause
damage to the overall system.
3. Maintenance
Maintenance on the sideshift unit should be performed on a
regular basis to receive the best performance from the unit.
Refer to the scheduled maintenance chart on page 67 for
service tasks and intervals.
NOTE! In a dirty environment or rough operations, it
is necessary to inspect the sideshift unit more
frequently.
496
Return
Service Manual
2001-03-15
F-code
Section
PS
S7.2
Version no
000
C-code
7211
Sideshifter
T-code
RTX35/RTX45
BT Prime-Mover Inc.
Return
Service Manual
2001-03-15
497
F-code
Section
C-code
PS
S7.2
Sideshifter
7211
Version no
T-code
000
RTX35/RTX45
498
Return
Service Manual
2001-03-15
F-code
Section
PS
S7.2
Version no
000
C-code
7211
Sideshifter
T-code
RTX35/RTX45
13. Install safety screw (28) into the hole with the set
screw (8). Torque safety screw to 70 ft-lb (100
Nm).
14. Connect hydraulic fittings to the sideshift cylinder.
Tighten fittings to 56 ft-lb (80 Nm).
15. Mount forks in the notches on the upper bar of
sideshift carriage.
16. Install fork stop bolt (7) with washer (9, 10) into
lower bar of the sideshift carriage.
17. Sideshift the unit several times to insure there are
no leaks. Check the sideshift unit for smooth
operation with no interference.
NOTE! Following assembly, check operation of
sideshift unit by sideshifting first without a
load, then with a load.
BT Prime-Mover Inc.
Return
Service Manual
2001-03-15
499
F-code
Section
C-code
PS
S7.2
Sideshifter
7211
Version no
T-code
000
RTX35/RTX45
3.4. Cylinder
1. Remove sideshift carriage from
Carriage Removal on page 497.
truck.
See
500
Return
Service Manual
2001-03-15
F-code
Section
PS
S7.2
Version no
000
C-code
7211
Sideshifter
T-code
RTX35/RTX45
4. Troubleshooting
Below are three symptoms and the corrective actions to be
taken for each.
4.1. No Sideshifting
1. Check that input pressure is not greater than 3200
psi (22060 kPa). Average working pressure should
be 1000 psi (6894 kPa). Recommended oil flow is
2 gallons per minute (7.5 liters per minute) and
should be a minimum of 1 gallon per minute (4
liters per minute).
2. Check carriage frame for damage.
3. Check relationship of lower hook (11) to truck
carriage.
4. Check for leaks in the hydraulic circuit or cylinder.
BT Prime-Mover Inc.
Return
Service Manual
2001-03-15
501
F-code
Section
C-code
PS
S7.2
Sideshifter
7211
Version no
T-code
000
RTX35/RTX45
502
Return
Service Manual
2001-03-15
F-code
Section
PS
C-code
S7.3
7241
Reach, Single (RTX35)
Version no
T-code
001
RTX35/RTX45
19
18
20
7
6
5
8
12
7
10
13
14 15
21
22
16
11
9
45 46
3
2
43 1
24
44
42
48
47
23
7
6
26
36
40
38
25
34
36
23
35
41
39
17
33
27
35
28
29
32
37
31
32
30
BT Prime-Mover Inc.
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Service Manual
2001-03-15
503
F-code
Section
C-code
PS
S7.3
7241
Reach, Single (RTX35)
Version no
T-code
001
RTX35/RTX45
Item
No.
504
Description
Item
No.
Description
Item
No.
Description
Screw, cap
17
Frame, forward
33
Bushing
Pin
18
Pin, roll
34
Frame, rear
19
Pin
35
Bumper
20
Bushing
36
Shim
Arm, left
21
Bar, fork
37
Shim
Bushing
22
Screw, cap
38
Screw, cap
Fitting, grease
23
Washer
39
Manifold
Bushing
24
Washer
40
Screw
Arm, inner
25
Pin
41
Clamp
10
Control valve
26
Arm, right
42
Washer, flat
11
Screw, lock
27
Washer, flat
43
Bracket
12
Cover, valve
28
Nut, jam
44
Nut
13
Clamp, poly
29
Set, bearing
45
Cap, bearing
14
Cover
30
46
Bearing
15
Screw
31
Cap
47
Reach cylinder
assembly
16
Manifold
32
Bearing
48
Return
Service Manual
2001-03-15
F-code
PS
Version no
001
Section
C-code
S7.3
7241
Reach, Single (RTX35)
T-code
RTX35/RTX45
2. Reach Repair
2.1. Removal
NOTE! The reach can be repaired without removal
from the mast.
1. Remove forks.
2. Remove load
page 532.
backrest.
See
Removal
on
2.1. Disassembly
2.1.1. Front Frame Removal
1. Disconnect hydraulic hoses from tilt and sideshift
cylinders from the input side of junction block. Cap
hoses with plugs to prevent contamination.
2. Secure front frame with a hoist to prevent
movement before removing cap screw (1) and pins
(25).
3. Remove cap screw (1) at the front frame (17).
4. Drive pins (25) to the outside by hitting with a soft
hammer.
5. Remove front frame (17) from inner arm (9) rollers
(46).
BT Prime-Mover Inc.
Return
Service Manual
2001-03-15
505
F-code
Section
C-code
PS
S7.3
7241
Reach, Single (RTX35)
Version no
T-code
001
RTX35/RTX45
506
Return
Service Manual
2001-03-15
F-code
PS
Version no
001
Section
C-code
S7.3
7241
Reach, Single (RTX35)
T-code
RTX35/RTX45
2.2. Assembly
Install new bearing, rollers, and pins as needed.
2.2.1. Reach Cylinder Installation
1. Install rear frame pins.
2. Install locking pins.
3. Connect hydraulic hoses.
2.2.2. Rear Frame Installation
NOTE! Install same number of shims as removed for
initial adjustment.
1. Install shims (37) and rollers (32).
NOTE! Adjust frame rollers so there is 0.000 to 0.030
inch (0 to 0.76 mm) side movement of the
rear frame at tightest part of the inner mast
channel.
2. Lower inner mast channel onto rear frame rollers
(32).
BT Prime-Mover Inc.
Return
Service Manual
2001-03-15
507
F-code
Section
C-code
PS
S7.3
7241
Reach, Single (RTX35)
Version no
T-code
001
RTX35/RTX45
See
Front
Frame
508
Return
Service Manual
2001-03-15
F-code
PS
Section
C-code
S7.3
7241
Reach, Single (RTX35)
Version no
001
T-code
RTX35/RTX45
3. Carriage Bumpers
The carriage/reach retract bumpers assure that the carriage
remains square with the truck in its nested position. The
RTX35 reach uses rectangular bumpers (35) attached to
each side and at the bottom of the carriage/reach rear frame.
These bumpers are attached with socket head screws (34).
Verify that the (3) reach retract bumpers (35) are in good
condition. There should be no splitting, cracking, or
deformation on the bumpers. The reach retract bumpers are
critical to the proper operation of the reach assembly and
must be inspected at every Planned Maintenance visit.
Bumpers that show signs of wear, cracking, splitting, or
deformation must be replaced.
BT Prime-Mover Inc.
Return
Service Manual
2001-03-15
509
F-code
Section
C-code
PS
S7.3
7241
Reach, Single (RTX35)
Version no
T-code
001
RTX35/RTX45
510
Return
Service Manual
2001-03-15
F-code
PS
Version no
001
Section
C-code
S7.3
7241
Reach, Single (RTX35)
T-code
RTX35/RTX45
5.1. Removal
1. Remove carriage/reach.
2. The carriage bearing should slide off the shaft with
hand pressure. If necessary, a suitable bearing
puller may be required for removal.
3. Repeat step 2 for the other three bearings.
BT Prime-Mover Inc.
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Service Manual
2001-03-15
511
F-code
Section
C-code
PS
S7.3
7241
Reach, Single (RTX35)
Version no
T-code
001
RTX35/RTX45
5.2. Installation
1. Install new bearing on shaft.
2. Repeat step 1 for the other three bearings.
3. Reinstall carriage/reach. See Shimming Carriage
with Mast on Truck on page 459.
4. Test lift/lower functions of the carriage.
5. Return truck to service.
512
Return
Service Manual
2001-03-15
F-code
Section
PS
C-code
S7.3
7241
Reach, Single (RTX45)
Version no
T-code
001
RTX35/RTX45
45
43
46
41
47
48
44
60
49
51
52
59
58
50
57
56
55
53
54
12
13
14
4
1
10
38
37 36
35
34
20
33 21 22 6
27
25
26
11 3
5
32 22
39
28
36
40
30
29
24
23
22
19
20
21
17
16
18
35
31
6
8
7
15
5
2
3
BT Prime-Mover Inc.
Return
Service Manual
2001-03-15
513
F-code
Section
C-code
PS
S7.3
7241
Reach, Single (RTX45)
Version no
T-code
001
RTX35/RTX45
Item
No.
514
Description
Item
No.
Description
Item
No.
Description
Screw
21
Lockwasher
41
Solenoid valve
Cap, bearing
22
Flat Washer
42
Frame, carriage
Bearing
23
Pin, cotter
43
Screw
Arm, left
24
Pin
44
Bearing
Fitting, grease
25
Bearing
45
Spacer
Bearing
26
Reach cylinder
46
Screw
Bearing
27
Pin
47
Ring, retainer
Bearing, thrust
28
Spacer
48
Shaft
Shim
29
Screw
49
Frame, fork
10
Arm, inner
30
Solenoid valve
50
Nut
11
Plug, wear
31
Frame, back
51
Screw
12
Screw
32
Screw
52
Lockwasher
13
Shaft-half
33
Lockwasher
53
Spacer
14
Shaft-half
34
Pin, pivot
54
Bumper
15
Arm, right
35
Shim
55
Screw
16
Nut
36
56
Screw
17
Lockwasher
37
Cap, bearing
57
Plate, wear
18
Bearing, thrust
38
Screw
58
Cylinder, tilt
19
Spacer
39
Guide, hose
59
Bearing
20
Screw
40
Screw
60
Bracket, cylinder
Return
Service Manual
2001-03-15
F-code
PS
Section
C-code
S7.3
7241
Reach, Single (RTX45)
Version no
001
T-code
RTX35/RTX45
2. Reach Repair
NOTE! The reach can be repaired without removal
from the mast.
1. Remove forks.
2. Remove load
page 532.
backrest.
See
Removal
on
2.1. Disassembly
2.1.1. Front Frame Removal
1. Disconnect hydraulic hoses from the tilt and
sideshift cylinders from the input side of the
solenoid valve. Cap hoses with plugs to prevent
contamination.
2. Remove screw (12) and half shafts (13 and 14)
from the front frame (42).
3. Remove front frame (42) from inner arm (10) rollers
(3).
2.1.2. Outer Arm Removal
1. Remove nut (16) and lockwasher (17).
2. Remove thrust bearing (18).
3. Remove right outer arm (15).
4. Repeat steps 1 thru 3 to remove left outer arm (4).
5. Remove shims (9), thrust bearing (8), and bearing
(7) from the center stud of outer arms (4 and 15).
6. Remove screws (1), bearing caps (2), and bearing
(3) from outer arms (4 and 15).
BT Prime-Mover Inc.
Return
Service Manual
2001-03-15
515
F-code
Section
C-code
PS
S7.3
7241
Reach, Single (RTX45)
Version no
T-code
001
RTX35/RTX45
516
Return
Service Manual
2001-03-15
F-code
PS
Section
C-code
S7.3
7241
Reach, Single (RTX45)
Version no
001
T-code
RTX35/RTX45
2.2. Assembly
Install new bearing, rollers, and pins as needed.
2.2.1. Reach Cylinder Installation
1. Install rear frame pins (27).
2. Install cotter pins (23), washers (21 and 22), and
screws (20).
3. Connect hydraulic hoses to reach cylinder.
2.2.2. Rear Frame Installation
NOTE! Install same number of shims as removed for
initial adjustment.
1. Install shims (35) and rollers (36).
2. Lower inner mast channel onto rear frame rollers
(36).
NOTE! Adjust frame rollers so there is 0.000 to 0.030
inch (0 to 0.76 mm) side movement of the
rear frame at the tightest part of the inner
mast channel.
3. Connect hydraulic hoses.
4. Connect electrical cable.
BT Prime-Mover Inc.
Return
Service Manual
2001-03-15
517
F-code
Section
C-code
PS
S7.3
7241
Reach, Single (RTX45)
Version no
T-code
001
RTX35/RTX45
518
Return
Service Manual
2001-03-15
F-code
PS
Section
C-code
S7.3
7241
Reach, Single (RTX45)
Version no
001
T-code
RTX35/RTX45
3.1. Removal
1. Partially extend the carriage so that the end of the
inner scissor arm (10) is midway down the track,
exposing the top and the bottom of the reach wear
strip (57).
2. Place a block on each side of the carriage between
the scissors lower back bearings and the
carriages bottom support plate.
3. Turn key switch OFF and disconnect battery
connector.
4. Unbolt two flat head screws (56) at the top and
bottom of reach wear strip (57).
3.2. Installation
1. Grease and wedge the new reach wear strip (57)
between bearing (3) and track.
2. Install top and bottom flat head screws (56).
3. Reconnect battery connector.
4. Remove blocking from the scissor mechanism.
BT Prime-Mover Inc.
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Service Manual
2001-03-15
519
F-code
Section
C-code
PS
S7.3
7241
Reach, Single (RTX45)
Version no
T-code
001
RTX35/RTX45
5. Carriage Bumpers
The carriage bumpers assure that the carriage remains
square with the truck in its nested position. The RTX45 reach
uses rectangular bumpers (54) attached to the chassis side
(back side) of the front frame (42).
6.1. Removal
1. Remove carriage/reach.
2. Remove socket head cap screw (38) and washer
(37) on the end of bearing (36).
3. The carriage bearing should slide off the shaft with
hand pressure. If necessary, a suitable bearing
puller may be required for removal.
520
Return
Service Manual
2001-03-15
F-code
PS
Version no
001
Section
C-code
S7.3
7241
Reach, Single (RTX45)
T-code
RTX35/RTX45
6.2. Installation
1. Install new bearing on shaft. Apply thread locking
compound to socket head cap screw (38). Fasten
cap screw (38) and washer (37) in place.
2. Reinstall carriage/reach. See Shimming Carriage
with Mast on Truck on page 459.
3. Test lift/lower functions of the carriage.
4. Return truck to service.
BT Prime-Mover Inc.
Return
Service Manual
2001-03-15
521
F-code
Section
C-code
PS
S7.3
7241
Reach, Single (RTX45)
Version no
T-code
001
RTX35/RTX45
522
Return
Service Manual
2001-03-15
F-code
Section
PS
S9.0
9311
Height Indication
Version no
000
C-code
T-code
RTX35/RTX45
Height Indication
+1/21
0
Item
No.
1
BT Prime-Mover Inc.
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Service Manual
2001-03-15
Description
Indicator, lift height
523
F-code
Section
PS
S9.0
Height Indication
Version no
T-code
000
RTX35/RTX45
C-code
9311
1. General
A height indicator is fitted to trucks with high lifting heights.
The height indicator shows the current position of the forks
within the staging zone. The character window (1) shows the
fork height, based on information from the sensing device
(pulse sensor) mounted on the mast.
2. Operation
The measurement in the staging zone starts when the
reference switch (S45) is activated and sends a signal to the
main electronic card. The pulse sensor sends pulses to the
main electronic card. The pulse sensor has two channels, A
and B, which give signals at 90 degrees to each other. This
gives information to the main electronic card on whether the
forks are moved up or down.
3. Error Code 13
To clear error code 13 (Height counter error): See Height
Indicator Error on page 336. Error code 13 only appears if
current is not flowing to the height indicator. Before checking
wires, turn key switch OFF and disconnect battery connector.
Check continuity for disconnected or broken electrical wire,
broken cable wire, or faulty terminal connection and repair as
necessary. Reconnect battery connector and turn key switch
ON. Error code 13 should disappear. If error code 13 fails to
disappear continue to check for faulty wires.
524
Return
Service Manual
2001-03-15
F-code
PS
Section
C-code
S9.0
9311
Height Indicator (RTX35)
Version no
T-code
000
RTX35/RTX45
13
17
18
1
14
10
16
11
12 15
7
6
8
19
Wiring
Harness
Item
No.
BT Prime-Mover Inc.
Return
Description
Item
No.
Description
Item
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
2001-03-15
525
F-code
Section
C-code
PS
S9.0
9311
Height Indicator (RTX35)
Version no
T-code
000
RTX35/RTX45
1. Pulse sensor
1.1. Repair
1. Unplug wiring harness at the sensing unit.
2. Remove screws (16) and cover (2).
3. To replace the pulse sensor (15), loosen setscrew
(14) and remove pulse sensor.
4. Remove screws (13) and arm (12). Reverse the
procedure to reinstall pulse sensor.
1.2. Cable
NOTE! Keep cable in good condition. Worn or cables
with deteriorated cable coatings will result in
less accurate lift height readings.
1.2.1. Removal
1. To replace cable (19), remove bolt from the bottom
anchor (3) relieving spring tension.
2. Remove spring (4) and anchor (3) from cable (19).
3. Remove cable (19) from the top anchor. Remove
cable from the pulley.
1.2.2. Installation
1. Install a new cable (19) on the top anchor. Wrap
cable once around the pulley wheel.
2. Attach spring (14) and bottom anchor (3) to the
cable (19).
3. Stretch the cable (19) tight and reinstall the bottom
anchor bolt.
526
Return
Service Manual
2001-03-15
F-code
PS
Section
C-code
S9.0
9311
Height Indicator (RTX35)
Version no
000
T-code
RTX35/RTX45
1.3. Pulley
1.3.1. Removal
1. To replace roller (5), remove cover (2), pulse
sensor, and cable (19).
2. Remove screw (11) and roller.
3. Remove bearing (9), retaining rings (7 and 8), and
bearing (6).
4. Reverse procedure to reinstall.
BT Prime-Mover Inc.
Return
Service Manual
2001-03-15
527
F-code
Section
C-code
PS
S9.0
9311
Height Indicator (RTX45)
Version no
T-code
000
RTX35/RTX45
16
10 11
1
13
14
15
19
12
Wiring
Connector
20
Item
No.
528
Return
Description
Item
No.
Description
Item
No.
Description
Support
Ring, locking
15
Device, sensing
Cover
Mount, bearing
16
Screw
Anchor, bottom
10
Washer
17
Nut
Spring
11
Screw
18
Screw
Roller
12
Arm
19
Cable
Bearing
13
Screw
20
Screw
Ring, retainer
14
Screw, set
Service Manual
2001-03-15
F-code
PS
Version no
000
Section
C-code
S9.0
9311
Height Indicator (RTX45)
T-code
RTX35/RTX45
1. Pulse sensor
1.1. Repair
1. Unplug wiring harness at the sensing unit.
2. Remove screws (16) and cover (2).
3. Loosen setscrew (14) and remove pulse sensor
(15).
4. Remove screws (13) and arm (12). Reverse
procedure to reinstall pulse sensor.
1.2. Cable
NOTE! Keep cable in good condition. Worn or cables
with deteriorated cable coatings will result in
less accurate lift height readings.
1.2.1. Removal
1. To replace cable (19), remove bolt from the bottom
anchor (3) relieving spring tension.
2. Remove spring (4) and anchor (3) from cable (19).
3. Remove cable (19) from the top anchor. Remove
cable from pulley.
1.2.2. Installation
1. Install a new cable (19) on the top anchor. Wrap
the cable once around the pulley wheel.
2. Attach spring (14) and bottom anchor (3) to cable
(19).
3. Stretch cable (19) tight and reinstall the bottom
anchor bolt.
BT Prime-Mover Inc.
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Service Manual
2001-03-15
529
F-code
Section
C-code
PS
S9.0
9311
Height Indicator (RTX45)
Version no
T-code
000
RTX35/RTX45
1.3. Pulley
1.3.1. Removal
1. To replace roller (5), remove cover (2), pulse
sensor, and cable (19).
2. Remove screw (11) and roller.
3. Remove bearing (9), retaining rings (7 and 8), and
bearing (6).
4. Reverse procedure to reinstall.
530
Return
Service Manual
2001-03-15
F-code
Section
PS
S9.1
9501
Load Backrest
Version no
C-code
T-code
001
RTX35/RTX45
Load Backrest
3
2
Item No.
BT Prime-Mover Inc.
Return
Service Manual
Description
Backrest
Screw, cap
Washer, flat
2001-03-15
531
F-code
Section
C-code
PS
S9.1
Load Backrest
9501
Version no
T-code
001
RTX35/RTX45
1. Removal
WARNING The load backrest extension also serves as
a fork stop. All BT Prime-Mover trucks are
shipped with the extension installed.
Removal of extension could result in injury
or product damage.
WARNING Block all wheels to prevent truck from
rolling. Park the truck on a level surface and
make sure all wheels are blocked to prevent
accidental movement.
1. Park truck on a level surface. Turn key switch OFF
and disconnect battery connector. Remove battery
from truck.
2. Turn key switch OFF and disconnect battery
connector.
3. Use a 3/4 inch (19 mm) socket to remove four
screws (2) (two on each side).
4. Lift backrest off the front fork frame.
5. If truck has sideshift, be sure to retrieve two shims
that go between the backrest and front fork frame.
2. Installation
1. Place load backrest on front fork frame.
2. For units with sideshift, slide shims between frame
and backrest, aligning mounting holes.
3. Insert mounting screws (2) and tighten.
4. Repeat steps 2 and 3 for the opposite side.
5. Reconnect battery connector.
6. Return truck to service.
532
Return
Service Manual
2001-03-15
Index
Carriage/Reach . . . . . . . . . . . . . 509
Adjustment Points . . . . . . . . . . . . . . . . 41
Alarm
Back-up . . . . . . . . . . . . . . . . . . . . 292
Travel . . . . . . . . . . . . . . . . . . . . . 292
Applications, Intended . . . . . . . . . . . . 33
Applications, Prohibited . . . . . . . . . . . 33
Aux. Power Hook-Up . . . . . . . . . . . . 308
B
Backrest, Load . . . . . . . . . . . . . . . . . 531
Back-up Alarm . . . . . . . . . . . . . . . . . 292
Battery . . . . . . . . . . . . . . . . . . . . . . . 285
Charging . . . . . . . . . . . . . . . . . . . 287
Cleaning Exterior . . . . . . . . . . . . . 287
Connector . . . . . . . . . . . . . . . . . . 295
History Record . . . . . . . . . . . . . . 288
Inspection and Care . . . . . . . . . . 286
Installation . . . . . . . . . . . . . . . . . . 285
Maintenance . . . . . . . . . . . . . . . . 286
Removal . . . . . . . . . . . . . . . . . . . 285
Retainer Plates . . . . . . . . . . . . . . 106
Rollers . . . . . . . . . . . . . . . . . . . . . 106
Storage . . . . . . . . . . . . . . . . . . . . 288
Bleeding Hydraulic System . . . . . . . . 401
Brake
Adjustment, Caster . . . . . . . . . . . 201
Caster . . . . . . . . . . . . . . . . . . . . . 199
Removal . . . . . . . . . . . . . . . . . 201
Electromagnetic . . . . . . . . . . . . . 177
Adjustment . . . . . . . . . . . . . . . 180
Armature & Coil . . . . . . . . . . . 181
Friction Plate . . . . . . . . . . . . . 182
Installation . . . . . . . . . . . . . . . 179
Removal . . . . . . . . . . . . . . . . . 177
Brake Pedal . . . . . . . . . . . . . . . . . . . 123
Adjustment . . . . . . . . . . . . . . . . . 128
Bearing Replacement . . . . . . . . . 125
Removal . . . . . . . . . . . . . . . 124, 127
Braking Caster Assembly . . . . . . . . . 199
Bumpers
Carriage . . . . . . . . . . . . . . . . . . . 520
Bumpers, Retract
C
Cable, Height Indicator
RTX35 . . . . . . . . . . . . . . . . . . . . 526
RTX45 . . . . . . . . . . . . . . . . . . . . 529
Card
Main Electronic . . . . . . . . . . . . . . 327
Carriage
Bumpers . . . . . . . . . . . . . . . . . . . 520
Reach, Wear Strip . . . . . . . . . . . 519
Roller Bearings
Installation . . . . . . . . . . . .512, 521
Removal . . . . . . . . . . . . .511, 520
Sideshifter . . . . . . . . . . . . . . . . . . 493
Pad Replacementl . . . . . . . . . .497
Removal . . . . . . . . . . . . . . . . .497
Troubleshooting . . . . . . . . . . .501
Carriage, Reach, RTX35 . . . . . . . . . 503
Adjustment . . . . . . . . . . . . . . . . . 509
Assembly . . . . . . . . . . . . . . . . . . 507
Disassembly . . . . . . . . . . . . . . . . 505
Maintenance . . . . . . . . . . . . . . . . 503
Repair . . . . . . . . . . . . . . . . . . . . . 505
Carriage, Reach, RTX45 . . . . . . . . . 513
Assembly . . . . . . . . . . . . . . . . . . 517
Disassembly . . . . . . . . . . . . . . . . 515
Maintenance . . . . . . . . . . . . . . . . 513
Repair . . . . . . . . . . . . . . . . . . . . . 515
Carriage/Reach
Bumpers, Retract . . . . . . . . . . . . 509
Caster Brake Adjustment . . . . . . . . . 201
Clipboard . . . . . . . . . . . . . . . . . . . . . 103
Codes
Error . . . . . . . . . . . . . . . . . . . . . . 339
Warning/Caution . . . . . . . . . . . . . 336
Codes, Standard . . . . . . . . . . . . . . . . . 1
Components
Control Handle . . . . . . . . . . . . . . . 37
Drive . . . . . . . . . . . . . . . . . . . . . . . 37
Hydraulic . . . . . . . . . . . . . . . . . . . . 37
Mast . . . . . . . . . . . . . . . . . . . . . . . 37
Steering . . . . . . . . . . . . . . . . . . . . 37
Components, Location . . . . . . . . . . . . 37
BT Prime-Mover Inc.
Return
533
Index
Contactor
Battery Cut-out
Installation . . . . . . . . . . . . . . . 315
Removal . . . . . . . . . . . . . . . . . 315
Lift Bypass
Installation . . . . . . . . . . . . . . . 313
Removal . . . . . . . . . . . . . . . . . 313
Testing Resistance . . . . . . . . . . . 309
Tip Inspection . . . . . . . . . . . . . . . 309
Control Handle . . . . . . . . . . . . . . . . . 120
Installation . . . . . . . . . . . . . . . . . . 121
Removal . . . . . . . . . . . . . . . . . . . 120
Control Valve . . . . . . . . . . . . . . . . . . 417
Repair . . . . . . . . . . . . . . . . . . . . . 421
Conversion Formulas . . . . . . . . . . . . . 52
Cover
Main Electronic Card Panel . . . . . 101
Motor Compartment Door . . . . . . . 97
Operator Compartment Panel, Left 100
Side Panel, Left . . . . . . . . . . . . . . . 98
Top Console . . . . . . . . . . . . . . . . . 96
Cylinder
Freelift . . . . . . . . . . . . . . . . . . . . . 429
Assembly . . . . . . . . . . . . . . . . 432
Disassembly . . . . . . . . . . . . . 432
Installation . . . . . . . . . . . . . . . 432
Removal . . . . . . . . . . . . . . . . . 430
Reach, RTX35 . . . . . . . . . . . . . . . 433
Assembly . . . . . . . . . . . . . . . . 437
Disassembly . . . . . . . . . . . . . 435
Inspection . . . . . . . . . . . . . . . 436
Installation . . . . . . . . . . . . . . . 438
Removal . . . . . . . . . . . . . . . . . 434
Reach, RTX45 . . . . . . . . . . . . . . . 439
Assembly . . . . . . . . . . . . . . . . 443
Disassembly . . . . . . . . . . . . . 441
Inspection . . . . . . . . . . . . . . . 442
Installation . . . . . . . . . . . . . . . 444
Removal . . . . . . . . . . . . . . . . . 440
Sideshifter . . . . . . . . . . . . . . . . . . 500
Staging . . . . . . . . . . . . . . . . . . . . 425
Assembly . . . . . . . . . . . . . . . . 427
Disassembly . . . . . . . . . . . . . 426
Installation . . . . . . . . . . . . . . . 427
Removal . . . . . . . . . . . . . . . . . 426
D
Data Plate . . . . . . . . . . . . . . . . . . . . . 36
Decals . . . . . . . . . . . . . . . . . . . . . . . 133
Definition
Caution . . . . . . . . . . . . . . . . . . . . . 13
Codes . . . . . . . . . . . . . . . . . . . . . . . 1
Danger . . . . . . . . . . . . . . . . . . . . . 13
Note . . . . . . . . . . . . . . . . . . . . . . . 13
Warning . . . . . . . . . . . . . . . . . . . . 13
Definitions . . . . . . . . . . . . . . . . . . . . . 93
Dimensional Data
RTX35 . . . . . . . . . . . . . . . . . . . . . 34
RTX45 . . . . . . . . . . . . . . . . . . . . . 35
Door, Motor Compartment . . . . . . . . . 97
Drive
Motor . . . . . . . . . . . . . . . . . 107, 165
Motor Direction Sensor . . . . . . . . 364
Motor Speed Sensor . . . . . . . . . . 364
E
Electrical Compartment Fan . . . . . . 141
Electrical Components, Location . . . 268
Electrical Functions . . . . . . . . . . . . . 221
Electrical Schematics . . . . . . . . . . . . 273
Electrical Symbols . . . . . . . . . . . . . . 271
Electrical Troubleshooting . . . . . . . . . 87
Emergency Disconnect Switch . . . . 299
Inspection . . . . . . . . . . . . . . . . . . 299
Installation . . . . . . . . . . . . . . . . . 300
Removal . . . . . . . . . . . . . . . . . . . 299
BT Prime-Mover Inc.
Return
534
Index
F
Fan
Electrical Compartment . . . . . . . . 141
Operator . . . . . . . . . . . . . . . . . . . 129
Fasteners . . . . . . . . . . . . . . . . . . . . . . 43
Designations . . . . . . . . . . . . . . . . . 46
Strength Identification . . . . . . . . . . 45
Torque Values . . . . . . . . . . . . . . . . 50
Truck Torque Specifications . . . . . 51
Filter, Hydraulic . . . . . . . . . . . . . . . . . 405
Floor Board . . . . . . . . . . . . . . . . . . . . 102
Fuses . . . . . . . . . . . . . . . . . . . . . . . . 305
G
Gear
Steering Motor . . . . . . . . . . . . . . . 139
General Troubleshooting . . . . . . . . . . 85
Glossary . . . . . . . . . . . . . . . . . . . . . . . 93
Guard
Overhead . . . . . . . . . . . . . . . . . . 131
H
Handle Interface Module . . . . . . . . . 119
Handle, Control . . . . . . . . . . . . . . . . . 120
Height Indicator
RTX35 . . . . . . . . . . . . . . . . . . . . . 525
RTX45 . . . . . . . . . . . . . . . . . . . . . 528
Horn . . . . . . . . . . . . . . . . . . . . . . . . . 293
Hydraulic Filter . . . . . . . . . . . . . . . . . 405
Hydraulic Pump . . . . . . . . . . . . . . . . 409
Hydraulic System
List of Symbols . . . . . . . . . . . . . . 394
Hydraulic System, Bleeding . . . . . . . 401
Hydraulic Troubleshooting . . . . . . . . . 92
I
Inspection and Care, Battery . . . . . . 286
Introduction . . . . . . . . . . . . . . . . . . . . . 27
Key Switch . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . .
L
Left Operator Compartment Panel . . 100
Left Side Panel . . . . . . . . . . . . . . . . . . 98
Lift Chain, 3 Stage Mast . . . . . . . . . . 476
Lift Limit Override Switch . . . . . . . . . 324
Installation . . . . . . . . . . . . . . . . . 324
Removal . . . . . . . . . . . . . . . . . . . 324
Lifting Gear, RTX35 . . . . . . . . . . . . . 485
Assembly . . . . . . . . . . . . . . . . . . 487
Disassembly . . . . . . . . . . . . . . . . 487
Installation . . . . . . . . . . . . . . . . . 488
Removal . . . . . . . . . . . . . . . 486, 505
Lifting Gear, RTX45 . . . . . . . . . . . . . 489
Assembly . . . . . . . . . . . . . . . . . . 491
Disassembly . . . . . . . . . . . . . . . . 491
Installation . . . . . . . . . . . . . . . . . 491
Removal . . . . . . . . . . . . . . . . . . . 490
Lights
Overhead Guard . . . . . . . . . . . . . 289
Warning . . . . . . . . . . . . . . . . . . . 290
Working . . . . . . . . . . . . . . . . . . . 291
Load Backrest . . . . . . . . . . . . . . . . . 531
Installation . . . . . . . . . . . . . . . . . 532
Removal . . . . . . . . . . . . . . . . . . . 532
Lubricants
Cold Storage . . . . . . . . . . . . . . . . . 65
Lubrication Chart . . . . . . . . . . . . . . . . 79
Lubrication Points . . . . . . . . . . . . . . . 40
M
Main Electronic Card . . . . . . . . . . . . 327
Maintenance . . . . . . . . . . . . . . . . . . . 72
Sideshifter . . . . . . . . . . . . . . . . . . 496
Maintenance Procedures, Planned . . 72
Maintenance Schedule . . . . . . . . . . . 67
Maintenance, Battery . . . . . . . . . . . . 286
BT Prime-Mover Inc.
Return
535
297
297
298
297
Index
Maintenance, Introduction . . . . . . . . . 63
Mast Switch . . . . . . . . . . . . . . . . . . . 301
Adjustment . . . . . . . . . . . . . . . . . 302
Installation . . . . . . . . . . . . . . . . . . 304
Removal . . . . . . . . . . . . . . . . . . . 303
Mast, 3 Stage
Lift Chain . . . . . . . . . . . . . . . . . . . 476
Module, Handle Interface . . . . . . . . . 119
Motor
Brush Performance . . . . . . . . . . . 145
Direction Sensor . . . . . . . . . . . . . 364
Drive . . . . . . . . . . . . . . . . . . 107, 165
General . . . . . . . . . . . . . . . . . 143
Operating Environment . . . . . 143
Troubleshooting . . . . . . . . . . . 144
Primary Sources . . . . . . . . . . . . . 148
Pump . . . . . . . . . . . . . . . . . . . . . . 110
Speed Sensor . . . . . . . . . . . . . . . 364
Steering . . . . . . . . . . . . . . . . . . . . 137
Motor Compartment Door . . . . . . . . . . 97
O
Operator Compartment Floor . . . . . .
Operator Fan . . . . . . . . . . . . . . . . . .
Operator Fan Switch . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . .
Overhead Guard . . . . . . . . . . . . . . . .
Overhead Guard Lights . . . . . . . . . .
Overhead Light Switch . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . .
102
129
325
325
325
131
289
325
325
325
Programming Parameters . . . . . . . .
Proximity Sensor
Steer Stop . . . . . . . . . . . . . . . . . .
Pulley, Height Indicator
RTX35 . . . . . . . . . . . . . . . . . . . .
RTX45 . . . . . . . . . . . . . . . . . . . .
Pulse Sensor, Height Indicator
RTX35 . . . . . . . . . . . . . . . . . . . .
RTX45 . . . . . . . . . . . . . . . . . . . .
Pump Motor . . . . . . . . . . . . . . . . . . .
Pump, Hydraulic . . . . . . . . . . . . . . . .
345
362
527
530
526
529
110
409
R
Reach Carriage, RTX35 . . . . . . . . . . 503
Adjustment . . . . . . . . . . . . . . . . . 509
Assembly . . . . . . . . . . . . . . . . . . 507
Disassembly . . . . . . . . . . . . . . . . 505
Maintenance . . . . . . . . . . . . . . . . 503
Repair . . . . . . . . . . . . . . . . . . . . . 505
Reach Carriage, RTX45 . . . . . . . . . . 513
Assembly . . . . . . . . . . . . . . . . . . 517
Disassembly . . . . . . . . . . . . . . . . 515
Maintenance . . . . . . . . . . . . . . . . 513
Repair . . . . . . . . . . . . . . . . . . . . . 515
Reach Wear Strip . . . . . . . . . . . . . . . 519
Roller Bearings
Carriage
Installation . . . . . . . . . . . .512, 521
Removal . . . . . . . . . . . . .511, 520
Rollers, Battery . . . . . . . . . . . . . . . . 106
RV2 Adjustment Procedure . . . . . . . 354
S
P
Panel, Left Operator Compartment . 100
Panel, Left Side . . . . . . . . . . . . . . . . . 98
Panel, Main Electronic Card . . . . . . . 101
Pivot Pins, Fork Carriage . . . . . 511, 520
Plate, Data . . . . . . . . . . . . . . . . . . . . . 36
Plates, Battery Retainer . . . . . . . . . . 106
Platform Switch . . . . . . . . . . . . . . . . . 357
Installation . . . . . . . . . . . . . . . . . . 358
Removal . . . . . . . . . . . . . . . . . . . 358
Safety
Battery . . . . . . . . . . . . . . . . . . . . . 19
Electrostatic Discharge . . . . . . . . . 23
General . . . . . . . . . . . . . . . . . . . . . 15
Jacking Procedure . . . . . . . . . . . . 64
Welding . . . . . . . . . . . . . . . . . . . . . 24
Sensor
Drive Motor Direction . . . . . . . . . 364
Installation . . . . . . . . . . . . . . . .365
Removal . . . . . . . . . . . . . . . . .364
BT Prime-Mover Inc.
Return
536
Index
Drive Motor Speed . . . . . . . . . . . 364
Installation . . . . . . . . . . . . . . . 365
Removal . . . . . . . . . . . . . . . . . 364
Steer Stop Proximity . . . . . . . . . . 362
Wheel Direction . . . . . . . . . . . . . . 360
Sensor, Pulse
RTX35 . . . . . . . . . . . . . . . . . . . . . 526
RTX45 . . . . . . . . . . . . . . . . . . . . . 529
Sideshifter
Carriage . . . . . . . . . . . . . . . . . . . 493
Pad Replacement . . . . . . . . . 497
Removal . . . . . . . . . . . . . . . . . 497
Cylinder . . . . . . . . . . . . . . . . . . . . 500
Installation . . . . . . . . . . . . . . . . . . 495
Maintenance . . . . . . . . . . . . . . . . 496
Operation . . . . . . . . . . . . . . . . . . 496
Spare Parts, Ordering . . . . . . . . . . . . . 59
Specification Plate . . . . . . . . . . . . . . . 36
Specifications, Oil and Grease . . . . . . 81
Staging Switch . . . . . . . . . . . . . . . . . 358
Installation . . . . . . . . . . . . . . . . . . 359
Removal . . . . . . . . . . . . . . . . . . . 359
Steer
Tachometer . . . . . . . . . . . . . . . . . 217
Wheel . . . . . . . . . . . . . . . . . . . . . 215
Steer Stop Proximity Sensor . . . . . . 362
Adjustment . . . . . . . . . . . . . . . . . 362
Installation . . . . . . . . . . . . . . . . . . 363
Removal . . . . . . . . . . . . . . . . . . . 363
Steering
Bearing . . . . . . . . . . . . . . . . . . . . 219
Motor . . . . . . . . . . . . . . . . . . . . . . 137
Storage, Battery . . . . . . . . . . . . . . . . 288
Switches
Emergency Disconnect . . . . . . . . 299
Key Switch . . . . . . . . . . . . . . . . . 297
Lift Limit Override . . . . . . . . . . . . 324
Mast Switch . . . . . . . . . . . . . . . . . 301
Operator Fan . . . . . . . . . . . . . . . . 325
Overhead Light . . . . . . . . . . . . . . 325
Platform Switch . . . . . . . . . . . . . . 357
Staging . . . . . . . . . . . . . . . . . . . . 358
Test/Inspection . . 297, 301, 323, 357
Work Light . . . . . . . . . . . . . . . . . . 325
Symbols
Caution . . . . . . . . . . . . . . . . . . . . .
Danger . . . . . . . . . . . . . . . . . . . . .
Ordinance . . . . . . . . . . . . . . . . . . .
Prohibitory . . . . . . . . . . . . . . . . . .
Warning . . . . . . . . . . . . . . . . . . . .
T
Tachometer, Steer . . . . . . . . . . . . . . 217
Technical Service Data . . . . . . . . . . . 55
Theory of Operation
Fork Tilt, Down . . . . . . . . . . . . . . 393
High Speed Extend . . . . . . . . . . . 381
Hydraulic Control Handle Interface 369
Hydraulic Supply . . . . . . . . . . . . . 373
Lifting . . . . . . . . . . . . . . . . . . . . . 375
Low Speed Extend . . . . . . . . . . . 379
Lowering . . . . . . . . . . . . . . . . . . . 377
Retract, High Speed . . . . . . . . . . 385
Retract, Low Speed . . . . . . . . . . 383
Sideshift, Left . . . . . . . . . . . . . . . 389
Sideshift, Right . . . . . . . . . . . . . . 387
Top Console . . . . . . . . . . . . . . . . . . . . 96
Transmission . . . . . . . . . . . . . . . . . . 169
Fluid Changing . . . . . . . . . . . . . . 115
Repair
Leakage, Lower Cover . . . . . .174
Leakage, Top Cover . . . . . . . .173
Wheel Bolts . . . . . . . . . . . . . . .175
Travel Alarm . . . . . . . . . . . . . . . . . . . 292
Troubleshooting
General Instructions . . . . . . . . . . . 85
Sideshifter . . . . . . . . . . . . . . . . . . 501
Troubleshooting Guidelines
Electrical . . . . . . . . . . . . . . . . . . . . 87
Hydraulic . . . . . . . . . . . . . . . . . . . . 92
Truck Installation
Cold Storage Conditioning . . . . . . 65
Truck Lubrication Points . . . . . . . . . . 79
Truck Specifications . . . . . . . . . . . . . . 33
Truck Torque Specifications . . . . . . . 51
V
Valve
BT Prime-Mover Inc.
Return
537
13
13
14
14
13
Index
Control . . . . . . . . . . . . . . . . . . . . .
Lowering Rate Adjustment . . . . .
Pressure Limiting, Repair . . . . . .
Pressure Reducing, Repair . . . . .
Pressure Setting . . . . . . . . . . . . .
Seal Kit . . . . . . . . . . . . . . . . . . . .
SWR14, Repair . . . . . . . . . . . . . .
417
423
422
421
422
423
421
W
Warning Lights . . . . . . . . . . . . . . . . . 290
Warning/Caution Codes . . . . . . . 336??
Wear Strip, Reach Carriage . . . . . . . 519
Wheel
Steering . . . . . . . . . . . . . . . . . . . . 215
BT Prime-Mover Inc.
Return
538
Return
Back Cover
Return