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F

Master Service Manual
RTX35/45
Electric Stand-Up Rider Truck
Effective Serial Number RTX3530317001 - UP

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WARNING Read and observe all warnings on this unit
before operating it.

WARNING DO NOT operate this equipment unless all
factory installed guards and shields are
properly secured in place.

Part no: 310428-000

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Date: July 30, 2001

Prime-Mover is a trademark of BT Prime-Mover Inc.,
© 2001 BT Prime-Mover Inc., Muscatine, Iowa.
All Rights Reserved.

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F-code

Section

C-code

BT Prime-Mover Standard Codes
Version no

T-code

000

BT Prime-Mover Standard Codes
B-Code

= Business area

F-Code

= Product family

T-Code

= Product type

C-Code

= Component function

Worksheet standard
W-Code = Working code
R-Code

= Reason code

SO-Code = Assortment
C-Code List
No Function Group

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C-Code

0

Chassis

0000

1

Drive Motor

1000

2

Drive Gear / Transmission

2000

3

Brake / Wheel System

3000

4

Steering System

4000

5

Electrical System

5000

6

Hydraulic / Pneumatic System

6000

7

Operating Function-lifting Mast / Cylinders

7000

8

Peripheral / Installation Equipment

8000

9

Options / Attachments

9000

Service Manual

2001-03-15

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Section

C-code

BT Prime-Mover Standard Codes
Version no

T-code

000

2

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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

Inch (SAE) and Metric Fasteners ...............................................................
Introduction ...............................................................................................
Nomenclature, Threads ............................................................................
Strength Identification ...............................................................................
Conversion of Metric and English Units ....................................................

43
43
44
45
52

Technical Service Data ................................................................................ 55
Ordering Spare Parts ................................................................................... 59
Contents, Section P ..................................................................................... 61
Planned Maintenance ............................................................................... 61
Introduction, Maintenance .......................................................................... 63
Safe Jacking Procedure ............................................................................ 64
Lubricants ................................................................................................. 65

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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

Driver Controls ............................................................................................ 117
Handle Interface Module .......................................................................... 119
Control Handle ......................................................................................... 120
Brake Pedal (RTX35) ...................................................................................
Pedal Removal ........................................................................................
Pedal Bearing Replacement ....................................................................
Pedal Adjustment .....................................................................................

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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

Internal Fittings ........................................................................................... 129
Operator Fan ........................................................................................... 129
Guards .......................................................................................................... 131
Overhead Guard ...................................................................................... 131
Decals ........................................................................................................... 133
Decal with Protective Sheet ..................................................................... 133
Decal without Protective Sheet ................................................................ 133
Steering Motor .............................................................................................
Removal ...................................................................................................
Installation ................................................................................................
Steering Motor Gear Replacement ..........................................................

137
137
138
139

Fan Motor ..................................................................................................... 141
Upper Electrical Compartment Fan ......................................................... 141
Operator Fan ........................................................................................... 142
Motor Maintenance
Schedule/Troubleshooting .........................................................................
General Information .................................................................................
Operating Conditions ...............................................................................
Troubleshooting .......................................................................................

143
143
143
144

Pump Motor (RTX35) ................................................................................... 151
Component Repair ................................................................................... 152
Motor Inspection ...................................................................................... 154
Pump Motor (RTX 45) .................................................................................. 161
Component Repair ................................................................................... 162
Motor Inspection ...................................................................................... 164
Drive Motor .................................................................................................. 165
Motor Disassembly .................................................................................. 166
Motor Inspection ...................................................................................... 167
Transmission. .............................................................................................. 169
Axle Sealing Ring .................................................................................... 171
Leakage ................................................................................................... 173

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Table of Contents
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

Drive Wheel ..................................................................................................
Removal ...................................................................................................
Installation ................................................................................................
Tire Pressing Procedure ..........................................................................

183
183
184
185

Non-Braking Caster Assembly ..................................................................
Caster Pivot .............................................................................................
Thrust Bearing .........................................................................................
Caster Springs .........................................................................................
Caster Stops ............................................................................................

187
189
191
193
195

Non-Braking Caster Wheels ....................................................................... 197
Removal ................................................................................................... 197
Installation ................................................................................................ 198
Braking Caster Assembly ........................................................................... 199
Removal ................................................................................................... 201
Braking Caster Wheel Assembly ............................................................... 203
Removal ................................................................................................... 204
Installation ................................................................................................ 205
Tandem Load Wheels ................................................................................. 207
Removal ................................................................................................... 208
Installation ................................................................................................ 209
Single Load Wheels .................................................................................... 211
Removal ................................................................................................... 212
Installation ................................................................................................ 213
Steering Wheel ............................................................................................ 215
Removal ................................................................................................... 215
Installation ................................................................................................ 216
Steer Tach .................................................................................................... 217

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Table of Contents
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

Electrical Symbols ...................................................................................... 271
Electrical Schematics .................................................................................
Circuit Diagram 1 (12) ..............................................................................
Circuit Diagram 2 (12) ..............................................................................
Circuit Diagram 3 (12) ..............................................................................
Circuit Diagram 4 (12) ..............................................................................
Circuit Diagram 5 (12) ..............................................................................
Circuit Diagram 6 (12) ..............................................................................
Circuit Diagram 7 (12) ..............................................................................
Circuit Diagram 8 (12) ..............................................................................
Circuit Diagram 9 (12) ..............................................................................
Circuit Diagram 10 (12) ............................................................................
Circuit Diagram 11 (12) ............................................................................
Circuit Diagram 12 (12) ............................................................................

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

Horn .............................................................................................................. 293
Removal ................................................................................................... 293
Installation ................................................................................................ 293
Battery Connector .......................................................................................
Location ...................................................................................................
Inspection ................................................................................................
Installation ................................................................................................

295
295
296
296

Start/Stop Switches ....................................................................................
General ....................................................................................................
Key Switch (S17) .....................................................................................
Emergency Disconnect Switch (S21) ......................................................

297
297
297
299

Mast Switch (S31) ........................................................................................
General ....................................................................................................
Adjustment ...............................................................................................
Removal ...................................................................................................
Installation ................................................................................................

301
301
302
303
304

Control Cable and Harness ........................................................................
Fuses .......................................................................................................
Wiring .......................................................................................................
Auxiliary Power Hook-up for
On-board Terminal ...................................................................................

305
305
306
308

Contactors ...................................................................................................
General ....................................................................................................
Directional Contactors .............................................................................
Lift Bypass Contactor ...............................................................................
Battery Cut-out Contactor ........................................................................

309
309
310
312
314

Transistor Panel (Drive) .............................................................................. 317
Motor Connections ................................................................................... 317
Circuit Check. .......................................................................................... 319
Transistor Panel (Pump) ............................................................................. 320

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...............................Table of Contents Motor Connections ...................................................................................................................................................................... Connectivity to Truck ......................... System Draining .......................................................... Bleeding Hydraulic System ................................................................................................... System Refilling .................................. Platform (Right Foot) Switch (S23) ................................. Parameters ................. Error codes .............................. S97 and S99) ....................................................................................... Removal ................................................................... Adjustment Procedures for Setting Brake Switch and Brake Transducer ............................................................................................ Hydraulic Fluid Selection ..... Staging Switch (S45) .............................. RV2 Adjustment Procedure .................................................................................................................................... Installation ...................................... RTX45 Hydraulic Schematic .................................................................................. Changing Hydraulic System Fluid ........................................................................................................................................................................................................... Display ..... Return 9 .................................................. Wheel Direction Sensor ................................................ 323 323 324 325 Main Electronic Card .......................... 403 Installation ......... 367 367 396 397 Hydraulic Fluid ...................................................................................................... Warning/Caution codes ............................................................................................. Optional Light and Fan Switches (S96..... General ......................................................................... 404 © BT Prime-Mover Inc............................................................................................................................... Operation ....................... General ....................................... Lift Limit Override Switch (S33) ..................................................................................................................... Running time .................... RTX35 Hydraulic Schematic ............................................................................................................................................................... 357 357 357 358 360 362 364 Hydraulic System ........................................ Drive Motor Speed/Direction Sensors ..................................................................................................................................... Programming Parameters ....................................................................................................................................................................................... 327 327 327 328 334 336 339 344 344 345 354 Switches and Sensors .......................................................................................................................................................................................................................................................... 399 399 399 400 401 401 355 Hydraulic Tank ........................................................................................................................... 403 Removal .............................. Steer Stop Proximity Sensor A and Sensor B ........................... 320 Micro Switches ...............

.............. 452 © BT Prime-Mover Inc.......................................................................... 433 434 435 436 437 438 Reach Cylinder (RTX45) .................................................................................................................... 425 Staging Cylinder Repair ......... Parts Inspection ............................ Inspection ....................................................................................................................................................................................................................................................... Removal ............................................................................ Removal ........... Installation .............................................................................. Pump Reassembly ............... Removal ............................................................. Removal ..................................................... Disassembly .................................................................................................................................................. Assembly ........................................................................ Installation ...................................................... 430 Reach Cylinder (RTX35) ................................................................................................................................................................................................ 3 Stage ...................................................................................... 407 Hydraulic Pump .................................................................. 429 Freelift Cylinder Repair ........................................... Disassembly ..................................... 426 Freelift Cylinder................................. Inspection ....................................... Pump Disassembly ...................................................................................................................................................................................................... 406 Hydraulic Filter Adapter ........................................................................................................................................ Assembly ............................................................................................................................................................................. Return 10 .............................................................................................................................................................................. Removal .. 409 410 410 413 414 416 Control Valve ................................................................................. Installation .................................................................................. Disassembly .......................................Table of Contents Hydraulic Filter and Adapter .. 405 Hydraulic Filter .................................................................................................................................................................................................................................................................................... Assembly ........................................................................................................................................................... Repair ......... 417 417 417 421 Staging Cylinder.................................... Installation ........................................................................................................................................ 3 Stage ......................................................................... 445 446 447 448 449 450 Tilt Cylinder (RTX45) .......... Inspection ................ 439 440 441 442 443 444 Tilt Cylinder (RTX35) ....................................................................................................................................... Testing ............... 451 Removal ...............................

........................................................... Fork Carriage Pivot Pins ...................................................................................................... 503 503 505 509 511 511 Reach....... Return 11 .. Installation ....................................................................... 461 Mast............... Maintenance ................................ 453 454 455 456 Mast................................................................................................................ Lift Chain Adjustment ............................................. Reach Carriage Wear Strip .............................................. Inspection ........................................................................................................................... 476 476 476 476 482 484 Lifting Gear (Crosshead) (RTX35) ................................................................................................................................................................................................................................................................................... Single (RTX35) ............................................................................... 489 Lifting Gear Repair ................................................................... Maintenance .................................... 459 Three Stage Mast .... Assembly .......................... 466 Shimming Carriage with Mast on Truck .................. 513 513 515 519 520 520 © BT Prime-Mover Inc.......................................................................................................................................................................................... Reach Repair ............................................................................................................ Single (RTX45) ....................... 457 Shimming Carriage with Mast on Truck ............................................................. Carriage Bumpers ................................................... Lift Chain Lubrication .......................................................................................................... Lift Chain Maintenance ........................................................................................... Lift Chain Replacement ................ Troubleshooting ....................................................... Lift Chain Inspection ....... Carriage Roller Bearings .................................................... Reach Repair ................. 3 Stage (RTX35) ...................................................................... Fork Carriage Pivot Pins ............. 3 Stage (RTX45) ............................................................................................................................................................................. Maintenance .................................................................................................................................................... Carriage Bumpers ..................................................................................... Mounting Instructions ...................................................... 485 Lifting Gear Repair ............................................................................................. 493 495 496 496 501 Reach................... 470 Lift Chain ........................................................................................................................................... 468 Three Stage Mast ............................................................................................................................................. Operation ............................ 490 Sideshifter .......................................................................................................................................Table of Contents Disassembly .................. 486 Lifting Gear (Crosshead) (RTX45) ..............................

............. 531 Removal .................. Operation ............................................................................................................................ 532 © BT Prime-Mover Inc................................................ 532 Installation .........................................................................Table of Contents Carriage Roller Bearings ...................................................................................................... 520 Height Indication . 526 Height Indicator (RTX45) ............................................................................................................................................... 529 Load Backrest .................. Error Code 13 ............................................. General .... Return 12 ........................................................................................................................................... 528 Pulse sensor ....................................................................................................... 523 524 524 524 Height Indicator (RTX35) .................................................................................................................................................................................................. 525 Pulse sensor ..................................................

WARNING Warns that an accident can occur if the instructions are not followed.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. DANGER Warns that an accident will occur if the instructions are not followed. NOTE! Marks the risk of an accident or breakdown if the instructions are not followed. The consequences are serious personal injury or possibly death. The consequences are personal injury and/or material damage. and/or large material damage. Return Service Manual 2001-03-15 13 . CAUTION Warns that an accident can occur if the instructions are not followed. © BT Prime-Mover Inc. describe the consequences. 1. The consequences are serious personal injury or possibly death. and instruct how to avoid accidents. Warning Levels Warning texts are given in four levels and provide information on the risks. and/or extremely large material damage.

safety shoes shall always be worn to avoid personal injury. OPEN FLAMES PROHIBITED If open flames are used in situations where open flames are prohibited. a serious accident can occur. GENERAL PROHIBITION If the prohibition is ignored.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. 14 Return Service Manual 2001-03-15 . PROTECTIVE GLASSES When the directive for protective glasses is given. 1. Ordinance Symbols SAFETY SHOES When the directive for safety shoes is given. a serious accident can occur. protective glasses shall always be worn to avoid personal injury. a serious accident can occur.

Know the truck’s controls and what they do.F-code Section C-code PS Safety Version no T-code 001 Safety 1. qualified. Do NOT operate this truck if it needs repair or if it is in any way unsafe. © BT Prime-Mover Inc. and authorized to do so and have read the Operator’s Manual. General Safety Do NOT operate or work on this truck unless trained. Return Service Manual 2001-03-15 15 .

maintenance.F-code Section C-code PS Safety Version no T-code 001 Operate this truck only from the operator’s position. Follow the scheduled inspection steps. 16 Return Service Manual lubrication. always turn the key switch to OFF and disconnect the truck’s battery connector (unless this manual tells otherwise). or jewelry when working on the truck. Before working on this truck. Do NOT wear watches. rings. and 2001-03-15 .

Do NOT use gasoline or other flammable liquids for cleaning parts. Do NOT take “shortcuts”. oil. © BT Prime-Mover Inc.F-code Section C-code PS Safety Version no T-code 001 Follow exactly the safety and repair instructions in this manual. BT Do NOT use an open flame near the truck. or grease that has leaked or spilled on the floor. Clean up any hydraulic fluid. Return Service Manual 2001-03-15 17 .

Do NOT add to or modify this truck without written approval from BT Prime-Mover. Do NOT wash this truck with a hose. Inc.F-code Section C-code PS Safety Version no T-code 001 Always operate and park this truck indoors. 18 Return Service Manual 2001-03-15 .

or filling batteries. © BT Prime-Mover Inc. and skin when checking. recommendations and specifications in the battery and battery charger manufacturer’s manuals. 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. handling. and a rubber apron. Return Service Manual 2001-03-15 19 . this explosive gas can remain in or around the battery for several hours after charging. An open flame or spark can ignite this gas. Be sure there are no open flames or sparks in the charging area. flush the area immediately with cold water. This equipment includes goggles or face shield. flush the area with cold water and get medical help immediately. an explosive gas mixture forms within and around each cell. If the area is not properly ventilated. Should the solution get on your face or in your eyes. Wear personal protective equipment to protect eyes.F-code Section C-code PS Battery Safety Version no T-code 001 Battery Safety WARNING As a battery is being charged. Read. resulting in serious damage or injury. understand. and follow procedures. face. rubber gloves (with or without arm shields).

Never smoke. Do NOT break live circuits at the battery terminals. 20 Return Service Manual 2001-03-15 .F-code Section C-code PS Battery Safety Version no T-code 001 Make sure a shower and eyewash station are nearby in case there is an accident. Keep the charger area well-ventilated to avoid hydrogen gas concentration. or use anything that gives off sparks near a battery. A spark often occurs at the point where a live circuit is broken. A battery gives off explosive gases. use an open flame. Turn the key switch off before disconnecting the battery from the truck at the battery connector.

Vent Hole © BT Prime-Mover Inc. Return Service Manual 2001-03-15 21 . A short circuit or explosion could result. or when the specific gravity is checked. Keep filler plugs firmly in place at all times except when the electrolyte level is checked. when water is added to the cells. Make sure vent holes in filler plugs are open to allow gas to escape from the cells. Keep plugs. terminals. Keep batteries clean. Corrosion causes shorts to the frame and possibly sparks. cables.F-code Section C-code PS Battery Safety Version no T-code 001 Do NOT lay tools or metal objects on top of the battery. and receptacles in good condition to avoid shorts and sparks.

Plug the battery charger ONLY into the battery connector from the battery. Follow the charging procedures in the “Battery Instruction Manual” and in the “Battery Charger Instruction Manual”. See the truck’s specification (data) plate for more information. A smaller or lighter weight battery could seriously affect truck stability. 22 Return Service Manual 2001-03-15 . or any foreign matter to enter the cell.F-code Section C-code PS Battery Safety Version no T-code 001 Do NOT allow cleaning solution. Never plug a battery charger into the truck’s battery connector. dirt. Make sure to install the correct size battery.

Static discharge is also possible through the air when a charged object is placed close to another surface at a different electrical potential. 3. 2. Whenever working on or near static-sensitive electronics. Static charges can accumulate from normal operation of the truck as well as movement or contact between nonconductive materials such as. Connect the ground clamp to an unpainted. Static discharge can occur without your seeing or feeling it. To transport static-sensitive components. © BT Prime-Mover Inc. always use static discharge precautions. place the components in an antistatic bag or box. A wrist strap that is not working properly will not alert that it is bad. grounded surface on the truck frame. synthetic clothing. Place a static discharge wrist strap around your wrist. synthetic soles on shoes. styrofoam coffee cups. including failed components being returned. 4. 1. Accumulated static can be discharged through human skin to a circuit board or component by touching the parts. called electrostatic discharge. The wrist strap and associated accessories should be tested monthly. place them on a properly grounded static mat. Return Service Manual 2001-03-15 23 . If removing or installing static-sensitive components.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. plastic bags. Connect the ground lead to the wrist strap connector. etc.

service. remove them before proceeding with the welding operation. make sure that: • Fire protection equipment is nearby. • Clean the area to be welded. • Know where the nearest eyewash station is. WARNING Coating removal may be by mechanical methods. • Check for shorts to frame. Before working on this truck. • Protect all truck components from heat. or repair the truck. weld spatter and debris. 24 Return Service Manual 2001-03-15 . Flame cutting and/or welding operations should be carried out only in well ventilated areas using local exhaust if necessary. 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. smoke and vapors. chemical methods or a combination of methods. If any shorts are detected. CAUTION Disconnect battery before attempting to inspect.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.

F-code

Section

C-code

PS
Welding Safety
Version no

T-code

001

• Attach the ground cable as close to the weld area as
possible.

• Disconnect all electrical cards before any type of electric
resistance welding is done.
• Do not perform any welding operations near the electrical
components.
• If welding must be done near the battery compartment,
remove the battery from the truck.
• When finished welding, perform all ground tests and
electrical inspections before the truck is operated.

© BT Prime-Mover Inc.

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Section

C-code

PS
Welding Safety
Version no

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001

26

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F-code

Section

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M
Introduction, Service Manual
Version no

001

T-code

RTX35/RTX45

Introduction, Service Manual
The information in this Service Manual covers models RTX35
and RTX45.
Federal and State laws require that operators be completely
trained in the safe operation of trucks in accordance with
OSHA1910.178.
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An Operator’s Manual is sent with every BT Prime-Mover
truck when it is manufactured. If the Operator’s Manual is
missing from the truck, a new manual may be obtained by
contacting:
BT Prime-Mover, Inc.
3305 N. Highway 38
Muscatine, Iowa 52761-8800
(563) 262-7700
This service manual is not a training manual. The information
contained in this service manual is intended as a guide to
help authorized technicians safely service this truck.
The service manual is divided into four separate sections
which cover different kinds of information needed for
servicing these truck types. The main subject for each of
these sections are as described below.
SECTION

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SUBJECT

M

MACHINE INFORMATION

P

PLANNED MAINTENANCE

S

SERVICE INSTRUCTIONS

O

OPTIONS

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Section

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M
Introduction, Service Manual
Version no

T-code

001

RTX35/RTX45

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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

GENERAL PRODUCT INFORMATION

M2.0

TECHNICAL SERVICE DATA

M3.0

ORDERING SPARE PARTS

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M
Contents, Section M
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Section

C-code

M1.0
General Product Information
Version no

000

T-code

RTX35/RTX45

General Product Information
1. Truck Presentation

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The RTX35 and RTX45 are battery powered reach trucks
intended solely to be operated handling pallets or similar load
carriers indoors. In their standard design, the trucks are
equipped with a steering wheel and operating controls within
easy access. The trucks have various maximum lifting
capacities (review the data plate on the truck to note the
maximum lifting capacity).
The trucks are equipped with a 24 or 36 volt electrical system.
Truck speed is regulated by means of a transistor regulator to
provide control of acceleration and speed while driving. Forks
and auxiliary functions are controlled by means of a transistor
regulator. The control of the lift and auxiliary functions and the
speed and positioning of the forks when stacking are done
electrically with the switches on the control handle.
The trucks can be fitted with different accessories including
sideshift, warning light, lights/fan package, travel alarm, and
adjustable driving lights. Trucks can be specially equipped to
work in cold conditions. Consult your local, authorized Dealer
for further information.

1.1. Truck Side Views
The terms rear and forward used indicate the front and back
side of the truck as viewed from the operator’s line of sight for
proper operation of truck. The terms right-hand and left-hand
used indicate the right and left side of the truck as viewed
from the operator’s line of sight for proper operation of truck.

Left Side

Rear

Forward

Right Side

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Section

C-code

M1.0
General Product Information
Version no

T-code

000

RTX35/RTX45

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

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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

1.3. Intended Truck Application
The trucks are solely designed and manufactured to handle
goods. Trucks should be fitted with the appropriate
accessories relevant to the application.

1.4. Prohibited Truck Application
The trucks are designed for handling goods indoors. It is not
permitted to use the trucks for other purposes including the
following:
-

As a towing tractor for trailers.

-

To tow other trucks.

-

To transport/lift passengers.

-

To drive on gravel or grass.

1.5. Truck Data
The following table provides information regarding some
technical data which is of value with daily use of the trucks.
The truck’s lifting capacity, lifting height, and weight can be
found on the truck’s data plate.

Truck data
Lifting capacity rated load
Lift height

RTX35

RTX45

3500 lbs (1587573 grams)

4500 lbs (2041166 grams)

270 inches (6858 mm)

270 inches (6858 mm)

Operating speed without load
24 Volt
36 Volt

6.0 mph (9.65 kph)
6.5 mph (10.46 kph)

6.5 mph (10.46 kph)

Operating speed with load
24 Volt
36 Volt

5.5 mph (8.85 kph)
6.0 mph (9.65 kph)

6.0 mph (9.65 kph)

Service weight without battery

5090 lb (2311 kg)

5800 lb (2633 kg)

Above + battery weight

Above + battery weight

Service weight including
battery
© BT Prime-Mover Inc.

Return

Service Manual

2001-03-15

33

F-code

Section

C-code

M1.0
General Product Information
Version no

T-code

000

RTX35/RTX45

1.6. RTX35 Dimensions
The following diagram shows external dimensions for the
RTX35 truck in its standard design.
Dimensions shown in parentheses are metric, others are inches.
65
(16 .05
52)

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)

10% Empty and 6% Loaded Gradient Performance

34

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Service Manual

2001-03-15

6 (17 9. Return Service Manual 2001-03-15 35 .5 31.0 General Product Information Version no 000 T-code RTX35/RTX45 1.0 (1270) 29. 42 (1066).0 (1168) 95. 50.0 (76) 2.0 (812) to to 30 (762).5 (749) 48 (1219) 1.6 (1894) B 7.0 (50) Battery Roller 7. Dimensions shown in parentheses are metric.5 (139) 74.75 (44) x 4. RTX45 Dimensions The following diagram shows external dimensions for the RTX45 truck in its standard design.0 (203) 32.5 (139) 8.0 (1524) 9.1 (231) Free Lift 10% Empty and 6% Loaded Gradient Performance © BT Prime-Mover Inc.7.5 65) 5.0 (2413) 22.0 (127) 60.0 (1219) +4° 11.0 (101) Forks 40. 36 (914).7 (195) A 46. others are inches.4 (416) 5.0 1028) (787) 5.0 (558) C 48.F-code Section C-code M1.75 (298) Step Height OALH -3° 3.0 (177) Height 16.

F-code Section C-code M1. (Lbs.1 IN EFFECT ON THE DATE OF MANUFACTURE. Maximum (Lbs. Data Plate The illustration below shows the data plate used on the truck.) Battery Wt. Inc. (Lbs. Amp Hr. Model Truck Serial Number 1 Battery Wt.0 General Product Information Version no T-code 000 RTX35/RTX45 1. C 14 Hour Rate 9 8 Attachment Mast Serial Number 10 Inches B 2 Truck Wt. Minimum (Lbs. Muscatine. IA 52761 A 310574-000 Legend 1 2 3 4 5 6 7 8 9 10 11 12 13 14 36 Return Truck model number Truck serial number Weight less battery Maximum battery weight Minimum battery weight Truck voltage DC Battery type UL class Battery maximum AMP hours Hour rate Truck type Mast serial number Attachment Maximum degree rear tilt Truck capacity Service Manual 2001-03-15 .) 11 12 Max ° Back Tilt C 13 B THIS FORKLIFT TRUCK MEETS OR EXCEEDS DESIGN SPECIFICATIONS OF ANSI/ASME B56.8.) DC Voltage A Cap.) 3 4 5 Use UL Class Battery Type 6 Type 7 Max. Less Batt. BT Prime-Mover.

0 General Product Information Version no 000 T-code RTX35/RTX45 2. time display. The orientation of the controls permit operation in a 45 degree or side stance configuration. and switches (key switch. 7 Data plate: See “Data Plate” on page 36. and electrical brake combined in the drive unit. Return Service Manual 2001-03-15 37 . and auxiliary). BT part number 25275-12 15 Steering circuit fuse (F51): 30A. 8 Cover: Removable to provide access for servicing. 2 Battery: 24/36V with different capacities and weights. parking brake. do not connect the battery charger to the battery connector at the truck chassis. The hydraulic functions (lift. gears. instrument panel. and battery status. 12 Mast: The mast is a clear view model. 5 Drive unit with brake: Drive motor. 14 Control circuit fuse (F50): 10A. and travel speed and direction are controlled through the control handle. 6 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). BT part number 25275-13 16 Drive motor fuse (F1): 250A. 13 Electronics: The electronics are in a protected compartment. 3 Battery connector: The truck is connected to the battery through the battery connector. drive wheel. 11 Instrument panel (Operator Display): Provides information on the truck’s running hours. 10 Control console: The operator controls are located either on the console cover or on the control handle. BT part number 305656-000 © BT Prime-Mover Inc. reach. horn. Main Components 1 Hydraulic valve: The valves are located to provide easy access. The steering wheel. emergency stop. and light/fan cluster) are on the console cover. 4 Hydraulic unit: Pump motor and pump are an integrated unit. 9 Pedal: Brake pedal. error codes.F-code Section C-code M1. When charging the battery.

0 General Product Information Version no T-code 000 RTX35/RTX45 17 Pump motor fuse (F3): RTX35 425A. The area of the operator’s compartment in the RTX35/45 is designed so that an operator can do so. BT part number 25275-11 21 12 volt sensor feed fuse (F53): 1/4A.F-code Section C-code M1. 20 Lift height indicator fuse (F52): 1/4A. BT part number 25275-12 25 Fuse (AF2): 10A. 19 Emergency stop The emergency stop switch will stop all control and power functions. BT part number 25275-11 23 Relay1 fuse (F55): 10A. BT part number 25275-15 38 Return Service Manual 2001-03-15 . This feature reinforces that the operator must take advantage of the area of the operator’s compartment and keep all of his or her body in the compartment. 24V BT part number 305656-002 RTX35 355A. BT part number 25275-12 24 Fuse (AF1): 10A. BT part number 25275-11 22 Display power fuse (F54): 1/4A. 36V BT part number 305656-001 RTX45 500A. BT part number 25275-12 26 Auxiliary power circuit fuse (AF3): 2A. A red triangle (reminder light) will be displayed on the instrument panel if the right foot pedal is not depressed. 36V BT part number 305656-004 18 Right foot pedal An operator must keep all of his or her body in the operator’s compartment at all times.

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 1 3 5 4 6 7 9 18 13 14 15 20 21 22 23 24 25 26 2 Main Components of Truck © BT Prime-Mover Inc. Return Service Manual 2001-03-15 39 .

0 General Product Information Version no T-code 000 RTX35/RTX45 3.F-code Section C-code M1. Grease Point Location 1+ 01/2 40 Return Service Manual 2001-03-15 .

F-code Section C-code M1. Return Service Manual 2001-03-15 41 .0 General Product Information Version no 000 T-code RTX35/RTX45 4. Mast Adjustment Points +1 1 0/2 © BT Prime-Mover Inc.

F-code Section C-code M1.0 General Product Information Version no T-code 000 RTX35/RTX45 42 Return Service Manual 2001-03-15 .

The SI system of measurement is described in ISO Standard 1000. This section describes the identification of some common fasteners.F-code Section C-code M1. Return Service Manual 2001-03-15 43 . cap screws. also called SI in all languages).1 Inch (SAE) and Metric Fasteners Version no T-code 001 Inch (SAE) and Metric Fasteners 5 9 10 5 9 10 1. 1973. A fastener used in a design application is selected in accordance with its specifications. Introduction Threaded fasteners such as bolts. nuts. Fasteners that are similar cannot be used as direct replacements. Fasteners made to each specification have identification marks for that specification. © BT Prime-Mover Inc. The metric system used is described as SI (International System of Units. and studs are made to specifications that describe the mechanical strength and hardness of the fastener. This specification is commonly called “grade” for SAE standards and “property” for metric standards. Service persons must use replacement fasteners that have the same specifications as the original.

e. The diameter of the shank of the fastener is shown first in the series. A cap screw will have the following description: INCH METRIC 1/2 x 13 UNC x 1-1/2 A B C D M12 x 1. M20=20 mm (1/2=1/2 inch. The length of a shank is often indicated as part of the description of a fastener. 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. Threads The thread design is specified by a series of numbers and letters for inch and metric fasteners (see figure below). 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. 3/4=3/4 inch).g.1 Inch (SAE) and Metric Fasteners Version no T-code 001 2.F-code Section C-code M1. This length is shown in inches for inch fasteners and in millimeters for metric fasteners.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 Return Service Manual A = THREAD SIZE B = PITCH C = LENGTH 2001-03-15 . Nomenclature. M12=12 mm.

When fasteners must be replaced. © BT Prime-Mover Inc. Strength Identification The most common property classes for metric fasteners are 8. The higher the number. The new fasteners must also be the correct size. Return Service Manual 2001-03-15 45 .8 and 10. The following tables show the marks that identify the grades and property classes for different fasteners.1 Inch (SAE) and Metric Fasteners Version no T-code 001 3. The property class is marked with a number on the head of the cap screw or on a nut. Grades for inch bolts go from 2 to 8.9. NOTE! Identification marks are according to bolt strength. Grade 2 fasteners normally do not have marks. Property classes less than 8.F-code Section C-code M1. indicates increased bolt strength.8 are often not marked. new CAUTION fasteners must be of same strength or greater than original fasteners. or increase in number of marks.

2 7 8 Hex Head Bolts & Cap Screws 5 4.9 12.8 5. Bolt and Screw Designations Types of Fasteners Inch Fasteners Metric Fasteners Strength Levels: SAE Grades Strength Levels: Property Classes * Markings Not Required 2 5 5.8 9.8* 8.9 8.8 4.9 12.8* 9.8* 5.1 Inch (SAE) and Metric Fasteners Version no T-code 001 Table 1.9 Hex Socket Head Cap Screws 5.8 4.8 9.9 Markings for size M5 and Larger 8 Hex Head Flange Screws Same As Above 5 8 12 Point Flange Screws Markings Not Required 8.8 SEMS 46 Return Service Manual 2001-03-15 .6 4.1 4.8 10.8 12.9 9.F-code Section C-code M1.8 10.6* 4.8 8.8 12.

8 9. 2 Hex Nuts Hex Slotted Nuts Hex Flange Nuts © BT Prime-Mover Inc.9 9.9 8.2* 8* 5.9 Markings for size M5 and Larger 12.8* 8.8 12.8* 4.9 8.F-code Section C-code M1.8 10. Stud and Nut Designations Types of Fasteners Metric Fasteners Inch Fasteners Strength Levels: Property Classes Strength Levels: SAE Grades * * Markings Not Required Markings Not Required 4.8 5.6 5* 4.8 10.1 or Studs Optional Geometric Symbols for Size M5 through M11 ONLY.6* 5. Return 5 5 8 9 5 8 9 5 8 9 10 12 10 12 10 12 8 or or Markings Not Required 5 8 9 10 12 5 8 9 10 12 5 8 9 10 12 5 8 9 10 12 Markings Not Required Service Manual 2001-03-15 47 .8 4.1 Inch (SAE) and Metric Fasteners Version no T-code 001 Table 2.

F-code Section C-code M1. Torque Nut Designations Types of Fasteners Inch Fasteners Strength Levels: SAE Grades A Metric Fasteners Strength Levels: Property Classes B C 5 9 10 B C 5 9 10 or All Metal Prevailing Torque Nuts F G 9 10 or All Metal Prevailing Torque Flange Nuts 9 10 or 48 Return Service Manual 2001-03-15 .1 Inch (SAE) and Metric Fasteners Version no T-code 001 Table 3.

F-code Section C-code M1. Return Service Manual 2001-03-15 49 . Torque Nut with Nylon Insert Designations Types of Fasteners Metric Fasteners Inch Fasteners Strength Levels: Property Classes Strength Levels: SAE Grades 5 9 10 5 9 10 or Nylon Insert Prevailing Torque Nuts Markings Not Required or or Markings Not Required 9 10 9 10 or Nylon Insert Prevailing Torque Flange Nuts © BT Prime-Mover Inc.1 Inch (SAE) and Metric Fasteners Version no T-code 001 Table 4.

8.9.9. Protective Treatment CMHC Specification “H” (zinc phosphate). Protective Treatment CMHC Specification “H” (zinc phosphate). ** Property class 10.1 Inch (SAE) and Metric Fasteners Version no T-code 001 Table 5. Protective Treatment CMHC Specification “H” (zinc phosphate).9*** N•m in-lbs N•m in-lbs N•m 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 ------------ N•m ft-lb N•m ft-lb N•m ft-lb M8 x 1. applies also to internally threaded fasteners made of property class 10 material.8 M6 x 1 M8 x 1. 50 Return Service Manual 2001-03-15 .F-code Section C-code M1.25 M10 x 1. Fastener Torque Values Size and Pitch Property.25 * Property class 8.5 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 0.75 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. *** Property class 12. Class 12.9** Property.8* Property. Class 10. applies also to internally threaded fasteners made of property class 8 material. applies also to internally threaded fasteners of property class 12 material.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 -----------40-45 -----------30-33 -----------60-65 22-26 44-48 34-40 70-75 26-30 52-55 M12 x 1. Class 8.

2-13.56 N•m) Loctite® 242 Hydraulic collar mounting bolts 44.82 N•m) Pump motor pole piece screws 250-300 in-lb (28-33 N•m) Drive axle bolts 81 ft-lb (110 N•m) Loctite® 242® Lower transmission cover bolts 18 ft-lb (25 N•m) Steering gear ring bolts 19 ft-lb (25 N•m) Drive tire axle nut 95 ft-lb (130 N•m) Steering wheel E-clip setscrew 5 in-lb (0.6 N•m) Transmission mounting bolts 90 ft-lb (122 N•m) Loctite® 242 Drive wheel nuts 65 ft-lb (88 N•m) Control handle shaft set screw 30 ft-lb (42 N•m) Overhead guard mounting bolts 200 ft-lb (271 N•m) Steering motor mounting bolt 35 in-lb (3.95 N•m) Loctite® 242® Steering motor gear mounting bolt 88 in-lb (10 N•m) Pump motor terminals 140 in-lb (15.5 N•m) Pump motor electrical power cable nuts 100-200 in-lb (11. Return Torque Specification Service Manual 2001-03-15 51 .1 Inch (SAE) and Metric Fasteners Version no T-code 001 Truck Torque Specifications Description Clipboard clip screws 31 in-lb (3.4 in-lb (50 N•m) Hydraulic pump rear cover bolts 42-46 ft-lb (57-62 N•m) Control valve hose clamp nuts 480 + 25 in-lb (54 N•m) Control valve assembly SWR14 mounting screws 15 ft-lb (20 N•m) Control valve lift/lower recondition seal kit screw and block screws 6 ft-lb (8 N•m) Lift chain adjusting nuts and locknuts 200 ft-lb (271 N•m) Mast mounting plate bolts 85 ft-lb (115 N•m) Battery box bolts 400 ft-lb (543 N•m) Overhead guard post base bolts 25 ft-lb (34 N•m) Sideshifter lower hook bolt 65 ft-lb (90 N•m) Sideshifter lower hook set screw 21 ft-lb (30 N•m) Sideshifter safety screw 70 ft-lb (100 N•m) Sideshifter cylinder hydraulic fittings 56 ft-lb (80 N•m) Single reach inner arm capscrew 85 ft-lb (115 N•m) Single reach outer arm nut 295 ft-lb (405 N•m) © BT Prime-Mover Inc.F-code Section C-code M1.

454 kilograms (kg) kilograms 2.280 feet (ft) yards 0.007 megapascal (MPa) megapascals 145.49 grams (g) grams 0.764 feet² (ft²) LINEAR Multiply By To Get Multiply By To Get inches 25.F-code Section C-code M1.305 meters (m) meter 3.) feet 0.4 millimeters(mm) millimeter 0.746 kilowatts (kW) kilowatts 1.001 tons (2000 lb) tons (2000 lb) 0.18 kilograms (kg) kilograms 0. Conversion of Metric and English Units AREA Multiply By To Get Multiply By To Get inches² 6.035 ounces (oz) pounds (lb) 0.914 meters (m) meter 1.094 yards (yd) miles 1.907 metric ton (t) metric ton 1.205 pounds (lb) tons (2000 lb) 907.451 centimeters² (cm²) centimeters² 0.145 pounds/in² (psi) pounds/in² 0.04 pounds/in² (psi) Return Service Manual 2001-03-15 .1 Inch (SAE) and Metric Fasteners Version no T-code 001 4.102 tons (2000 lb) POWER Multiply By To Get Multiply By To Get horsepower 0.093 meters² (m²) meters² 10.621 miles (mi) MASS Multiply By To Get Multiply By To Get ounces (oz) 28.34 horsepower (hp) PRESSURE 52 Multiply By To Get Multiply By To Get pounds/in² 6.155 inches² (in²) feet² 0.895 kilopascal (kPa) kilopascals 0.039 inches (in.609 kilometers (km) kilometer 0.

785 liters liters 0.264 gallons.S.S.113 Newton meter (N•m) Newton meter 8. (qt) gallons.S.205 gallons. 1.738 foot pounds ft-lb VELOCITY Multiply By To Get Multiply By To Get miles/hour 1. U. 3.57 milliliters (ml) milliliters 0. 0.S. U. (gal) gallons. 1.061 inches³ (in³) inches³ 0.034 ounces (oz) © BT Prime-Mover Inc.621 miles/hour (mph) VOLUME Multiply By To Get Multiply By To Get inches³ 16.946 liters liters 1. U.S.F-code Section C-code M1.387 centimeters³ (cm³) centimeters³ 0. U.56 Celsius (C) (Celsius x 1.8) +32 Fahrenheit (F) By To Get TORQUE Multiply By To Get Multiply inch pound 0. Imp. U.609 kilometer/hour (km/h) kilometer/hour 0. Imp.016 liters liters 61.83 quarts.S.851 inch pounds in-lbs feet pound 1. (qt) quarts. U.S. 0.356 Newton meter (N•m) Newton meter 0. Return Service Manual 2001-03-15 53 . U.205 quarts.83 gallons.057 quarts. (gal) gallons. (gal) ounces 29.S. Imp. Imp. U. 0.024 inches³ (in³) quarts. (qt) quarts.1 Inch (SAE) and Metric Fasteners Version no T-code 001 TEMPERATURE Multiply By To Get Multiply By To Get (Fahrenheit -32) 0.

1 Inch (SAE) and Metric Fasteners Version no T-code 001 54 Return Service Manual 2001-03-15 .F-code Section C-code M1.

57 17.8 inch (20 mm) Minimum commutator diameter 2.57 Oil volume 1 gallons (3. MODEL RTX35 (192 inch mast) RTX45 (210 inch mast) Series .79 liters) 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.9 kw (36 volt lift motor) Duty factory 1 hour continuous 1 hour continuous Minimum brush length 0.4 oz. Specifications are subject to change without notice.0 Technical Service Data Version no T-code 000 RTX35/RTX45 Technical Service Data NOTE! When the battery is fully charged. performance may vary due to motor and system efficiency tolerance. (180 grams) 6.79 liters) 1 gallons (3.DC Series .F-code PS Section C-code M2.90 inches (74 mm) 2.8 inch (20 mm) 0. Technical service data represents nominal values obtained under typical operating conditions.25 hp/4. Return Service Manual 2001-03-15 55 .66 kw (36 volt drive motor) 16hp/11. (180 grams) Vertical motor spiral-bevel output Vertical motor spiral-bevel output Gear ratio 17.DC DRIVE MOTOR Type Power 5 hp/3.90 inches (74 mm) Minimum brush spring tension 6.725 kw (24 volt drive motor) 6.4 oz.

6860 (3114 2000 lb battery 16.5 x 10. lbs. (kg) HYDRAULIC UNIT Power (upper staging lift reading with worn-in motor) 24 volt 36 volt Revolutions/minute at work pressure Duty factor 24V -1400 empty-750 loaded 36V .5 x 10. lbs.F-code Section C-code PS M2.4 oz (180 grams) 40 oz (1120 grams) Pressure at rated load 2450 psi (16890 kPa) 2450 psi (16890 kPa) 56 Return Service Manual 2001-03-15 .80 inches (72 mm) Minimum brush spring tension 6.5” BC . (kg) 1600 lb battery 14.8 inch (20 mm) 0.6 inches (127 x 91 mm) 5.0 x 3.3240 (1471) 2000 lb battery 16.2100 empty-1500 loaded 36 volt 11.4910 (2229) Drive wheel weight with rated load and battery.4025 (1827) 95 ft-lb (130 N•m) 95 ft-lb (130 N•m) 5.90 inches (74 mm) 2.4315 (1959) 2000 lb battery 16.5” BC .8690 (3945) 300 Amp 400 Amp Not Applicable (N/A) 425 Amp WHEELS Torque axle nut Load wheel Load wheel weight with rated load.5” BC .0 inches (343 x 140 x 254 mm) 13.5” BC .0 inches (343 x 140 x 254 mm) Drive wheel weight without load with battery.4750 (2156) 2400 lb battery 21” BC .2250 empty-1450 loaded 36V .5 x 5.0 Technical Service Data Version no T-code 000 RTX35/RTX45 MODEL RTX35 (192 inch mast) RTX45 (210 inch mast) Drive wheel 13.5” BC . (kg) 1600 lb battery 14. lbs.5” BC .5” BC .6 HP with 20% duty cycle 20% on 5 minute cycles Minimum brush length 0.5” BC .3430 (1557) 2000 lb battery 16.0 x 3.3780 (1716) 2400 lb battery 21” BC .8595 (3902) 2400 lb battery 21” BC .7145 (3244) 2000 lb battery 16.62 inch (16 mm) Minimum commutator diameter 2.5 x 5.5” BC .6735 (3054) 2000 lb battery 16.6 inches (127 x 91 mm) 1600 lb battery 14.

Amp-hrs.0 inches (533 mm) 2400 lb (1089 kg) (2900 lb (1317 kg) 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 Capacity (Max.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 14.0 inches (417 x 986 x 813 mm) 20.0 inches (531 x 986 x 813 mm) 1020 Amp hours 1000 Amp hours 875 Amp hours N/A 1000 Amp hours 875 Amp hours 14.8 x 32.8 x 32. Return Service Manual 2001-03-15 57 .0 inches (417 x 986 x 813 mm) 16.4 x 38.5 inches (419 mm) 2000 lb (908 kg) (2300 lb / 1044 kg) 16.5 inches (368 mm) 1600 lb (726 kg) (2300 lb / 1044 kg) 16.4 x 38.8 x 32.0 inches (366 x 986 x 813 mm) 16.F-code Section PS C-code M2.9 x 38.4 x 38.8 x 32.) 24 volt E EE Weight Minimum (Maximum) © BT Prime-Mover Inc.5 inches (419 mm) 2000 lb (908 kg) (2300 lb / 1044 kg) 21.

) N/A 95 fpm (29 m/min.0 Technical Service Data Version no T-code 000 RTX35/RTX45 MODEL RTX35 (192 inch mast) RTX45 (210 inch mast) Without load and hot motor 24 volt 36 volt 6. type EE 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 .) 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 Lift with rated load CURRENT READINGS Driving without load Driving with rated load Lifting without load 24 volt 36 volt.) Lower without load. type E 36 volt. electrical valve 80 fpm (24.46 kph) With rated load and hot motor 24 volt 36 volt 5.5 mph (10.) Lower with rated load.85 kph) 6.3 m/min.3 m/min. electrical valve 80 fpm (24.) 95 fpm (29 m/min.65 kph) N/A 6.46 kph) N/A 6. type E 36 volt.0 mph (9.37 m/min.) 24 volt 36 volt 34 fpm (10.0 mph (9. type EE Lifting with rated load 24 volt 36 volt.5 mph (8.) 90 fpm (27.) 60 fpm (18.F-code Section C-code PS M2.4 m/min.4 m/min.65 kph) 6.0 mph (9.5 mph (10.65 kph) 24 volt 36 volt 57 fpm (17.5 m/min.) 80 fpm (24.4 m/min.4 m/min.) N/A 60 fpm (18.

5. the truck may malfunction. component parts may not be interchangeable. © BT Prime-Mover Inc. and battery voltage. If the model. call your local BT PrimeMover Dealer for assistance. Identify truck model. serial number. 2. 4. Return Service Manual 2001-03-15 59 . The following is an explanation of a serial number: RTX 45 3 1 125 001 Number of unit for that day Day of year (365) Year (2001) Decade (2000) Capacity (4500lb) Model (RTX) CAUTION Although some trucks appear to be similar. Call your local BT Prime-Mover Dealer and indicate the part number. 7.F-code PS Version no Section C-code M3. 6.0 Ordering Spare Parts T-code 000 Ordering Spare Parts 1. serial number. If an incorrect part is used. Locate the item number in the table. or the article number cannot be found on the truck. Note the part number. Locate the fault on the truck. Locate the page with the exploded diagram and find the item number for the part required. 3. Select the column for the actual truck model and serial number.

0 Ordering Spare Parts Version no T-code 000 60 Return Service Manual 2001-03-15 .F-code Section C-code PS M3.

0 OIL AND GREASE SPECIFICATIONS Service Manual 2001-03-15 61 . Return P1.0 INTRODUCTION.0 LUBRICATION CHART P4.F-code PS Version no Section C-code P Contents. Section P T-code 001 Contents. Planned Maintenance © BT Prime-Mover Inc. Section P 1.0 SERVICE SCHEDULE P3. MAINTENANCE P2.

F-code Section C-code PS P Contents. Section P Version no T-code 001 62 Return Service Manual 2001-03-15 .

Maintenance A regularly scheduled recommended to enable: maintenance program is • Maximum truck performance • Maximum truck life • Reduction of costly down time • Avoidance of unnecessary repairs Scheduled maintenance includes: • Lubrication • Cleaning • Inspection • Service The schedules of maintenance and lubrication given in this section of the service manual cover up to one year’s operation of a truck. © BT Prime-Mover Inc. not as a rigid structure.0 Introduction.Use only spare parts approved by BT Prime-Mover. . Operators of trucks may wish to adapt to local requirements. but it is emphasized that the schedules represent minimum manufacturer requirements. When operating under abnormal or severe conditions.F-code PS Section C-code P1. . These schedules are based on hourly usage and can be adapted to suit most normal one shift patterns. 30 hours per week usage Double shift. perform these services more often to keep the unit in good operating condition. Maintenance Version no T-code 000 Introduction. The following hourly usage figures have been used when calculating the schedule: Single shift. Return Service Manual 2001-03-15 63 . and all items should be included in a service program to ensure minimum downtime and a high safety status of the equipment. 90 hours per week usage The schedules are intended only as a guide. 60 hours per week usage Triple shift.Always clean the equipment and carry out a full safety check after service.

stabilize the top of the mast with an overhead chain hoist.50 inch (12. 3. Maintenance Version no T-code 000 1. Place the jack under the designated jacking points. Use jack stands or solid blocks to support the truck.7 mm). If possible. Never block the truck between the mast column and floor. Safe Jacking Procedure To perform maintenance that requires the truck to be lifted from the floor. Place the jack in the designated jacking position. Keep hands and feet clear from beneath truck while jacking. Jack the side of the truck so that the load wheel is off the floor no more than 0. Elevate Either Side of Truck 1. Turn key switch OFF and disconnect battery connector. 2. 5. Before jacking the truck. 2. Jack only in these areas 1. observe the proper safety precautions as follows: Stop block Pivot plate 1. Use a suitable hoist to stabilize the mast. Jack the rear of the truck so the drive tire is off the floor no more than 3 inches (76 mm). Block truck in place. 1. if necessary. 3. If the block is excessively worn or missing. take the truck out of service. 2. Lower the forks completely. Install stop block on pivot plate.F-code Section C-code PS P1. do not rely on jacks. Elevate Rear of Truck 1. WARNING Use extreme care whenever the truck is jacked up for any reason. 4. 64 Return Service Manual 2001-03-15 .1.0 Introduction. 3. check the stop block on pivot plate to make sure it is good.1. Block truck in place. Remove any load. Place the jack in the designated jacking position.

it is recommended that all electrical connections be inspected and the electrical compound replenished if necessary. trucks equipped with cold storage or freezer conditioning packages have electrical compound applied to all electrical connections during assembly.1. 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.0 Introduction. Compound is applied to the front and backside of each individual electrical lug and around the base of the plug to the power amplifiers. 2. During scheduled maintenance.F-code PS Section C-code P1. If the truck is to be used in a cold storage application. Lubricants 2. Maintenance Version no T-code 000 2. 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. A freezer conditioning package is available for applications with continuous operation to -31° F (-35° C). Return Service Manual 2001-03-15 65 . 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). Electrical Component Cold Storage Conditioning To prevent moisture contamination in the electrical system. © BT Prime-Mover Inc.2.

0 Introduction. Maintenance Version no T-code 000 66 Return Service Manual 2001-03-15 .F-code Section C-code PS P1.

7 2550 2550.3 1700 1700.2 1700. Return 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 X X X X X X X X 2001-03-15 67 . 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.1 1700.1 0640. Check electrical armature (See “Armature Electrical Check” on page 157.6 1700.2 0640.F-code Section PS P2. copper.1 3300 3300.) Drive Gear Check for oil leakage Brake Clean dust and debris © BT Prime-Mover Inc.3 1700. Planned Maintenance Schedule ITEM 0000 0000.4 1700. and plastic particle accumulations from the motor using compressed air.5 1700.3 0000.1 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.4 0000.2 0000.1 0000.5 0640 0640.0 Service Schedule Version no C-code T-code 001 RTX35/RTX45 Service Schedule 1.

2 5300.2 5110 5110.F-code Section C-code PS P2.3 5300.5 5400 5400.1 5110. 0.2 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.2 3500.4 3500 3500.3 5110.4 5200 5200.1 5400. 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.2 5110.1 5300 5300.1 5300.4 4100 4100.1 4100.3 3300.5 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).2 3300.4 5300. 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 X Service Manual X X 2001-03-15 .0 Service Schedule Version no T-code 001 RTX35/RTX45 ITEM 3300.3 3500.1 3500.

5 7100.7 7100.2 7200.4 5400.1 6000 6000.5 5400.8 7100.1 7200.2 6000.3 7100.3 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).3 5400.6 5710 5710.4 7100. 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.F-code Section PS P2.0 Service Schedule Version no T-code 001 ITEM 5400.3 6000.6 7100. 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. Return 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 X X 2001-03-15 69 .9 7200 7200.4 6000.1 6000.5 7100 7100.1 7100.2 7100.

2 7400. 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 X 2001-03-15 .5 7200.1 7310.1 7400.6 7400. 7400.6 7200.2 7400.5 7400.3 7400.4 7400.F-code Section C-code PS P2.4 7200.0 Service Schedule Version no T-code 001 RTX35/RTX45 ITEM 7200.7 7310 7310.7 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.

Return Service Manual 2001-03-15 71 .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 3300 (RTX35 HAS NO BRAKE ON CASTER WHEEL BRAKE ON TOP OF DRIVE MOTOR ONLY) Planned Maintenance Schedule © BT Prime-Mover Inc.

1. Hydraulic System Inspect the entire truck for leaks. DO NOT operate the truck until it has been inspected and repaired by a qualified technician. 2. This prevents overloading the battery and increases the operating economy of the truck. (See “Parameter 13 “Battery Type” Adjustment” on page 347.1. It is the operator's responsibility to report any problems with the truck to the appropriate personnel. When the battery has reached a charge level equivalent to 70% discharge. A further 10% of the battery’s capacity can then be used before the battery discharge indicator slows down the lift function. a warning signal is given via flashing lights. 72 Return Service Manual 2001-03-15 .1. Battery Discharge Indicator with slow down The battery discharge indicator indicates the current charge status of the truck’s battery. As with the “Schedule”.) 1 Full charge battery 1/2 Half charged battery 0 Discharged battery The battery discharge indicator has an integrated cut-out function that slows down the truck’s lift function when a predetermined charge level has been reached.1.F-code Section C-code PS P2. especially around the hydraulic pump assembly and the lift cylinders.2. The operator is ultimately responsible for the safe operation of the truck. Planned Maintenance Procedures This section describes how to perform the services listed in the Schedule of Planned Maintenance Operations. Report any problems to the appropriate personnel.0 Service Schedule Version no T-code 001 RTX35/RTX45 2. 2. Any sign of oil on the floor under the truck is an indication that the truck may be leaking hydraulic oil or transmission fluid. 2. this section is subdivided into service intervals. The truck should not be operated until it has been inspected and repaired by a qualified technician. Services Performed Daily or Every 8 Operating Hours The daily inspection is to be made by the operator prior to each operating shift.

4. Report any problems to the appropriate personnel. DO NOT operate the truck until it has been inspected and repaired by a qualified technician.2.5.3. lift and lower functions. 2. Trash that is wrapped around wheels and axles will cause premature tire wear and bearing damage.3. Brake When the foot is lifted from the brake pedal it should stop a fully loaded truck at full speed in approximately one truck length. Inspection All of the services and inspections listed for the daily inspection should be performed at this time. All shields must be in place and functional. The inspection procedure should be more thorough. 2.1.F-code Section PS P2. Return Service Manual 2001-03-15 73 .1. Services Performed Monthly or Every 120 Operating Hours The monthly planned maintenance service should be performed by a qualified technician. 2. The floors should be kept clear of trash to prevent damage to the wheels and tires. Functions/Operations Test the truck for the proper operation of all functions including the travel controls.1. Report any problems to the appropriate personnel.1.0 Service Schedule Version no 001 C-code T-code RTX35/RTX45 2.2. the brakes. 2. damaged or missing parts. Frame/Sheet Metal Inspect the truck for loose.2. and the emergency disconnect (stop) button.2. © BT Prime-Mover Inc. 2. Safety devices must be operational.2. Minor deficiencies should be corrected. 2. Wheels/Tires Inspect wheels and tires for wear and damage. Transmission Inspect for oil leakage. DO NOT operate the truck until it has been inspected and repaired by a qualified technician.

6. However. 2. Drive Motor Blow out the drive motor fan and vents.F-code Section C-code PS P2. Contactor Tips (NOT Sealed) Inspect contactor tips for arcing. the di-electric compound in the plug-in connectors should be renewed.0 Service Schedule Version no T-code 001 RTX35/RTX45 2.170 at the 80% discharged level.4. or burning. the tips should be replaced. DO NOT file tips. 2. Replace tips only in complete sets. Check for any signs of oil on the drive motor fan and air vents. Plug-in connectors should be unplugged and plugged back in to clean the terminals. Minimum brush lengths are given in the specifications section of this manual. 74 Return Service Manual 2001-03-15 .8. Battery Contact your battery dealer for specific instructions on care and maintenance of the battery.5.2. Electrical Connections All electrical connections should be checked that they are clean and tight.0625 inch (1. 2. However. 2. Only the battery manufacturer can accurately determine the fully charged and 80% charged levels. pitting. As a rule of thumb.6 mm) of touching the brush holder. Minor pitting of the tips is not a problem.2. and then only with effective chip-guarding and personal protective equipment worn. Some contactors have concealed tips or are fully sealed so that tips cannot be replaced. Motor Brushes The drive motor is equipped with a brush wear sensor which will indicate when the brushes need replacing. freezer use. Check for any damage to the fan or air vents. An average battery will have a specific gravity of 1. Contact the battery manufacturer for this information. WARNING Compressed air used for cleaning MUST be reduced to less than 30 psi (206 kPa).7. the brushes should be replaced if the brush spring is within 0. there are many different batteries on the market.2. If the truck is equipped with any of the cold storage.2.2. if the tips are pitted through the tip to the copper bar. or corrosive environment application packages.

© BT Prime-Mover Inc. freezer use.2.10.11. machine oil. Frame Lube (“Lubrication Chart” on page 79) The pressure type grease fittings (zerk fittings) should be lubricated with Texas Refineries #880 Crown and Chassis lubricating grease. Hydraulic Reservoir Check the fluid level in the hydraulic reservoir. The total number of grease fittings depends on the truck options when built. Regular fittings may be found on the transmission mounting bearing and the mast chain sheave shafts. Pivot Points There are some pivot points and other items that need to be lubricated but do not have grease fittings. A truck with a cold storage.0 Service Schedule Version no 001 C-code T-code RTX35/RTX45 2. or corrosive environment application package will have more grease fittings than a standard truck. Lubricate these non-greasable wear points with a drip oil can using 10 wt. 2.2. 2. Look for flush-type grease fittings on the load wheel axles.2.9.F-code Section PS P2. Return Service Manual 2001-03-15 75 .

1. etc. All deficiencies should be corrected. the following recommendations are suggested for periodic maintenance inspections for the drive motor armature. 2. Sudden temperature changes (continuous in-dooroutdoor movement) that is refrigeration plant.1.0 Service Schedule Version no T-code 001 RTX35/RTX45 2. Inspection All of the services and inspections listed for the daily and monthly inspection should be thoroughly performed at this time. foundries.3. 3.F-code Section C-code PS P2. 2. High temperature areas. • Routine inspection every 480 hours (4 months). lumber or flour mills. that is cement plant. Services Performed Every 480 or 960 Operating Hours The planned maintenance service should be performed by a qualified technician. etc. that is steel mills.4. Dusty or sandy locations. coal dust or stone-crushing areas. 2. 2. • Normal Service 8 hours per day operation • Routine inspection every 960 hours (8 months).4. 76 Return Service Manual 2001-03-15 .3. This would be a good time to arrange other repairs that have been noted on the monthly service. • Severe Service 24 hours of daily operation 1. Drive Motor Since the operating environment of material handling equipment varies widely. Services Performed Annually or Every 1440 Operating Hours The annual planned maintenance service will take a longer period of time to complete than does the monthly service.

This can only be done by properly equipped and trained personnel. allow solution to run out of drain port while transmission is running. Transmission The transmission fluid should be drained once a year. Replace the drain plug bolt. Pour clean solution into the fill port accessed from battery compartment. With drive tire off the floor. Refill the transmission with the proper clean oil before operating the truck.4. © BT Prime-Mover Inc. Flush the transmission case. Remove the bolt to drain the transmission fluid.F-code Section PS P2.4. To drain the reservoir.4.2. Hydraulic System The hydraulic system should be drained. so that truck will lift a rated load. Put a rated truck capacity load on the forks and adjust pressure relief valve. WARNING Before siphoning oil from reservoir. The drain port is located on the lower portion of the side cover opposite the drive tire. and the pressure relief valve setting should be checked and adjusted. Allow the solution to drain well before replacing the drain plug bolt.4. Operate the raise and lower function several times to purge air from system. contact an authorized battery dealer to determine the overall condition of the battery. Fill the reservoir with proper clean oil. 2. This will maintain proper lubrication properties within the system. flushed and refilled.3. Stop flushing when the solution runs clean. Check the oil level.0 Service Schedule Version no 001 C-code T-code RTX35/RTX45 2. Return Service Manual 2001-03-15 77 . if necessary. Battery At approximately 1500 hours. Determine if the battery needs to be washed down. Siphon oil from the reservoir and purge the oil out of hydraulic system. remove the reservoir filter assembly. 2. make certain siphon is clean.

Retighten jam nut and torque. The friction disc should be replaced once thickness is 0. Remove the brake assembly and inspect the friction disc for wear. Lift and carriage chains should be checked every 720 hours.003 inch (0. Adjust chains until the top of the forks are 2.5.4. loosen jam nut and tighten chains equally until the top of the rails are level in the fully lowered position. The air gap should not exceed 0. To adjust inner rails.25 inch (6 mm) or less.6.8 mm) off of the floor.4. The armature and magnetic coil should be adjusted if machine will not meet stopping and holding specifications.F-code Section C-code PS P2.076 mm) throughout the circumference.014 inch (0.0 Service Schedule Version no T-code 001 RTX35/RTX45 2. Carriage chains should be adjusted in the fully lowered position with the forks level. Lift and Carriage Chains.36 mm) and should remain within 0.0 inches (50. 78 Return Service Manual 2001-03-15 . 2. A chain gauge should be used to check stretch of the links. Brakes Follow procedures for brake removal before inspecting.

Return Service Manual 2001-03-15 79 .) A A D B A C O = Oil change 2 3 + 1/21 0 4 6 5 1 1 Truck Lubrication Points © BT Prime-Mover Inc. 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 81.0 Lubrication Chart Version no C-code T-code 000 RTX35/RTX45 Lubrication Chart Interval/Running Hours Pos.F-code Section PS P3.

F-code Section C-code PS P3.0 Lubrication Chart Version no T-code 000 RTX35/RTX45 80 Return Service Manual 2001-03-15 .

Approved Oils and Grease Specification Lubricant Standard and Corrosion Continuous Operation Above 23° F (-5° C) Cold Storage Freezer Continuous Operation To 5° F (-15° C) Intermittent Operation To -13° F (-25° C) Continuous Operation To 31° F (-35° C) Application area Bearings and bushings Hydraulic system A Grease Mystik JT-6 Mystik JT-6 Mobiltemp SHC 32 B 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. © BT Prime-Mover Inc. Sideshift D Transmission oil Motor Oil E Grease Molykote 200025 * Molykote 200025 Molykote 200025 E Grease 49670-00 * 49670-00 49670-00 C * Refer to section 10000 of Parts Book for special lubricants.0 Oil and Grease Specifications Version no T-code 000 RTX35/RTX45 Oil and Grease Specifications 1. Reach. Reach. Return Service Manual 2001-03-15 81 .F-code Section C-code PS P4. Sideshift Mast rails.

0 Oil and Grease Specifications Version no T-code 000 RTX35/RTX45 D E B + 1/21 0 C A A 82 Return Service Manual 2001-03-15 .F-code Section C-code PS P4.

Section S 1. Section S Version no T-code 000 Contents. Return Service Manual 2001-03-15 83 .F-code PS Section C-code S Contents. Service Instructions NO FUNCTION GROUP C-CODE TROUBLESHOOTING GUIDELINES 0 CHASSIS 0000 1 MOTORS 1000 2 DRIVE GEAR / TRANSMISSION 2000 3 BRAKE / WHEEL SYSTEM 3000 4 STEERING SYSTEM 4000 5 ELECTRICAL / PNEUMATIC SYSTEM 5000 6 HYDRAULIC SYSTEM / CYLINDERS 6000 7 LIFTING MAST 7000 8 PERIPHERAL / INSTALLATION EQUIPMENT 8000 OPTIONS / ATTACHMENTS 9000 9 © BT Prime-Mover Inc.

Section S Version no T-code 000 84 Return Service Manual 2001-03-15 .F-code Section C-code PS S Contents.

The “negative side” of any component refers to the terminal on that component that is farthest electrically from the battery positive terminal.2 volts for a 24 volt system. The battery voltage must be at least 37. “Forward direction” refers to travel with the forks first. If it is not. and in many cases desirable. If the truck is still not repaired. After the final test is completed. If the battery voltage is below 22 volts (no load). 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. General Troubleshooting can be broken down into two sections: (1) mechanical and (2) electrical circuits. © BT Prime-Mover Inc. the “positive side” of any component refers to the terminal on that component that is closest electrically to the battery positive terminal. When testing voltage. then verify test results and possibly re-evaluate the failure symptoms. Many hours of troubleshooting time can be saved by knowing the exact operational symptoms.8 volts for a 36 volt system. “Rear direction” refers to travel in the direction of the truck with the forks trailing. Return Service Manual 2001-03-15 85 . It is possible. The battery voltage must be at least 25. If the proper switch operates for the chosen direction and speed. If the battery voltage is below 33 volts (no load).0 Troubleshooting Guidelines Version no 000 T-code RTX35/RTX45 Troubleshooting Guidelines 1. to measure battery voltage on the negative side of a component. Electrical circuits can be further broken down into control circuit and power circuit. Charge the battery before starting the troubleshooting procedures. the problem can be found in the controller or the power circuit of that function. the controller may not operate properly. verify the negative connection to the battery by touching the positive meter lead to the positive battery post.F-code Section C-code PS S0. First. then call your local authorized BT Prime-Mover Dealer for assistance. the truck should be repaired and operating properly. the controller may not operate properly.

DO NOT forget that these systems are designed to prevent operation in the event of improper operating procedures. Check for ground faults from the electrical system to the frame with an ohmmeter. Contactors must be free to move and the tips must not be welded or burnt. Operate the truck in all modes to determine the exact symptoms. Check that the battery is fully charged and connected. 86 Return Service Manual 2001-03-15 . A minimum of 20.F-code Section C-code PS S0.0 Troubleshooting Guidelines Version no T-code 000 RTX35/RTX45 The following information is required when placing a service call: • Truck model and serial number • Service hour meter • Actual battery voltage at open circuit • Actual battery voltage at open circuit at hydraulic operation under full load • Operating symptoms • Exact results of the testing performed Perform the following steps before starting all troubleshooting procedures: 1. 4. Inspect truck for physical damage or mechanical malfunction. 2. 3.000 ohms resistance from the frame to any and all wiring is acceptable.

Make sure the battery is clean. Electrical Many problems are caused by a faulty or dirty battery.F-code Section C-code PS S0. For error code listings see pages 336 and 340. Shorts to Frame Test “Shorts to frame” is an industry term for unintentional current leakage paths between normally isolated electrical circuits and their metal enclosures. CAUTION Be sure to block the truck whenever a troubleshooting procedure requires turning key switch (S17) ON. Electrical current can damage the ohmmeter. © BT Prime-Mover Inc. Visually inspect all wiring and electrical components for the following: • Loose connections or connectors • Loose or broken terminals • Damaged terminals. Return Service Manual 2001-03-15 87 . This will avoid accidents caused by unexpected truck travel. such as a wire conductor contacting metal through worn insulation.0 Troubleshooting Guidelines Version no 000 T-code RTX35/RTX45 2. More often. shorts to frame are resistive “leakage” paths caused by contamination and/or moisture. For programming parameters see page 345. disconnect the battery connector when checking electrical circuits or components with an ohmmeter. CAUTION Unless otherwise directed. 2. Shorts to frame may be metallic connections. blocks. Check the electrolyte level and state of charge.1. 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.

Turn the key switch OFF and disconnect the battery connector. Shorts to frame can be caused by the following: • Accumulation of dirt • Battery electrolyte leakage • Motor brush dust • Motor brush leads touching the housing • Breakdown in insulation • Bare wires • Pinched wiring harness • Improper mounting of circuit cards Shorts to frame can occur at numerous locations on a truck. 88 Return Service Manual 2001-03-15 . 2.0 Troubleshooting Guidelines Version no T-code 000 RTX35/RTX45 These leakage paths can result in unwanted electrical noise on the metallic truck structure. and may result in improper operation. and harnesses • Heat sinks • Bus bars • Solenoids • Contactors • Terminal strips • Switches • Power panel insulation • Circuit card mounts To test for shorts to frame: 1.F-code Section C-code PS S0. connect a 12-volt test light to the battery case from battery B+. even momentarily. If the light comes on at all. there is a problem with the battery. including: • Batteries • Motors • Cables. To test the battery for shorts to case. wiring. and then to the battery case from battery B-.

If the test light does not come on. Install another battery in the truck and repeat this procedure from step 1.Heat sinks . Do not reconnect components one at a time.001 ampere (1 mA). a. Install another battery in the truck and repeat this procedure from step 1. The most likely areas to check include: . To identify the cause of the short to frame. DO NOT continue until this condition is corrected.2 mA).(NOT battery B+ and B-). With the battery disconnected (or removed and disconnected) from the truck. With the battery disconnected from the truck. remove the battery from the truck. Your meter may be damaged if proceeding before correcting this condition. A reading of more than 0. A reading of less than 1000 ohms indicates a short.2 mA) and less than 0. If the current is less than 0. Return Service Manual 2001-03-15 89 . use a digital ohmmeter to measure the resistance from the truck frame to truck B+. DO NOT continue until this condition is corrected. DO NOT continue until this condition is corrected.0 Troubleshooting Guidelines Version no 000 T-code RTX35/RTX45 either external contamination or internal damage. then continue with step 4. disconnect circuit components until the low resistance condition disappears.001 ampere (1 mA) indicates a short. 4.0002 ampere (0.F-code Section C-code PS S0. b. continue to the next step.0002 ampere (0. go to step 4. If the current is greater than 0.Motors . Your meter may be damaged if proceeding before correcting this condition. but leave them disconnected until the low resistance reading disappears. Begin measuring at the highest Ampere scale and work toward the lowest. Your meter may be damaged if proceeding before correcting this condition. and to all fuses and motors. Prevent disconnected terminals or connectors from touching truck frame or other conductive surfaces. 3. to truck B.Power cables © BT Prime-Mover Inc. Ensure the battery case does not touch the truck frame during the remaining tests. use a digital volt/ohm/ammeter on the ampere function to measure the leakage current from the battery case to battery B+ and from the battery case to battery B-.

go to step 7. one at a time. Reconnect all other components previously disconnected. repair or replace as appropriate. e. and all fuses and motor terminals. Prevent disconnected terminals or connectors from touching truck frame or other conductive surfaces.0 Troubleshooting Guidelines Version no T-code 000 RTX35/RTX45 . that component or its wiring is defective. To identify the cause of the short to frame. and readings are greater than 1000 ohms. continue with the next step. If a reading is less than 1000 ohms when reconnecting a component. 6.001 ampere (1 mA).F-code Section C-code PS S0.001 ampere (1 mA). then repeat Step 4. continue with the step below. If the current is more than 0. Begin measuring at the highest ampere scale and work toward the lowest. b. The most likely areas to check include: - 90 Return Motors Heat sinks Power cables Power circuit components Control circuit components Service Manual 2001-03-15 .Control circuit components c. after all components are reconnected. When. If the current is less than 0.001 ampere (1 mA). 5.Power circuit components . B-. disconnect circuit components until the leakage current reads less than 0. d. but leave them disconnected until the leakage current reads less than 0. measuring resistance between steps. ensure the battery case does not touch the truck frame. If the battery was previously removed. Reconnect the battery connector to the truck and turn the key switch ON. Use a volt/ohm/ammeter on the current function meter to measure leakage current to the truck frame from B+. Do not reconnect components one at a time. Repair or replace the component causing the low resistance condition. a.001 ampere (1 mA).

and a reading is less than 0.0 Troubleshooting Guidelines Version no 000 T-code RTX35/RTX45 c. Repeat step 6. If a reading is more than 0. Repair or replace the component(s) causing the leakage current. If the battery was previously removed from the truck. Repair/replace as appropriate. Reconnect all other components previously disconnected.001 ampere (1 mA) there is no short to frame condition with the truck or the battery. © BT Prime-Mover Inc.F-code Section C-code PS S0.001 ampere (1 mA) when reconnecting a component. d. measuring current between steps. After all components are reconnected. Return Service Manual 2001-03-15 91 . that component or its wiring is defective. reinstall the battery. 7.

• Whenever possible. • Lower the carriage fully and retract the reach mechanism fully. • If the truck is equipped with tilt. preliminary checks should be made of the following: For error code listings see pages 336 and 340. Use extreme care when blocking the mast for any reason. keep the key switch OFF and the battery connector disconnected. 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. set the forks level. score. Contaminants drawn into the pump may cause the pump to stick. Never remove a block when it is supporting the mast. make sure hydraulic lines and components are fully installed. For programming parameters see page 345. not tilted either up or down. be sure to use blocks to secure the carriage. If the hydraulic pump assembly does not operate properly. 92 Return Service Manual 2001-03-15 . • When checking voltage at solenoids. • Proper oil level • All electrical connections tight • Battery fully charged CAUTION After elevating or reaching the carriage for troubleshooting. • If the truck is equipped with sideshift. center the forks horizontally.0 Troubleshooting Guidelines Version no T-code 000 RTX35/RTX45 3.F-code Section C-code PS S0. or fail.

carriage assembly. Return Service Manual 2001-03-15 93 .0 Troubleshooting Guidelines Version no 000 T-code RTX35/RTX45 4. Open Circuit. A hydraulic function other than lift/lower. The switch in the truck that must be closed to allow reach truck operation. This is a safety feature that limits the speed of travel with an elevated mast and helps prevent unstable load conditions. Mast Assembly. and sideshift. when such a circuit is tested. Definitions Auxiliary Function. At overtemperature the drive current limit is linearly decreased from full set current down to zero. Pulse Width Modulation (PWM). © BT Prime-Mover Inc.F-code Section C-code PS S0. lift chains. Brake Pedal Switch. A lack of a continuous path between two or more electrical connections. It is activated by the operator stepping on the foot pedal thus engaging the brake pedal. which bolts to the chassis section adjacent to the battery. Some auxiliary functions. A switch on the mast that is actuated when the carriage is above a certain height on the mast. High Speed Travel Limit. Overtemperature of the motor power amplifier is from 185o F (85o C) and above. Mast Switch. Generally. A reduced speed initiated when the truck is driven while the carriage is elevated above a certain mast height. it will have a resistance greater than ten megohms. Pulse Width Modulation. Continuity. It is used to activate the speed limit feature to limit travel speed when the carriage is elevated. tilt. typically having a resistance of less than 1 ohm. Travel is prohibited when the brake is applied. lift cylinders. Plug current is not reduced to provide full vehicle braking under all thermal conditions. etc. The truck includes: reach/retract. also called “chopping. The elevating section of the truck. The mast assembly consists of column sections. A continuous and uninterrupted path between two or more locations in an electrical circuit. or “aux” functions are optional features on the truck.” controls the speed of the motor by switching the battery voltage to the motor on and off very quickly. Overtemperature (Power Amplifier).

94 Return Service Manual 2001-03-15 . which is adjacent to the battery. Chassis. the current limit is cut back resulting in reduced travel speed. motors. The mast assembly bolts to the truck. The body section of the truck that contains the battery.0 Troubleshooting Guidelines Version no T-code 000 RTX35/RTX45 Short Circuit or “Short”. Example: A power cable from the battery to a junction post in the reach truck has had the insulation worn away. and handle. controls. drive unit. Because the conductors inside each wire are now touching each other. A short circuit is an unspecified path in a circuit that provides unwanted full or partial continuity between two or more locations in an electrical circuit.F-code Section C-code PS S0. Undertemperature. there is a short circuit. there is a short circuit of the battery cable. Example: Two insulated wires are physically next to each other and the insulation has been worn off each of the wires. When the power amplifier is operating at less than −13o F (−25o C). Because the wire conductors are touching the frame.

General t The chassis has several panels and covers that are removable. Return Main Electronic Card Access Panel Service Manual 2001-03-15 95 .1 Version no 001 C-code 0340 Chassis T-code RTX35/RTX45 Chassis 1. all panels and covers must be secured to the chassis. Clip Board Top Console Left Side Panel Contactor Plate/Bracket Floor Board Motor Compartment Door Left Operator Compartment Panel © BT Prime-Mover Inc. The purpose of bolton panels and covers is for easier access to components when servicing the truck. During operation of the reach truck.F-code Section PS S0.

Align the bolt holes in the cover with the ones in the frame. Remove hardware securing the top console to the frame. removing it from the truck. key switch. 2. 2. 6. Attach the harness connections to the operator display. emergency disconnect switch. Lift the top console off the steering wheel and control handle.2. Installation 1. optional push-button switches. Return truck to service. Turn keyswitch OFF and disconnect the battery connector. and the operator display. 4. 4. Removal 1. the emergency disconnect switch. 5. and optional push-button switches are mounted in the top console. and the optional push-button switches. Reconnect battery connector. and contactors. emergency disconnect switch.F-code Section C-code PS Chassis S0. Park truck on a level surface and block. the drive and pump transistor regulators. It covers the motor compartment.1. 2. 3. 5. Top Console The top console is a one piece unit. the key switch. Secure cover to the frame. Lift the cover up enough to disconnect the wiring harness connections to the key switch. 3. Place the top console over the steering wheel and control handle. 2. The operator display.1 0340 Version no T-code 001 RTX35/RTX45 2. 96 Return Service Manual 2001-03-15 .

Open the door fully. Use an Allen wrench to turn the latch screw clockwise one quarter turn. Removal 1. Set the door in place so the hinge pins are securely mounted in the panel hinge.1 Version no 001 C-code 0340 Chassis T-code RTX35/RTX45 3. CAUTION Do not force the Allen head screw past one quarter turn or the latch can become loose. Tighten the latch screw count.2. © BT Prime-Mover Inc. Return Service Manual 2001-03-15 97 . Close the door. Motor Compartment Door 3. Installation 1.F-code Section PS S0. 2. 2. Lift upward to release the door from the hinge pins and set aside.1. 3.

to prevent damage to the wires if the post shifts as the bolts are removed. Turn keyswitch OFF and disconnect the battery connector. CAUTION The left side panel is heavy. 7. into the overhead guard post before the bolts are removed. Park truck on a level surface and block. it is a more difficult and time consuming task.1. Pull the left side panel outward and set aside. Two are located under the control console by the hydraulic tank. Disconnect wiring harness at the post if applicable. The drive motor may be removed with the side cover on. The third flanged nut can be accessed through the left side of the battery box or by removal of the operator’s compartment left side panel. 8. 2. however.59 inch (15 mm) socket. 6. NOTE! Be sure the wire assemblies are pushed up.F-code Section C-code PS Chassis S0. 5. Removal 1. 4. Remove top console (see page 96). Remove three flanged nuts using a 0. Left Side Panel (Exterior) Removal of the left side panel allows for easier access to components that affect traction and lift functions. 4. 98 Return Service Manual 2001-03-15 . Remove 0. Remove four bolts securing the overhead guard post. Remove motor compartment door (see page 97).1 0340 Version no T-code 001 RTX35/RTX45 4.511 inch (13 mm) bolt at the rear of the panel. Help may be required to remove it from the truck. 3. located by drive motor.

2. 2. NOTE! Be sure the wire assemblies are pushed up. Installation 1. Install motor compartment door. CAUTION The left side panel is heavy. 8. 7. © BT Prime-Mover Inc.59 inch (15 mm) socket. Install four bolts securing the overhead guard post. Help may be required to remove it from the truck. Return Service Manual 2001-03-15 99 . Reconnect the wiring harness at the post if applicable. 6. Reconnect battery connector. 4. Two are located under the control console by the hydraulic tank. Install three flanged nuts using a 0. Install top console.F-code Section PS S0. The third flanged nut can be accessed through the left side of the battery box.1 Version no 001 C-code 0340 Chassis T-code RTX35/RTX45 4.511 inch (13 mm) bolt at the rear of the panel located by the drive motor. Install 0. This will prevent damage to the wires if the post shifts as the bolts are replaced. 5. into the overhead guard post before the bolts are installed. Lift left side panel up to align the three studs on the panel with the holes in the frame. 3. Return truck to service.

about 1/2 way using a 0.F-code Section C-code PS Chassis S0. 6. 2. Park truck on a level surface and block.1 0340 Version no T-code 001 RTX35/RTX45 5. 4. Removal 1.1. 5. Turn keyswitch OFF and disconnect the battery connector.393 inch (10 mm) nut at the top of the panel near the motor compartment door. 3. Tighten bolt near the brake pedal. Lift panel up and set aside. 2. Installation 1. Left Operator Compartment Panel 5. Install bolt at the top of the panel.2. near the brake pedal. 3. 5. Remove 0. Loosen bolt. Remove bolt securing the top of the panel at the front of the operator compartment (toward the battery). Slide left compartment panel into position. 100 Return Service Manual 2001-03-15 .511 inch (13 mm) wrench.

Return Service Manual 2001-03-15 101 .F-code Section PS S0. Park truck on a level surface and block. Lift the main electronic card panel out and set to the side. Tilt panel in. 6. 5. Turn keyswitch OFF and disconnect the battery connector. 3. Place slots along the lower edge of the main electronic card panel over the bottom two retaining screws. then tighten the two lower screws. Main Electronic Card Panel The main electronic card panel is located to the right of the operator compartment. This panel covers the main electronic card and the fuse bracket. Reconnect battery connector and return truck to service. 4.2. remove the two screws at the bottom of the main electronic card panel. If the operator compartment floor is to be removed. Remove two Allen head screws at the top of the main electronic card panel. Installation 1. © BT Prime-Mover Inc.1 Version no 001 C-code 0340 Chassis T-code RTX35/RTX45 6.1. 2. 2. 3. toward the operator compartment. 6. Loosen two lower Allen head screws if access to the main electronic card is required. Install two top screws. Removal 1.

5.1. Remove floor board by pulling up and pivoting plate toward motor compartment. 2.1 0340 Version no T-code 001 RTX35/RTX45 7. 7. Remove main electronic card panel.2. Push down on left foot (brake) pedal with one hand. 3. 2. Release brake pedal as the floor board pivots down. 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 left foot pedal as the floor board pivots up. keep fingers clear of the floor board cutout while holding down the left foot (brake) pedal. Removal 1. 3. Truck must be properly blocked at this time. CAUTION Disconnect wire connections to the right foot pedal switch (S23) prior to removal of the floor board. 4.F-code Section C-code PS Chassis S0. CAUTION Pinch point. With floor board raised. Turn keyswitch OFF and disconnect battery connector. Install main electronic card panel. Installation 1. Floor Board 7. Remove floor board and set it to one side. disconnect wires from right foot switch (S23). Reconnect wires to the right foot switch. 102 Return Service Manual 2001-03-15 . Park truck on a level surface and block.

Installation 1. Place 1 of the following items on each shaft of clip in the following order: Screw (2) Small Flat Washer (2) - Large flat washer Compression spring Small flat washer 4.5 N•m). and large flat washer from each clip shaft.2. Remove screw. Torque to 31 inlbs (3. Loosen top console to gain access to the clip mounting hardware.1. 3. Return Large Flat Washer (2) Service Manual 2001-03-15 103 . Compression Spring (2) © BT Prime-Mover Inc. 8. + 1 1/2 0 8. Clipboard The clipboard is located on the top console near the steering wheel. Raise top console to allow reach of clipboard mounting holes from underside of the cover. Secure both screws into the clip. compression spring. small flat washer.F-code Section PS S0. Insert console through the holes in the top console.1 Version no 001 C-code 0340 Chassis T-code RTX35/RTX45 8. Lift clip from the top console. Compression Spring Small Flat Washer 2. 2. Clip Large Flat Washer 3. Removal 1.

F-code

Section

C-code

PS
Chassis

S0.1

0340

Version no

T-code

001

RTX35/RTX45

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Section

C-code

PS
S0.2
0391
Battery Retainer Plates and Rollers
Version no

001

T-code

RTX35/RTX45

Battery Retainer Plates and
Rollers

3
1
2
1
4

Item No.

Description

1

Bearing

2

Roller, battery

3

Shaft, battery

4

Plate, battery retainer

CAUTION Before working on the battery, review
Battery Safety, beginning on page 19.
Batteries may weigh more than 1,000
pounds (453 kg). Use extreme care during
replacement. Use a suitable battery
replacement device or hoist for lifting.
The reach truck is equipped with battery rollers and battery
retainer plates for ease of battery removal and replacement.

© BT Prime-Mover Inc.

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F-code

Section

C-code

PS
S0.2
0391
Battery Retainer Plates and Rollers
Version no

T-code

001

RTX35/RTX45
f

1. Battery Retainer Plates

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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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.

Return

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

Drive motor assembly

20

Ring, retainer

27

Brake assembly

21

Bearing

28

Sensor assembly

22

Ring, seal

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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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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.

© BT Prime-Mover Inc.

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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

1

Lift Pump Assembly

3

Bracket, pump mounting

5

Washer, flat

2

Screw

4

Screw

6

Shock, mount

The pump motor and lift pump should be removed and
installed as a single unit.

110

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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

1. Park the truck on a level surface and make sure all
wheels are blocked to prevent accidental
movement.
2. Lower carriage completely.
3. Drain hydraulic fluid. See “System Draining” on
page 400.
4. Turn key switch OFF and disconnect battery
connector.

Motor
Bracket
Mounting
Bolts

5. Remove top console, motor compartment door,
and operator compartment left side panel. See
“Top Console” on page 96.
Lift
Pump

6. Disconnect hose from the pump to control valve at
the control valve. Plug both the port and hose to
prevent contamination of the hydraulic system.

Pump
Motor

7. Remove control valve from the bracket and lay
over the reservoir.
8. Remove pump motor electrical power cables. Use
a M10 wrench to remove the nuts on the motor
terminals. Note the proper location of each wire on
the motor. The terminal number should be marked
on the power cables. If the marking is worn or
missing, remark the cable.
9. Move all wires and cables up out of the way.
10. Remove four bolts (4) attaching bracket to the truck
frame using an 9/16 inch (13 mm) socket. If drive
motor has not been removed, a 24 inch (609 mm)
extension will be required to reach the back
mounting bolt.
11. Loosen screws in hose clamp for hose connecting
the pump to the reservoir. Slide hose clamp back.
Remove hydraulic line from pump to the reservoir.
Drain the line as required into a small container.

© BT Prime-Mover Inc.

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Section

C-code

PS
S0.3
Mounting Points

0451

Version no

T-code

001

RTX35/RTX45

Plug port and hose to prevent contamination of the
hydraulic system.
12. Disconnect brush wear indicator terminals at the
back of the motor.
13. Remove motor and pump assembly from truck. If a
hoist is available, attach a hoist to the bracket and
lift the assembly out. If a hoist is not available,
carefully lift the assembly out while standing in the
operator compartment. Use proper lifting practices
to avoid back injuries.

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

3. Install mounting bolts (4) to secure the motor/pump
into position. Apply Loctite® to the four mounting
bolts. Insert bolts through the large washer (5),
then through the bracket mounting plate into truck
frame. Tighten bolts using an 9/16 inch (13 mm)
socket and extension if needed.
4. Install control valve on the bracket.
5. Install hydraulic line from the pump to the control
valve.
6. Install pump motor electrical power cables to the
motor, following the markings on the cables.
Tighten terminal nuts using a M10 wrench. Torque
motor cable securing nuts to 100-120 in-lbs (11.213.6 N•m). Use a second wrench on the stud
terminal securing nut to avoid twisting the stud.

112

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S0.3
0451
Mounting Points

Version no

001

C-code

T-code

RTX35/RTX45

7. Attach brush wear indicator connections using
needle nosed pliers. Connectors are male and
female with one large and one small.
8. Fill hydraulic reservoir with hydraulic fluid.
9. Install top console.
10. Remove blocks from truck.
11. Reconnect battery connector.
12. Bleed hydraulic system. See “Bleeding Hydraulic
System” on page 401.
13. Test hydraulic operation of truck.

© BT Prime-Mover Inc.

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113

3 Mounting Points 0451 Version no T-code 001 RTX35/RTX45 3. Description 7 Plate. Transmission 18 17 16 15 14 13 12 10 7 11 8 9 Item No. cap Return Service Manual 2001-03-15 . cap 10 Drive wheel assembly 14 Plate. target 12 Cap. 114 Description Item No. Description Item No. flat head 15 Screw.F-code Section C-code PS S0. steering 9 Transmission assembly 13 Gasket. stop 11 Screw. “EE” 17 Screw. plug 16 Stop. “EE” 8 Plate. “EE” 18 Screw.

5. 6.1.1 above. Jack the rear of truck (see “Safe Jacking Procedure” on page 64). 3. See “Removal” on page 183. 2. No warranty will be paid on component damage resulting from incorrect fluid selection. 3. The capacity of the drive unit is 1 gallon (3.F-code Section PS S0. 2. Using an 3/4 inch (19 mm) socket remove six bolts (18) that secure the transmission to truck frame. Slide it under the transmission to act as a cradle to keep the transmission upright when it is unbolted from truck frame. Turn key switch OFF and disconnect battery connector. CAUTION Incorrect selection of fluid. may cause damage.2. Removal 1.3 0451 Mounting Points Version no 001 C-code T-code RTX35/RTX45 3. for a particular application. Remove drive motor before removing the transmission (see page 108). © BT Prime-Mover Inc. There should be an 1 inch (25. Place drive tire face down on the floor. Remove drain plug (item 28. Fluid Changing Procedure 1.785 liters). Refill using the proper grade fluid. Return Service Manual 2001-03-15 115 . See paragraph 3. 7. 4. Drain transmission fluid.4 mm) gap between the tire and the transmission before the transmission is unbolted. 4. page 169). Remove drive tire. Reinstall drain plug. Park the truck on a level surface. The fluid level of the drive unit may be checked by removing the fill level plug (item 35. 3. page 169) from drive unit and drain all the fluid.

in the tire cradle. Torque wheel nut to 65 ft-lb (88 N•m).F-code Section C-code PS S0. 5. Place transmission in drive tire and slide transmission. 9. 4. 9. lower the truck frame onto the transmission. Transmission mounting bolts (18) should be torqued to 90 ft-lbs (122 N•m). beneath the truck. 6. lift the truck high enough to slide the transmission. into the recess in the back of the drive tire. Be careful not to pinch hands between the transmission and the truck frame. Using a 3/4 inch (19 mm) wrench to help get the bolts started straight. Guide the transmission. Tap transmission with a rubber mallet to break it loose from the frame. Lower truck and remove blocks. 3.3. Secure drive wheel with wheel nut. The transmission will draw tight to the truck frame mounting surface as the bolts are tightened. Installation 1. Line grease fittings up with the indentations in the frame. Install drive wheel. 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. Install drive motor (see page 109). 10. Add transmission fluid. 116 Return Service Manual 2001-03-15 .3 Mounting Points 0451 Version no T-code 001 RTX35/RTX45 8. 3. Using a hoist. out from underneath the truck. Reconnect battery connector. in the tire cradle. The transmission will drop down.) 8. 2. Using a hoist. Clean and apply Loctite® 242® to the transmission mounting bolts (18). (See “Fluid Changing Procedure” on page 115. 7. while lowering the frame onto the transmission. Lubricate wheel nut. with one hand through the hole in the truck frame.

4 0640 Driver Controls Version no C-code T-code 001 RTX35/RTX45 Driver Controls 1 Drive Handle Assembly 17 8 16 15 9 10 3 4 2 5 11 14 12 9 13 8 31 6 7 18 28 7 27 19 18 22 29 20 30 26 25 24 23 © BT Prime-Mover Inc.F-code Section PS S0. Return Service Manual 2001-03-15 21 117 .

heat shrink 20 Shaft 5 Screw 21 Bearing 6 Screw 22 Screw 7 Screw 23 Spring 8 Screw.F-code Section C-code PS S0. connector 14 Card assembly (cold storage) 30 Cable assembly 15 Actuator. left hand 18 Switch. button 31 Insulator. 118 Return Item No. wire 12 Bracket 28 Housing. set 9 Screw. connector 13 Potentiometer 29 Pin. set 25 Spacer 10 Knob. control 17 Button. Description Description 1 Handle.4 Driver Controls 0640 Version no T-code 001 RTX35/RTX45 Item No. set 24 Screw. push button 3 Handle. auxiliary 2 Handle. right hand 19 Heater (cold storage) 4 Insulator. left 26 Potentiometer 11 Spring 27 Tie. heat shrink 16 Spring Service Manual 2001-03-15 .

Connect wiring harnesses from main electronic card and control handle. 3.4 0640 Driver Controls Version no 001 C-code T-code RTX35/RTX45 1. 5. beneath and to the left of the base of the control handle. 4. Remove top console (see page 96). Installation 1. Turn key switch OFF and disconnect battery connector.2. 2. They pass through the handle interface module with no processing. Position handle interface module at the contactor plate/bracket. Inputs from the travel and lift lower controls are analog. Install top console. requesting activation of solenoids and the hydraulic system. Remove interface module from truck. Install two thread forming screws to secure module to bracket. Return Service Manual 2001-03-15 119 .1. The module processes digital inputs from the control handle auxiliary function switches. Return truck to service. It then forwards analog outputs to the main electronic card. Disconnect wiring harnesses to the control handle and main electronic card. 4. Handle Interface Module The handle interface module is located on the contactor plate/ bracket. Remove two thread forming screws securing the interface module to the bracket. 5. Removal 1.F-code Section PS S0. aligning mounting holes. Handle Interface Module © BT Prime-Mover Inc. Screw 3. Test the operation of truck. 2. to the main electronic card where they are acted upon. 1. 1.

Removal 5 6 2 4 1. lift/lower.F-code Section C-code PS S0. 5. set 8 Screw 3 2. Turn key switch OFF and disconnect battery connector. Loosen Allen head screw (4) that secures the control handle assembly to its support travel bracket (3). and auxiliary functions. to the right of the steering wheel.4 Driver Controls 0640 Version no T-code 001 RTX35/RTX45 2. 3. 6. travel 7 Module. 2. out of its support bracket. control 5 Screw 2 Pin. Control Handle The control handle is the operator’s means of controlling travel. 4. Unplug control handle wiring harness from the handle interface module (7). keeper 3 Support. The control handle assembly is located in the middle of the top console. 7 CAUTION Be sure to observe proper precautions against electrostatic discharge (see “Static Safety” on page 23). Cut any tie-straps that secure the wiring harness. Lift/lower Knob Item No. Allen head screw Keep 14” of cable off of the control handle straight 1 Description Item No. Description 1 Handle. dowel 6 Plate. 120 Return Service Manual 2001-03-15 . Slide the control handle assembly to the left. interface 4 Screw.1. Remove top console (see page 96).

Torque the set screw to 30 ft-lb (42 N•m). 8. 3. Release SW1 to prepare the main electronic card for calibration of the control handle. Return Service Manual 2001-03-15 121 . To clear error code 30 (Control Handle Calibration Error 1): Key OFF the truck. Secure the control handle wiring harness in place with tie-straps. © BT Prime-Mover Inc. 6.F-code Section PS S0. Align the hole in the shaft with the set screw hole. 4. This calibrates the handle travel and limit positions. Make sure 14 inches (355 mm) of the cable off of the control handle is kept straight. Installation 1. Hold the control handle in place. CAUTION To ensure long handle cable life. Reinstall top console. 2.3. 7. Apply thread-locking compound to the threads of the Allen head screw (4). 2. move the control handle forward and backward the full range of travel until the code 38 disappears. 38 or 33 appear on the operator display. Route the control handle wiring harness up and plug it into the Handle Interface Module (7). proper wire routing is necessary. Key ON truck until truck powers-up and the display turns on. Insert the shaft of the control handle assembly into the support bracket (3). Reconnect battery connector and turn key switch ON. Press and hold SW1 on the main electronic card. To clear error code 38 (Accelerator Pot Span Calibration Error): With both foot pedals released. Recalibration Recalibration of the control handle is necessary whenever error codes 30. Ensure the cable extends out of the handle as straight as possible to avoid kinking.4 0640 Driver Controls Version no 001 C-code T-code RTX35/RTX45 2.2. 5.

1. 122 Return Service Manual 2001-03-15 .6V Rev Nom.2V Fwd 1.6V Rev Nom. Therefore.6V Rev Nom. the control handle is calibrated and the truck is ready for normal operation. 2. 2. 0. 2.4V Max. The following table shows the relationship of the selected control handle function to the output of the control handle interface card. rotate the lift/lower thumb knob to both ends of travel (full lift and full lower) until the code 33 disappears. Voltages at the main electronic card inputs greater than 6.2V Fwd Wire # The control handle interface card decodes and conditions the digital signals from the control handle for use by the main electronic (A5) card.4V Max.4V Max.6 volts indicate shorted or open signal wires for travel and lift/lower. 1. 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. 50 Main Electronic Card (A5) Input Pin (measured with respect to 510) 505 Main Electronic Card (A5) Nominal Input Voltage Min. 0. 0.4 Driver Controls 0640 Version no T-code 001 RTX35/RTX45 To clear error code 33 (Lift Pot Span Calibration Error): With both foot pedals released.F-code Section C-code PS S0.75 volts and less than 0. 1.2V Fwd Control Handle Interface Card Output Pin (measured with respect to HM110) HM105 Control Handle Interface Card Nominal Output Voltage Min. The center and travel limits of the travel and lift/lower potentiometers are learned. When the readings are within the parameters listed. Analog signals (travel and lift/lower) from the control handle are relayed unchanged to the main electronic card. 2. the voltages listed are a rough approximation.

pedal 3 Bumper 8 Screw 13 Nut. return 10 Potentiometer 15 Screw © BT Prime-Mover. brake 5 Spring. twin 4 Bracket. brake 9 Screw 14 Switch. Inc.5 0642 Brake Pedal (RTX35) Version no T-code 000 RTX35/RTX45 Brake Pedal (RTX35) 12 6 2 1 2 5 8 4 3 8 9 7 13 14 10 11 Item No. Return 15 Service Manual Description 2001-03-15 Item No. 1 Pedal. brake 6 Bumper 11 Screw 2 Bearing. Description Item No.F-code Section PS C-code S0. Description 123 . flanged 7 Plate 12 Mat.

Park truck on a flat surface. Remove the floor board. Pedal Removal 1. 5. 6. 2. Remove the brake pedal assembly from the truck to service.5 Brake Pedal (RTX35) Version no T-code 000 RTX35/RTX45 C-code 0642 1. Disconnect battery at the battery connector. Remove the main electronics card panel (see page 101). CAUTION Disconnect the wire connections to the right foot pedal switch prior to removal of the floor board. CAUTION Pinch point. 124 Return Service Manual 2001-03-15 . Loosen four mounting bolts holding the brake pedal assembly to the frame. keep fingers clear of the floor board cutout while holding down the left foot brake pedal. 3. Check to make sure the battery retainer plates are in place. Jack the rear of the truck (see “Safe Jacking Procedure” on page 64). 4. Remove screws (11) holding the brake potentiometer (10) and remove wires from the brake switch (14). 7.F-code Section PS S0.

remove the brake pedal return spring (5). Inc. 3. Pedal Bearing Replacement 1. 8. it should be threaded down until the stop makes contact with bracket (4). 2.5 0642 Brake Pedal (RTX35) T-code RTX35/RTX45 2. Remove brake pedal assembly from bracket (4) and remove bearings (2). engaging them in the bracket. 4. Install brake pedal assembly into the bracket (4). Remove flange bearing mounting screws (8) on both bearings. See “Adjustment Procedures for Setting Brake Switch and Brake Transducer” on page 355. Pedal Adjustment 1. 5. Loosen set screws on the bearing collars and slide bearing assemblies back. Install bearing mounting screws (8). Slide bearings forward. 3. When replacing bumper (6).F-code PS Version no 000 Section C-code S0. © BT Prime-Mover. Install bearings (2) on the brake pedal shaft (1). Return Service Manual 2001-03-15 125 . 6. 2. 7. Install the brake pedal return spring (5). To replace the bearing assemblies on the brake pedal (1).

F-code Section PS S0.5 Brake Pedal (RTX45) Version no T-code 000 RTX35/RTX45 C-code 0642 Brake Pedal (RTX45) 12 6 2 1 2 17 8 16 5 4 3 8 13 9 14 7 10 11 15 126 Return Service Manual 2001-03-15 .

pedal Description Item No. Park truck on a flat surface. brake 3 Bumper 9 Screw 15 Screw 4 Bracket. 5. Remove brake cable pin with cotter pin (17). CAUTION Disconnect the wire connections to the right foot pedal switch prior to removal of the floor board. 6. brake 5 Spring. keep fingers clear of the floor board cutout while holding down the left foot brake pedal. twin 2 Bearing. 4. Return Service Manual 2001-03-15 127 . brake 7 Plate 13 Nut. Description Item No.F-code PS Version no 000 C-code S0. Inc. 2. Remove the brake pedal assembly from the truck to service. Disconnect battery at the battery connector. Section Description 1. 3.5 0642 Brake Pedal (RTX45) T-code RTX35/RTX45 Item No. CAUTION Pinch point. Loosen mounting bolts holding the brake pedal (1) assembly to the frame. Check to make sure battery retainer plates are in place. © BT Prime-Mover. 1 Pedal. 7. Remove the floor board. return 11 Screw 17 Pin with cotter pin 6 Bumper 12 Mat. Jack the rear of the truck (see “Safe Jacking Procedure” on page 64). Remove the main electronics card panel (see page 101). Pedal Removal 1. brake 10 Potentiometer 16 Cable. flanged 8 Screw 14 Switch. Remove screws (11) holding the brake potentiometer (10) and remove the wires from the brake switch (14).

To replace bearing assemblies on brake pedal (1). Pedal Adjustment 1.F-code Section PS S0. 2. Remove flange bearing mounting screws (8) on both bearings. 7. 3.5 Brake Pedal (RTX45) Version no T-code 000 RTX35/RTX45 C-code 0642 2. 128 Return Service Manual 2001-03-15 . remove the brake pedal return spring (5). Install the bearing mounting screws (8). Install brake pedal assembly into the bracket (4). Install the brake cable pin with cotter pin (17) and brake pedal return spring (5). Install bearings (2) on the brake pedal (1) shaft. 8. 2. See “Adjustment Procedures for Setting Brake Switch and Brake Transducer” on page 355. 3. 4. Pedal Bearing Replacement 1. Loosen set screws on the bearing collars and slide bearing assemblies back. When replacing the bumper (6). Slide bearings forward. engaging them in the bracket. 6. it should be threaded down until the stop makes contact with the bracket (4). 5. Remove brake pedal assembly from the bracket (4) and remove the bearings (2).

therefore. Return 5 9 Service Manual 2001-03-15 129 .6 0681 Internal Fittings Version no 001 C-code T-code RTX35/RTX45 Internal Fittings 1. These switches are located to the right of the key switch on the top console. There are separate switches for the operator fan and the overhead light. The operator fan/ overhead light is an option. 1 2 3 3 4 13 14 6 7 8 12 11 10 © BT Prime-Mover Inc. Operator Fan The operator fan/overhead light is located in the compartment on the left side of the overhead guard.F-code Section PS S0. it may not be on your particular truck.

Remove the light/fan assembly from the truck. Reconnect the harness connections. 5. Reassemble the light/fan console assembly.2. 3.F-code Section C-code PS S0. 3. filler 12 Shroud 6 Washer.1. Description 1 Screw 8 Nut 2 Screw 9 Screw 3 Nut. Removal 1. 2. 1. Install the mounting screws (1) through the top of the overhead guard to secure the assembly. then return truck to service. Turn key switch OFF and disconnect battery connector. flat 13 Tie. Lower the light/fan assembly enough to disconnect it from the harness. clip 10 Console 4 Bracket. 5. Be sure the clip nuts (3) are positioned over the mounting holes for attachment to the overhead guard. 4.6 Internal Fittings 0681 Version no T-code 001 RTX35/RTX45 Item No. Test the operation of the light assembly. 4. 130 Return Service Manual 2001-03-15 . Description Item No. 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). Installation 1. Reconnect battery connector. hanger 11 Louver 5 Plate. From the top of the overhead guard. wire 7 Lockwasher 14 Fan motor 1. remove four screws (1) securing the light/fan assembly. 2.

7 Version no 001 C-code 0811 Guards T-code RTX35/RTX45 Guards 4 1. 3 5 2 Description 1 Overhead guard 2 Bolt 3 Screw. cap 4 Nut 5 Post. Return Service Manual 2001-03-15 131 . Checking tightness of the mounting bolts (2) is recommended on a regular basis. overhead guard Remove of the overhead guard is not recommended. Overhead guard mounting bolts should be torqued to 200 ft-lb (271 N•m). Overhead Guard 1 Item No. © BT Prime-Mover Inc.F-code Section PS S0.

F-code Section C-code PS Guards S0.7 0811 Version no T-code 001 RTX35/RTX45 132 Return Service Manual 2001-03-15 .

Touch up the paint in the area of the decal. © BT Prime-Mover Inc. straight. place the decal into position. Use caution not to scratch or damage the paint on the truck when removing the decal. Decal with Protective Sheet To install this style. Do not wrinkle the decal. peel off the backing. as required. Remove a damaged decal by using a sharp edge to peel the decal from the surface. Smooth the decal into place using clean fingers. Be sure all the edges are secured to the surface. Allow the surface to completely dry. Rub over the protective over-sheet with a firm. Return Service Manual 2001-03-15 133 . Decal without Protective Sheet To install this style. Peel off the over-sheet. 1. thoroughly clean the surface of the truck before applying a new decal.F-code Section PS S0. and press the decal into place. Replace any missing decals. 2. peel off the backing. plastic edge to remove air bubbles and any wrinkles. place the decal into position. Using the required cleaning solution. be sure that there is no residue.8 Version no 001 C-code 0851 Decals T-code RTX35/RTX45 Decals Remove and replace any decals that are damaged. and press the decal into place. Do not wrinkle the decal.

) TruckBatt.8 0851 Version no T-code 001 RTX35/RTX45 12 KEEP HANDS CLEAR 1 11 2 10 +1/21 0 9 8 7 Model Serial Number Cap.) DC Volt age UseULType Class Battery Type Mast Serial Number A 6 BInches C Max. Muscatine.) Less Battery Wt. IA 52761 5 3 4 134 Return Service Manual 2001-03-15 . (Lbs. Amp. °Tilt Attachment Back Truck as ratedat factory conforms torequirements of Part III of ASMEB561-1993 306040-000 C B A BTPrime-Mover. (Lbs. Wt. (Lbs. Max. Min.)Battery Wt. Inc. Hours Max...F-code Section C-code PS Decals S0. (Lbs.

Return Description Item No. BT Prime-Mover Logo 9 Decal. Data 12 Decal. RTX45 2 Decal. UL 11 Decal WARNING 6 Plate. WARNING 8 Decal. © BT Prime-Mover Inc. T-code RTX35/RTX45 Description 1 Decal. special oil 4 Box. travel control 5 Plate.F-code Section PS S0. Reverse Steering Service Manual 2001-03-15 C-code 0851 Decals 135 .8 Version no 001 Item No. WARNING 7 Decal. Manual 10 Decal. RTX35 3 Decal.

8 0851 Version no T-code 001 RTX35/RTX45 136 Return Service Manual 2001-03-15 .F-code Section C-code PS Decals S0.

Spacer 6. 2001-03-15 137 .F-code Section PS S1. Be sure to keep the spacer with the steering motor for reassembly. Return Service Manual 7. Gently lift the motor upward. The rubber gasket should remain on each bolt. 1. Block truck to prevent accidental movement. The black rubber spacer under the steering motor is to reduce noise. 5. Turn key switch OFF and disconnect battery connector. Disconnect steering motor from the main electrical harness. Park truck on a level surface. 2. O-Rings © BT Prime-Mover Inc. Be sure the two O-rings stay on the bottom of the steering motor. Remove motor compartment door to access the steering motor (see page 97). Use an 13/64 inch (5 mm) Allen wrench to remove four bolts securing the steering motor to the truck frame. It is to the right of the drive motor and beneath the control valve.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. 3. Rock it a little to unseat it if necessary. 4. 1. Removal WARNING Block all wheels to prevent truck from rolling.

3.F-code Section C-code PS S1. Place the electrical connectors toward the lift motor. 10. Apply a little grease so the motor will slide into the frame without cutting the O-rings. Insert the steering motor into the truck frame. 4.203 inch (5 mm) Allen wrench torque to 35 inlbs (3.95 N•m). Test truck for proper operation. Apply black graphite grease to the gear to help prevent excessive wear. Remove blocks from truck. 8.0 Steering Motor 1730 Version no T-code 001 RTX35/RTX45 2. Reconnect the electrical harness connections. 9. Install the motor compartment door. Install the four bolts with rubber grommets. Apply Loctite® 242® to the mounting bolt threads. 138 Return Service Manual 2001-03-15 . Return truck to service. 5. Make sure the rubber spacer and two O-rings are on the end of the steering motor. Reconnect the battery connector. 6. Installation 1. 7. Using an 0. 2.

Return Service Manual 2001-03-15 139 .1. Return steering motor to the truck following the installation procedure on page 138.F-code Section PS S1. 2. 3. Install mounting bolt in the steering gear. Slide steering gear onto the steering motor shaft. 4.0 1730 Steering Motor Version no 001 C-code T-code RTX35/RTX45 3. Remove steering gear from the motor shaft. © BT Prime-Mover Inc. 3. Steering Motor Gear Replacement 3.2. Installation 1. 2. Torque gear mounting bolt to 88 in-lbs (10 N•m). Remove steering motor following the procedure on page 137. 3. Loosen bolt attaching steering gear to the steering motor shaft. Removal 1.

0 Steering Motor 1730 Version no T-code 001 RTX35/RTX45 140 Return Service Manual 2001-03-15 .F-code Section C-code 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. 5. Disconnect electrical connections from the fan to the main wiring harness. 3. 2. Remove four nuts (1) from upper electrical compartment side. 5. 4. Remove four screws (2) from the mast side of the truck compartment. 4. 1.1. Connect electrical connections to the main wiring harness. This fan vents heat out of the upper electrical compartment toward the mast. Install fan assembly by inserting four screws (2) through the truck frame from the mast side. 1 2 1. Remove the fan assembly from truck. Install four nuts (1) from the electrical compartment side. 6. Return Service Manual 2001-03-15 141 . Remove top console (see page 96). Turn key switch OFF and disconnect battery connector. 1. 2. Upper Electrical Compartment Fan The upper electrical compartment fan is located in the front of the truck section. Install top console. Installation 1. Reconnect battery and return truck to service.2.F-code Section PS S1. It is standard equipment on all reach trucks. 3. Removal 1. © BT Prime-Mover Inc. An optional operator cooling fan is also available.

142 Return Service Manual 2001-03-15 . it may not be on your particular truck. see “Internal Fittings” on page 129. Operator Fan The operator fan is located in the compartment with the overhead light on the left side of the overhead guard.F-code Section C-code PS Fan Motor S1. To service the operator fan. therefore. The operator fan/overhead light is an option.1 1740 Version no T-code 001 RTX35/RTX45 2.

or constant usage. Operating Conditions Operating environment of reach truck motors varies widely: The following recommendations should be applied as actual conditions dictate. Extreme Service: yChemical Processing yFreezer operation yProcessing plants (poultry. 2. Severe Service: Extended operating hours. 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. When brushes are in need of replacement. meat) © BT Prime-Mover Inc. Normal Service: Basically an eight hour day of indoor material handling. Return Service Manual 2001-03-15 143 .F-code Section C-code PS S1. The drive motor and pump motor are both equipped with brush sensors. long-life and trouble-free operations is related to the time spent making inspections and correcting minor problems as they occur.2 1700 Motor Maintenance Schedule/Troubleshooting Version no 000 T-code RTX35/RTX45 Motor Maintenance Schedule/Troubleshooting 1. a warning code C-17 will show on the dash display. The goal of any maintenance program.

Table 2 Primary sources of unsatisfactory brush performance. 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. Service Manual 2001-03-15 .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.F-code Section C-code PS S1. 144 Return Table 1 Unsatisfactory brush performance.

F-code Section C-code PS S1. See “Sparking” Severe sparking Imperfect contact with commutator Wrong brush grade 11-14-15-16-51-52 54-58 Glowing at Brush Face Embedded copper Faulty machine adjustment Severe load condition Bad service condition Wrong brush grade See “Copper in brush face” 7-12 38-39-41-42 46-47 57-61-62 Copper in Brush Face Commutator surface 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 Commutator surface condition Looseness in machine Faulty machine adjust High friction Wrong brush grade See specific surface in evidence 15-16-17 10-11 6-43-45-49-52-58-59 55-58-59 © BT Prime-Mover Inc. Return Service Manual 2001-03-15 145 .2 1700 Motor Maintenance Schedule/Troubleshooting Version no 000 T-code RTX35/RTX45 Table 1. Unsatisfactory Brush Performance Indications Immediate Causes Primary Faults Sparking Commutator surface condition Overcommutation Undercommutation Too rapid reversal of current Faulty machine adjustment Mechanical fault in machine Electrical fault in machine Bad load condition Poor equalized parallel operation Vibration Chattering of brushes Wrong brush grade Fluctuating contact drop 1-2-3-43-44-45-46-49-59-60 7-12-31-33 7-12-30-32 7-12-30-32 8-9-11 6-14-15-16-17-18-19-20-21-28 29 25-27-28-29-38-39-40-41-42 7-13-23-34 51-52 See “Chattering or Noisy Brushes” 55-57-59 50 Etched or burned bands on brush face Overcommutation Undercommutation Too rapid reversal of current 7-12-31-33 7-12-30-32 7-12-30-32 Pitting of Brush Face Glowing Embedded copper See “Glowing at brush face” See “Copper in brush face” Rapid Brush Wear Commutator surface condition See specific surface fault in evidence. Also see 50.

F-code Section C-code PS S1.2 1700 Motor Maintenance Schedule/Troubleshooting Version no T-code 000 RTX35/RTX45 Table 1. Unsatisfactory Brush Performance Indications Immediate Causes Primary Faults Brush Chipping or Breakage Commutator surface condition Looseness in machine Vibration Chattering See specific surface fault in evidence 15-16-17 52 See “Chattering or Noisy Brushes” 14 Sluggish brush movement Rough or Uneven Surface 1-2-3-4-17 Dull or Dirty Surface 5-44-60 Eccentric Surface 1-19-22-52 High Commutator Bar Sparking 17 Low Commutator Bar Streaking or Threading of Surface Sparking Copper or foreign material in brush face Glowing 2-25 2-3-43-44-45-46-47-48-49-59-61 Bar Etching or Burning Sparking Flashover 2-3-7-12-30-31-32-33 5-11-14-35-38-39-41-53 Bar Marking at Pole Pitch Spacing Sparking 25-37 Bar Marking at Slot Pitch Spacing Sparking 7-12-30-57-60 Flat Spot Sparking Flashover Lack of attention 19-23-25-41-53 5-11-14-35-38-39-41-53 1-5-11 Discoloration of Surface High temperature Atmospheric condition Wrong brush grade See “Heating at Commutator” 44-46 60 Raw Copper Surface Embedded copper Bad service condition Wrong brush grade See “Copper in Brush Face” 43-45-47-49 59-61 Rapid Commutator Wear with Blackened Surface Burning Severe sparking 2-3-11-14 See “Sparking” Rapid Commutator Wear with Bright Surface Copper Dragging Foreign material in brush face Wrong brush grade Brush vibration 43-45-47-49 61 39-52-58-59 146 Return Service Manual See “Glowing at Brush Face” 2001-03-15 .

Return Service Manual 2001-03-15 7-13-23-24 147 .2 1700 Motor Maintenance Schedule/Troubleshooting Version no 000 T-code RTX35/RTX45 Table 1. Unsatisfactory Brush Performance Indications Immediate Causes Primary Faults Heating in Windings Severe load condition Unbalanced magnetic field Unbalanced armature currents Poorly equalized parallel operation Lack of ventilation 38-41-42-53 18-19-20-21-27-28-29 8-19-22-25-27-28-29-37 Severe load condition Severe sparking High friction Poor commutator surface Depreciation High contact resistance 38-41-42 7-8-9-12-20-33-45-57 10-11-36-43-45-49-58-59 See specific surface fault in evidence 6-24 56 Severe load condition Faulty machine adjustment Severe sparking Raw streaks on commutator surface Embedded copper Wrong brush grade 38-41-42 7-10-11-12-26 See “Sparking” See “Streaking or Threading of Surface” See “Copper in Brush Face” 57-58-59-61-62 Heating at Commutator Heating at Brushes © BT Prime-Mover Inc.F-code Section C-code PS S1.

F-code Section C-code PS S1. Loose or worn bearings 20. Unequal pole spacing 22. Unequal brush spacing 9. Poor alignment of brush holders 10. Variable angular velocity Service Manual 2001-03-15 . Incorrect spring tension 12. Primary Sources of Unsatisfactory Brush Performance Preparation and Care of Machine 1. Dynamic unbalance 23. Feather-edge mica 4. Poor preparation of commutator surface 2. Series field improperly adjusted Mechanical Fault in Machine 148 Return 14. Interpoles improperly adjusted 13. Brushes too loose in holders 16. Unequal air gaps 21. High mica 3. Bar edges not chamfered after undercutting 5. Brushes in wrong position 8. Brush holders loose at mounting 17. Clogged ventilating ducts Machine Adjustment 7.2 1700 Motor Maintenance Schedule/Troubleshooting Version no T-code 000 RTX35/RTX45 Table 2. Brushes tight in holders 15. Incorrect brush angle 11. Commutator loose 18. Loose pole pieces or pole-face shoes 19. Need for periodic cleaning 6.

Commutating zone too wide 32. Return 38. Open or high resistance connection at commutator 26. Commutator too small Electrical Fault in Machine 25. Oil on commutator or oil mist in air 47. Primary Sources of Unsatisfactory Brush Performance 24. Brushes too thick 34. Insufficient cross connection of armature coils Load or Service Condition © BT Prime-Mover Inc. Poor connection at shunt terminal 27. Plugging 42. “Contact poisons” 46. Magnetic saturation of interpoles 35. High ratio of brush contact to commutator surface area 37. Ground in field or armature winding 29. High bar-to-bar voltage 36. Brushes too thin 33. Contaminated atmosphere 45. Low average current density in brushes 44. Reversed polarity on main pole or interpole Machine Design 30.F-code Section C-code PS S1. Overload 39. Reversing operation of non-interpole machine 41. Dynamic braking 43. Commutating zone too narrow 31.2 1700 Motor Maintenance Schedule/Troubleshooting Version no 000 T-code RTX35/RTX45 Table 2. Rapid change of load 40. Abrasive dust in air Service Manual 2001-03-15 149 . Short circuit in field or armature winding 28.

Coefficient of friction too high 59. Humidity too high 49. Lack of film forming properties in brush 60. External short circuit or very heavy load surge 54. “Commutation factor” too low 56.F-code Section C-code PS S1. Primary Sources of Unsatisfactory Brush Performance 48. Loose or unstable foundation 52. “Commutation factor” too high 55.2 1700 Motor Maintenance Schedule/Troubleshooting Version no T-code 000 RTX35/RTX45 Table 2. Brushes too abrasive 62. Silicone contamination Disturbing External Condition 150 Return 51. Lack of polishing action in brush 61. External source of vibration 53. Contact drop of brushes too low 58. Contact drop of brushes too high 57. Lack of carrying capacity Service Manual 2001-03-15 . Humidity too low 50.

drive end 13 Washer. wave 5 End head. 1 Motor assembly 10 Holder. drive 14 End head.C. commutator end 7 Bearing 16 Hardware. fan 8 Brush 17 Shroud.W. shroud Counterclockwise when viewed from commutator end. brush 15 Fan.F-code Section PS C-code S1. fan 9 Spring 18 Hardware. Description 151 . Return 15 12 Description Service Manual 2001-03-15 Item No. commutator 6 Spring.3 1750 Pump Motor (RTX35) Version no T-code 000 RTX35 Pump Motor (RTX35) 3 2 5 4 6 7 1 18 8 13 17 16 11 9 10 14 ROTATION Item No. brush 2 Frame & field assembly 11 Lead assembly 3 Armature & fan assembly 12 Bearing 4 Fan.E.C. © BT Prime-Mover Inc. C.

If shaft. 6. Most motors have a slip fit bearing at the commutator end. Motor Disassembly 1. Use a brush hook to reach into the motor and lift the brush springs (9). 152 Return Service Manual 2001-03-15 . Separate armature (3) from the drive end head (5).1. Remove commutator end head retaining screws. 7. 2. the armature or the drive spline must usually be replaced. Either position brushes outside the motor or remove brush retaining screws. and end head can be removed with very little trouble. 4. Remove bearing with a puller. they can save time when the motor does not have locating pins. Component Repair 1. Scribe or center punch locating marks in the end head and frame. Separate bearing (6) from end head (4). the bearing is retained with a snap ring. Pull the brushes (8) out of the brush holders.F-code Section PS S1. by pressing the armature out of the drive end bearing. Although locating marks are not always necessary. CAUTION Use caution and DO NOT damage armature during removal. protecting the end of the armature shaft with a nut or a thick flat washer. Remove the snap ring. coupling. Press the bearing out of the end head. 3.3 Pump Motor (RTX35) Version no T-code 000 RTX35 C-code 1750 1. 5. Separate armature (3) and drive end head (5) as an assembly from the frame and field coil assembly. On larger motors. Remove pump motor from truck (see page 111). and remove brushes (8) from the motor. or spline is damaged when removing the drive end head. Some of the smaller pump motors retain the drive end head with the motor through bolts. Remove drive end head retaining screws if necessary.

Install a puller and apply slight pressure against the fan. they must be heated to be removed without damage. Use “Loctite® Retaining Compound 40®” or equivalent on the inside of the fan hub when reassembling fan. When the fan (4) is reassembled on the shaft. Use “Loctite” on this area of shaft © BT Prime-Mover Inc.3 1750 Pump Motor (RTX35) T-code RTX35 8. Return Service Manual 2001-03-15 153 . 10. When the fan becomes loose on the shaft. Once the fans have been pressed onto the armature. remove as quickly as possible. After the motor has been separated into all its major subassemblies. as evidenced by the puller becoming loose. 9. The ventilation fans (4) are cast aluminum.F-code PS Version no 000 Section C-code S1. the components should be cleaned and inspected for wear or damage. make sure it is a tight fit. Use a small propane torch to heat the area of the fan around the shaft.

5. Internal and external spline drives must be periodically lubricated in accordance with the original manufacturer’s recommendation. Motor Inspection A good planned maintenance program will save many hours of future “down time” on a piece of equipment. Make visual inspection of brush and commutation area. 154 Return Service Manual 2001-03-15 .F-code Section PS S1. 3. if present. 2. Cooling holes must be kept free of any debris or restriction. Maintenance schedules should consist of periodic routine inspections of motors. Headband. should be removed for clear. Check for clean. tight terminal studs and mounting bolts. Check for any sign of oil leaks.1. 4.3 Pump Motor (RTX35) Version no T-code 000 RTX35 C-code 1750 2. which would prevent proper airflow and hamper cooling. External Motor Routine motor inspection should include the following: 1. battery and wiring circuitry. 2. proper viewing.

2.3 1750 Pump Motor (RTX35) Version no T-code 000 RTX35 2. Good commutation will be indicated by a dark brownish. the armature should be placed in lathe and the commutator lightly sanded with No. Brush and commutator inspection can usually be accomplished be removing the cover band (if equipped) from the commutator end of the motor. With the armature supported on both bearing journals.001 inch (0. By recognizing undesirable commutator and/or brush conditions. corrective action can be taken before a major component is damaged beyond serviceability. mica segments GOOD UNDERCUT 0. The brushes and commutator should be inspected for even wear and good communication. Total indicated run-out should not exceed 0. See “Table 1. polished commutator and an evenly polished brush wearing surface.F-code Section PS C-code S1. After the commutator has been undercut. scored or has signs of burning or heavy arcing between the commutator bars.0762 mm) or 0. commutator must be turned and reundercut. the motor should be disassembled. This will remove any burrs left from the undercutting operation.003 inch (0. Unsatisfactory Brush Performance” on © BT Prime-Mover Inc. If the commutator appears rough. Return Service Manual 2001-03-15 155 . If the readings fall outside this limit. For a detailed inspection of the commutator. 00 sandpaper.0254 mm) bar to bar.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. Clean commutator with dry compressed air and recheck commutator run-out. check run-out of commutator with a dial gauge. Brush and Commutator The most important part of any planned maintenance schedule is the brush and commutator inspection. the motor should be removed for servicing. pitted.

A brush spring that does not apply equal pressure on the center of the brush will cause the brush to wear unevenly. After the installation of new brushes. the complete brush set should be replaced. Check the brush springs for correct alignment on the brush. See drawing below: Put Spring In This Position For Brush Removal Do not substitute brushes. Check for correct clearance and freedom of brush movement in the holder.F-code Section PS S1. Substituting brushes of the wrong grade can cause commutator damage or excessive brush wear. no load and brushes seated to the commutator with a dressing Minimum commutator diameter 156 Return Service Manual 2001-03-15 . Check the brush holders for physical damage and make sure they are not loose on the end head or the brush holder plate. Do not replace just one or two brushes. If any of the brushes are worn to the point that replacement is necessary. the motor should be operated at 12 Volts.3 Pump Motor (RTX35) Version no T-code 000 RTX35 C-code 1750 page 145. The brushes are matched to the motor type and application to provide the best service. When brush service is required on the motor. lift brush spring over holding bracket before removing brush.

Check armature for grounded circuits by placing one test lead of a Dielectric Breakdown Tester on the commutator and the other lead at the armature shaft. All motor armatures are wave wound and can be short circuit tested. Bearings may have been damaged during removal. Although the bearings may appear and feel good. see page 67. one armature is tested on a growler using a hacksaw plate to locate any shorted windings. the following test should be performed. © BT Prime-Mover Inc. 2.3. 2.F-code PS Version no 000 Section C-code S1. For helpful maintenance guides for proper servicing of motors. If the test light comes on. 3. Bearings After the motor has been disassembled. Return Service Manual 2001-03-15 157 . the bearing races could be brinelled and fail within a relatively short period of service. 1. it is recommended that new bearings are installed. Armature Electrical Check Before the armature is reassembled into the motor. For short circuit connection. the armature is grounded.3 1750 Pump Motor (RTX35) T-code RTX35 before armature needs to be replaced is specified on original manufacturer’s test specification. 2.4.

5. 158 Return Service Manual 2001-03-15 . The insulation of the field coils is easily damaged by this method. the frame and field must be oven-cured for one hour at 300°F (148°C). After cleaning. Pole piece screws should be torqued to 250-300 in-lbs (28-33 N•m).F-code Section PS S1. This is a Class H water soluble varnish. It is not uncommon that the frame and field of a motor becomes exceptionally dirty after many hours of operation. If new field coils are installed the cross-over connection should be brazed for a good sound connection and to prevent breakage due to vibration.3 Pump Motor (RTX35) Version no T-code 000 RTX35 C-code 1750 2. A similar air-dry varnish may also be used providing it has a Class H thermal specification. grease and other foreign materials. Frame & Field Service Recommendation Motors disassembled for servicing should also include a complete inspection of the frame and field assembly. Clean the complete frame and field in a cleaning solution. NOTE! Do not use a torch for the crossover connection. A high capacity resistance power unit with a plier-type handpiece may be used for brazing field connections. Add a coat of WS200 PT George Varnish for proper insulation protection. It is not recommend that connections be soldered. Motor terminals should be torqued to 140 in-lbs (15.82 N•m). This may result in a grounding condition due to dirt.

© BT Prime-Mover Inc. the motor should be tested against a NO LOAD POINT outlined on the specification.3 1750 Pump Motor (RTX35) T-code RTX35 2. Return Service Manual 2001-03-15 159 . Press against the race that is absorbing the pressure. Assembly/Testing Refer to the following drawing whenever a bearing is installed into an end head or shaft. 3. Use a new bearing when servicing a motor. In the event no dynamometer is available for testing. 4. Reinstall pump motor on truck (see page 112).6.F-code PS Version no 000 Section C-code S1. WARNING Do not run motor NO LOAD at full motor voltage. After assembly. Press Ram Pipe Same Size As Inner Race Bearings Inner Race End Head Armature Shaft Snap Ring 1. 2. 5. the motor should be tested per the original motor manufacturer.

3 Pump Motor (RTX35) Version no T-code 000 RTX35 160 Return C-code 1750 Service Manual 2001-03-15 .F-code Section PS S1.

commutator 6 Kit. Description ROTATION 1 Ring. 3 End head. lead assembly Counterclockwise when viewed from commutator end.W.F-code PS Section C-code S1. 2 Bearing 10 Kit. brush © BT Prime-Mover Inc.C. drive 11 Bearing 4 Fan 12 Washer. Return Service Manual 2001-03-15 161 . wave 5 Armature & fan Assembly 13 End head. brush wear 8 Spring. field coil 14 Band.4 1750 Pump Motor (RTX 45) Version no T-code 000 RTX45 Pump Motor (RTX 45) 1 6 4 5 2 3 15 12 11 14 10 8 9 13 Item No.E. retainer 9 Plate assembly. cover (optional) 7 Brush 15 Indicator kit. brush C.C. Description 7 Item No.

Remove the bearing with a puller.1. 7. they can save time when the motor does not have locating pins. 6. Motor Disassembly 1.F-code Section PS S1. 4. Remove pump motor from truck (see page 111). 3. Remove cover band (14) from the commutator end of the motor. 162 Return Service Manual 2001-03-15 . by pressing the armature out of the drive end bearing. Separate the armature (12) and drive end head (3) as an assembly from the frame and field coil assembly. and remove the brushes (7) from the motor. CAUTION Use caution and DO NOT damage the armature during removal. Use a brush hook to reach into the motor and lift the brush springs (8). protecting the end of the armature shaft with a nut or a thick flat washer. Scribe or center punch locating marks in the end head and the frame.4 Pump Motor (RTX 45) Version no T-code 000 RTX45 C-code 1750 1. the armature or the drive spline usually must be replaced. 5. coupling. 2. Remove the commutator end head retaining screws. and the end head can be removed with very little trouble. 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. Pull the brushes (7) out of the brush holders. or spline is damaged when removing the drive end head. Although locating marks are not always necessary. Component Repair 1. Most motors have a slip fit bearing at the commutator end. If the shaft. Either position the brushes outside the motor or remove the brush retaining screws. Separate the armature (12) from the drive end head (3).

Use “Loctite® Retaining Compound 40®” or equivalent on the inside of the fan hub when reassembling fan. make sure it is a tight fit. the bearing is retained with a snap ring. Then press the bearing out of the end head. Install a puller and apply slight pressure against the fan.F-code PS Version no 000 Section C-code S1. 10.4 1750 Pump Motor (RTX 45) T-code RTX45 8. as evidenced by the puller becoming loose. Remove the snap ring. Use “Loctite” on this area of shaft © BT Prime-Mover Inc. Use a small propane torch to heat the area of the fan around the shaft. Return Service Manual 2001-03-15 163 . On larger motors. they must be heated to be removed without damage. remove as quickly as possible. 11. the components should be cleaned and inspected for wear or damage. After the motor has been separated into all its major subassemblies. Separate the bearing (2) from the end head (3). When the fan becomes loose on the shaft. The ventilation fans (4) are cast aluminum. 9. Once these fans have been pressed onto the armature. When the fan (4) is reassembled on the shaft.

164 Return Service Manual 2001-03-15 .F-code Section PS S1. Motor Inspection See “Motor Inspection” on page 154.4 Pump Motor (RTX 45) Version no T-code 000 RTX45 C-code 1750 2.

5 Version no C-code 1760 Drive Motor T-code 000 RTX35/RTX45 Drive Motor 5 3 1 4 2 2 10 6 12 11 7 9 8 13 Item No. brush 12 Bearing 4 Fan 9 Kit. Description Item No Description Item No Description 1 Kit. retainer 3 Armature and fan assembly 8 Plate assembly.F-code Section PS S1. field coil 6 Brush 10 Indicator kit. brush 11 Ring. lead assembly 13 End head. Return Service Manual 2001-03-15 165 . commutator 5 End head. drive © BT Prime-Mover Inc. brush wear 2 Key 7 Spring.

Remove drive motor from truck (see page 108). if necessary. Scribe or center punch locating marks in the end head and the frame. Remove the drive end head retaining screws. Either position the brushes outside the motor or remove the brush retaining screws and remove the brushes from the motor. 8.F-code Section C-code PS S1. remove the head band from the commutator end of the motor. Remove the commutator end head retaining screws. 166 Return Service Manual 2001-03-15 . Although locating marks are not always necessary because of locating pins in some motors. and the end head can be removed with very little trouble. For EE motors. by pressing the armature out of the drive end bearing. Press bearing (12) out of the commutator end head. Separate the armature (3) from the drive end head (5). 5. Most motors have a slip fit bearing (12) at the commutator end. 6. If the shaft. 7. they can save a lot of time when the motor does not have locating pins. Pull the brushes (6) out of the brush holders. Remove retainer (11) from the commutator end head (13). Separate the armature (3) and drive end head (5) as an assembly from the frame and field coil assembly. 4. 2. or spline is damaged when removing the drive end head. Use a brush hook to reach into the motor and lift the brush springs (7). the components should be cleaned and inspected for wear or damage. 3. Motor Disassembly 1. After the motor has been separated into all its major subassemblies. CAUTION Use caution and DO NOT damage the armature during removal. the armature or the drive spline usually must be replaced. 9. coupling.5 Drive Motor 1760 Version no T-code 000 RTX35/RTX45 1.

Motor Inspection See “Motor Inspection” on page 154. Return Service Manual 2001-03-15 167 .F-code Section PS S1. © BT Prime-Mover Inc.5 Version no 000 C-code 1760 Drive Motor T-code RTX35/RTX45 2.

5 Drive Motor 1760 Version no T-code 000 RTX35/RTX45 168 Return Service Manual 2001-03-15 .F-code Section C-code PS S1.

Return 34 Service Manual 2001-03-15 28 169 . Before disassembly of parts. Version no C-code T-code 000 RTX35/RTX45 Transmission.F-code Section PS S2.0 2550 Transmission. thoroughly clean the outside of the assembly with cleaning solution or other non-corrosive cleaning fluid and air dry parts 1 2 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.

shim 41 O-ring 21 Cover ring Service Manual 2001-03-15 . Description Description 1 Transmission assembly 22 Screw 2 Gear. spare parts (Bearing) 24 Washer 4 Kit. 170 Return Item No. shim 33 Gear. spare parts (Sealing) 25 Spacer 5 Kit. wheel 30 Washer. spare parts (Helical gear) 26 Ring.F-code Section C-code PS S2. 2550 Version no T-code 000 RTX35/RTX45 Item No. locking 7 Kit. drain 8 Gear. fill 15 O-ring 36 Keeper 16 Screw 37 Cover 17 Axle 38 Case 18 Washer.0 Transmission. locking (not part of item #1) 10 Nut 31 Washer (not part of item #1) 11 Bearing 32 Screw 12 Kit. copper 39 Bearing 19 Bearing 40 Screw 20 Kit. bevel 13 Kit. ring 23 Bearing 3 Kit. sealing 6 Kit. spare parts (Bevel gear) 28 Plug. wheel 29 Nut (not part of item #1) 9 Gear. shim 34 Screw 14 Bearing 35 Plug. spare parts (Wheel shaft) 27 Ring.

7. 4. Remove lower case cover (37). Using a brass punch and hammer. Remove copper washer (18) from drain plug (28). Using a puller. Remove transmission page 115). Axle Sealing Ring Replace the axle sealing ring when there is oil leakage from the drive axle. 3. 6. Remove bolts (34) from lower case cover (37). from the truck (see 2. Remove seal ring (26) transmission case (38). Return Service Manual 2001-03-15 from axle (17) or 171 . Remove bolts (16) and keeper washer (36). 5. Loosen drive axle bolts (16).F-code Section PS S2. use a split bearing puller.1. knock out the drive axle (17). 1. Version no C-code T-code 000 RTX35/RTX45 1. NOTE! To avoid bearing damaging during removal. NOTE! The seal ring (26) may remain in the transmission case (38).0 2550 Transmission. Disassembly 1. Remove O-ring (15) from cover. remove bearing (23) from drive axle (17). © BT Prime-Mover Inc.

F-code Section C-code PS S2. Install lower cover (37). Press new seal ring (26) into transmission case (38). Secure lower cover (37) with new bolts (34). Use Loctite® 242® on bolts (16). Install drain plug (28) in the transmission. Press drive axle (17) into the transmission case. 4. Install a new O-ring (15) on the lower cover (37). 172 Return Service Manual 2001-03-15 . 6. 2550 Version no T-code 000 RTX35/RTX45 1. NOTE! Use care when pressing the new seal ring into place so the seal is seated correctly in the gear housing. Torque bolts (34) to 18 ft-lb (25 N•m). Torque axle bolts (16) to 81 ft-lb (110 N•m). 2. Place drive axle outer bearing (23) in the transmission case (38). Assembly 1. Make sure O-ring (15) is not damaged during installation.0 Transmission. Lubricate new bolts (34). 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). Install a new copper washer (18) on drain plug (28). . 7. Fill transmission with oil (see “Approved Oils and Grease” on page 81). Place keeper washer (36) onto the drive axle end and install new bolts (16). Install transmission on truck (see page 116). Install fill level plug (35) in the transmission case. 5. 3.2.

Install a new copper washer (18) on drain plug (28). Remove steering gear ring (2) from the transmission case (38). Lubricate bolts (32) and install on the steering gear ring. Carefully clean the sealing surfaces of steering gear ring and transmission case. Top Cover 1. Install drain plug (28) in transmission. 5. Install fill level plug (35) in the transmission case. 7.1. 3. proceed as follows: 2. Version no 000 C-code T-code RTX35/RTX45 2. © BT Prime-Mover Inc. to the transmission case (38). Apply sealant. 2. Remove transmission from truck. type Loctite® 515®. Install steering gear ring (2). Torque bolts (32) to 19 ft-lb (25 N•m). following the instructions given on the sealant container. Fill transmission with oil. 4.0 2550 Transmission. Remove bolts (32) securing steering gear ring (2) to the transmission case (38).F-code Section PS S2. Install transmission on truck. Return Service Manual 2001-03-15 173 . Leakage When there is leakage from the transmission top cover. 6.

0 Transmission. 2550 Version no T-code 000 RTX35/RTX45 2. 174 Return Service Manual 2001-03-15 . Remove lower cover (37) from the transmission case (38).F-code Section C-code PS S2. proceed as follows: 1. 4. Drain transmission oil by removing drain plug (28). 2.2. Remove bolts (34) from the cover (37). Fill the transmission with oil. Torque bolts (34) to 18 ft-lb (25 N•m). Secure lower cover (37) with new bolts (34). Remove O-ring (15) from the cover (37). Install drain plug (28) in the transmission. Install the cover (37). Lubricate the new bolts (34). Install fill level plug (35) in the transmission case. Lower Cover When there is leakage from the transmission lower cover. 3. Remove washer (18) from drain plug (28). Make sure O-ring (15) is not damaged during installation. Install a new copper washer (18) on drain plug (28). Install a new O-ring (15) on the cover (37).

Remove transmission from truck. Wheel Bolt 1.F-code Section PS S2. 5. Return Service Manual 2001-03-15 175 . Remove drive axle from the transmission case. Install transmission on truck. 3. 6. Smooth away any burring around the bolt hole. Install drive axle into the transmission case (see page 172). 2. Version no 000 C-code T-code RTX35/RTX45 3. Drain transmission oil by removing drain plug (28). NOTE! Always install a new drive axle seal during assembly. Press or knock out the damaged bolt from the drive axle rim. 7. 4. Press or knock new bolt into place.0 2550 Transmission. © BT Prime-Mover Inc.

0 Transmission. 2550 Version no T-code 000 RTX35/RTX45 176 Return Service Manual 2001-03-15 .F-code Section C-code PS S2.

0 3371 Electromagnetic Brake Version no T-code 001 RTX35/RTX45 Electromagnetic Brake 13 1 11 Item No. Park the truck on a level surface and make sure all wheels are blocked to prevent accidental movement. 6 2. socket head 12 Screw 13 Spacer 1. © BT Prime-Mover Inc. Remove top console. socket head 10 Washer 11 Screw. 3. and left side panel to allow access to electromagnetic brake. mounting 7 Spacer. 9 10 2 3 8 7 4 12 5 Description 1 Brake assembly 2 Coil 3 Armature 4 Hub 5 Plate. Adjustable 8 Spring 9 Screw. friction 6 Plate. motor compartment door. 1.F-code Section PS C-code S3. Turn key switch OFF and disconnect battery connector. Return Service Manual 2001-03-15 177 . Removal WARNING Block all wheels to prevent truck from rolling.

If only the brake is being changed. Remove mounting plate (6) from the electric drive motor if drive motor is to be replaced.F-code Section C-code PS S3. 8. 5. Slide the friction plate (5) off the hub (4) spline and away from the mounting plate (6). mounting plate may be reused for the new brake assembly. 6. Lift upward to remove the armature (3) and coil (2) from the top of the drive motor.5 mm. Electrically disconnect the brake assembly. Refer to Section 3000 of the Parts Book for part number of screw (11). Fully tighten two manual release screws (11). Remove brake hub (4) from motor shaft. Avoid moving the adjustable spacers (7) if possible. 4. Screws (11) are used as a tool for braking.25 thread x 37. 178 Return Service Manual 2001-03-15 . thus maintaining correct axial air gap when reassembled. Size of screw is 8 mm x 1. Remove three screws (9) which hold brake parts and set aside.0 3371 Electromagnetic Brake Version no T-code 001 RTX35/RTX45 WARNING The two manual release screws (11) must be fully tightened before removing the three brake retaining screws (9). 9. 7.

Check air gap and adjust if necessary. 5.25 thread x 37. ensuring all parts are clean and dry. © BT Prime-Mover Inc. WARNING The magnetic coil (2) and armature (3) are under pressure. Avoid moving the adjustable spacers (7) if possible.5 mm. 1. Size of screw is 8 mm x 1. Secure brake hub (4) to motor shaft. It should not interfere with mounting plate (6). For adjustment procedures see “Adjustments” on page 180. 6.0 3371 Electromagnetic Brake T-code RTX35/RTX45 2. 3. The mounting plate is secured to drive motor with retaining screw (9). Installation WARNING Block all wheels to prevent truck from rolling. Return Service Manual 2001-03-15 179 . Carefully secure in place. Place armature (3) and coil (2) of the brake over the mounting plate (6) and line up screws (9). Screws (11) are used as a tool for braking. Once brake is fully secured in position. Refer to Section 3000 of the Parts Book for part number of screw (11). 7. thus maintaining correct axial air gap when reassembled. 2. Fully tighten two manual release screws (11) . DO NOT remove the retaining screws (9) without the manual release screws (11) securely in place. remove manual release screws (11) and set aside. 8. WARNING The two manual release screws (11) must be fully tightened before removing the three brake retaining screws (9). Remove three retaining screws (9) which hold brake parts and set aside.F-code PS Version no 001 Section C-code S3. 4. Be sure truck is securely blocked with key switch OFF and battery disconnected. Slide friction plate (5) onto the hub spline and up to the mounting plate (6).

0 3371 Electromagnetic Brake Version no T-code 001 RTX35/RTX45 9.20 to 0.014 inch (0. The gap should be checked on each side of the brass nut to assure consistency in the setting. NOTE! Be sure to tighten the Allen head retaining screw (9) before checking the air gap. thus changing the air gap. Using a 9/16 inch (14 mm) wrench. This changes the relative position of the armature and end plate.F-code Section C-code PS S3. 1. check that the brake will release when power is applied. 2. 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.003 inch (0. Adjustment is carried out by using a 9/16 inch (14 mm) open end wrench and a 1/4 inch (6 mm) socket key. After making adjustments. The air gap should be set to 0. to allow adjustment of threaded spacers (7).008 inch to 0. 3. 3. Turn Allen head retaining screws (9) counterclockwise to loosen one at a time.36 mm) and be within 0.08 mm) throughout the entire circumference. the brass nut on the threaded spacers (7) can now be threaded in or out of the magnet. 180 Return Service Manual 2001-03-15 . Adjustments NOTE! Do not remove retaining screws (9).

F-code PS Section C-code S3. Return Service Manual 2001-03-15 181 . Turn key switch OFF and disconnect battery connector. Do not remove retaining screws (9) without the manual release screws (11) securely in place. 5. Removal WARNING Block all wheels to prevent truck from rolling. WARNING The magnetic coil (2) and armature (3) are under pressure. 6. Remove three brake retaining screws (9). Coil Check On Brake • 24V coil at 70° F (20° C) should be 9 ohms • 36V coil at 70° F (20° C) should be 22 ohms 5. 2. Fully tighten two manual release screws (11).1. motor compartment door. Armature and Magnetic Coil 5.0 3371 Electromagnetic Brake Version no 001 T-code RTX35/RTX45 4. Remove top console. Park the truck on a level surface and make sure all wheels are blocked to prevent accidental movement. Electrically disconnect brake assembly and lift upwards to remove. 4. 1. and left side panel to allow access to electromagnetic brake. 3. © BT Prime-Mover Inc. Electromagnetic Brake.

20 to 0. 2. Brake Friction Plate 6.2344 inch (6 mm) or less. connect battery. 6. remove and install new plate. Inspection The brake friction plate should be replaced when the thickness is 0. 5.2. Installation NOTE! Make certain brake friction plate (5) and armature (3) are clean and free of fluid. 4.003 inch (0. 182 Return Service Manual 2001-03-15 .008 inch to 0. Replacement If the brake friction plate needs replaced. To test operation of the brake. Align and tighten three brake retaining screws (9).08 mm) throughout the entire circumference.1.014 inch (0. Set the air gap to 0. Remove two manual release screws (11) and electrically connect the brake. 6.2.F-code Section C-code PS S3.36 mm) and be within 0. 3. This will allow the truck to operate. turn key switch ON. and depress brake pedal.0 3371 Electromagnetic Brake Version no T-code 001 RTX35/RTX45 5. 1. Set armature (3) and magnetic coil (2) on the base plate (6).

1.F-code Section PS S3. drive 4 Washer. 4. spherical 1. Check to make sure battery retainer plates are in place. Remove seven wheel retaining nuts (3) and spherical washers (4). Removal NOTE! Replace drive wheel when traction problems develop.1 Version no C-code 3531 Drive Wheel T-code 000 RTX35/RTX45 Drive Wheel 3 4 1 2 Item No. Turn key switch to OFF and disconnect battery at the battery connector. Description Item No. Jack the rear of the truck (see “Safe Jacking Procedure” on page 64). 2. Park truck on a level surface. Description 1 Tire 3 Nut 2 Wheel. Return Service Manual 2001-03-15 183 . © BT Prime-Mover Inc. 3. Pull tire (1) and drive wheel (2) from the transmission drive axle hub.

184 Return Service Manual 2001-03-15 . Press hub to the center of the tire (1). Press tire (1) from drive wheel (2). Install drive tire assembly on the transmission axle hub. Press drive tire on wheel hub. 2. Torque drive tire retaining nuts to 95 ft-lb (130 N•m).F-code Section C-code PS S3. Installation 1.1 Drive Wheel 3531 Version no T-code 000 RTX35/RTX45 5. 2. This is usually done while pressing off the old tire.

The outside diameter of the ram must be small enough to fit loosely in the insert of the tire but must be large enough to rest squarely on the flat surface on the outer edge of the hub. 6. 3. The chamfered edge must always be the leading edge when a tire is pressed onto the hub. The outside edge of the hub has a chamfer to help guide the new tire onto the wheel. measure how far the hub is recessed inside the tire. 4. © BT Prime-Mover Inc. If the outside edge of the hub is not flush with the edge of the metal insert in the old tire. Position new tire with its chamfered insert facing the hub. Position hub assembly with the old tire on the top of the circular ram so the outside of the wheel is positioned upward. Place a circular ram on the press table. Remove any scaling or rust with sandpaper.1 Version no 000 C-code 3531 Drive Wheel T-code RTX35/RTX45 3. The new tire must be placed in the same position the old tire was installed on the hub. Tire Pressing Procedure Outside of Hub and Tire Assembly New Tire Worn Tire Circular Ram Press Table 1. Center hub assembly on top of the ram and make sure that they mate squarely. Clean the inside of the metal insert and lubricate it with a soap solution. 5. Align new tire and hub so that they are concentric. Return Service Manual 2001-03-15 185 . A spacer (slightly smaller in diameter than the inside diameter of the tire insert and the same thickness as the depth of the recess) can be used to obtain the proper amount of recession. 2. Check the inside surface of the metal insert on the new tire.F-code Section PS S3. The length of the ram must be longer than the width of the old tire to allow complete removal of the old tire.

Inspect wheel and tire assembly. A sharp jar with a soft-headed mallet will usually realign the tire on the hub. 186 Return Service Manual 2001-03-15 . stop the press and realign the tire. To prevent damage. and old tire from the press table. tire assembly.1 Drive Wheel 3531 Version no T-code 000 RTX35/RTX45 CAUTION Misalignment of the tire and hub while the tire is being pressed onto the hub can cause damage to the hub. Remove wheel. If the tire begins to cock to one side. Run the press slowly for the first few inches of travel. because this is the critical stage of the operation. replace the hub.235 kg) force.F-code Section C-code PS S3. Install wheel assembly following the procedure for the specific type of wheel. Begin pressing new tire onto hub and old tire off the hub. The chamfers help to center the hub and tire during the pressing operation and reduce the possibility of misalignment. the hub must be installed on the circular ram with its chamfered side up. 7. NOTE! If the new tire does not press on with a minimum of 5 tons (5080. For this reason. chamfers have been provided on the outside edge of the hub and on the end of the inside diameter of the tire’s metal insert. Release the press. 9. 8.

Return Service Manual 2001-03-15 187 .2 3541 Non-Braking Caster Assembly Version no 001 T-code RTX35 Non-Braking Caster Assembly 1 2 5 3 6 4 7 8 9 17 10 11 12 19 20 18 13 14 17 15 16 © BT Prime-Mover.F-code Section C-code PS S3. Inc.

Description Item No. Nilos 10 Nut 17 Fitting. caster 20 Screw. thrust Service Manual 2001-03-15 . set 16 Block 3 Ring. grease 4 Bearing 11 Screw. cap 18 Bushing 5 Screw. cap 12 Nut 19 Washer 6 Nut 13 Pivot. Description 1 Locknut 8 Spring 15 Caster assembly 2 Lockwasher 9 Screw. cap 7 Guide. spring 14 Bearing. 188 Return Description Item No.2 3541 Non-Braking Caster Assembly Version no T-code 001 RTX35 Item No.F-code Section C-code PS S3.

F-code Section C-code PS S3. Turn key switch OFF and disconnect battery connector. 2.2 3541 Non-Braking Caster Assembly Version no 001 T-code RTX35 1. Loosen nuts (5) to release spring tension. Jack the rear of the truck (see “Safe Jacking Procedure” on page 64). © BT Prime-Mover. NOTE! For models with a brake on the caster wheels. Bend lockwasher (2) tab down and remove locknut (1). the cable linkage must be disconnected before removal of the brake pedal. Remove caster pivot (13). 6. Inc. 8. Remove mounting bolts (20 11. 10.1. Check to make sure the battery retainer plates are in place. See “Main Electronic Card Panel” on page 101. Removal 1. Turn and secure transmission to access the mounting bolts (20). 5. Park truck on a level surface. WARNING Secure caster pivot before removing mounting bolts (20). Inspect and replace bushings and bearings as needed. Return Service Manual 2001-03-15 189 . 7. 9. Remove floor board. Serious injury could occur if failure to comply with this requirement. Remove caster assembly. 3. Remove Nilos ring (3) and bearing (4). Caster Pivot 1. 12. 4. Remove main electronic card panel.

6. 10. Install pivot block (16) closest to the battery compartment first. 190 Return Service Manual 2001-03-15 . Maneuver caster pivot (13) in place between the frame. 4. Tighten locknut (1) while turning the caster wheel assembly until tight. 3. Installation 1. the cable linkage must be installed. Install main electronic card panel. 8.2. Install brake pedal.F-code Section C-code PS S3. then return to service. Set spring tension and stops. NOTE! Make certain Nilos ring and lockwasher are in the correct position. Install rear pivot block (16) on caster pivot (13). 2. Install floor board. 11. 9. See “Caster Springs” on page 193. then back off 1/4 turn. 7. Install caster assembly in the caster pivot (13). Test truck operation.2 3541 Non-Braking Caster Assembly Version no T-code 001 RTX35 1. Bend the tab on lockwasher (2) up to secure the locknut (1). 5. NOTE! For models with a brake on the caster wheels.

Thrust Bearing 2. 8. lockwasher (2) and Nilos ring (3). Return Service Manual 2001-03-15 191 . © BT Prime-Mover. Check to make sure the battery retainer plates are in place.1. Removal 1.2 3541 Non-Braking Caster Assembly Version no 001 T-code RTX35 2. Turn key switch OFF and disconnect battery connector. Remove main electronic card panel. 6. Jack the rear of the truck.F-code Section C-code PS S3. 5. Inc. Remove locknut (1). Inspect and replace bearings as needed. Bend the tab down on the lockwasher (2). Remove floor board. 4. 7. 3. remove the brake arm. 2. Park truck on a level surface. NOTE! For models with brakes on the caster wheels.

Nilos ring (3). 192 Return Service Manual 2001-03-15 . Installation 1. lockwasher (2) and locknut (1). 7. Test caster operation. NOTE! For models with brakes on the caster wheels. 2. Install caster assembly in the caster pivot (13).2 3541 Non-Braking Caster Assembly Version no T-code 001 RTX35 2. install the brake arm. 5. 6. 4.2. Install bearing (4). then back off 1/4 turn. Install the race (4) in the caster pivot and the thrust bearing (14) on the caster assembly. Bend the lockwasher tab (2) up to secure the locknut (1).F-code Section C-code PS S3. Tighten locknut (1) while turning the caster wheel assembly until tight. 3. The truck must be properly blocked at this time.

Loosen the stop bolt (11) to allow the caster pivot to rest on the frame stop.50 inches (136. Park truck on a level surface. Park truck on a level surface. disconnect connector.2. Worn Free Length is 6. Inc. loosen the jam nuts (6) and tighten or loosen the bolts (5).1. 5. The springs must be removed from the side. 4.2 3541 Non-Braking Caster Assembly Version no 001 T-code RTX35 3. 3. Remove main electronic card panel. 2.7 mm). To change the adjustment. Remove the floor board. 5.5-139.F-code Section C-code PS S3. Remove the bolts (5). Measure from the top of the spring spacer to the caster pivot plate. Loosen the jam nuts (6) and release all spring tension with the adjusting bolts (5). Caster Springs 3.375-5. 3. The measurement range should be within 5. 5. Turn key switch OFF and disconnect battery connector. 4. Adjustment 1. battery 3.5 inches (165 mm) or Less. Remove main electronic card panel. Remove the jam nut (12). © BT Prime-Mover. Return Service Manual 8. Removal New Free Length is 7 inches (178 mm) 1.375-5. 2001-03-15 193 . 6. Check to make sure the battery retainer plates are in place. Turn key switch OFF. and securely block the truck. Jack the rear of the truck. 7.50 inches 2.

Refer to the following table to determine if the maximum dimension for the truck can be increased.2 3541 Non-Braking Caster Assembly Version no T-code 001 RTX35 3. 9 10 12 4. Installation 5 6 1.375 inch (9.375 inch (9. Install caster springs.375-5. Install adjusting bolts (5). Install main electronic card panel.375 inch (9.375 inch (9. 194 Return Service Manual 2001-03-15 .25 inch (6.375 inch (9.3.375-5.53 mm) 0.375 inch (9.375 inch (9.53 mm) N/A 0.375 inch (9.53 mm) 0.50 inches 2.53 mm) 0.53 mm) 0. 9. Lower the truck to the floor and remove the hoist.5-137.53 mm) 0. 6.50 inches (136. battery weight.53 mm) N/A 0. The recommended dimension between the stop bolts and the stop block is 0.35 mm). 5.375 inch (9.53 mm) 0. Mast Height Compartment Size / Minimum Battery Weight 192 inches (4877 mm) 210 inches (5334 mm) 240 inches (6096 mm) 270 inches (6858 mm) 14. Test truck operation. 11 5.5 inches (419 mm) / 2000 lb (908 kg) minimum battery weight 21 inches (533 mm) / 2400 lb (1090 kg) minimum battery weight 21 inches (533 mm) / 2600 lb (1180 kg) minimum battery weight 0.375 inch (9. 8.53 mm) N/A 0.375 inch (9.F-code Section C-code PS S3. Adjust the top stop bolts (11). and mast height can result in serious injury.53 mm) N/A 7.53 mm) 0.5 inches (368 mm) / 1600 lb (726 kg) minimum battery weight 16. Install the floor board.53 mm) 0.125 inch (3 mm) clearance on the stop.375 inch (9. Tighten adjusting bolts (5) until there is 5. 3. CAUTION Failure to determine battery compartment size.9 mm) between the top of the spring spacer and the caster pivot plate. Adjust the bottom stop bolt (9) to 0.

25 inch (6.35 mm). Park truck on a level surface. © BT Prime-Mover. Refer to the previous table to determine if the maximum dimension for the truck can be increased. 5. The measurement range should be within 5. Caster Stops 6 4. Remove floor board. 6.375-5.5-139.50 inches (136. then return to service.7 mm). 10. Install the floor board.1. Measure from the top of the spring spacer to the caster pivot plate. Install main electronic card panel. Return Service Manual 2001-03-15 195 . and mast height can result in serious injury. 12 4. Securely block the truck. The recommended dimension between the stop bolts and the stop block is 0. 7. Test truck operation. Secure the jam nuts (12). Adjust the caster spring if necessary. Adjust the top stop bolts (11). battery weight. Adjustment 5. NOTE! The stop bolts must NOT be touching the stop blocks when measuring spring compression. CAUTION Failure to determine battery compartment size. Remove main electronic card panel. 9 2. 9. 10 3. Adjust the bottom stop bolt (9) to 0.F-code Section C-code PS S3.375-5. Turn key switch OFF and disconnect battery connector. Inc. 8.50 inches 11 1.2 3541 Non-Braking Caster Assembly Version no 001 5 T-code RTX35 4.125 inch (3 mm) clearance on the stop.

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 .

caster 5 Lockwasher 2 Bracket. 3 5 6 7 8 Description 1 Wheel. Park truck on a level surface. Description Item No. wheel 1. (See “Caster Springs” on page 193. 2. Removal NOTE! Replace caster wheel when caster spring can no longer be adjusted. 5. © BT Prime-Mover Inc. Turn key switch to OFF and disconnect battery at the battery connector.F-code Section C-code PS S3.3 3542 Non-Braking Caster Wheels Version no T-code 000 RTX35 Non-Braking Caster Wheels 1 2 1 3 4 4 Item No.) 1. Nilos 7 Fitting. caster 6 Locknut 3 Ring. 3. Check to make sure the battery retainer plates are in place. Bend lockwasher (5) tab down and remove locknut (6). Remove wheel cap (8). Return Service Manual 2001-03-15 197 . 4. Jack the rear of truck (see “Safe Jacking Procedure” on page 64). grease 4 Bearing 8 Cap.

Install Nilos ring (3) on the axle. lockwasher (5) and locknut (6). Bend lockwasher (5) tab to secure locknut (6). Install caster wheel assembly. tighten locknut (6) until the wheel becomes tight. Install Nilos ring (3). 3. 7. 4. 5. Back off locknut (6) until the caster wheel turns freely.3 3542 Non-Braking Caster Wheels Version no T-code 000 RTX35 6. Replace wheel cap (8). Grease as needed. 7. 2. Remove caster wheel assembly. The locknut (6) and lockwasher (5) tab should be aligned. 6. While turning the caster wheel. 2. 198 Return Service Manual 2001-03-15 . Installation 1. Inspect and replace the race and bearing (4) as needed.F-code Section C-code PS S3. 8.

4 3543 Braking Caster Assembly T-code RTX45 Braking Caster Assembly 1 2 3 5 4 25 26 23 6 24 23 7 9 17 21 8 22 10 11 12 20 19 13 18 14 16 © BT Prime-Mover Inc.F-code PS Version no 001 Section C-code S3. Return 15 17 Service Manual 2001-03-15 199 .

roll 7 Guide. set 18 Bushing Service Manual 2001-03-15 . cap 9 Screw. Nilos 12 Nut 21 Shaft 4 Bearing 13 Pivot. cap 20 Screw. Description 1 Locknut 10 Nut 19 Washer 2 Lockwasher 11 Screw. cap 3 Ring. grease 26 Screw. caster 22 Bracket 5 Screw. thrust 23 Bearing. cap 14 Bearing. flanged 6 Nut 15 Caster assembly 24 Pin. 200 Return Description Item No. spring 16 Block 25 Pivot 8 Spring 17 Fitting. Description Item No.4 3543 Braking Caster Assembly Version no T-code 001 RTX45 Item No.F-code Section C-code PS S3.

6. This can be felt by a change in force at the pedal by the spring tension.4 3543 Braking Caster Assembly Version no 001 T-code RTX45 1.F-code PS Section C-code S3.5 inches (89 mm). Return Service Manual 2001-03-15 201 . The pedal setpoint is 50 percent down or 1. Adjuster nuts © BT Prime-Mover Inc. the brake must be adjusted at the caster wheels.1. Check to make sure the battery retainer plates are in place. Jack the rear of truck (see “Safe Jacking Procedure” on page 64). 5. the caster wheels should stop rotating due to the brakes making contact with the caster wheel drums. Caster Brake Adjustment 1. electronic card panel (see CAUTION Pinch point. 4. 7. 8. Keep fingers clear of the floor board cutout while holding down the left foot brake pedal. Adjust the cable threaded end to allow for more engagement required by a worn brake. At the 50 percent pedal up position.8 inch (45. Remove main page 101). Remove floor board. Park truck on a flat surface. Removal NOTE! For models with a brake on the caster wheels. 2. Loosen adjusting nuts of the cable end at the caster assembly bell crank. Total travel of the left foot brake pedal from up to down is 3.7 mm). 1. Disconnect battery at the battery connector. 3. CAUTION Disconnect wire connections to the right foot pedal switch prior to removal of floor board. When the cable can no longer be adjusted for caster braking.

4 3543 Braking Caster Assembly Version no T-code 001 RTX45 9. The caster wheel should stop rotating due to the brake starting to make contact with the drums. Remove brake assembly from caster wheel. Adjust double nuts at the brake rod up or down by tightening the brake arm.F-code Section C-code PS S3. Reassemble and test for proper brake operation. 14. Check brake at 50 percent pedal up position. Lock double nuts together. 12. Remove only one caster wheel. Rod Spring Adjusting nuts 202 Return Service Manual 2001-03-15 . on page 204. full threads toward the caster assembly. 13. 11. 10. Refer to caster wheel removal. Run the cable adjustment back to the original position.

brake 5 Lockwasher 11 Screw. caster 7 Fitting. Nilos 9 Ring.5 3544 Braking Caster Wheel Assembly Version no T-code 000 RTX45 Braking Caster Wheel Assembly 16 15 1 13 9 14 2 11 10 13 12 9 10 11 3 1 4 4 3 5 Item No. wheel 14 Pivot. cap 6 Locknut 12 Nut © BT Prime-Mover Inc. caster 8 Cap. E 15 Spring 4 Bearing 10 Brake assembly 16 Plunger. Description Item No. grease 13 Washer 2 Bracket.F-code Section C-code PS S3. Return Service Manual 2001-03-15 203 . Description Item No. 6 7 8 Description 1 Wheel. brake 3 Ring.

5. 10. Remove wheel cap (8). Check to make sure the battery retainer plates are in place. washer (13). Bend down lockwasher (5) tab and remove locknut (6). 7. (See “Caster Brake Adjustment” on page 201.5 3544 Braking Caster Wheel Assembly Version no T-code 000 RTX45 1. Jack the rear of truck (see “Safe Jacking Procedure” on page 64). Remove caster wheel assembly. and slide brake plunger (16) up to remove brake pivot (14) and other washer (13). 8. Turn key switch to OFF and disconnect battery at the battery connector. 9.F-code Section C-code PS S3. Remove brake plunger (16) and spring (15). 4. Remove nuts (12). Park truck on a level surface. 6. otherwise replace brake shoes. Removal NOTE! Replace caster wheel when caster spring can no longer be adjusted. 204 Return Service Manual 2001-03-15 . 2. Remove E-ring (9) and cap screws (11) if brake assembly is to be replaced.) 1. Inspect and replace the race and bearing (4) as needed. 3.

Move brake pivot (14) around to install an E-ring (9) on both brake assemblies (10). Replace wheel cap (8). Install caster wheel assembly. Installation 1.F-code Section C-code PS S3. Install Nilos ring (3). Secure assembly together with a nut (12). 6. and locknut (6). 5. While turning caster wheel. 12. 7. 10. Install a second washer (13) on the brake plunger against the brake pivot (14). Install a second nut (12) to lock the first nut in place. Slide spring (15) in the caster bracket (2) and install brake plunger (16). 4. 2. Then slide the brake pivot (14) on the brake plunger (16). The locknut (6) and lockwasher (5) tab should be aligned. 8. Bend lockwasher (5) tab to secure locknut (6). Back off locknut (6) until the caster wheel turns freely. Install washer (13) on the brake plunger (16). lockwasher (5). Install Nilos ring (3) on the axle. 9. Grease as needed. tighten locknut (6) until the wheel becomes tight. 11. 3. 13.5 3544 Braking Caster Wheel Assembly Version no 000 T-code RTX45 2. against the washer (13). © BT Prime-Mover Inc. Return Service Manual 2001-03-15 205 . Install brake assembly (10) with cap screws (11).

5 3544 Braking Caster Wheel Assembly Version no T-code 000 RTX45 206 Return Service Manual 2001-03-15 .F-code Section C-code PS S3.

shoulder 6 Washer. Return Description Item No. Description 1 Axle 7 Washer. retainer 10 Nut 5 Fitting. grease 11 Bolt. 16 gauge 2 Toe box 8 Bearing 3 Plate.F-code Section PS C-code S3. © BT Prime-Mover Inc. 10 gauge Service Manual 2001-03-15 207 . rocker 9 Wheel. load 4 Ring.6 3551 Tandem Load Wheels Version no T-code 000 RTX35/RTX45 Tandem Load Wheels 1 2 11 3 4 10 5 6 7 8 9 8 7 6 Item No.

Park truck on a level surface. Removal NOTE! Replace load wheels when traction problems develop. Use a piece of rod or a punch to tap the axle (1) back out through the wheels.8 mm) off the floor and securely block. Check to make sure the battery retainer plates are in place. 4. Inspect bearings (8). Remove retainer ring (4) from the axles. 7.F-code Section PS S3. 2. The axle is welded into the rocker plate. Lower the carriage fully 3.6 Tandem Load Wheels Version no T-code 000 RTX35/RTX45 C-code 3551 1. 5. 6. Disconnect the battery at the battery connector. 208 Return Service Manual 2001-03-15 . Turn key switch to OFF. Hoist truck so the load wheels are approximately 2 inches (50. 1. Remove rocker plate (3). WARNING Block all wheels to prevent truck from rolling. Remove two washers (6 and 7) on each side of the wheel (9). Remove the load wheel (9) from the toe box (2).

washers (6 and 7) and rocker plate (3). NOTE! Place a block behind the axle (1) to hold it in place while assembling the rocker plate and snap rings. Pack bearings with grease. WARNING Install bearing shield and 10 gauge washer (6) properly. Install bearings (8) in the load wheel (9). 9. Install axle (1). Test operate truck. Remove blocking and lower truck to the floor. 5. 10. Grease as needed.F-code PS Section C-code S3. 8. Return Service Manual 2001-03-15 209 . Install load wheel assembly in the toe box (2). Return truck to service. Reconnect battery connector. 6. Installation 1. 4. 3.6 3551 Tandem Load Wheels Version no 000 T-code RTX35/RTX45 2. 2. 7. Install retainer rings (4) to axle (1). © BT Prime-Mover Inc.

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 .

© BT Prime-Mover Inc. 8 Description 1 Toe box. load 11 Load wheel assembly 6 Wheel Service Manual 2001-03-15 211 .7 3555 Single Load Wheels Version no T-code 000 RTX35/RTX45 Single Load Wheels 1 10 2 3 4 11 5 4 3 7 2 6 9 Item No. right 7 Toe box. Return Description Item No. shoulder 5 Tire.F-code PS Section C-code S3. 18 gauge 9 Nut 4 Bearing 10 Bolt. grease 3 Washer. left 2 Washer. 10 gauge 8 Fitting.

7. Hoist truck so the load wheels are approximately 2 inches (50.7 Single Load Wheels Version no T-code 000 RTX35/RTX45 C-code 3555 1. 6. Disconnect the battery at battery connector.8 mm) off the floor. 8. Check to make sure the battery retainer plates are in place. 4. Turn key switch to OFF. 2. Inspect bearings and replace if necessary. and securely block. Grease as needed. Park truck on a level surface. 9. WARNING Be sure to install the bearing shield and 10 gauge washer (2) properly. Removal NOTE! Replace load wheels when traction problems develop. 212 Return Service Manual 2001-03-15 . Remove right toe box (1) and load wheel (6).F-code Section PS S3. Remove axle nut (9). 1. WARNING Block all wheels to prevent truck from rolling. 3. Lower carriage fully. Press load tire (5) from wheel (6). 5. Remove toe box retaining nuts (9) and bolts (10).

7. Remove blocking and lower truck to the floor. Inspect and replace bearing (4) as needed. 5. 2. 9. Install toe box assembly on the support arm. Apply Loctite® 242® to nuts (9) and bolts (10). 4. Reconnect battery connector. Test the operation of the load wheel and truck. 3. © BT Prime-Mover Inc. Install load wheel assembly (11) on toe box axle.7 3555 Single Load Wheels Version no 000 T-code RTX35/RTX45 2. Install axle nut (9). Return truck to service.F-code PS Section C-code S3. Press new load tire (5) on wheel (6). Installation 1. Return Service Manual 2001-03-15 213 . Install right toe box (1). 6. 8.

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 S3.

Description 1 Cap. retainer 4 Spinner 13 Coupler 5 Wheel. 14 5. Release set screw in the coupler (13). flanged 17 Support. See “Top Console” on page 96. 6 18 17 7 11 8 9 7 12 16 10 15 13 1. flat 16 Washer.0 4110 Steering Wheel Version no T-code 001 Spring RTX35/RTX45 Steering Wheel E-Clip Item No. Lift up on spring (7) and remove E-clip (12). Lift steering wheel (5) from bracket (10). spinner 10 Bracket 2 Nut 11 Spring 3 Washer 12 Ring. steering 14 Tachometer 6 Spacer. © BT Prime-Mover Inc. Removal 4 5 WARNING Block all wheels to prevent truck from rolling. Set screw Coupler C-code 1 2 3 Description Item No. steering 15 Screw 7 Bushing.F-code Section PS S4. 2. Return Service Manual 2001-03-15 215 . Park truck on a level surface and block wheels. 3. Inspect and replace bushings (7 and 8) as needed. Turn key switch OFF and disconnect battery connector. flat 8 Bushing. 6. 4. steering 9 Screw 18 Screw 1. Remove top console.

5. Remove blocks and return truck to service. 2.0 Steering Wheel 4110 Version no T-code 001 RTX35/RTX45 2. 216 Return Service Manual 2001-03-15 .F-code Section C-code PS S4. Tighten set screw in the coupler (13) to 5 in-lbs (0. Apply Loctite® 242® to setscrew. Installation 1.56 N•m). Check steering wheel for ease of operation. 4. Place steering wheel in the mounting bracket (10). 3. Lift up on the spring (11) and install E-clip (12). 7. Test the operation of steering wheel and truck. Replace top console. 6.

18 17 7 11 2. Return Service Manual 2001-03-15 217 . 5. 6. steering 14 Tachometer 6 Spacer. 7 12 3. Lift up on spring (11) to remove E-clip (12). Description 1 Cap. Disconnect steer tach from the main electrical harness. See “Top Console” on page 96. Remove top console. Use an Allen wrench to loosen one set screw in the flexible coupler (13). spinner 10 Bracket 2 Nut 11 Spring 3 Washer 12 Ring. flanged 17 Support.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. Park truck on a level surface and block wheels. Item No. 8 9 16 10 15 13 14 4. steering 9 Screw 18 Screw 1. Set screw Coupler 1 2 3 Description Item No.F-code Section PS S4. © BT Prime-Mover Inc. flat 8 Bushing. Removal 4 WARNING Block all wheels to prevent truck from rolling. retainer 4 Spinner 13 Coupler 5 Wheel. 5 6 1. flat 16 Washer. steering 15 Screw 7 Bushing. Turn key switch OFF and disconnect battery connector. Remove remaining set screw and remove coupler from the tach shaft.

218 Return Service Manual 2001-03-15 . 2.56 N•m). Remove blocks and return truck to service. Lift up on spring (11) to install E-clip (12). 3. 5. Install top console (see page 96). Installation 1. Reconnect the electrical harness. 2. Tighten set screw in the coupler (13) to 5 in-lbs (0. Attach steering tach (14) to the underside of mounting bracket (10) with two screws (9).F-code Section C-code PS S4. Use an Allen wrench to remove two screws (9) securing steer tach (14) to the mounting bracket (10). 8. 7. 4. 6. Apply Loctite® 242® to setscrew. Test to see that the steering functions properly.0 Steer Tach 4110 Version no T-code 001 RTX35/RTX45 7. Attach flexible coupler (13) to the tach shaft.

Return Service Manual Description 1 Bearing 2 Screw 3 Transmission assembly 2001-03-15 219 . © BT Prime-Mover Inc.F-code Section PS S4.1 4181 Steering Bearing Version no 000 C-code T-code RTX35/RTX45 Steering Bearing 1 2 3 Item No.

2. 220 Return Service Manual 2001-03-15 . Check to make sure the battery retainer plates are in place.) 1. 5. Removal NOTE! The transmission and drive motor must be removed from the truck to access the steering bearing. Remove mounting ring. 3. 4. and page 115 for removal of transmission. Refill transmission as needed. Install drive motor. 6. Park truck on a level surface. Remove the motor compartment door and left side panel to access the motor compartment. Jack the rear of truck (see “Safe Jacking Procedure” on page 64). 9. 3. Connect all electrical connections. Turn key switch to OFF and disconnect the battery at battery connector. 2.F-code Section C-code PS S4. (See page 97 and page 98. Install transmission mounting plate and transmission in the truck. Torque the six mounting bolts to 90 ft-lb (122 N•m). Disconnect all electrical connections on the drive motor and brake assembly. Remove transmission.) 5. Remove fifteen bolts (11) retaining the steering bearing (1). 2. Install new steer bearing (1). Installation 1. Remove drive motor. (To remove drive motor see page 108. 7. Test the steering and truck operation. 6.1 Steering Bearing 4181 Version no T-code 000 RTX35/RTX45 1. 4. 8.

and parameter set mode. right foot switch indicator. See “Electrical Schematics” on page 273 and “Hydraulic System” on page 367.1. Directional/Speed Control Handle A5 + 1 1/2 0 © BT Prime-Mover Inc. To retract the reach. Five basic control functions available on the control handle allow the operator to perform work with the truck. 1. A thumb controlled lever at the end of the control handle selects lift or lower. steering. push the push direction) button located rearward on the handle. Pushing the push buttons in a particular sequence activates a high speed reach Control Handle function. The five functions include: travel. General The braking.F-code PS Version no 001 Section C-code S5. drive motor transistor regulator.0 5000 Electrical Functions T-code RTX35/RTX45 Electrical Functions 1. steering components. An operator instrument panel displaying actual time. Travel direction is selected by moving the handle in the desired direction of travel. but at a higher Service Manual 2001-03-15 221 . main electronic card containing steer control. hourmeter/error code. pump motor transistor regulator. reach/ retract. The control system of the reach truck consists of the following components: control handle. lift/lower. control handle interface card. These five functions can be further broken down for more specialized control. The reach will continue to extend. For a listing of parameters see page 345. and brake. and travel control systems on the reach truck are electrically controlled and monitored. tilt. push the retract button with extend button activated. and sideshift. push the push button located (travel speed / forward on the handle. For a listing of error codes see pages 336 and 340. Rotating the lever upward selects lift and downward selects lower. To extend the reach. Lift and lower speeds are dependent upon the distance the lever is rotated in the desired function direction. parking brake indicator. The lift/ lower and auxiliary function systems are electrically controlled and hydraulically operated. There are two push buttons conveniently located under the handle select reach or retract functions. Return The directional/speed control handle is the operator’s input interface to the truck. For information on the fuses and their location see page 305. To extend the reach in high speed.

3. Control Handle Interface Card The control handle interface card decodes and conditions the digital signals from the control handle for use by the main electronic card (A5). The results of the decisions are communicated to the slaves.35-Volt power supply on the handle interface card provides the control handle potentiometer and push button voltage. This circuitry is designed to drive a high impedance horn input. The control handle analog signals are relayed unchanged to the main electronic card (A5). tilt down.35-Volt Power Supplies” on page 251. and sideshift. A thumb controlled rocker switch selects tilt up.2. The handle interface card contains horn driver circuitry activated when the horn push button is pushed. system functions. and sideshift right. The digital signals are decoded by converting the possible combinations of push buttons to different analog voltage levels.35-Volt power supply is covered in “7. but at a higher speed. 1. and other input devices. tilt.35-Volt power supply signal sent from the main electronic card (A5). push the extend button with retract button activated. A horn push button is also located on the control handle. The master microprocessor makes decisions based on the information received from its inputs and the two slave processors.) This supply is referenced to a 7. sideshift left. The result is then conditioned and passed to the main electronic card (A5) for processing. A green LED indicates the handle interface card power status. The analog signals are from the travel and lift/ lower potentiometers.0 Electrical Functions Version no T-code 001 RTX35/RTX45 C-code 5000 speed. All three microprocessors share in control of digital and analog outputs. (The 7. control handle functions. Output devices controlled include: 222 Return Service Manual 2001-03-15 . Main Electronic Card The main electronic card (A5) contains three microprocessors. The digital signals from the control handle include: reach. One microprocessor operates as a master and the other two as slaves. To retract the reach in high speed. The microprocessors monitor the state of switches. The reach will continue to retract.F-code Section PS S5. The three microprocessors share various digital and analog input functions. 1. A 7. sensors.

© BT Prime-Mover Inc.0 5000 Electrical Functions T-code RTX35/RTX45 solenoids. steer motor. contactors. the operator is alerted by a visible tool bar icon and error code numbers displaying on the operator display. A history log records error codes by date and time. and optional equipment. Return Service Manual 2001-03-15 223 . The combination of chip and battery allows clock and date settings to remain in memory when the truck’s battery is disconnected. The main electronic card (A5) contains a clock/calendar chip with an internal battery. motor controllers. For any identified problems. The diagnostic tests assist in repair by identifying problems and minimizing truck downtime. An audible alarm is sounded when an error is detected. The main electronic card (A5) performs diagnostic tests at start-up and during truck operation. and brake.F-code PS Version no 001 Section C-code S5.

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 A 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 Start Up Battery Connected Legend ELECTRIC POSITIVE ELECTRIC NEGATIVE LED OFF ( Not lit) LED input (lit) LED output (lit) 224 Return Service Manual 2001-03-15 .

the steer servo fuse (F51). Start Up With the battery connected to the reach truck. steer servo. wire #1 connects battery voltage to the battery terminal of the main contactor (K10). Control fuse F50 and wire #21 connect voltage to the main electronic card (A5) connector pin 808 (and connector pin 501 for 36V trucks). Accessory fuse (F55) and wire #15 connect battery voltage to the accessories relay(s). Steer servo fuse (F51) and wire #25 connect battery positive to the main electronic card (A5) connector pin 901 (steer servo).0 5000 Electrical Functions T-code RTX35/RTX45 2. and the accessory fuse (F55). © BT Prime-Mover Inc. The main electronic card (A5). Return Service Manual 2001-03-15 225 . and the control handle interface card. Wire #40 is battery negative. the control fuse (F50). and control handle interface card are powered when the battery is connected.F-code PS Version no 001 Section C-code S5. the positive terminal of one section of the emergency disconnect (S21) switch.

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 A 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 Start Up E.F-code Section C-code PS S5.Stop Released/Key ON Legend ELECTRIC POSITIVE ELECTRIC NEGATIVE LED OFF ( Not lit) LED input (lit) LED output (lit) 226 Return Service Manual 2001-03-15 .

Return Service Manual 2001-03-15 227 . The drive transistor regulator (A1) performs an internal safety test. The main electronic card (A5) monitors the state of wire #34 through input 101. electricity flows through wire #22 to the main electronic card (A5) input 809 and the normally closed brake switch (S48). output at connector pin 7 wire #34 goes to battery voltage. If the test is successful. the main electronic card (A5) performs a start-up diagnostic test and. K10 energizes and applies battery voltage to the drive transistor regulator B+ terminal through fuse (F1) and the pump transistor regulator B+ terminal through fuse (F3). Wire #34 carries electricity through second section of the emergency disconnect (S21) switch connects to wire #44 connected to the coil of the main contactor (K10). the truck is now powered and ready to begin operation. and main electronic card (A5) input 111. applies power to the card’s outputs. Electricity also flows through wire #22 to the drive transistor regulator (A1) connector pin 1 and to the pump transistor regulator (A2) connector pin 1. if successful.F-code PS Version no 001 Section C-code S5. If all tests are successful. With power at input 809. © BT Prime-Mover Inc.0 5000 Electrical Functions T-code RTX35/RTX45 Start Up E. Wire #34 supplies an input to terminal 101 of the main electronic card (A5).Stop Released/Key ON By closing the emergency disconnect switch (S21) and key switch (S17).

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.F-code Section C-code PS S5.304 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 Return Service Manual 2001-03-15 .

• Turning the steer tachometer clockwise sends 0 to +2. The negative is wire #40 connected to the main electronic card (A5) connector pin 902.1. The steer motor is connected to the main electronic card (A5) through wire #60 output 903 (+) and wire #61 output 904 (-). Parameter 11 adjusts steer direction (forks trailing or forks first). the higher the voltage produced by the tachometer (U1). If a fault is sensed in the steer tachometer.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. steer motor. 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 master processor on the main electronic card (A5) processes the tachometer signal and communicates the result to the steer slave processor. Turning the steering wheel clockwise directs B. The steer slave processor controls the steer chopper to obtain the appropriate output voltage and polarity to drive the steer motor (M6). © BT Prime-Mover Inc. The input is a tachometer (DC generator (U1) connected to the steering wheel. The main electronic card (A5) monitors the steer system. Three parameters can be modified to adjust the steering for custom control. Current through the main electronic card (A5) connector pins 903 (+) and 904 (-) determine the steer motor direction. steer controller. The direction of tachometer (U1) rotation determines the polarity of the signal. or wiring. Parameter 2 adjusts steering sensitivity (tachometer response).current to the steer motor through a series of steps: • The steer tachometer determines the rate and direction of steer wheel rotations. Return Service Manual 2001-03-15 229 . Steering Components 3. an error code will appear on the Operator Display (A6) indicating the steering problem. Steering System The steering system is electrically controlled.F-code PS Version no 001 Section C-code S5. The faster the steering wheel is turned. The tachometer (U1) is connected to the main electronic card (A5) by wire #62 to input 503 (-) and by wire #63 to input 502 (+).0 5000 Electrical Functions T-code RTX35/RTX45 3. Parameter 1 adjusts speed sensitive steering (reduced steering sensitivity at high speed).

connector pin 904. forks leading truck to the left. 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.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. forks leading truck to the right. • Turning the steer tachometer counter-clockwise sends 0 to -2. 230 Return Service Manual 2001-03-15 .F-code Section PS S5. • The drive wheel steers in a clockwise direction turning the forks of a moving. connector pin 904. • 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. • The drive wheel steers in a counter-clockwise direction turning the forks of a moving.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.

Return Service Manual 2001-03-15 231 .0 5000 Electrical Functions T-code RTX35/RTX45 This page intentionally left blank © BT Prime-Mover Inc.F-code PS Version no 001 Section C-code S5.

F-code Section C-code 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) Wheel Direction Sensors Legend ELECTRIC POSITIVE ELECTRIC NEGATIVE LED OFF ( Not lit) LED input (lit) LED output (lit) 232 Return Service Manual 2001-03-15 .

© BT Prime-Mover Inc. the main electronic card (A5) stops the steer request to the steer controller. channel “B” steering stop proximity sensor (S67). signaling the main electronic card (A5) to the drive wheel position. Steering in the opposite direction will allow the drive wheel to steer away from the electrical stop. The three sensors. Return Service Manual 2001-03-15 233 . S67 connector is blue in color and located in the back. S65 is connected to the main electronic card input 202 (Wire #57). the steering electrical stops no longer function and the stopping of the drive wheel steering relies on the mechanical stop.F-code PS Version no 001 Section C-code S5. The steer wheel position proximity sensor and the steer stop proximity sensors work in conjunction to determine drive wheel position information and electrically limit drive wheel steering rotation. The Steer Wheel Position sensor (S65) requires battery voltage to operate. Failure to replace a failed sensor could result in mechanical stop failure and additional sensor damage. As the drive wheel is steered toward the electrical stops the sensors change state. Wheel Direction Sensors This diagram covers the channel “A” steering stop proximity sensor (S66). S67 is connected to the main electronic card input 203 (wire #59). Steer Wheel Position (S65). S66 connector is grey in color and located in the front. an error code will display on the operator display indicating a sensor problem. Steering Stop A (S66) and Steering Stop B (S67) monitor the drive wheel steering position and relay the ON or OFF state to the main electronic card (A5). signaling the electrical stop has been reached. provides power to the Steering Stop A sensor (S66). and main electronic card (A5).2. Continuing to steer in the same direction will not steer the drive wheel any farther.0 5000 Electrical Functions T-code RTX35/RTX45 3. steering wheel position sensor (S65). When a steering sensor failure occurs. fuse (F53). and Steering Stop B sensor (S67). When the sensors are in specific ON/OFF states. If the main electronic card (A5) detects all sensors ON or all sensors OFF. S66 is connected to the main electronic card input 204 (wire #58). The 12-Volt power supply is covered in “12-Volt Power Supply” on page 249. The main electronic card (A5) monitors the steering sensors.

F-code Section C-code PS S5.0 Electrical Functions Version no T-code 001 RTX35/RTX45 5000 Table 1: Sensor Sequence S65 Steer Wheel Position A5 input 202 wire #57 S66 Steering Stop A A5 input 204 Wire #58 S67 Steering Stop B A5 input 203 Wire #59 Drive Wheel Steering Clockwise (viewed from top) Sensor Status Drive wheel is parallel to truck ON OFF OFF Drive wheel steers and approaches steering stop ON ON OFF Drive wheel continues steering toward steering stop OFF ON OFF At the Steering Stop OFF ON ON Drive Wheel Steering Counter-Clockwise (viewed from top) Sensor Status Drive wheel is parallel to truck ON OFF OFF Drive wheel steers and approaches steering stop ON OFF ON Drive wheel continues steering toward steering stop OFF OFF ON At Steering Stop OFF ON ON Drive Wheel Steering Direction Sensor Status 234 Return Failure – Error OFF OFF OFF Failure – Error ON ON ON Service Manual 2001-03-15 .

The main electronic card (A5) responds by turning on output 805 (wire #64) sending current to the magnetic brake coil (Y1). The emergency switch (S21) ON. Return Service Manual 2001-03-15 235 .0 5000 Electrical Functions Version no T-code 001 RTX35/RTX45 4. The brake potentiometer (R3) output goes to a higher voltage than when the brake pedal is released (up).F-code Section PS C-code S5. Brake Release Brake release occurs when the brake pedal is fully depressed. 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 1 40 29 504 +7.65V K13 M1 K11 902 A 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. 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 main electronic card (A5) senses the increase in voltage at terminal 511 (wire #65).35V 50 505 +3.

F-code Section C-code PS S5. Forks First Legend ELECTRIC POSITIVE ELECTRIC NEGATIVE LED OFF ( Not lit) LED input (lit) LED output (lit) 236 Return Service Manual 2001-03-15 .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 Travel Request.0 Electrical Functions 5000 Version no T-code 001 RTX35/RTX45 + K10 K10 A1 F1 3 A2 M1 A1 FIELD M1 K11 B7 10 ARMATURE 2 K11 B+ 44 A K13 11 6 34 36 22 1 37 35 M 1 902 40 611 609 - A71 HM104 HM105 29 504 +7.

F-code PS Version no 001 Section C-code S5.in a direction to cause the drive motor to rotate counter-clockwise and move the truck in the forks first direction.0 5000 Electrical Functions T-code RTX35/RTX45 5. Travel Request. The electrical path created by the contact position of K11 and K13 allows current to flow from the battery to the motor terminal (A2) through the motor brushes and armature to motor terminal (A1) through K11 (NO) the motor field K13 (NC) to drive transistor (A1) regulator terminal M. Forks First CAUTION Releasing the brake pedal while on an incline will cause the truck to move. and the brake pedal depressed. The drive transistor (A1) regulator sends the amplified signal to the drive motor commanding travel. closing the normally open (NO) contact tips and opening the normally closed (NC) contact tips. The control handle interface card senses this increase in voltage at HM210. Both speed request and current limit signals range from 0 volts to approximately 4. Forks first travel occurs when the brake pedal is depressed and the control handle is moved toward the forks. A battery voltage potential is provided to the drive transistor (A1) regulator terminal A. A drive © BT Prime-Mover Inc. key switch (S17) ON. The main electronic card (A5) turns on speed request output 610 (wire #36) to a level proportional to the control handle travel request.5 volts and are measured with respect to the main electronic card (A5) output 609 (wire #35) to drive transistor (A1) regulator input pin 6 (wire #35). moving the directional/speed control handle in a forks first direction (away from the operator) causes the travel potentiometer (R1) to output a voltage higher than when in the neutral position. The main electronic card (A5) monitors the drive motor temperature limit. A current limit signal proportional to the control handle travel request is sent from the main electronic card (A5) output 611 (wire #37) to the A1 drive transistor regulator input pin 11 limiting the current from the transistor regulator to the motor. Return Service Manual 2001-03-15 237 . With the emergency switch (S21) ON. The (forks trailing) direction contactor (K13) remains in the de-energized state. This signal is sent to the drive transistor (A1) regulator input pin 10. The interface card output HM105 wire #50 sends the travel request signal to the main electronic card (A5) input 505. The main electronic card (A5) responds by turning on output 803 (wire #51) and sending current to the fork direction contactor (K11).

located on the motor and connected to main electronic card (A5) input 104 (wire #39). Make sure the throttle and lift/lower pots are centered and the brake pedal and left foot pedal are released (up). A reduction in maximum travel occurs for the following conditions: 1. opens if the motor frame exceeds 257° F (125° C). When the display appears on the dash display (A6) release SW1. When the truck is traveling and the right foot pedal is not depressed. (See “Wheel Direction Sensors” on page 233. Control handle calibration is required by the display of certain error codes. A drive motor over temperature condition (S60). move the lift/ lower pot through the full range of pot movement. (See page 252 and page 254. Press SW1 on the electronic card (A5) and key ON the truck. Error code E38 should be displayed.0 Electrical Functions Version no T-code 001 RTX35/RTX45 5000 temperature switch (S60). S66 or S67). Travel speed is proportional to directional/speed handle movement. (See page 252 and page 254.) 2.) 5. A steer controller over temperature (internal to the main electronic card (A5). key off the truck. the warning triangle on the operator display will flash signaling the operator to depress the right foot pedal switch (S108).) The main electronic card (A5) will request less speed from the drive transistor regulator if any of these conditions occur by reducing the speed request signal. 4. A5 238 Return The center and travel limits of the travel potentiometer are learned during control handle calibration. Error codes will be displayed for all conditions except number 5. When this is completed no error codes should be Service Manual 2001-03-15 . truck travel forks first and forks trailing. Mast switches (S31 and S45) sequence error. The mast is extended above free lift height (S31). lift and lower. 3. To calibrate the control handle. When this is completed error code E33 should be displayed. To clear code E38 move the control handle through the full range of pot movement.F-code Section C-code PS S5. when a new control handle is installed or when the A5 card is replaced (for calibration see page 121). A steering sensor failure (S65. To clear error code E33. The main electronic card (A5) reduces the drive speed request and the drive transistor regulator responds by reducing the commanded motor speed.

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. • Wire #35. a failed control module (A5) or wiring. a failed control handle interface card. • The speed request voltage is from the main electronic card (A5) terminal 610 through wire #36 to the drive transistor (A1) regulator pin 10. The travel potentiometer (RI) voltage is approximately 0.16 volt increase of the travel potentiometer (R1). connecting the drive transistor (A1) regulator pin 6 and the main electronic card (A5) pin 609. the speed request will increase approximately 1 volt. Other codes could be caused by incorrect calibrating procedure.4 to 2. is the common reference for the speed request/current limit voltages. • Moving the control handle away from the operator causes voltage to increase from 1. a bad control handle.2 volts with the center at approximately 1.4 volts.6 to 2. For every 0. © BT Prime-Mover Inc. Return Service Manual 2001-03-15 239 .F-code PS Version no 001 Section C-code S5. 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.2 volts.

F-code Section C-code PS S5.35V 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 Travel Request. Forks Trailing Legend ELECTRIC POSITIVE ELECTRIC NEGATIVE LED OFF ( Not lit) LED input (lit) LED output (lit) 240 Return Service Manual 2001-03-15 .0 Electrical Functions 5000 Version no T-code 001 RTX35/RTX45 + K10 K10 A1 44 F1 3 A2 M1 B+ 7 ARMATURE 2 A1 FIELD K11 M1 K11 B10 A K13 11 6 34 22 1 101 610 37 M 1 902 40 611 609 - A71 HM104 35 HM105 29 504 +7.

F-code PS Version no 001 Section C-code S5. The electrical path created by the contact position of K13 and K11 allows current to flow from the battery to the motor terminal (A2) through the motor brushes and armature to motor terminal (A1) through K13 (NO) the motor field K11 (NC) to drive transistor regulator (A1) terminal M. This signal is sent to the drive transistor (A1) regulator input pin 10. Forks Trailing CAUTION Releasing the brake pedal while on an incline will cause the truck to move. Both speed request and current limit signals range from 0 volts to approximately 4. key switch (S17) ON and the brake pedal depressed. The interface card output HM105 wire #50 sends the travel request signal to the main electronic card (A5) input 505. Return Service Manual 2001-03-15 241 . The forks first wheel direction contactor (K11) remains in the de-energized state.0 5000 Electrical Functions T-code RTX35/RTX45 6. A current limit signal proportional to the control handle travel request is sent from the main electronic card (A5) output 611 (wire #37) to the A1 drive transistor regulator input pin 11 limiting the current from the transistor regulator to the motor.5 volts and are measured with respect to the main electronic card (A5) output 609 (wire #35) to A1 drive transistor (A1) regulator input pin 6 (wire #35). closing the normally open (NO) contact tips and opening the normally closed (NC) contact tips. With the emergency switch (S21).in a direction to cause the drive motor to rotate clockwise and move the truck in the forks tailing direction. moving the directional/speed control handle in a forks trailing direction (toward the operator) causes the travel potentiometer (R1) to output a voltage lower than when in the neutral position. A battery voltage potential is provided to the drive transistor (A1) regulator terminal A. The main electronic card © BT Prime-Mover Inc. The control handle interface card senses this decrease in voltage at HM210. Travel Request. The drive transistor (A1) regulator sends the amplified signal to the drive motor commanding travel. The main electronic card (A5) turns on speed request output 610 (wire #36) to a level proportional to the control handle travel request. Forks trailing travel occurs when the brake pedal is depressed and the control handle is moved from the forks. The main electronic card (A5) responds by turning on output 802 (wire #52) and sending current in the forks trailing direction to the direction contactor (K13).

Travel speed is proportional to directional/speed handle movement.) The main electronic card (A5) will request less speed from the drive transistor regulator if any of these conditions occur by reducing the speed request signal. A drive temperature switch (S60).F-code Section PS S5. The main electronic card (A5) reduces the drive speed request and the drive transistor regulator responds by reducing the commanded motor speed. Make sure the throttle and lift/lower pots are centered and the brake pedal and left foot pedal are released (up). When the display appears on the dash display (A6) release SW1. A drive motor over temperature condition (S60). Error code E38 should be displayed. (See page 252 and page 254. When this is completed error code E33 should be displayed. opens if the motor frame exceeds 257° F (125° C). lift and 242 Return Service Manual 2001-03-15 .) 5. Control handle calibration is required by the display of certain error codes. truck travel forks first and forks trailing. 4. Mast switches (S31 and S45) sequence error. The center and travel limits of the travel potentiometer are learned during control handle calibration. Press SW1 on the electronic card (A5) and key ON the truck. To clear code E38. (See “Wheel Direction Sensors” on page 233. The mast is extended above free lift height (S31). when a new control handle is installed or when the A5 card is replaced (for calibration see page 121). To clear error code E33. (See page 252 and page 254. To calibrate the control handle. key off the truck. the warning triangle on the operator display will flash signaling the operator to depress the right foot pedal switch (S108). A steering sensor failure (S65. S66 or S67). A reduction in maximum travel occurs for the following conditions: 1. Error codes will be displayed for all conditions except number 5. located on the motor and connected to main electronic card (A5) input 104 (wire #39). move the control handle through the full range of pot movement.) 2.0 Electrical Functions Version no T-code 001 RTX35/RTX45 C-code 5000 (A5) monitors the drive motor temperature limit. A steer controller over temperature (internal to the main electronic card (A5). move the lift/ lower pot through the full range of pot movement. When the truck is traveling and the right foot pedal is not depressed. 3.

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.2 volts with the center at approximately 1. the speed request will increase approximately 1 volt.16 volt increase of the travel potentiometer (R1). © BT Prime-Mover Inc.4 to 2. When this is completed no error codes should be displayed and the control handle has been calibrated for truck operation. connecting the drive transistor (A1) regulator pin 6 and the main electronic card (A5) pin 609.4 volts. • Moving the control handle away from the operator causes voltage to increase from 1. The travel potentiometer (RI) voltage is approximately 0. If control handle calibration was not successful the same or other codes may be displayed. • The speed request voltage is from the main electronic card (A5) terminal 610 through wire #36 to the drive transistor regulator (A1) pin 10. a failed control handle interface card.F-code PS Version no 001 Section C-code S5. • Wire #35.2 volts. For every 0. a bad control handle.0 5000 Electrical Functions T-code RTX35/RTX45 lower. a failed control module (A5) or wiring.6 to 2. Return Service Manual 2001-03-15 243 . Other codes could be caused by incorrect calibrating procedure. is the common reference for the speed request/current limit voltages.

+ K10 - K10 A1 3 A2 M1 B+ K11 A FIELD 8 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.F-code Section C-code PS S5.35V 505 +3.0 Electrical Functions 5000 Version no T-code 001 RTX35/RTX45 .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 Return Service Manual 2001-03-15 .

There are two methods of plug braking available on the reach truck. 7. The second method is accomplished through raising the brake pedal and is detailed second. the drive transistor regulator (A1) and the main electronic card (A5) into plug braking. At approximately 0. lighting LED 103. The main electronic card (A5) begins to “ramp up” speed request output 610 (wire #36) from zero volts. The one is using the directional/speed control handle and is detailed first.5 volts “locking“ the system of the drive motor. that the drive motor and drive transistor regulator (A1) are in plug brake mode. A current limit © BT Prime-Mover Inc.5 volts speed request the drive transistor regulator (A1) recognizes the drive motor is plugging and the drive switches to plug brake mode. The directional contactor for the current travel direction is de-energized and the directional contactor for traveling in the opposite direction is energized as the control handle is moved from travel to plugging.5 volts as long as the drive transistor regulator (A1) output pin 8 (wire #38) signals the main electronic card (A5) that the drive transistor regulator (A1) and the drive motor are in plug brake mode. Directional/Speed Control Handle Method Control handle plugging is used to slow or stop the truck. Return Service Manual 2001-03-15 245 . Speed request output 610 (wire #36) from the main electronic card (A5) remains at 2. The main electronic card (A5) responds by setting speed request output 610 (wire #36) at 2.F-code PS Version no 001 Section C-code S5.0 5000 Electrical Functions T-code RTX35/RTX45 7. A movement of the directional/speed control handle in the opposite direction of travel causes the travel potentiometer (R1) to output a voltage to the main electronic card (A5) requesting travel in the opposite direction. The drive transistor regulator (A1) output pin 8 (wire #38) signals the main electronic card (A5) input 103. This signal is sent to the drive transistor regulator (A1) input pin 10 (wire #36). Plug Braking CAUTION Releasing the brake pedal while on an incline will cause the truck to move. The drive transistor regulator (A1) sends the amplified signal to the drive motor commanding plugging.1.

With the pedal depressed. To use the plug brake method. stopping the truck in the shortest possible distance.0 volts as the pedal is raised. Raising the brake pedal while the truck is moving causes an increase in voltage from the brake transducer (R3) to the main electronic card (A5) input 511 (wire #65).5 volts and controls the plugging force. located on top of the drive motor. sends pulses to the main electronic card (A5) input 201 (wire #56). Plug braking force is regulated with the direction/speed control handle movement. Completely releasing the brake pedal is the method used for emergency braking. 246 Return Service Manual 2001-03-15 . the higher the current limit signal voltage and the greater the plug braking force. Drive motor direction is determined by using both S64 and S125 and the relationship between the pulses from each device.0 volts with respect to main electronic (A5) input 510 (wire #30). 7.0 Electrical Functions Version no T-code 001 RTX35/RTX45 C-code 5000 signal proportional to the control handle plug request is sent from the main electronic card (A5) output 611 (wire #37) to the drive transistor regulator (A1) input pin 11. Brake Pedal Method The second plug brake method available on the reach truck is used for slowing the truck. The increase in voltage signals the main electronic card (A5) to the pedal brake request.5 – 2 inches disables travel and applies the parking brake. Both speed and current limit signals are measured with respect to the main electronic card (A5) output 609 (wire #35). The main electronic card (A5) looks at the drive motor speed sensor (S64) and drive motor direction sensor (S125) to determine the current drive motor speed/travel direction. The voltage increases toward 4. located on top of the drive motor. The drive speed sensor (S64). sends pulses to the main electronic card (A5) input 105 (wire #23).F-code Section PS S5. The greater the movement of the control handle. the voltage at main electronic card (A5) input 511 should read approximately 3. Releasing the brake pedal more than 1. raise the brake pedal while the truck is moving.2. The drive direction sensor (S125). The current limit signal ranges from 0 volts to approximately 4. The direction of travel is not changed when using this method of plug brake. Directional control handle must be returned to neutral to continue travel.

The drive transistor regulator (A1) sends the amplified signal to the drive motor commanding plugging. the parking brake is applied and the truck is stopped. The greater the brake pedal is raised the higher the current limit signal voltage and the greater the plug braking force. lighting LED 103. The drive transistor regulator (A1) output pin 8 (wire #38) signals the main electronic card (A5) input 103. © BT Prime-Mover Inc. At approximately 0.5 volts speed request the drive transistor regulator (A1) recognizes the drive motor is plugging and the drive switches to plug brake mode. that the drive motor and drive transistor regulator (A1) are in plug brake mode. The main electronic card (A5) responds by setting speed request output 610 (wire #36) at 2. The main electronic card (A5) monitors the truck speed using the speed sensor (S64).40 kph) before the brake pedal is pushed down. Plug braking force is regulated with the brake pedal.0 5000 Electrical Functions T-code RTX35/RTX45 Knowing the drive motor direction. The current limit signal ranges from 0 volts to approximately 4. the main electronic card (A5) de-energizes the directional contactor for the current travel direction and energizes the directional contactor for plug braking as the brake pedal is raised.25 mph (0.5 volts and controls the plugging force. Speed request output 610 (wire #36) from the main electronic card (A5) remains at 2.5 volts as long as the drive transistor regulator (A1) output pin 8 (wire #38) signals the main electronic card (A5) that the drive transistor regulator (A1) and the drive motor are in plug brake mode. The main electronic card (A5) begins to “ramp up” speed request output 610 (wire #36) from zero volts.F-code PS Version no 001 Section C-code S5. This signal is sent to the drive transistor regulator (A1) input pin 10 (wire #36). If the truck speed drops below approximately 0. Return Service Manual 2001-03-15 247 . A current limit signal proportional to the brake pedal request is also sent from the main electronic card (A5) output 611 (wire #37) to the drive transistor regulator (A1) input pin 11.5 volts “locking” the system of the drive motor. Both speed request and current limit signals are measured with respect to the main electronic card (A5) output 609 (wire #35). the drive transistor regulator (A1) and the main electronic card (A5) into plug braking.

F-code Section PS S5. If plug braking is request from both the control handle and the bake pedal simultaneously. the main electronic card (A5) will only process the signal from the brake pedal pot (R3). During pedal plugging. Travel input from the control handle pot (R1) is ignored. 248 Return Service Manual 2001-03-15 . Fully releasing the brake pedal at any time will immediately apply the parking brake.0 Electrical Functions Version no T-code 001 RTX35/RTX45 C-code 5000 To return control to the direction/speed control handle pot (R1). the brake pedal must be fully depressed again. the input requesting the greatest plug braking force controls plugging and the other is ignored.

F-code Section PS C-code S5. steering stop “B” sensor (S67) and height counter (U10). steering stop “A” sensor (S66). This supply has limited power capacity and is not designed for user connection. the drive motor direction sensor (S125).0 5000 Electrical Functions Version no T-code 001 RTX35/RTX45 8. 12-Volt Power Supply A power supply on the main electronic card (A5) produces 12-Volts. Return Service Manual 2001-03-15 249 . 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- 12-Volt Power Supply LED OFF ( Not lit) LED input (lit) LED output (lit) © BT Prime-Mover Inc. It supplies power to the drive motor speed sensor (S64).

35-Volt Power Supplies ELECTRIC POSITIVE ELECTRIC NEGATIVE LED OFF ( Not lit) LED input (lit) LED output (lit) 250 Return Service Manual 2001-03-15 .F-code Section C-code 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 HM106 HM211 HM110 82 30 504 +7.4V 506 +1.35V HM104 29 50 HM105 R11 HM208 +7.35V R1 R3 HM210 511 21 HM213 F50 1 Legend 7.65V 510 0V HM111 HM215 +7.35V 505 +1.

the sideshift right (S212). It also supplies power to the reach extend (S55) and retract (S56) push buttons.35-Volt power supply on the control handle interface card increases the current capability of the 7. left (S211) switches. This is a precision supply with limited power capability and not designed for user connection. and horn (S18) push button.35-Volt Power Supply Control Handle Interface Card The 7. 7. 7. 7. It supplies power to the brake pedal potentiometer (R3) and the control handle interface card.35-Volt Power Supplies 9. © BT Prime-Mover Inc.F-code PS Version no 001 Section C-code S5. tilt up (S52) and down (S51) switches.35-Volt Power Supply Main Electronic Card A power supply on the main electronic card (A5) produces 7. Return Service Manual 2001-03-15 251 . This is a precision supply with limited power capability and not designed for user connection.35-Volt power supply from the main electronic card (A5).35-Volts. 9.0 5000 Electrical Functions T-code RTX35/RTX45 9.2. The control handle interface card supplies power to the control handle travel (R1) and lift/lower (R11) potentiometers.1.

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 Blue/white stripe HM215 Orange/black stripe HM210 610 35 10 201 Red/white stripe HM213 31 32 107 S64 56 Speed Limit (S31) and Mast (S45) Switches Legend ELECTRIC POSITIVE ELECTRIC NEGATIVE LED OFF ( Not lit) LED input (lit) LED output (lit) 252 Return Service Manual 2001-03-15 .

© BT Prime-Mover Inc. Limit Switches 10. When the mast is lowered and the presence of the lower mast tie bar is detected. When the inner columns are elevated. the speed limit switch turns ON sending voltage to the main electronic card (A5).F-code PS Version no 001 Section C-code S5. Speed limit mast switch turns OFF removing voltage to the main electronic card (A5) input 107 (wire #79). and the load is above freelift. Truck Travel Speed Limiting The speed limit proximity switch (S31) is located on the mast tie bar at the bottom of the mast. Return Service Manual 2001-03-15 253 . It senses the presence or absence of the lower mast tie bar on the inner column.0 5000 Electrical Functions T-code RTX35/RTX45 10. the absence of the lower mast tie bar is detected. The main electronic card (A5) limits the speed request to the drive transistor regulator (A1) limiting truck travel speed proportional to the value programmed by the Reduce Speed Parameter 4. The speed request to the drive transistor (A1) regulator is no longer limited and the truck is allowed to return to full travel speed.1.

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 Speed Limit (S31) and Mast (S45) Switches Legend ELECTRIC POSITIVE ELECTRIC NEGATIVE LED OFF ( Not lit) LED input (lit) LED output (lit) 254 Return Service Manual 2001-03-15 .F-code Section C-code PS S5.

Carriage lowering speeds are limited during the transition from staging to free height.F-code PS Version no 001 Section C-code S5. The mast proximity switch (S45) is located on the carriage. and the absence of the inner column is detected. The lift is allowed to return to full lift speed. The speed limit proximity switch (S31) is located on the mast tie bar at the bottom of the mast. The lowering is allowed to return to full lowering speed. The speed limit proximity switch (S31) is also used to signal the main electronic card (A5) for staging speed limiting.0 5000 Electrical Functions T-code RTX35/RTX45 10. The mast switch turns OFF removing voltage to the main electronic card (A5) input 207 (wire #106). As the inner column lowers the presence of the lower mast tie bar is detected. limiting lowering speed during the transition. The main electronic card limits the signal to the proportional lowering valve (Y10). The speed limit switch turns OFF removing voltage to the main electronic card (A5) input 107 (wire #79). Return Service Manual 2001-03-15 255 . As the carriage is lowered. The signal to the proportional lowering valve (Y10) is no longer limited. and the presence of the inner column is detected. The mast switch turns on sending voltage to the main electronic card (A5) input 207 (wire #106). Mast Staging Speed Limiting Carriage lift speeds are limited during the transition from free height to staging. It senses the presence or absence of the lower mast tie bar on the inner column. © BT Prime-Mover Inc.2. When the carriage is raised the mast switch (S45) exists the top of the inner column at the end of free height. The speed request to the lift transistor regulator (A2) is no longer limited. It senses the presences or absence of the inner column. The main electronic card limits the speed request to the lift transistor regulator (A2) during the transition. The speed limit switch (S31) turns on sending voltage to the main electronic card (A5) input 107 (wire #79). When the inner column begins to lift the absence of the lower mast tie bar is detected. the mast switch (S45) enters the top of the inner column at the beginning of free height.

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

A

B
32

811

Legend

Height Indicator

ELECTRIC POSITIVE
ELECTRIC NEGATIVE
LED OFF ( Not lit)
LED input (lit)
LED output (lit)

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Version no

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Section

C-code

S5.0
5000
Electrical Functions
T-code

RTX35/RTX45

11. Height Indicator
The height indicator is designed to display the fork height in
the main lifting zone. The components of the height indicator
system include: height counter (U10); fuse F52, height
display (A8); staging switch (S45); and main electronic card
(A5). The height counter is a two-counter pulse generator
(encoder). The height indicator provides a digital display of
fork height in English or metric units. The staging switch
(S45) signals the beginning and end of freelift. The main
electronic card (A5) processes the information from the
height counter (U10), mast switch (S45), and Fork Reference
Parameter 10. The result of the processed information is a
fork height value to be displayed by the height display.
Communication to the height display from the main electronic
card (A5) is by a two wire proprietary data communication
scheme.
With the battery connected, emergency switch ON and the
key OFF, the height display (A8) will display four vertical half
bars. This is the correct indication showing the height display
not communicating with the main electronic card (A5). When
the key is turned ON, the height display will go to four solid
decimal points. If the decimal points flash, lower the forks
below the reference height, into the freelift zone. Set the
Special Height Parameter 9 to the lift limit height or to the
maximum mast height. If the decimal points continue to flash,
check for a broken communication wire (wire #125 and #126),
a failed staging switch (S45), a failed height display (A8), or a
failed main electronic card (A5). When lifting, the height
display will show solid decimal points until the staging switch
(S45) turns OFF, removing voltage to the main electronic
card (A5) input 207 (wire #106). The main electronic card
(A5) responds by communicating the Fork Reference
Parameter 10 to the height display from outputs 405 (wire
#125) and 402 (wire #126). The height display shows the
Fork Reference Parameter value. When the intermediate
columns begin to lift, the mast cable turns the height counter.
The height counter is powered from the main electronic card
(A5) 12 volt supply, output 810 (wire #67), fuse F53 (wire
#31) and common, output 811 (wire #32). As the counter
turns, the two outputs (A and B) send pulses to the main
electronic card (A5), inputs 205 (wire #98) and input 206 (wire
# 99). The counter signals pulse between +12V and Gnd and
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S5.0
Electrical Functions
Version no

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RTX35/RTX45

C-code

5000

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

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F-code

Section

PS

C-code

S5.0
5000
Electrical Functions

Version no

T-code

001

RTX35/RTX45

12. Drive Motor Brush Wear Indicator
Switches
Diagram covers the drive motor brush indicator switches
(SA1 and SA2). The drive motor on the reach truck contains a
pair of brush wear indicator switches. When the brushes need
replacing, an error code (C016) will display on the operator
display. This is accomplished by metal bars, connected by
wires to a connector in the motor frame, contacting the brush
spring as the brush wears down. This completes a circuit
allowing high side armature voltage to main electronic card
(A5) input 209 (wire #42) and/or low side armature voltage to
main electronic card (A5) input 208 (wire #41) depending on
whether the north or south pole brushes are worn. Brushes
should be inspected on a regular basis and replaced when
the error code displays.

+

-

K10

K10
A5

A1

F1

44
3

SA2

B+

B-

S21
101

34
M1

7

ARMATURE
2

SA1

902

40

A

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)

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C-code

PS
S5.0
Electrical Functions

5000

Version no

T-code

001

RTX35/RTX45

13. Pump Motor Brush Wear Indicator
Switches
Diagram covers the pump motor brush wear indicator
switches (SA1 and SA2). The pump motor on the truck
contains a pair of brush wear indicator switches. When the
brushes need replacing, an error code (C017) will display on
the operator display. This is accomplished by metal bars,
connected by wires to a connector in the motor frame,
contacting the brush spring as the brush wears down. This
completes a circuit allowing high side armature voltage to
main electronic card (A5) input 211 (wire #78) and/or low side
armature voltage to main electronic card (A5) input 210 (wire
#77) depending on whether the north or south pole brushes
are worn. Brushes should be inspected on a regular basis
and replaced when the error code displays.

+

A2

14

F3

9
ARMATURE
M3
SA2

B+

B-

40

FIELD
M3

10

M

SA1
A5

77

210

Legend
ELECTRIC POSITIVE

78

ELECTRIC NEGATIVE

211

LED OFF ( Not lit)
LED input (lit)
LED output (lit)

260

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Section

PS

C-code

S5.0
5000
Electrical Functions

Version no

T-code

001

RTX35/RTX45

14. Safety Check
Diagrams (Safety Check A and B) cover the safety checks on
the drive transistor regulator (A1). Once a year a safety check
of the system must be performed. The safety check is
performed by connecting the battery, turning the emergency
switch ON, turning the key switch ON, and placing a jumper
from the drive transistor regulator B-terminal to connector pin
2. The jumper will cause the line contactor (K10) to open and
the main electronic card (A5) to respond with an error code
E102. Successful completion of check confirms the circuit is
operating.

+

K10

K10

A1
3

A2
M1

B+

ARMATURE
2

K11

FIELD

B7

A1

A

A5

44

F1

S21
34

101
902

40

2

K13

M1
K11

K13
8

M

Legend

Safety Check A
ELECTRIC POSITIVE
ELECTRIC NEGATIVE
LED OFF ( Not lit)
LED input (lit)
LED output (lit)

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Section

C-code

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

A

A5

44

F1

S21
34

101
902

40

2

K13

M1
K11

K13
8

M

Legend

Safety Check B

ELECTRIC POSITIVE
ELECTRIC NEGATIVE
LED OFF ( Not lit)
LED input (lit)
LED output (lit)

262

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PS

Section

C-code

S5.0
5000
Electrical Functions

Version no

T-code

001

RTX35/RTX45

15. Shunt Power Cable
The shunt power cable measures the total truck current
flowing to the negative side of the battery. This is a special
length and gauge of wire and must be replaced with the
correct parts for proper operation. Polarity of the two shunt
power cable lead wires (#606 + and #607 -) must be
observed when connecting to the main electronic card (A5).
The voltage measured by the main electronic card (A5)
across the shunt is used for battery discharge indication.

Shunt Wire

+
1

-

40

A5
606
607

608

Legend
ELECTRIC POSITIVE

606 -(+)
607 -(-)

608 +

Shunt Power Cable

ELECTRIC NEGATIVE
LED OFF ( Not lit)
LED input (lit)
LED output (lit)

© BT Prime-Mover Inc.

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263

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PS
S5.0
Electrical Functions
Version no

T-code

001

RTX35/RTX45

5000

List of Symbols

264

Return

Symbol

Designation

Function

Remark

A1

Drive transistor regulator

Drive Motor

A2

Pump transistor regulator

Pump Motor

A5

Electronic card

Main Card

A6

Electronic card

Display

A7

Electronic card

Height Preset

A8

Electronic card

Height Indication

A71

Electronic card

Signal Conditioning Module

BT

Battery

E1

Light

Overhead Guard

E3

Light

Work

E4

Light

Work

E21

Heater

A1/A2

E22

Heater

Handle

E23

Heater

Handle

E24

Heater

Left Foot Switch

E25

Heater

Right Foot Switch

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

Lift Height Indicator

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

Main Electronic Card and Control
Handle Heaters (Option)

10 Amp

F82

Fuse

Transistor Requlators and Pedal
Switch Heaters (Option)

10 Amp

F83

Fuse

Aux. Power Circuit

2 Amp

H1

Horn

Alarm

H2

Flashing light

Light

option

H3

Traction

Alarm

option

K10

Contactor

Main Contactor

K11

Contactor

Driving in Direction of Forks

Forks leading

K13

Contactor

Driving in Direction of Operator

Forks Trailing

K34

Contactor

Bypass Lift

RTX45 only

K101

Relay

Fan and Working Light

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

Solid State Horn

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

Left Foot 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 Steer Wheel Reference 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 Ambient Temperature Thermostat Service Manual Push Button 2001-03-15 .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 Lift Limit Override S45 Inductive sensor Carriage Sensor S48 Switch Brake.F-code Section C-code PS S5.

Function Remark S113 Switch A5 Thermostat S125 Inductive sensor Drive Direction S211 Switch Tilt Up S212 Switch Tilt Down SA1 Switch Carbon Brush Indicator. Drive/pump Motor (-) SA2 Switch Carbon Brush Indicator.F-code PS Version no 001 Section C-code S5. Drive/pump Motor (+) U1 Tachometer Steering U10 Pulse sensor Height Counter V101 Zener diode Voltage Regulator X Return Designation Battery Connector X101 Connector Aux. Power Strip Y1 Brake coil Parking Brake Y10 Valve Lift/Lower Y10/2 Valve Lift Of Forks Y10/3 Valve Proportional Valve.0 5000 Electrical Functions T-code RTX35/RTX45 List of Symbols Symbol © BT Prime-Mover Inc. Lower Of Forks Y11 Valve Dump Valve Coil 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 .

0 Electrical Functions Version no T-code 001 RTX35/RTX45 5000 Component Location (Figure 1 of 2) S33. S211.F-code Section C-code PS S5. S96 S21 S97. S52. S56 K11 A2 A1 K13 4 2 3 1 K10 K34 Y14 +1 01/2 Y15 Y17 Y16 268 Return Service Manual 2001-03-15 . S51 U1 + 1 1/2 0 S18 R11 S55. S17 S212.

0 5000 Electrical Functions Version no T-code 001 RTX35/RTX45 Component Location (Figure 2 of 2) S125 Y12 S18 M3 Y11 Y13 1+01/2 Y1 M1 S64 M6 F50 F51 A5 S48 © BT Prime-Mover Inc. Return Service Manual R3 2001-03-15 269 .F-code Section PS C-code S5.

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. Return M 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 .1 5000 Electrical Symbols T-code RTX35/RTX45 Electrical Symbols Electrical Symbols Symbol © BT Prime-Mover Inc.

F-code Section C-code PS S5.1 Electrical Symbols 5000 Version no T-code 000 RTX35/RTX45 Electrical Symbols Symbol P Description Push button switch (normally closed) Symbol P Description Push button switch (normally open) Resistor Switch Switch (normally closed) Switch (normally open) Valve 272 Return Service Manual 2001-03-15 .

1. Circuit Diagram 1 (12) © BT Prime-Mover Inc.2 5000 Electrical Schematics Version no 001 T-code RTX35/RTX45 Electrical Schematics Legend Sh.F-code PS Section C-code S5. Return Service Manual 2001-03-22 273 . = Sheet or page of Diagram First number = Previous page wire was found. Second number = Next page wire is found.

2 Electrical Schematics Version no T-code 001 RTX35/RTX45 C-code 5000 Legend Sh. Second number = Next page wire is found. = Sheet or page of Diagram First number = Previous page wire was found.F-code Section PS S5. Circuit Diagram 2 (12) 274 Return Service Manual 2001-03-22 . 2.

= Sheet or page of Diagram First number = Previous page wire was found. Second number = Next page wire is found. Circuit Diagram 3 (12) © BT Prime-Mover Inc. 3.2 5000 Electrical Schematics Version no 001 T-code RTX35/RTX45 Legend Sh. Return Service Manual 2001-03-22 275 .F-code PS Section C-code S5.

Second number = Next page wire is found. 4. Circuit Diagram 4 (12) 276 Return Service Manual 2001-03-22 . = Sheet or page of Diagram First number = Previous page wire was found.2 Electrical Schematics Version no T-code 001 RTX35/RTX45 C-code 5000 Legend Sh.F-code Section PS S5.

= Sheet or page of Diagram First number = Previous page wire was found. Circuit Diagram 5 (12) © BT Prime-Mover Inc. 5.2 5000 Electrical Schematics Version no 001 T-code RTX35/RTX45 Legend Sh. Second number = Next page wire is found. Return Service Manual 2001-03-22 277 .F-code PS Section C-code S5.

= Sheet or page of Diagram First number = Previous page wire was found. Circuit Diagram 6 (12) 278 Return Service Manual 2001-03-22 .2 Electrical Schematics Version no T-code 001 RTX35/RTX45 C-code 5000 Legend Sh. 6.F-code Section PS S5. Second number = Next page wire is found.

= Sheet or page of Diagram First number = Previous page wire was found. Circuit Diagram 7 (12) © BT Prime-Mover Inc.F-code PS Section C-code S5. 7. Return Service Manual 2001-03-22 279 .2 5000 Electrical Schematics Version no 001 T-code RTX35/RTX45 Legend Sh. Second number = Next page wire is found.

Second number = Next page wire is found. 8. = Sheet or page of Diagram First number = Previous page wire was found.2 Electrical Schematics Version no T-code 001 RTX35/RTX45 C-code 5000 Legend Sh.F-code Section PS S5. Circuit Diagram 8 (12) 280 Return Service Manual 2001-03-22 .

2 5000 Electrical Schematics Version no 001 T-code RTX35/RTX45 Legend Sh.F-code PS Section C-code S5. Circuit Diagram 9 (12) © BT Prime-Mover Inc. Return Service Manual 2001-03-22 281 . 9. Second number = Next page wire is found. = Sheet or page of Diagram First number = Previous page wire was found.

10. Second number = Next page wire is found. Circuit Diagram 10 (12) 282 Return Service Manual 2001-03-22 .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.F-code Section PS S5.

Return Service Manual 2001-03-22 283 .F-code PS Version no 001 Section C-code S5. 11.2 5000 Electrical Schematics T-code RTX35/RTX45 Legend Sh. = Sheet or page of Diagram First number = Previous page wire was found. Circuit Diagram 11 (12) © BT Prime-Mover Inc. Second number = Next page wire is found.

Second number = Next page wire is found.F-code Section PS S5. = Sheet or page of Diagram First number = Previous page wire was found.2 Electrical Schematics Version no T-code 001 RTX35/RTX45 C-code 5000 Legend Sh. Circuit Diagram 12 (12) 284 Return Service Manual 2001-03-22 . 12.

tilt the edge toward the mast slightly forward to disengage the tongue on the operator compartment end. Reconnect battery connector. review Battery Safety. Installation 1. 5. Use extreme care during replacement. 4. and test the operation of truck. Return Service Manual 2001-03-15 285 . Battery Roller 2. Remove battery with lifting device. Be sure the battery has no more than 0. Lift battery retainer plate upward. Install battery retainer plate (see page 106). 2. turn key switch ON. beginning on page 19.F-code Section PS S5. Removal 1. Batteries may weigh more than 1. Battery Retainer Plate 3. 5. Disconnect battery connector located at the top of the truck cover. turn key switch to the OFF position. Move lifting device from the area. 1. After the truck is stopped and the brake pedal is returned to the full up position.50 inch (13 mm) of “free play” movement in the battery compartment. © BT Prime-Mover Inc. Use a suitable battery replacement device or hoist for lifting. position the lifting device at the truck according to the manufacturer’s recommendations.3 Version no 001 C-code 5110 Battery T-code RTX35/RTX45 Battery Battery Connector CAUTION Before working on the battery. 3.000 pounds (453 kg). 4. Position battery replacement device in accordance with the manufacturer’s recommendations. 2. Position the battery in the compartment. With a fully charged and tested battery on the lifting device.

understand. since the acid in the electrolyte does not evaporate. The top of the battery becomes wet and stays wet. determine the cause and correct the problem. Battery Inspection and Care NOTE! Read. Shim or block to restrain them. When inspecting batteries. Notify your supervisor if there are any concerns or questions regarding battery safety or procedures. understand.F-code Section C-code PS Battery S5. 3. If covers are wet. 2.3 5110 Version no T-code 001 RTX35/RTX45 3. 286 Return Service Manual 2001-03-15 . Battery Maintenance The following information does not supercede or replace information supplied by the battery and battery charger manufacturer. The acid also causes corrosion of cell posts. and follow procedures. Wet covers can indicate overfilling. in combination with certain kinds of dirt. This moist surface. Read. recommendations. and follow the procedures in the manual supplied with the battery and battery charger. and specifications in the battery and battery charger manufacturer’s manuals. Make sure batteries cannot move more than 0. or excessive gassing during charge. 2. check the following: 1.5 inch (13 mm) in any horizontal direction. nuts. connectors and the steel battery case.1. Batteries in industrial reach trucks pick up various kinds of dirt and dust depending on their surroundings and the types of material handled. This degrades battery performance and truck operation. becomes electrically conductive and permits stray currents to flow externally over the top of the battery. the following occurs: 1. 3. If cells are overfilled and electrolyte collects on the covers. leaky seals at posts.

Plug the charger ONLY into the connector from the battery. 3. Battery Exterior Cleaning Refer to the recommended battery manufacturer’s guidelines for details.3 Version no 001 C-code 5110 Battery T-code RTX35/RTX45 3. for protecting charging equipment from damage by reach trucks and for adequate ventilation of fumes from gassing batteries. This will severely damage the truck’s electrical system. Return Service Manual 2001-03-15 287 . understand. To charge a battery. and follow procedures. Such areas must provide for flushing and neutralizing spilled electrolyte. CAUTION NEVER plug the battery charger into the truck. Charging OSHA regulations require that battery charging installations be located in areas designated for that specific purpose. recommendations and specifications in the battery and battery charger manufacturer’s manuals.2. for fire protection.F-code Section PS S5.3. Charging time is 5% to 20% longer than discharge time. Read. © BT Prime-Mover Inc. direct current is passed through the battery cells in the direction opposite that of discharge.

and service data • Specific gravity and voltage readings for each cell • Temperature of the air and electrolyte • Electrolyte • Amperes • Condition of connectors. Each report should contain: • Battery number. A properly supervised record system can detect and call attention to such operating irregularities as: • Overcharging • Undercharging • Over-discharging • Excessive water consumption • Excessive dirt and corrosion • Worn-out batteries • Excessive current consumption of trucks Records should be kept for each battery. Store battery in a clean. filler plugs are tight. Check the electrolyte level and specific gravity every 30 days during storage. Your battery supplier should be able to provide maintenance record sheets. sealing compound and tray • General cleanliness • Number of total cycles • Average specific gravity drop • Watering frequency • User comments and observations 288 Return Service Manual 2001-03-15 . Storage Before storing the battery. Whenever the specific gravity is less than 1. dry location away from radiators and other sources of heat.3 5110 Version no T-code 001 RTX35/RTX45 4. Battery History Record A battery record system is essential because battery failure can cause production slowdowns and increased battery operating costs. serial number. covers. type.F-code Section C-code PS Battery S5. charge the battery. and battery is fully charged. 5. cool. make sure the electrolyte is at the proper level in all the cells.230.

Lower the light/fan assembly enough to disconnect it from the harness. remove four screws securing the light/fan assembly. 5. 2. Description 1 Light. 4. Removal 1. Item No.F-code Section PS S5. Reassemble the light/fan console assembly. 3. Remove light/fan assembly from truck.4 5121 Light Assemblies Version no 001 C-code T-code RTX35/RTX45 Light Assemblies 1 1. © BT Prime-Mover Inc. 1. Reconnect harness connections. From the top of the overhead guard. The switches for the lights are located in the switch cluster to the left of the key switch on the top console. wire 1.1. Overhead Guard Lights (Option) 2 3 The overhead guard lights are mounted in a compartment on the left side of the overhead guard.2. Return Service Manual 2001-03-15 289 . 3. 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. 2. dome 2 Bezel. Turn key switch OFF and disconnect battery connector. Be sure clip nuts are positioned over mounting holes for attachment to the overhead guard. Install mounting screws through the top of overhead guard to secure the assembly. light 3 Tie. Installation 1.

Installation 1.2. 3. Remove two hex head screws (1) securing light assembly (2) to the overhead guard bracket (3). Reconnect battery connector. The color of the lights are by customer request.4 Light Assemblies 5121 Version no T-code 001 RTX35/RTX45 4.F-code Section C-code PS S5. 3 Description Item No. Test the operation of light assembly. 1 2 5. 4. 290 Return Service Manual 2001-03-15 . Disconnect electrical connection at the warning light. Test the operation of warning lights. 2. Reconnect wiring harness. Description 1 Screw. 3. 2.1. 4 Item No. then return the truck to service. mounting 2. Removal 1. to the right of the back post. travel 2 Light 5 Screw 3 Bracket. 2. 4. Secure light assembly to the overhead guard bracket (3) with two hex head screws (1). Warning Lights (Option) 5 The warning lights are strobe lights. slotted 4 Alarm. then return truck to service. Turn key switch OFF and disconnect battery connector. 2. Replace light bulb or light assembly as required. Warning lights are mounted at the back of the overhead guard. Reconnect battery connector.

3. Turn key switch OFF and disconnect battery connector. 4.F-code Section PS S5. Remove screws securing light assembly to the overhead guard. Working Lights (Option) The working lights option consists of two flood lights mounted on the underside of the overhead guard. Return Service Manual 2001-03-15 291 . 4. 2. 3.2. then return truck to service. 2. Reconnect battery connector. Installation 1. Secure light assembly to the overhead guard. Reconnect wiring harness. © BT Prime-Mover Inc. 3. Test the operation of the working lights. Disconnect electrical connection at the working light.4 5121 Light Assemblies Version no 001 C-code T-code RTX35/RTX45 3. Removal 1.1. Replace light bulb or light assembly as required. 3.

5 Item No.2. then return truck to service. 4. 2. 2. Disconnect electrical connection at the travel/backup alarm. Turn key switch OFF and disconnect battery connector. Secure the travel/back-up alarm assembly to the overhead guard bracket (3) with two hex head screws (5).F-code Section C-code PS S5. 3. Remove two hex head screws (5) securing the travel/back-up alarm (4) to the overhead guard bracket (3). forks first travel only. This alarm may be configured to sound any one of three ways: forks trailing travel only. Reconnect wiring harness. Installation 1. 3. 4. Description 1 Screw. 292 Return Service Manual 2001-03-15 . slotted 4 Alarm.1. Replace alarm assembly as required. or both forks first and forks trailing travel. 4. Removal 1. travel 2 Light 5 Screw 3 Bracket. Travel/Back-up Alarm (Option) 1 2 The travel/back-up alarm option is installed to the bottom of the overhead guard. 4 Description Item No.4 Light Assemblies Version no T-code 001 RTX35/RTX45 5121 4. Reconnect battery connector. Test the operation of the alarm. mounting 3 4.

2. © BT Prime-Mover Inc. 2.F-code Section PS S5. 4. 3. 3. 2 1. Close motor compartment door.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. 1 2. Return Service Manual 2001-03-15 293 . Removal 1. Turn key switch OFF and disconnect battery connector. 4. Reconnect battery connector and test operation. Installation 1. Attach the three wires. Disconnect three wires from the horn. Attach the horn to the truck frame and tighten mounting bolt (2). Remove horn mounting bolt (2) using a 1/2 inch (13 mm) socket and ratchet. Open motor compartment door to access the horn.

5 5160 Version no T-code 001 RTX35/RTX45 294 Return Service Manual 2001-03-15 .F-code Section C-code PS Horn S5.

6 5192 Battery Connector T-code RTX35/RTX45 Battery Connector 2 3 1 4 Item No. above the battery. Positive 1. f © BT Prime-Mover Inc. Negative 4 Cable. Return Service Manual 2001-03-15 295 . Battery Connector Description 1 Connector. Location The battery connector is located on the right side of the truck. SB-350 2 Cap screw 3 Cable.F-code PS Version no 001 Section C-code S5.

3. dirt. with no corrosion. Check cables at the battery terminals. Look inside the connector. To remove a cable from the connector.6 Battery Connector Version no T-code 001 RTX35/RTX45 C-code 5192 2. DO NOT use a metal object to clean the connector. Inspection 1. Check battery connector for damaged cables. 3. or corrosion. Installation The cables to either half of the connector have a lip on their forward end. Check to see if battery cables are pulling out of the connector. 4. This lip snaps over a spring-loaded retainer which is part of the connector. 5. Turn key switch OFF and disconnect battery connector. Connections should be tight. push retainer down while pulling the battery cable towards the rear and out of the connector. Check internal contacts for damage.F-code Section PS S5. 2. 296 Return Service Manual 2001-03-15 .

To test a switch. the ohmmeter should read greater than 10 megohms. In an open position. Return Service Manual 2001-03-15 297 . 2. The truck is equipped with cold storage freezer package option. making sure all wires are labeled and identified for reconnection.7 5311 Start/Stop Switches T-code RTX35/RTX45 Start/Stop Switches 1. The horn can be sounded only with the key switch in the ON position. isolate it from the electrical circuit. 2. discoloration. Use an ohmmeter set to a low resistance scale to measure the resistance across the switch. Test/Inspection Examine the switch for signs of arcing. The heaters will operate with the Key Switch in the Off position. In the OFF position. the switch should show a resistance greater than 10 megohms. In a closed position. cracking. Remove all the connections from the switch. overheating. Key Switch (S17) Key Switch + 1 1/ 2 0 - The reach truck is equipped with a two position (off/on) key switch. Replace switch if such damage is present. or other physical damage. 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. 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.F-code PS Version no 001 Section C-code S5.1. and in the © BT Prime-Mover Inc. the switch should be less than 1 ohm. which energizes all truck operations. 1. Inspection With the battery plugged in and key switch in the ON position. The key switch is located on the top console to the left of the emergency disconnect switch and operator display. including the horn.

4. 2. 4. Installation 1. Install top console.F-code Section PS S5. 2. Install new key switch and tighten locking nut. 3. 2. Remove key switch. Reconnect battery connector. the ohmmeter should read less than 1 ohm.3. 298 Return Service Manual 2001-03-15 . Remove top console (see page 96). 5. 5. Turn key switch OFF and disconnect battery connector. Reconnect battery connector and check operation. 3. 2. Turn key switch OFF and disconnect battery connector. Disconnect wires from the bottom of the key switch. Removal 1. Connect wires to the terminals. Remove mounting nut from the stem of the key switch.7 Start/Stop Switches Version no T-code 001 RTX35/RTX45 C-code 5311 ON position.2. 6. If not. replace the switch.

© BT Prime-Mover Inc.F-code PS Version no 001 Section C-code S5. 3. 3. 2. and in the ON position. Disconnect electrical harness from the base of the emergency disconnect switch. Turn key switch OFF and disconnect battery connector. In the OFF position. Remove top console (see page 96). Press two halves of the emergency disconnect switch together and turn counterclockwise to disconnect the switch body from the top console. 6. Return Service Manual 2001-03-15 299 . 4. replace the switch. Finish removing two screws. 7. Removal 1. Repair or replace as necessary. Emergency Disconnect Switch (S21) Emergency Stop Switch + 1 1/ 0 2 - The emergency disconnect or stop (S21) switch is located to the left of the operator display on the top console. the ohmmeter should read greater than 10 megohms. If not. 5. All reach truck functions should be disabled when the emergency disconnect switch is depressed. the ohmmeter should read less than 1 ohm. Inspection With the battery plugged in and the emergency disconnect switch OUT. battery voltage B+ should be present on both terminals of the switch. in the ON position.2.1. 3. Use a small phillips head screwdriver to loosen two screws in the backside of the top console. Test the emergency disconnect switch with an ohmmeter after removing it from the electrical system.7 5311 Start/Stop Switches T-code RTX35/RTX45 3.

5. Turn the halves clockwise to engage the latches. Attach switch body to the operator from the backside of the top console. 8. 300 Return Service Manual 2001-03-15 . 7. Reconnect electrical harness to the base of the emergency disconnect switch.7 Start/Stop Switches Version no T-code 001 RTX35/RTX45 C-code 5311 3. Install top console. then return to service.3. 3. Reconnect battery connector. 4. 6. Test truck operation.F-code Section PS S5. 2. Secure the base of the emergency disconnect switch to the back of the top console with two screws. Installation 1. Place switch operator down through the opening in the top console.

1.8 5332 Mast Switch (S31) Version no T-code 001 RTX35/RTX45 Mast Switch (S31) Mast Switch (S31) is a proximity switch located at the bottom of the mast. +01/21 To test a switch. In the truck speed limiting function. the mast switch (S31) is provided to reduce travel speed to approximately 2. discoloration. General Refer to the electrical schematic to identify the electrical circuit location of the switch (see Circuit Diagrams on page 273 through page 284).5 MPH after the “first stage” of lift. Test/Inspection Examine the switch for signs of arcing. Replace switch if such damage is present. the mast switch signals the main electronic card to limit lift speed during the staging transition. 1. or other physical damage. Do this by removing all the connections from the switch. cracking. overheating. In the mast staging speed limiting function. The first stage of lift ends when the mast inner columns begin to extend from the main mast frame. Return 2 3 Service Manual Description 1 Screw. isolate it from the electrical circuit. bracket mounting 2 Bracket. 1 High Speed Travel Limit Switch © BT Prime-Mover Inc. switch 3 Sensor 2001-03-15 301 . Item No. 1.F-code Section PS C-code S5. making sure all wires are labeled and identified for reconnection. Mast Switch (S31) serves two functions: truck speed limiting and mast staging speed limiting.

187 inch (4. Loosen jam nut securing the mast switch to the mast. Tighten jam nut. Making sure the mast channel are pushed completely to the rear. 11. Test the truck operation to verify normal travel speed with the mast lowered. 302 Return Service Manual 2001-03-15 . 4. 3.F-code Section PS S5. Verify that the tie bar does not contact the switch under normal working conditions. Remove blocks and hoist. 6. Check the clearance with jam nut tightened. 2. Adjustment 1. Allowable tolerance is +0. Raise the empty carriage until the bottom of the tie bar is even with the bottom of the mast switch. 7. 5.8 Mast Switch (S31) Version no T-code 001 RTX35/RTX45 C-code 5332 2.59 mm) and -0 mm. Secure the carriage with blocks and a hoist to prevent any movement. adjust the switch to 0. 9.76 mm). Remove the load from forks.0625 inch (1. 10. Place a maximum capacity load on the forks. 8. Adjust the clearance as necessary to achieve proper clearance when fully loaded.

Removal 1.F-code PS Version no 001 Section C-code S5. 3. Loosen jam nut securing the mast switch to the mast. Secure the carriage with blocks and a hoist to prevent any movement. Disconnect switch from the harness. 2. 5. © BT Prime-Mover Inc.8 5332 Mast Switch (S31) T-code RTX35/RTX45 3. Raise the empty carriage until the bottom of the tie bar is even with the bottom of the mast switch. 4. Return Service Manual 2001-03-15 303 . Remove mast switch from the mast. Turn key switch OFF and disconnect battery connector. 6.

Tighten jam nut to secure the switch. 5. Adjust switch following the procedure on page 302.8 Mast Switch (S31) Version no T-code 001 RTX35/RTX45 C-code 5332 4. 2. 304 Return Service Manual 2001-03-15 .F-code Section PS S5. Return truck to service. 4. 3. Install new mast switch. Attach wiring harness. Installation 1. 6. Reconnect battery connector.

Do this by removing the fuse from the truck or by removing all the connections from one side of the fuse. RTX35) 355 Pump Circuit (36 volt. remove it or isolate it from the electrical circuit.9 5391 Control Cable and Harness RTX35/RTX45 Control Cable and Harness 1. Fuses F83 Examine the fuse for signs of overheating. RTX35) 500 Pump Circuit (RTX45) F50 10 Control Circuit F51 30 Steer Circuit F52 1/4 Height Indicator Circuit F53 1/4 Sensor Feed Circuit F54 1/4 Operator Display Circuit F55 10 Relay1 F81 10 Main Electronic Card and Control Handle Heaters (Option) F82 10 Transistor Regulators and Pedal Switch Heaters (Option) F83 2 Auxiliary Power F50 F51 Located under Top Console Function BB+ A M F1 F3 © BT Prime-Mover Inc. Replace the fuse if damage is found. discoloration.F-code PS Section Version no T-code 001 Located on right side of Operator Compartment C-code S5. Amp F52 F1 250 Drive Motor Circuit F3 425 Pump Circuit (24 volt. cracking. The resistance should be less than 1 ohm. or other physical damage. F81 Use an ohmmeter set to Rx1 scale and measure the resistance across the fuse. F55 F54 F53 Fuse No. F82 To test a fuse. Return Service Manual 2001-03-15 305 .

cable ties. • Do not pry apart connectors with unspecified tools. it is sometimes necessary to unmate a connector. damage from overheating or burns. Note carefully the location of the wire and all protective or securing attachments before moving the harness. Harness Whenever working on the truck. • Check harness wires for abrasions. During troubleshooting and repairs. brackets. This includes spiral wrap. 306 Return Service Manual 2001-03-15 . • Carefully mate and unmate all connectors. There should be a wire marker at each termination. return or replace all protective and/or securing hardware to its original condition. use care around the wiring harnesses. 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. Wiring 2. nicks in the wire. After repair.F-code Section C-code PS S5. remark the wire to allow easier identification. Protective materials are necessary to provide reliable performance of the interconnect system. exposed wires. flexible conduit. • Replace terminations with exposed wire visible at the connectors.9 5391 Control Cable and Harness Version no T-code 001 RTX35/RTX45 2. or other general insulation damage. cut a cable tie. • Examine and maintain any added materials used to dress or protect the wire. • Do not pull on wires. or remove the wire from a bracket. scrapes. or damaged connectors can cause operational failure of the truck. fasteners. Damaged terminations. If the marker is missing or unreadable.1. etc. move a harness.

2. remark the cable with the correct information. If the marking is missing or is not readable. Power cables are marked on the terminal lug with the location where they belong. © BT Prime-Mover Inc.9 5391 Control Cable and Harness Version no 001 T-code RTX35/RTX45 2. The terminal lugs should be crimped tightly and securely on the wire. Replace the lug if overheating is evident and repair or replace faulty connectors as necessary. Power Cables Power cables should be checked for damage. including: • Evidence of overheating • Burned spots in the cable • Nicks in the insulation • Damaged or overheated terminal lugs • Damaged mounting hardware or brackets Repair or replace damaged cables or mounting hardware as necessary.F-code PS Section C-code S5. Return Service Manual 2001-03-15 307 .

F-code

Section

C-code

PS
S5.9
5391
Control Cable and Harness
Version no

T-code

001

RTX35/RTX45

3. Auxiliary Power Hook-up for
On-board Terminal
Auxiliary power hook-up is standard on the trucks. The
terminal strip is located under the control handle. The top
console must be removed to access the terminal strip.
Auxiliary power hook-up is wired separately from the key
switch, which allows power with the key switch in the OFF
position. A 2 amp fuse is included in the power circuit to
protect components.

+01/21

An optional accessory power cable for data transfer terminal
is also available.

Item No.

2
1

3

4

308

Return

Description

1

Fitting, wire

2

Lockwasher

3

Screw

4

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 truck’s 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.

1.2. Contactor Tip Inspection
When inspecting contactor tips, follow these guidelines:
• Disconnect battery
contactor tips.

before

inspecting

or

servicing

• Darkened points do not indicate burning.
• Burning indicates a loss of contact point material.
• Replace contact points if there is not enough contact point
material to last until the next regular inspection.
Severe Pitting

• The silver alloy part of the point is usable contact material;
the copper backing is not.
• Do not file contact points to remove discoloration or minor
irregularities. This practice produces a surface more
susceptible to sticking.

© BT Prime-Mover Inc.

Return

Service Manual

2001-03-15

309

F-code

Section

C-code

PS
S5.10
Contactors

5441

Version no

T-code

001

RTX35/RTX45

2. Directional Contactors

5

1

2

4
3

310

Return

Item
No.

Description

Item
No.

1

Contactor assembly

4

Base

2

Screw

5

Kit, service

3

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

7. Reconnect battery connector.

© BT Prime-Mover Inc.

Return

Service Manual

2001-03-15

311

F-code

Section

C-code

PS
S5.10
Contactors

5441

Version no

T-code

001

RTX35/RTX45

3. Lift Bypass Contactor

2

1

3

Item No.

312

Return

Description

1

Contactor

2

Kit, service

3

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

7. Reconnect battery connector.

© 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

4. Battery Cut-out Contactor

4

2
3

1

Item No.

314

Return

Description

1

Screw

2

Contactor

3

Cover, bridge

4

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

7. Reconnect battery connector.

© BT Prime-Mover Inc.

Return

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

Transistor Panel (Drive)
2

5

6

3
4

1

Item
No.

Description

Item
No.

1

Transistor controller, drive

4

Nut

2

Screw

5

Screw

3

Lockwasher

6

Screw

Description

1. Motor Connections
The drive transistor regulator has four connections for power
cables, described in the table below.
Terminal
Number

A

Brake diode to the motor's series field and armature

B-

Battery minus

B+

Battery plus

M

© BT Prime-Mover Inc.

Return

Function

Service Manual

Minus connection to the motor's series field

2001-03-15

317

Connections for controls LED No.1.F-code Section C-code PS S5. Color 1 Green Supply voltage 2 Yellow Upper/lower temperature 3 Red Fault in power circuits 4 Red Fault in reference value circuit Terminal Number Connection 2 1 I Start/stop and internal supply I Safety test 7 1 318 Return Function Function 7 8 9 1 3 4 2 10 11 5 3 Not connected 4 Logic OV 5 Logic OV 6 6 I Common differential 7 O Safety circuit 8 O Braking indication 9 O Voltage output 10 I Speed command 11 I Current limit command Service Manual 2001-03-15 .11 5461 Transistor Panel (Drive) Version no T-code 001 RTX35/RTX45 1.

Control current connector © BT Prime-Mover Inc. 71 7 8 9 10 11 1 2 3 4 5 6 5. Return truck to its original condition after the check. 2. Service Manual 2001-03-15 319 . Battery negative 4. Return 6. Reset the safety circuits by turning the ignition key to the OFF position. 1.F-code PS Version no 001 Section C-code S5. Remove console cover (see page 96). 3. replace the entire drive transistor regulator. Turn key switch so that the main electronic card is ON.11 5461 Transistor Panel (Drive) T-code RTX35/RTX45 2. should now open to indicate that the drive transistor regulator’s safety system is functioning. Connect a jumper wire between the battery negative (B-) and the contact for the control current (pin number 2 of the control current connector) in the drive transistor regulator. This check applies to reach trucks equipped with a transistor regulator type. Circuit Check. If K10 does not open. Jack up the rear of the truck (see “Safe Jacking Procedure” on page 64). K10. The main contactor.

Terminal Number B- Battery minus B+ Battery plus M 320 Return Function Minus connection to the motor's series field Service Manual 2001-03-15 . Motor Connections The pump transistor regulator has three connections for power cables. described in the table below. Description Item No. lift 4 Nut 2 Screw 5 Screw 3 Lockwasher 6 Screw Description 1.11 5461 Transistor Panel (Pump) Version no T-code 001 RTX35/RTX45 Transistor Panel (Pump) 2 6 5 1 3 4 Item No.F-code Section C-code PS S5. 1 Transistor controller.

1. Return Start/stop and internal supply Common differential Not connected 8 O Temperature value 9 O Voltage output 10 I Speed command 11 I Current limit command Service Manual 2001-03-15 321 .11 5461 Transistor Panel (Pump) Version no T-code 001 RTX35/RTX45 1. Connections for controls LED No.F-code PS Section C-code S5. Color 1 Green Supply voltage 2 Yellow Upper/lower temperature 3 Red Fault in power circuits 4 Red Fault in reference value circuit Terminal Number Connection 1 I Function Function 7 1 7 8 9 10 11 1 2 2 3 4 3 O Current value 4 O Voltage value 5 6 Not connected 5 6 Logic OV I 7 © BT Prime-Mover Inc.

11 5461 Transistor Panel (Pump) Version no T-code 001 RTX35/RTX45 322 Return Service Manual 2001-03-15 .F-code Section C-code PS S5.

In an open position. the switch should be less than 1 ohm. © BT Prime-Mover Inc. overheating. Replace switch if such damage is present. Remove all the connections from the switch.F-code Section PS S5. Use an ohmmeter set to a low resistance scale to measure the resistance across the switch. isolate it from the electrical circuit. or other physical damage. discoloration.12 5511 Micro Switches Version no 001 C-code T-code RTX35/RTX45 Micro Switches 1. Examine the switch for signs of arcing. cracking. the switch should show a resistance greater than 10 megohms. In a closed position. General Refer to the electrical schematic to identify the electrical circuit location of the switch (see Circuit Diagrams on page 273 through page 284). Return Service Manual 2001-03-15 323 . To test a switch. making sure all wires are labeled and identified for reconnection.

12 Micro Switches Version no T-code 001 RTX35/RTX45 C-code 5511 2. Secure top console to the truck. 324 Return Service Manual 2001-03-15 . If the carriage drops below the cutout height. Pull two wires off the tabs on the back of the switch. 2. Lift switch from the switch cluster. 2. Attach two wires to the tabs on the back of the switch. the override switch must be pressed again to reactivate lift. Unscrew nut securing the switch in the switch cluster. Removal 1. 5. Turn key switch OFF and disconnect battery connector. 5.1. 4. Installation 1. 2. or the hydraulic system is inactive for a set time. then return truck to service. Check the operation of the truck. pressing the switch on the top console will allow lift to function above the cutout height. Reconnect battery connector.F-code Section PS S5. the operator can lift and lower without pressing the override switch again. As long as the carriage remains above the preset cutout height. The lift limit cutout height is a programmable parameter setting on the main electronic card. Lift Limit Override Switch (S33) Lift Limit Override Switch The lift limit override switch (S33) is located in the switch cluster to the left of the key switch on the top console.2. 4. Secure switch with nut. Loosen top console to allow access to the wiring harness connection at the switch cluster. If the lift limit with override option is available. 3. Place new switch in the switch cluster. 6. 2. 3.

5. S97 and S99) The optional light and fan switches are located in a switch cluster to the left of the key switch on the top console. Attach two wires to the tabs on the back of the switch.1. Pull two wires off the tabs on the back of the switch. Secure switch with the nut. Operator Fan Switch Overhead Light Switch 3. Optional Light and Fan Switches (S96.12 5511 Micro Switches Version no 001 Working Light Switch C-code T-code RTX35/RTX45 3. Secure top console to truck. then return truck to service. 3. The switch for working lights (S97) is in the upper right corner of the cluster. Unscrew nut securing the switch in the switch cluster. A blank cap indicates the option is unavailable. © BT Prime-Mover Inc. 3. Installation 1. 4. Place new switch in the switch cluster. Lift switch from the switch cluster. Removal 1. 3. Loosen the top console to allow access to wiring harness connection at the switch cluster. The overhead light switch (S99) is located in the lower left corner.2. 5. The operator fan switch (S96) is in the upper left corner of the cluster. Turn key switch OFF and disconnect battery connector. 6. 2. Reconnect battery connector.F-code Section PS S5. Check operation of truck. 2. Return Service Manual 2001-03-15 325 . 4.

12 Micro Switches Version no T-code 001 RTX35/RTX45 326 Return C-code 5511 Service Manual 2001-03-15 .F-code Section PS S5.

Remove main page 101). 2. Install main electronic card panel.13 5711 Main Electronic Card Version no 001 T-code RTX35/RTX45 Main Electronic Card The main electronic card is located in the right side electrical compartment and enclosed in a protective casing. 4. Be sure to note connection points for installation. adjustment procedure (see 7. Removal 1. 2. © BT Prime-Mover Inc. Align mounting holes. Disconnect all electrical cables from main electronic card. 1. 5. Test operation of truck. electronic card panel (see 3.F-code PS Section C-code S5. Replacement of main electronic card should be as an entire unit (card and enclosure). 4. 2. 5. Reconnect battery connector. Turn key switch OFF and disconnect battery connector. Place main electronic card unit against the outside wall of the chassis. Perform RV2 page 354). Installation 1. Remove main electronic card unit from truck. Return Service Manual 2001-03-15 327 . then return to service. 6. 3. Remove four Allen head mounting screws. Reconnect all electrical cables to main electronic card. Secure main electronic card to truck frame with four Allen head screws.

with a slight rotational wiggling action. To install the connectors. depress the connector’s latch and unplug the connector. Connectivity to Truck The main electronic card is connected to the truck’s circuitry by nine connectors. green LED. push the connector onto the pins making sure all of the pins are captured by the connector. 328 Return Service Manual 2001-03-15 . red LED 3. To install. O=Output.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. unplug the connector. To remove connectors one through eight. grasp the connector (do not grasp the wires) and. push the connectors together until the latch snaps into position. To remove connector nine.

Return Terminal Number LED No. and power output (1). For the truck to be operational. When the main electronic card is connected correctly to the truck’s battery. The digital output LEDs light red when the output is on and battery voltage is present at output pin.OK Right foot switch Plug braking Drive. analog inputs (1). 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 Height indication -TX. transmits data Service Manual Function Traction power amplifier .F-code Section PS C-code S5. temperature sense Drive direction Lift limit override Speed reduction Brake switch 2001-03-15 329 . communications (2). the digital input LEDs light green indicating that the input is on and battery voltage is present at the input pin. The communications and analog voltage inputs and outputs do not have LEDs.13 5711 Main Electronic Card Version no T-code 001 RTX35/RTX45 The nine connectors are grouped functionally from the top down: digital inputs (2). Six green LEDs near connector 9 indicate the main electrical card status. digital outputs (2). all six LEDs must be ON. The ninth connector is power for the steer motor. The main electronic card’s top eight connectors and light emitting diodes (LED) are clearly identified by numbers. analog outputs (1). © BT Prime-Mover Inc.

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 Drive wheel directional reference Steering stop B Steering stop A Height counter A Height counter B Height reference Brush wear indicator .13 Main Electronic Card 5711 Version no T-code 001 RTX35/RTX45 Terminal Number LED No.F-code Section C-code PS S5.(traction motor) Brush wear indicator + (traction motor) Brush wear indicator .(pump motor) Brush wear indicator + (pump motor) 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 S5.35 volts Speed request value Lift/lower Reach/retract Tilt Sideshift Zero voltage I 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 Analog brake transducer 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 .13 5711 Main Electronic Card RTX35/RTX45 Function 24/36 volt select Steering/tach + Steering/tach Positive 7.

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. fork direction (forks first) Fork lower Brake coil +24/36 volt supply outputs Sensor feed + (12 volt) Sensor feed - Service Manual 2001-03-15 .F-code Section C-code PS S5. 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 Traction alarm control I O +24/36 volt Function Drive. operator direction (forks trailing) Drive.

13 5711 Main Electronic Card RTX35/RTX45 Function +24/36 volt steer motor Zero voltage + steer motor . all voltage is fed to the electronic card Voltage feed to control electronics Steering OK L 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 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.steer motor Function Indication.

Press SW2 to see the next registered error code. 211 207 209 3. Service Manual 2001-03-15 . 303 301 RV1 403 RV2 401 305 304 • 404 405 • 501 505 503 • • Press SW1 to see the date the error code registered.F-code Section C-code PS S5. Press button SW3. Remove main electronic card panel in the operator’s compartment. SW3 SW2 SW1 To look at the truck’s specific register: 111 107 109 105 101 103 1. 4. three times to view the specific registers. the truck must be serviced. Display SW3 ANTY L It is possible to look at the truck’s specific register and program the clock. Press SW1 again to see the time the error code registered. A • • B If only the colon (A) displays when the key switch is turned to the ON position. SW1 has no function at this time. - + 1 1/2 0 H G F E D 334 Return Press SW2 to scroll through the parameters.13 Main Electronic Card Version no T-code 001 RTX35/RTX45 SW1 SW2 5711 4. C The character window (B) will present the different functions: • Warning and error codes • Parameters • Running time The address register will be shown in the left-hand section and the value in the right-hand section for the “Warning or Error Codes” and “Parameters”. on the main electronic card. Turn key switch OFF or wait approximately 20 seconds to return to run mode. Turn key switch so the main electronic card is ON. The truck cannot be driven with any functions when it is in the programming mode. 205 204 202 2. Press SW3 once again to view the parameters setting.

the character box (F) will light.1. When the parameters are displayed in the character window (B). 111 107 109 2.13 5711 Main Electronic Card T-code RTX35/RTX45 4. the character box (E) will light. Time SW3 ANTY L It is possible to program the clock. Save the values and display the function by pressing SW3. 205 204 202 3. SW3 SW2 SW1 105 101 103 1. Wait approximately 20 seconds. Turn the key switch OFF. B - + 1 1/2 When error codes are displayed in the character window (B).F-code PS Version no 001 SW1 SW2 Section C-code S5. Change the time by stepping up using SW2 or down using SW1. 211 207 209 301 303 • • • RV1 305 304 RV2 403 401 Press SW3 three more times. it is not possible to reprogram the parameters in this mode. Exiting this function can be done in three ways. Programming mode will quit if a key is not pressed within 10 seconds. Return C Complete the programming process by turning the key switch OFF and ON once. However. see “Programming Parameters”. The hour character window (A) will flash after pressing SW3. 0 H G F E D © BT Prime-Mover Inc. Service Manual 2001-03-15 335 . 405 404 Function 501 Value 505 503 Hours Minutes A 09=9h 35=35 min. Press SW3 again and the minutes will flash. To change to the programming mode.

If the error remains after 1 minute.13 Main Electronic Card Version no T-code 001 RTX35/RTX45 5711 5. A code is displayed for 10 seconds on the right-hand side of the character window (B).F-code Section C-code PS S5. This process continues until the fault is corrected. the truck can be driven with all functions as set out in the warning table. 336 C Error Code Name 5 10 11 13 14 Bad Pump Type Parameter Pump Chopper Limit Steer Chopper Limit Height Indicator Error Fork Reference Error 16 17 18 19 20 21 22 23 24 Pump Brush Error Drive Brush Error Nov Ram Error Default Par Pump Voltage Error Lift Pot Z Error Tilt Request Z Error Reach Request Z Error Sideshift Request Z Error Return WARNING Always contact a service technician before the truck is used again after an error code has been displayed. 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 Lift pot not centered at key on time Tilt request at key on time Reach request at key on time Sideshift request at key on time Service Manual 2001-03-15 . the warning and buzzer will be reactivated for an additional 2 second period. Warning/Caution codes Character Error Warning/ Caution A B - + When an error occurs a buzzer will sound. 1 1/2 The error is also indicated in the indicator window (F). 0 H G F E D Error No. However.

Lift potentiometer not centered within calibration limits. Significant travel speed requested with minimum movement detected. Allowed operation may be limited. Accelerator potentiometer not centered within calibration limits. No lift/ lower operation. Accelerator potentiometer zero memory value or span memory value error. Function of drive motor speed and direction sensors.13 5711 Main Electronic Card Version no 001 T-code RTX35/RTX45 Error No. Center. Error Code Name Comment 25 27 28 30 31 Accelerator Pot Z Error Bat Measure Error Motor Overtemperature Control Handle Calibration Error 1 Lift Pot Memory Value Error 32 Lift Pot Zero Calibration Error 33 Lift Pot Span Calibration Error 35 Control Handle Calibration Error 2 36 Accelerator Pot Memory Value Error 1 37 Accelerator Pot Zero Calibration Error Accelerator Pot Span Calibration Error Accelerator pot not centered at key on time Low battery voltage detected Drive motor overtemperature Control handle calibration required . Return Service Manual 2001-03-15 337 . Complete lift potentiometer calibration by moving the lift lever to both ends of travel. Left (brake) and right foot pedals must be released during calibration. A mast switch has opened or closed incorrectly relative to the state of the other switch. Shorted or opened lift valve output Shorted or opened tilt valve output Shorted or opened direction A valve output Shorted or opened direction B valve output Shorted or opened sideshift valve output Shorted or opened hydraulic dump valve output Shorted or opened alarm output Shorted or opened reach in valve output Shorted or opened reach out valve output Shorted or opened lowering proportional valve output Shorted or opened forward contactor output 38 40 Travel Error 45 Mast Switch Sequencing Error 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. Control handle calibration required. Control handle calibration required (see page 121). recalibrate. recalibrate. Travel speed limited. or replace control handle. No travel operation.F-code PS Section C-code S5.No operation Lift potentiometer zero memory value or span memory value error. Complete accelerator potentiometer calibration by moving the control handle to both ends of travel. Control handle calibration required. No lift/lower operation. or replace control handle. Center. Left foot pedal (brake) must be released during calibration.

If all three sensors are on or if all three sensors are off. 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 . One or more of the drive wheel steering limit control sensors are not correctly signalling the control module. 338 5711 Error Code Name 64 80 O Backward Contactor Error Steer Sense Error 89 Lift Pot Max Error 90 91 92 93 Lift Pot Error Tilt Request Error Reach Request Error Sideshift Request Error Return Comment Shorted or opened backward contactor output Shorted or opened steer limit sensor(s). A minimum of one sensor and control module input LED should be on during the allowed steering rotational distance of the drive wheel.F-code Section C-code PS S5. error code 80 will be displayed.13 Main Electronic Card Version no T-code 001 RTX35/RTX45 Error No.

1/2 0 H G F E D © BT Prime-Mover Inc. Return C Service Manual 2001-03-15 339 . A B The error is also indicated in the window (F). - + 1 WARNING Always contact a service technician before the truck is used again after an error code has been displayed. If the error remains when the key is turned ON. the buzzer will sound and the error code will display again. The truck cannot be used when the Error Codes listed on the next page are displayed in the character window (B). The buzzer will sound until the key switch is turned OFF. An error code is displayed on the right-hand side of the character window (B).13 5711 Main Electronic Card T-code RTX35/RTX45 6.F-code PS Version no 001 Section C-code S5. Error codes Character Error Error When an error occurs a buzzer will sound.

340 5711 Error Code Name 100 101 102 104 Pump Temperature Error Pump Current Error Drive Chopper Error Accelerator Pot Memory Value Error2 105 106 Accelerator Pot Error Accelerator Pot Max Error 110 111 112 113 114 115 116 117 120 121 122 123 124 125 126 127 130 131 132 133 140 Pot Ref Error P Brake Pot Error P Brake Switch Error P Brake Out Error Speed and Direction Sensor Error Speed Sensor Error Direction Sensor Error Reversing Signal Error Steer Data Error Steer Chopper Error Steer Overtemperature Error Steer Volt Error Steer Current Error Steer Tacho Error Steer Connection Error Steer Comm Error Slave Comm Error Security Rel Error 1 Steer Power Error Security Rel Error 2 Check Sum Error Return Comment Pump chopper over or under temperature Drive chopper internal error (see page 341) Accelerator potentiometer zero or maximum travel memory value error.F-code Section C-code PS S5. Control handle calibration required (see page 121).13 Main Electronic Card Version no T-code 001 RTX35/RTX45 Error No.motor or connection failure Control module internal error Control module internal error Security relay error 1 Steer chopper supply voltage under-voltage Security relay error 2 Control module internal error Service Manual 2001-03-15 . Shorted or opened accelerator potentiometer input. 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 Steer tacho error Opened steer motor output . Accelerator potentiometer end point value(s) exceeded the maximum limit. Lift/lower may also be in error and disabled.

the drive transistor regulator (A1) internal capacitors will not be allowed to charge correctly and will cause this error code.13 5711 Main Electronic Card T-code RTX35/RTX45 6. paragraph 6. the following checks should be performed: 1.1. verify that all the thermostats and heaters are working. Verify that wire #16 and #17. Drive chopper upper/lower temperature.1. If the main contactor (K10) does not close when the truck is powered up.1. are wired to the battery positive side of the main contactor (K10). A blown fuse will cause this error when the truck is powered up. 6. The LED’s are as follows: LED1 LED2 Green Yellow LED3 Red LED4 Red Drive chopper detects no faults. (Will not display an error code) Fault in the power circuits (See Power Circuit Checks. Check for welded main contactor (K10) tips. © BT Prime-Mover Inc. E102 Troubleshooting Procedures The top console cover should be removed to expose the drive transistor regulator (A1). pump transistor regulator (A2) or main electronic card (A5) may cause this error. Check the 250 amp drive fuse. Return Service Manual 2001-03-15 341 . Moisture contamination at the drive transistor regulator (A1). 2. A partially severed fuse will not cause this error until the operator attempts to accelerate. If the #16 and #17 wires have been placed on the normally open (N.F-code PS Version no 001 Section C-code S5.1) Fault in the reference value circuit (See Reference Value Circuit Checks. The drive transistor regulator (A1) has 4 LED indicators to assist in determining faults. POWER CIRCUIT CHECKS (LED #3) NOTE! Do not manually close the main contactor (K10) with the battery connected. Both symptoms are typically caused from the operator pushing loads.) side of the main contactor (K10). page 343) If the machine is cold storage.O.1. control power wires for cold storage.

F-code Section PS S5. check for an open wire from the key switch to the drive transistor regulator (A1). Check the voltage at pin #101. This input should be battery voltage when machine is powered up. check for an open line on wire #34 between the drive transistor regulator (A1) and the emergency disconnect switch (S21). If 0 volts. should be battery voltage when the drive transistor regulator (A1) detects no faults. Check the voltage at the control plug on the drive transistor regulator (A1) at pin #7. This should be battery voltage when the drive transistor regulator (A1) detects no faults. This input voltage from the drive transistor regulator (A1). 5. 4. wire #34. This should be battery voltage when the truck is powered up. If 0 volts.13 Main Electronic Card Version no T-code 001 RTX35/RTX45 C-code 5711 3. check for a loose or missing connection on wire #44 at the emergency disconnect switch (S21). wire #44 or wire #40. 8. at the main electronic card (A5) with respect to battery negative. Check the voltage at wire #34 at the emergency disconnect switch (S21) with respect to battery negative. 7. If 0 volts. This output should be battery voltage when the drive transistor regulator (A1) detects no faults. Check for a loose or open connection at the main contactor (K10) coil. 342 Return Service Manual 2001-03-15 . If 0 volts (there will be no LED indicator lit at the drive transistor regulator). Check for loose or open connections at the emergency disconnect switch (S21). Check the voltage at the control plug on the drive transistor regulator (A1) at pin #1. Check for an open line on wire #44 between the emergency disconnect switch (S21) and the connections at the main contactor (K10). Check the voltage on wire #44 at the emergency disconnect switch (S21). 6. 9. wire #22 with respect to battery negative. check for an open line on wire #34 between the drive transistor regulator (A1) and the main electronic card (A5). wire #34 with respect to battery negative. Check for a faulty emergency disconnect switch (S21).

3. © BT Prime-Mover Inc. If a pump transistor regulator (A2) or related power cable is suspected to be shorted or defective. 6. pin #10.93 volts. REFERENCE CIRCUIT VALUE CHECKS (LED #4) 1. with respect to battery negative. 4. Voltage should be 0. Check for pitted or burned contactor tips. wire #35. pin #11. wire #35. A partially severed fuse will not cause this error until the operator attempts to accelerate. A defective or shorted pump transistor regulator (A2) may cause this error. Voltage should be 0. Check the 250 amp drive fuse. Check for battery voltage through the main contactor (K10). 2.2. voltage should be approximately 4.1. Both symptoms are typically caused from the operator pushing loads. drive transistor regulator (A1) and pump transistor regulator (A2).15 volts when the accelerator is in the static position. 5.75 volts when the accelerator is in the static position. Check for dirt or dust contamination at the contactor tips. When the accelerator is at full throttle. NOTE! Care must taken to keep power cables that are removed from shorting. wire #36 with respect to pin #6. when the contactor is closed. 2. Check the voltage at the control plug on the drive transistor regulator (A1). the following checks should be performed: 1. wire #37 with respect to pin #6. main contactor (K10).F-code PS Version no 001 Section C-code S5. Check for loose or shorted power cable connections at the 250 amp drive power fuse. it may be disconnected from the system to verify that it is causing the error. Return Service Manual 2001-03-15 343 . A blown fuse will cause this error when machine is powered up. Check the voltage at the control plug on the drive transistor regulator (A1).13 5711 Main Electronic Card T-code RTX35/RTX45 If the main contactor (K10) closes when the truck is powered up. All cable ends should be wrapped with electrical tape.

press SW2 or SW3. Check the voltage at the control plug on the drive transistor regulator (A1). 3. If these checks are performed and the error still exist. Voltage should be 0 volts when the accelerator is in the static position. contact your authorized BT Prime-Mover representative. SPECIAL NOTE SW1 SW2 All warranty claims concerning the replacement of the Drive Transistor Regulator (A1) will be expected to have these checks performed and documented on the warranty claim to receive warranty consideration.F-code Section C-code PS S5.13 Main Electronic Card Version no T-code 001 RTX35/RTX45 5711 When the accelerator is at full throttle. 7. To see the different parameters. Running time 205 204 202 When the running time reading is shown. wire #38. pin #8. voltage should be approximately 4. Parameters SW3 ANTY L The significance of the different parameters is shown in the “Programming Parameters” table on the next page. the character box (b) is illuminated. SW3 SW2 SW1 111 107 109 105 101 103 8.3 volts. with respect to battery negative. The time is shown as follows: 211 207 209 301 303 Character Time RV1 305 304 Key time RV2 403 401 Total running time 405 404 501 Drive motor time 505 503 Pump motor time 344 Return Service Manual 2001-03-15 .

5 Accel Par 10-100% (50) 5 % of maximum acceleration Acceleration reduction. - + 1 1/2 0 3. Return Service Manual Spare parameter. 6 Reach Scale Par 10-100% (80) 5 % of maximum reach speed Reach movement speed reduction. 7 Decel Par 50-100% (70) 5 % of maximum deceleration Deceleration reduction parameter. 4 Red Speed Par 10-50% (40) 5 % of maximum speed Limited speed reduction. Change the value using SW1 or SW2. 2 Steer Wheel Par 0-3 (0) 1 0-Least sensitivity 2-Most sensitivity Steer tachometer sensitivity. Programming Parameters B 1. (0) 1 10 Fork Ref Par 60-177 in. Do not change any parameters without the necessary knowledge. Speed curve selection has a greater affect at high speed. Maximum allowed lifting height 2001-03-15 Special height 345 . H G F E D 4. Press SW3 on the electronic card at the same time as the key switch is turned ON. Scroll through the parameter options using SW2 (up) and SW1 (down) to reach the parameter to be changed.F-code PS Version no 001 A Section C-code S5. Press SW3 to accept the value (the character window stops flashing).13 5711 Main Electronic Card T-code RTX35/RTX45 9. If more parameters are to be changed. scroll using SW1 or SW2 to reach the parameter to be change and repeat from “Step 3”. 8 Not Used 0 (0) 0 9 Spec Height Par 0-531 in. Press SW3 (the character window flashes). Not used. CAUTION Modifying specific truck parameters will change the driving characteristics of the truck. 2. Programming Parameters No.) 1-Forward (US) Steer direction © BT Prime-Mover Inc. C 5. 3 Top Speed Par 10-100% 100 5 % of maximum speed Drive speed reduction. Parameter Name Value Range Default Inc Values Comment 1 Steer Prog Par 1-6 (1) 1 1-Least sensitivity 5-Most sensitivity 6-Test curve Speed curve selection. (90) 1 Mast free height Mast reference height 11 Steer Dir Par 0-1 (1) 1 0-Backward (Eur.

pump. Parameter Name Value Range Default Inc Values Comment 12 Timer Sel Par 1-4 (2) 1 1-Key time (total time) 2-Drive. (RTX35) 2-Reserved 3-36V HD.531 MAST HEIGHT (INCH) See Table 3 2001-03-15 .13 Main Electronic Card 5711 Version no T-code 001 RTX35/RTX45 Programming Parameters No.) RANGE 0 .F-code Section C-code PS S5. (RTX35) 1-24V Std. and lowering time (active time) 3-Drive time 4-Pump time Displayed timer 13 Battery Par 1-30 (15) 1 1-Shallow discharge 29-Deep discharge (not a permanent parameter) 30-Force BDI to full charge battery indication (not a permanent parameter value. 17 Clock Year 0-99 (0) 1 18 Clock Day 0-31 (0) 1 Clock Day 19 Clock Month 0-12 (0) 1 Clock Month 20 Clock Hour 0-24 (0) 1 Clock Hour (set in normal operating mode) 21 Clock Minute 0-59 (0) 1 Clock Minute (set in normal operating mode) Clock Year Table 2: PARAMETER NUMBER 9 Without U10 Pulse Counter With U10 Pulse Counter and With Customer Specified Value With U10 Pulse Counter and Without Customer Specified Value 346 Return Service Manual RTX35 RTX45 0 CUSTOMER VALUE (IN.) Battery discharge curve 14 Pump Type Par 0-3 (0) 1 0-36V Std. (RTX45) Hydraulic pump type 15 Alarm Options Par 0-2 (0) 1 0-None 1-Travel Alarm 2-Backup Alarm Value determines alarm options enabled 16 Hyd Options Par 0-3 (0) 1 0-All Auxiliary Hydraulic Functions enabled 1-No Reach Function 2-No Sideshift Function 3-No Reach and Sideshift Functions Value determines hydraulic option(s) enabled.

1 volts per cell.1. The Parameter 13 has a value setting between 1 and 30.0 volts . Return Service Manual 2001-03-15 347 . A setting of 1 will result in the most shallow discharge. A full charge level on the BDI display should have an open battery voltage of approximately 2. Parameter 13 should be adjusted so the 10 bar BDI display will reflect the battery discharge as the BDI display decrements down from the fully charged level. A setting of 29 will result in the deepest discharge. Parameter 13 “Battery Type” Adjustment Parameter 13 is the battery type parameter.36 volt truck is 37.24 volt truck is 25 volts .36 volt truck is 31.5 volts © BT Prime-Mover Inc. The 80% discharged level on the BDI display should reflect the preferred battery discharge level.5 volts Fully discharged battery voltage: .75 volts per cell under load. this is not a permanent setting. A setting of 30 will force the BDI to reset to full charge.24 volt truck is 21. Fully charged battery BDI full scale reset voltage: . Parameter 13 may be programmed to manipulate the BDI display so that the battery voltage reading at 80% discharge will reflect a voltage reading other than 1. to the 80% discharged level (see charts on page 350 or page 352). This parameter will allow the programmer a variety of options relating to the BDI display reading.13 5711 Main Electronic Card T-code RTX35/RTX45 Table 3: PARAMETER NUMBER 10 RTX35 RTX45 MAST HEIGHT (INCH) 72 X 192 78 78 210 90 90 240 x 95 258 102 102 270 9.F-code PS Version no 001 Section C-code S5.

Program Parameter 13 with the value from the table. Response time will increase with larger Parameter 13 values. To initially set Parameter 13. etc. Parameter 13 values listed on the following page represent a starting guide only. “Typical” RTX45 applications are “Medium” Duty. Response time decreases with smaller Parameter 13 values and larger shunt currents. The final value depends on the application. 348 Return Service Manual 2001-03-15 . battery capacity. battery condition. Select the desired discharged battery voltage under load.13 Main Electronic Card Version no T-code 001 RTX35/RTX45 C-code 5711 The minimum shunt current necessary to activate the BDI is approximately 150A.F-code Section PS S5. “Typical” RTX35 applications are “Light” Duty. select the operating duty of the machine. Fully discharged battery BDI response time is approximately 2 operating hours from full battery indication with Parameter 13 set to value 20 at minimum shunt current. Final values are valid only for different batteries of equal performance characteristics and equal applications.

66 1.66 1.96 1.74 1.59 1.67 Force Reset 1.87 2.74 1.81 1.81 1.F-code PS Section C-code S5.53 Force Reset Service Manual 2001-03-15 Force Reset 349 .03 1.88 1.81 1.57 © BT Prime-Mover Inc.73 1. Return Battery Exceeds Full Discharge 1.09 1.94 1.13 5711 Main Electronic Card Version no T-code 001 RTX35/RTX45 Parameter 13 Initial Value Table Parameter 13 Value Operating “Light Duty” Battery Voltage/Cell Operating “Medium Duty” Battery Voltage/Cell Operating “Heavy Duty” Battery Voltage/Cell 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 2.52 NOT VALID 1.89 1.

88 24.00 24.00 23.55 22.00 23.36 24.80 22.20 1.20 22.94 22.00 24.95 23.08 22.75 24. 24 Volt Unit Adjustment Battery Discharge Indicator Bar Level Chart (24Volt) Bar Level Color 10 min.90 23.00 24. Green 5 min.8 volts 25.39 21. Green 6 max.F-code Section PS S5.60 23.66 22.95 volts Open Cell Voltage 25. Green 9 max.35 23.44 24.13 24.76 23. Yellow 4 min.1.18 1.81 24.70 24.24 22.25 24. Green 8 max.03 21.81 21.78 23.08 22. Red 1 max.73 24.40 23.94 23.13 Main Electronic Card Version no T-code 001 RTX35/RTX45 C-code 5711 The previous chart represents the discharge voltage measured under load.80 23.31 24. Green 4 max.30 23.09 22. Green 9 min.18 24.63 23.86 24. Green 5 max. Red 2 min.90 22.79 24.00 24.03 21.30 24.94 23. Yellow 2 max.60 21. based on battery state-of-charge.49 23.25 23.04 23.88 2. The charts on the following pages allow BDI bar levels to be checked and adjusted. using open voltage measurements.51 23. Green 7 max.50 23.80 24.53 1.45 22.85 1.65 24. 9.50 24.06 24.59 24. Red 1 min. Red Open Circuit Voltage Discharge Level 350 Return Open Cell Open Cell Open Cell Open Cell Voltage Voltage Voltage Voltage 25.56 24.66 22.60 23.50 24.58 24. Green 7 min.60 24.38 24.88 22.1.9 volts 25.73 22.15 23.21 23.85 volts Service Manual 25.48 24.83 24. Yellow 3 min.13 23.10 24.73 23. Green 8 min.00 24.30 23.20 24.38 22.69 24.90 24.43 23.90 23.40 24. Green 6 min.0 volts 2001-03-15 .63 24. Yellow 3 max.30 24.45 24.70 23.94 24.19 24.31 24.

the following procedures should be followed. Power-up the truck and verify the 10 bar indicator is lit to the top bar (green). 6. 4. Install a fully charged battery into the truck. If the open circuit voltage of the battery is lower than the corresponding BDI bar level from the chart. the Battery Parameter 13 should be decreased. A fully charged 24 volt battery should have an approximate open voltage of 25. 7.2 volts. This indicates a fully charged battery. Yes) Battery Parameter 13 needs no further adjustment.F-code PS Version no 001 Section C-code S5. To verify the BDI display reflects the preferred open battery voltage discharge. NOTE! Do not charge the battery at anytime during the shift until adjustment of Parameter 13 is complete. © BT Prime-Mover Inc. 8. Put the truck into service for an 8 hour shift. If the open voltage of the battery is higher than the corresponding BDI bar level from the chart. Return Service Manual 2001-03-15 351 . Check voltage reading to see if it matches the corresponding bar level and respond accordingly. 3. 1. Take an open voltage reading across the battery terminals. Parameter 13 should be set to the specific battery that will be used to insure an accurate BDI reading. Take an open voltage reading across the battery terminals. 2. the Battery Parameter 13 should be increased. No) Go to step 7. Find the column containing the preferred discharge level from the chart above.13 5711 Main Electronic Card T-code RTX35/RTX45 Due to the variety of different batteries available. Repeat steps 1 through 7. 5.

Power-up the truck and verify the 10 bar indicator is lit to the top bar (green).31 33. A fully charged 36 volt battery should have an approximate open voltage of 37.8 volts. Yellow 3 max.3 33. Green 7 max. Yellow 2 max. Green 5 min. Green 9 max. Parameter 13 should be set to the specific battery that will be used to insure an accurate BDI reading.05 36. Take an open voltage reading across the battery terminals.45 36.88 36.68 36.85 35.55 35.26 36. Green 9 min.29 37.85 35.61 34.F-code Section PS S5.84 36.79 1.75 36.98 36.76 1. Yellow 3 min.6 36. This indicates a fully charged battery.95 34.22 37.47 36.1 34.8 1.5 37.88 34.35 37.5 37.9 Volts 37.19 36.09 36 35.04 32.56 33. Green 6 max.35 34. Install a fully charged battery into the truck.5 37.95 Volts 37.91 35. Green 7 min.04 32.85 Volts 37. Green 4 max. Red 1 max.41 34.82 34.31 37. Green 5 max.41 37. 352 Return Service Manual 2001-03-15 .09 33.0 Volts Due to the variety of different batteries available.64 35.93 35.68 36. the following procedures should be followed.59 35.77 1.5 37.86 36.61 34.95 34.75 36.1.23 35.7 35.4 35.08 31. 36 Volt Unit Adjustment Battery Discharge Indicator Bar Level Chart (36Volt) Bar Level Color 10 min. Red Open Circuit Voltage Discharge Level Open Cell Open Cell Open Cell Open Cell Open Cell Voltage Voltage Voltage Voltage Voltage 37.06 35.36 33.09 36.24 36.25 35.03 36.94 36.4 35.4 32.2 33.3 36.38 36.54 36.63 34.27 34.13 Main Electronic Card Version no T-code 001 RTX35/RTX45 C-code 5711 9. Green 8 max.13 37.28 36.2.23 35.68 33.14 34.56 36. Yellow 4 min. Green 8 min.5 37.91 35. Green 6 min.81 2.68 35.19 35.18 36.03 34. Red 1 min. Red 2 min. 1. To verify the BDI display reflects the preferred battery discharge.8 Volts 37.83 33.15 36 35.47 36. 3.45 36.71 36.99 33.9 36.99 33.2 37.44 35. 2.72 32.

F-code PS Version no 001 Section C-code S5. No) Go to step 7. Return Service Manual 2001-03-15 353 .13 5711 Main Electronic Card T-code RTX35/RTX45 NOTE! Do not charge the battery at anytime during the shift until adjustment of Parameter 13 is complete. the Battery Parameter 13 should be decreased. Check voltage reading to see if it matches the corresponding bar level and respond accordingly. Take an open voltage reading across the battery terminals. 8. 4. If the open circuit voltage of the battery is lower than the corresponding BDI bar level from the chart. © BT Prime-Mover Inc. the Battery Parameter 13 should be increased. If the open voltage of the battery is higher than the corresponding BDI bar level from the chart. 6. 7. Repeat steps 1 through 7. Find the column containing the preferred discharge level from the chart above. Put truck into service for an 8 hour shift. 5. Yes) Battery Parameter 13 needs no further adjustment.

The RV2 trim pot will be just above the right corner of the #4 electrical connector. NOTE! This adjustment must be performed each time the main electronic card is replaced. Over turning the Pot can cause damage to the Pot.F-code Section PS S5. 354 Return Service Manual 2001-03-15 . RV2 Adjustment Procedure RV2 Trim Pot 1. NOTE! The RV2 Trim Pot is a 270 degree turn Pot. Raise fork carriage so that it is visible from the operator compartment.13 Main Electronic Card Version no T-code 001 RTX35/RTX45 C-code 5711 10. 4. Locate RV2 trim pot on main electronic card. Turn RV2 Trim Pot fully clockwise. Remove main electronic card panel. 2. 3.

Programming Parameters. rotate the lift/lower knob 0.6 mm). 11. Remove main electronic card access panel (see page 101). Remove floor plate (see page 102). 8. 4. Go into programming mode. Adjust the RV2 trim pot so the fork carriage will just begin to lower. - Refer to Set parameter 12 at 4 Set parameter 17 at 50 5. 2001-03-15 355 . verify that 247 appears on the display. loosen bolts on brake transducer and adjust until 10 appears on the display. The brake switch should be adjusted so it actuates between 45 and 52 on the display when depressing the pedal. 2. Set parameter 17 to the current year. programming mode. The display should read 10 with the pedal way up. Verify pedal up and down bumpers are in good condition. After making adjustments. After changing these parameters. With the pedal all the way down. 7. While standing on the platform switch. With the pedal all the way up. Return Service Manual go back into Set parameter 12 at 2. 9. Press brake pedal all the way down. 3. switch OFF and turn back ON. © BT Prime-Mover Inc.0625 inch (1. 11. 10. 6. The display should read 247.F-code PS Version no 001 Section C-code S5. Adjustment Procedures for Setting Brake Switch and Brake Transducer 1.13 5711 Main Electronic Card T-code RTX35/RTX45 5.

Reinstall the floor plate and the main electrical card access panel. 356 Return Service Manual 2001-03-15 .13 Main Electronic Card Version no T-code 001 RTX35/RTX45 C-code 5711 12.F-code Section PS S5.

overheating. - + 1 Item No.F-code PS Section C-code S5. Test/Inspection Examine the switch for signs of arcing. The indicator also lights if the truck is driven without both the brake pedal and the platform (right foot) switches engaged. Platform (Right Foot) Switch (S23) The platform (right foot) switch (S23) is located under the floor board of the operator compartment. machine 2 Switch. While selecting a hydraulic function. isolate it from the electrical circuit. Return Service Manual 1 Screw. 2. right foot 3 Nut. discoloration. if either the brake pedal (left foot) or platform (right foot) switch is not successfully engaged a red triangle (H) lights on the operator display. General Refer to the electrical schematic to identify the electrical circuit location of the switch (see Circuit Diagrams on page 273 through page 284). Activation of the platform switch allows lift and auxiliary functions to operate without depression of the brake pedal.14 5751 Switches and Sensors Version no T-code 001 RTX35/RTX45 Switches and Sensors 1. Replace switch if such damage is present. or other physical damage. twin 2001-03-15 357 .1. 1. Do this by removing all the connections from the switch. 1/2 Description 0 H © BT Prime-Mover Inc. cracking. To test a switch. making sure all wires are labeled and identified for reconnection.

1. 3. Install two screws (1) through switch (2) into twin nut (3) on the opposite side of the switch bracket. the main electronic card receives a signal. Test operation of platform switch before returning the truck to service. Installation f 1. Remove two screws (1) securing switch (2) to twin nut (3) at switch bracket. 3. Reconnect battery connector. 2 3. Removal 1.1. Remove floor board (see page 102). Raise the empty carriage until the top of the staging switch is even with the top of the staging column. preventing the load on the forks from being jarred. When the sensor extends beyond the limits of the inner columns. 1 3 4. This triggers a slowing of lift and allows a smoother transition as the columns begin to move.14 5751 Switches and Sensors Version no T-code 001 RTX35/RTX45 2. 358 Return Service Manual 2001-03-15 .2. Adjustment 1. Turn key switch OFF and disconnect battery connector. 3. Staging Switch (S45) The staging switch (S45) is a proximity sensor located on the outside of the carriage. Install floor board. 2. 3. 2. Its function is to let the main electronic card know when the carriage has almost completed the first stage of lift (freelift).F-code Section C-code PS S5. Loosen switch mounting bracket screws. 2. Secure carriage with blocks and a hoist to prevent any movement. 2.

2.3. Test mast operation to verify proper operation of staging switch. Check clearance with the screws tight. 4. Installation 1. © BT Prime-Mover Inc. 3. 4.187 inch (4. Turn key switch OFF and disconnect battery connector. 5. Secure carriage with blocks and a hoist to prevent any movement. 7. 6.2. Return Service Manual 2001-03-15 359 . Remove blocks and hoist. 6. Disconnect switch from wiring harness. Adjust switch following the procedure on page 358.76 mm). Raise empty carriage until the top of the staging switch is above the top of the staging column. 3. Remove switch mounting bracket screws. Removal 1. 3.F-code PS Section C-code S5. 8.14 5751 Switches and Sensors Version no 001 T-code RTX35/RTX45 4.59 mm) and -0 mm. Tighten switch mounting bracket screws.0625 inch (1. Install switch on the mounting bracket. Reconnect battery connector. Connect switch to wiring harness. Allowable tolerance is +0. Tighten switch mounting bracket screws. Return truck to service. 5. 5. 3. Adjust switch to 0. 2.

S66 and S67 are approximately 90 degrees right of center allowing a total of 180 degrees steering. Turn key switch OFF and disconnect battery connector. Adjustment CAUTION Adjustment of sensor with wheel nuts facing inward will result in shearing of sensor when the drive wheel is rotated. 360 Return Service Manual 2001-03-15 . Reconnect battery connector.F-code Section C-code PS S5. Remove top console. 6. 4. 5. Position drive wheel with wheel nuts facing outward. Back sensor out by turning counterclockwise 1-1/4 turns. S65 is 90 degrees left of center. motor compartment door. 3. and left side panel to allow access to drive unit. 2. This sensor works in conjunction with the steer stop proximity sensors (S66 and S67) located directly across the drive unit. 1. Tighten jam nut securing the sensor to the frame.1. Loosen jam nut securing the sensor to the frame. Wheel Direction Sensor S65 The wheel direction sensor (S65) detects directional information from the top of the drive unit.14 5751 Switches and Sensors Version no T-code 001 RTX35/RTX45 4. 8. the sensor 7. 4. Test operation of the sensor. 9. Turn wheel direction sensor by hand in a clockwise direction until it contacts the drive unit housing.

Loosen jam nut securing the sensor to the frame. 4. Reconnect battery connector. Set the proper sensor distance by turning the sensor counterclockwise 1-1/4 turns. Return Service Manual 2001-03-15 361 . © BT Prime-Mover Inc.3. Turn sensor counterclockwise to remove it from the frame. Disconnect sensor at the main wiring harness. 2. Turn key switch OFF and disconnect battery connector. 4. 5. Installation 1.F-code PS Section C-code S5.14 5751 Switches and Sensors Version no 001 T-code RTX35/RTX45 4. 2. Reconnect sensor electrical connection to the main wiring harness.2. 3. 4. 6. Tighten by hand in a clockwise direction until it just contacts the drive unit housing. Return truck to service. 3. Removal 1. 7. Tighten jam nut securing the sensor to the frame. Install sensor in the frame.

and left side panel to allow access to drive unit. 2. Test operation of the sensor. STEER STOP SENSORS 4. Remove top console. motor compartment door. TURN DRIVE WHEEL INWARD 90o 362 Return Service Manual 2001-03-15 . Turn steer stop sensors by hand until they contact the drive unit housing. 11. Install battery in truck. Back sensors out by turning the sensors 1-1/4 turns. Tighten jam nuts securing the sensors to the frame. Turn key switch OFF and disconnect battery connector.1. S66 connector is grey in color and located in the front. Loosen jam nuts securing the sensors to the frame. The steer stop proximity sensors work as a pair in conjunction with switch S65 to detect drive S67 wheel direction and position information from the top of the drive unit. 7. 9. Steer Stop Proximity Sensor A and Sensor B The steer stop proximity sensors (S66 and S67) are located on the frame behind the steer motor. Return truck to service. 8. 10. 6.F-code Section C-code PS S5. 5. 5. Adjustment CAUTION Adjustment of sensors with wheel nuts facing outward will result in shearing of sensors when the drive wheel is rotated. Reconnect battery connector. 3. 1. Position drive wheel with wheel nuts facing inward.14 5751 Switches and Sensors Version no T-code 001 RTX35/RTX45 S66 5. S67 connector is blue in color and located in the back.

2. 6. 2. © BT Prime-Mover Inc.F-code PS Section C-code S5. Turn key switch OFF and disconnect battery connector. 4. following the procedure on 5. Overtightening can cause damage to the sensors. Place new sensors in the frame. 2. 3. 4. 5. NOTE! Do not overtighten jam nuts. Remove sensors from truck.3. Removal 1. Return Service Manual 2001-03-15 363 . Installation 1. Disconnect sensors from wiring harness. Return truck to service. Adjust sensors page 362. Secure sensors to frame with jam nuts. 3. Test operation of truck. Remove jam nuts securing the sensors to the frame. Reconnect wiring harness.14 5751 Switches and Sensors Version no 001 T-code RTX35/RTX45 5.

Their purpose is to detect speed and directional information from the sensor nut attached to the top of the drive motor. These drive motor speed/direction sensors are not adjustable. Removal 1 1. Item No. Description Item No. Service Manual 2001-03-15 . 5 4. Remove cap screw (4) securing sensor (7 or 5) to spacer (6). speed (male plug) S64 2 Nut. Turn key switch OFF and disconnect battery connector.1. sensor 6 Housing. 7 6 364 Return 2. sensor 3 Spacer. Disconnect drive motor speed and/or directional sensor from main wiring harness. Description 1 Screw 5 Sensor. Remove sensor (7 or 5) from spacer (6). Drive Motor Speed/Direction Sensors The drive motor speed (S64)/direction (S125) sensors are located in the spacer mounted on top of the brake assembly.14 5751 Switches and Sensors Version no T-code 001 RTX35/RTX45 6. direction (female plug) S125 4 Screw. cap 6. 2 4 3 3. Note the style of the wire ends (male or female) and location for reassembly.F-code Section C-code PS S5. brake sensor 7 Sensor.

14 5751 Switches and Sensors 2. Sensors that are improperly installed will result in an error code appearing when the truck is returned to service. Install cap screw (4). Be sure the style of the wire ends and location match the ones noted during removal.2.F-code PS Section Version no 001 1 T-code RTX35/RTX45 6. 4. © BT Prime-Mover Inc. Install sensor (7 or 5) in spacer (6). Installation 2 1. 5. 4 3 7 6 C-code S5. Return Service Manual 2001-03-15 365 . Test operation of truck before returning to service. Reconnect sensor to main harness assembly. Reconnect battery connector. 5 3.

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 .

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.F-code Section PS S6. Use a piece of cardboard or paper to search for leaks. For a listing of error codes see pages page 336 and 340. Return Service Manual 2001-03-15 367 . Tighten all connections before applying pressure. Escaping fluid under pressure can penetrate the skin causing serious injury. 1. Keep hands and body away from pinholes and nozzles which eject fluids under high pressure. Relieve pressure before disconnecting hydraulic or other lines. © BT Prime-Mover Inc. Operation See “RTX35 Hydraulic Schematic” on page 396 or “RTX45 Hydraulic Schematic” on page 397. For information on the fuses and their location see page 305. For a listing of parameters see page 345.

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 S212 TILT DOWN 84 508 HM204 S51 SIDESHIFT LEFT HM205 85 509 HM108 S52 SIDESHIFT RIGHT HM206 R1 TRAVEL ORANGE/BLACK STRIPE R11 LIFT BLUE/BLACK STRIPE 50 HM210 HM105 HM211 HM106 505 82 506 Control Handle Interface Schematic LEGEND PRESSURE OIL RETURN OIL ELECTRIC POSITIVE ELECTRIC NEGATIVE 368 Return Service Manual 2001-03-15 .F-code Section C-code PS S6.

tilt. The following table shows the relationship of the selected control handle function to the output of the control handle interface card. Control Handle Interface. Hydraulic Control Operation The control handle interface card decodes and conditions the digital signals from the control handle for use by the main electronic (A5) card.F-code Section PS S6. and sideshift.0 6000 Hydraulic System Version no 000 C-code T-code RTX35/RTX45 1. Return Service Manual 2001-03-15 369 . Digital signals from the control handle include reach.1. © BT Prime-Mover Inc. The digital signals are decoded by converting the possible combinations of push-buttons to different analog voltage levels. Analog signals (travel and lift/lower) from the control handle are relayed unchanged to the main electronic card.

873V Sideshift Left HM205 7.880V Max. 5.65V Max.880V Max. 1.573V Nom.513V Nom. 1. 5.470V Max 1. 4. 2.F-code Section C-code PS S6. 5.307V Sideshift Right HM206 7.35V HM109 Min.103V Nom. and sideshift. 1. 4.410V Max. 1. 2. The center and travel limits of the travel and lift/lower potentiometers are learned.940V Max.615 volts and less than 0.35V HM108 Min.6V Lift Nom.410V Max. 4.573V Nom.410V Max. Voltages at the main electronic card inputs greater than 6.103V Nom.307V 85 509 Min.043V Nom.247V 83 507 Min. 4. 0. 2.410V Max.103V Nom. 2. 1. 5.777V Retract High Speed HM202 and HM201 7.470V Max 1.307V 83 507 Min.513V Nom. 3. Service Manual 2001-03-15 . 4. Voltages at the main electronic card (A5) inputs greater than 6. 6.940V Max. 2.35V HM109 Min. 2. 5.65V Max. 6.513V Nom.7V Lwr 82 506 Min. 4. 3. the voltages listed are a rough approximation. 1.0 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. 2. 4.735 volts indicate shorted or open signal wires for reach.410V Max.573V Nom.043V Nom. 1.4V Max. 0. 6. 4.043V Nom. 3. 2.573V Nom. 1.573V Nom.247V 83 507 Min. 1. 4.6 volts indicate shorted or open signal wires for travel and lift/lower. 2. 2. 5. 2. 1. 2.777V 83 507 Min. 4.7V Lwr Notes: 370 Return 1.873V 84 508 Min.103V Nom. 4. 1.247V No Tilt Function Selected HM203 and HM204 0V (both inputs) HM109 Min.940V Max.35V HM107 Min. 4.6V Rev Nom. 2. 3. 0.513V Nom. 2.7V Lwr HM106 Min.35V HM107 Min.777V 85 509 Min.4V Max. 3.470V Max 1.873V Reach Low Speed HM201 7.2V Fwd Lift/Lower HM211 Min. 0.470V Max 1.410V Max. 3. Therefore. 1. tilt. Voltages at the main electronic card inputs other than the stated voltages will select no function for reach. 1.043V Nom.043V Nom.103V Nom.4V Max.307V Tilt Down HM204 7. 5. 1. 4.777V No Sideshift Function Selected HM205 and HM206 0V (both inputs) HM108 Min. 0.940V Max.470V Max 1.65V Max.247V Retract Low Speed HM202 7.777V Travel HM210 Min. 5. 2.880V Max.470V Max 1. 2. 4. 6. 2. 2. 1. tilt. 4. 4.103V Nom. and sideshift.75 volts and less than 0.6V Rev Nom. 4. 0.940V Max.2V Fwd 50 505 Min. 1.307V 84 508 Min.873V 83 507 Min.873V 85 509 Min.940V Max. 3. 4.6V Lift Nom.35V (both inputs) HM107 Min.777V 84 508 Min.35V HM108 Min.573V Nom.043V Nom. 1.6V Lift Nom.880V Max. 1. 2.2V Fwd HM105 Min.307V Reach High Speed HM201 and HM202 7.873V Tilt Up HM203 7. 4.6V Rev Nom.35V (both inputs) HM107 Min.

Return Service Manual 2001-03-15 371 .F-code Section PS S6.0 6000 Hydraulic System Version no 000 C-code T-code RTX35/RTX45 This page intentionally left blank © BT Prime-Mover Inc.

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 (+) 9 M 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 .

or both. By depressing the right foot pedal and releasing the brake pedal setting the parking brake. The electronic card (A5) turns on speed request output 702 (wire #75) to a level proportional to the control handle request. © BT Prime-Mover Inc. 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).2. The pump transistor regulator sends the amplified signal to the pump motor (M3) commanding pumping. the right foot pedal.5 volts and are measured with respect to main electronic card (A5) output 701 (wire #74). Hydraulic functions can be performed by using the brake pedal.F-code Section PS S6. sideshift (S51/ S52). Supply A voltage from lift (R11). If the pressure in the system increases to the preset value of the relief valve. Both speed request and current limit signals range from 0 volts to approximately 4. Returned oil is filtered at the hydraulic tank. The combination of the oil from both sections through the Y11 dump valve is used for lifting. Appropriate solenoids are activated opening valves and the auxiliary functions are performed. it will open directing oil back to the hydraulic tank. The small section of the pump is used for the auxiliary functions. This signal is sent to the pump transistor regulator (A2) input pin 10. Return Service Manual 2001-03-15 373 . The lowering function is powered by gravity and proportionally controlled. 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. Oil is pumped by a two-section pump from the hydraulic tank into the hydraulic system.0 6000 Hydraulic System Version no 000 C-code T-code RTX35/RTX45 1. hydraulic functions can be performed with the truck “parked” in position. reach (S55/S56).

0 Hydraulic System 6000 Version no T-code 000 RTX35/RTX45 3 11 11 R11 1 2 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 C-code PS S6.

The free lift cylinder. Return Service Manual 2001-03-15 375 . After the free lift cylinder has reached full extension. The main electronic card (A5) responds by enabling voltage to the dump valve coil (Y11) and the lift valve coil (Y10/2). rotating the lift/lower control lever upward on the control handle causes R11 to output a voltage less than when in the neutral position.F-code Section PS S6. Lifting With the key switch ON and brake pedal and/or right foot switch depressed. oil flows back to the hydraulic tank. the main lift cylinders will begin to lift. © BT Prime-Mover Inc. having less weight on it. Oil is fed from the pump to the lift valve (Y10) and from the valve to the free lift and main lift cylinders. will lift first. If the pressure in the system increases to the relief valve’s preset value. 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 lift speed can be infinitely varied to the maximum lift speed.0 6000 Hydraulic System Version no 000 C-code T-code RTX35/RTX45 1.3.

0 Hydraulic System 6000 Version no T-code 000 RTX35/RTX45 11 3 11 R11 2 1 A71 HM211 HANDLE INTERFACE MODULE A5 804 HM106 88 506 704 89 Y10/2 Y10/3 (-) 40 P R Lowering Schematic LEGEND PRESSURE OIL RETURN OIL ELECTRIC POSITIVE ELECTRIC NEGATIVE 376 Return Service Manual 2001-03-15 .F-code Section C-code PS S6.

returning to the hydraulic tank. tilt. The control handle interface card senses this increase in voltage at terminal HM211 and notifies the main electronic (A5) card input 506 (wire #82). rotating the lift/lower control lever downward on the control handle causes R11 to output a voltage greater than when in the neutral position. © BT Prime-Mover Inc. The lowering speed is regulated by the proportional lowering valve (Y10/3) in direct proportion to the voltage from (R11). A reach. Oil flows from the cylinders through the valve.F-code Section PS S6.4. The main electronic (A5) card enables voltage to the proportional lower solenoid coil (Y10/3). or sideshift function can be performed while lowering.0 6000 Hydraulic System Version no 000 C-code T-code RTX35/RTX45 1. Return Service Manual 2001-03-15 377 . Proportional lower solenoid coil (Y10/3) is normally closed. Lowering With the key switch ON and brake pedal and/or right foot switch depressed.

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 P R Low Speed Extend Schematic LEGEND PRESSURE OIL RETURN OIL ELECTRIC POSITIVE ELECTRIC NEGATIVE 378 Return Service Manual 2001-03-15 .F-code Section C-code PS S6.

Speed request is dependent on truck voltage and reach model.5. through Reach1 (Y14) valve to the rear ports on the reach cylinders.F-code Section PS S6. The control handle interface card encodes the digital signal sensed at HM201 to an analog voltage level of approximately 2. • Enabling the reach solenoid(s) (Y14 and Y15) on the reach carriage from outputs 707 (wire #92) and 708 (wire #93). • Sending a speed request to the pump transistor regulator. The main electronic (A5) card responds by: • Enabling voltage to the direction A solenoid coil (Y12) from output 705 (wire #90). and drives the pistons outwards. Reach solenoids Y14 and Y15 are combined into one solenoid on some reach models. © BT Prime-Mover Inc.94 volts at HM107 and sends to the main electronic (A5) card input 507 (wire #83). pressing the reach button causes voltage to be sensed at HM201 on the control handle interface card. through Reach2 (Y15) valve to direction A (Y12) valve. and back to the hydraulic tank. The truck voltage and reach model is configured by Pump Type Parameter 14.0 6000 Hydraulic System Version no 000 C-code T-code RTX35/RTX45 1. The speed request signal to the pump transistor regulator provides the PWM frequency rate to pulse the pump motor. Return Service Manual 2001-03-15 379 . Low Speed Extend Reach extends the forks away from the mast assembly when the reach button on the control handle is depressed. Oil is fed through direction A (Y12) valve. The oil flows from the front ports of the cylinders. With the key switch ON and the brake pedal and/or right foot pedal depressed.

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 P R High Speed Extend Schematic LEGEND PRESSURE OIL RETURN OIL ELECTRIC POSITIVE ELECTRIC NEGATIVE 380 Return Service Manual 2001-03-15 .

through Reach2 (Y15) valve to direction A (Y12) valve. and drives the pistons outwards.88 volts at HM107 and sends to the main electronic (A5) card input 507 (wire #83). Speed request is dependent on truck voltage and reach model. The oil flows from the front ports of the cylinders. Return Service Manual 2001-03-15 381 . high speed reach occurs. The speed request signal to the pump transistor regulator provides the PWM frequency rate to pulse the pump motor.6. • Enabling the reach solenoid(s) (Y14 and Y15) on the reach carriage from outputs 707 (wire #92) and 708 (wire #93). With the key switch ON and the brake pedal and/or right foot pedal depressed. Oil is fed through direction A (Y12) valve. • Sending a larger value speed request to the pump transistor regulator. © BT Prime-Mover Inc. High Speed Extend Reach extends the forks away from the mast assembly when the reach button on the control handle is depressed. The truck voltage and reach model is configured by Pump Type Parameter 14.F-code Section PS S6. and back to the hydraulic tank. pressing the reach and then retract button causes voltage to be sensed at HM201 and HM202 on the control handle interface card. The main electronic (A5) card responds by: • Enabling voltage to the direction A solenoid coil (Y12) from output 705 (wire #90). Reach solenoids Y14 and Y15 are combined into one solenoid on some reach models. through Reach1 (Y14) valve to the rear ports on the reach cylinders. The control handle interface card encodes the digital signal sensed at HM201 and HM202 to an analog voltage level of approximately 5. When the reach button is held and the retract button is depressed.0 6000 Hydraulic System Version no 000 C-code T-code RTX35/RTX45 1.

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 P R Low Speed Retract Schematic LEGEND PRESSURE OIL RETURN OIL ELECTRIC POSITIVE ELECTRIC NEGATIVE 382 Return Service Manual 2001-03-15 .

The speed request signal to the pump transistor regulator provides the PWM frequency rate to pulse the pump motor. and back to the hydraulic tank. Low Speed Retract Retract withdraws the forks toward the mast assembly when the retract button on the control handle is depressed.7. With the key switch ON and the brake pedal and/or the right foot pedal depressed.41 volts at HM107 and to A5 input 507 (wire #83). • Sending a speed request to the pump transistor regulator. © BT Prime-Mover Inc. The control handle interface card encodes the digital signal sensed at HM202 to an analog voltage level of approximately 4. Return Service Manual 2001-03-15 383 . The main electronic (A5) card responds by: • Enabling voltage to the direction B solenoid coil (Y13) from output 706 (wire #91). pressing the retract button causes voltage to be sensed at HM202 on the control handle interface card.0 6000 Hydraulic System Version no 000 C-code T-code RTX35/RTX45 1. Reach solenoids Y14 and Y15 are combined into one solenoid on some reach models. Oil is fed through direction B (Y13) valve. through Reach1 (Y14) valve to direction B (Y13) valve. The truck voltage and reach model is configured by Pump Type Parameter 14. The oil flows from the rear ports of the cylinders.F-code Section PS S6. • Enabling the reach solenoid(s) (Y14 and Y15) on the reach carriage from outputs 707 (wire #92) and 708 (wire #93). Speed request is dependent on truck voltage and reach model. through Reach2 (Y15) valve to the front ports on the reach cylinders. and drives the pistons inwards.

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 P R High Speed Retract Schematic LEGEND PRESSURE OIL RETURN OIL ELECTRIC POSITIVE ELECTRIC NEGATIVE 384 Return Service Manual 2001-03-15 .

• Sending a larger value speed request to the pump transistor regulator. The truck voltage and reach model is configured by Pump Type Parameter 14. Reach solenoids Y14 and Y15 are combined into one solenoid on some reach models. through Reach1 (Y14) valve to direction B (Y13) valve.8. Speed request is dependent on truck voltage and reach model. The oil flows from the rear ports of the cylinders. through Reach2 (Y15) valve to the front ports on the reach cylinders. The speed request signal to the pump transistor regulator provides the PWM frequency rate to pulse the pump motor. With the key switch ON and the brake pedal and/or right foot pedal depressed. The main electronic (A5) card responds by: • Enabling voltage to the direction B solenoid coil (Y13) from output 706 (wire #91). pressing the retract and then reach button causes voltage to be sensed at HM202 and HM201 on the control handle interface card. and back to the hydraulic tank.F-code Section PS S6. and drives the pistons inwards. Oil is fed through direction B (Y13) valve. When the retract button (S56) is held and the reach button (S55) is pushed high speed retract occurs. • Enabling the reach solenoid(s) (Y14 and Y15) on the reach carriage from outputs 707 (wire #92) and 708 (wire #93). Return Service Manual 2001-03-15 385 . High Speed Retract Retract withdraws the forks toward the mast assembly when the retract button (S56) on the control handle is depressed.88 volts at HM107 and to A5 input 507 (wire #83). The control handle interface card encodes the digital signal sensed at HM202 and HM201 to an analog voltage level of approximately 5.0 6000 Hydraulic System Version no 000 C-code T-code RTX35/RTX45 1. © BT Prime-Mover Inc.

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 P R Right Sideshift Schematic LEGEND PRESSURE OIL RETURN OIL ELECTRIC POSITIVE ELECTRIC NEGATIVE 386 Return Service Manual 2001-03-15 .F-code Section C-code PS S6.

With the key switch ON and the brake pedal and/or right foot pedal depressed. Return Service Manual 2001-03-15 387 . • Enabling the sideshift solenoid (Y16) on the reach carriage from output 709 (wire #95). The truck voltage and reach model is configured by Pump Type Parameter 14. Oil is fed through direction B (Y13) valve to the sideshift (Y16) valve. and returns to the hydraulic tank. Right Sideshift Sideshift allows the operator to move the fork carriage to the right or left in relation to the mast. The speed request signal to the pump transistor regulator provides the PWM frequency rate to pulse the pump motor. The amount of sideshift is 2 or 4 inches (50 or 100 mm) depending on the baseleg opening (BLO). The control handle interface card encodes the digital signal sensed at HM206 to an analog voltage level of approximately 4. to the rear port of the sideshift cylinder driving the piston outward.F-code Section PS S6. to the direction B (Y13) valve. The main electronic (A5) card responds by: • Enabling voltage to the direction B solenoid coil (Y13) from output 706 (wire #91).0 6000 Hydraulic System Version no 000 C-code T-code RTX35/RTX45 1. to the sideshift (Y16) valve.9. Speed request is dependent on truck voltage and reach model.41 volts at HM108 and sends to main electronic (A5) card input 509 (wire #85). • Sending a speed request to the pump transistor regulator. The oil flows from the front port of the cylinder. © BT Prime-Mover Inc. pressing the sideshift right button (S52) causes voltage to be sensed at HM206 on the control handle interface card.

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 P R Left Sideshift Schematic LEGEND PRESSURE OIL RETURN OIL ELECTRIC POSITIVE ELECTRIC NEGATIVE 388 Return Service Manual 2001-03-15 .F-code Section C-code PS S6.

The oil flows from the rear port of the cylinder. to the direction A (Y12) valve.F-code Section PS S6. to the front port of the sideshift cylinder. driving the piston inward. With the key switch ON and the brake pedal and/or right foot pedal depressed.10.0 6000 Hydraulic System Version no 000 C-code T-code RTX35/RTX45 1. pressing the sideshift left button (S51) causes voltage to be sensed at HM205 on the control handle interface card.94 volts at HM108 and sends to main electronic (A5) card input 509 (wire #85). The main electronic (A5) card responds by: • Enabling voltage to the direction A solenoid coil (Y12) from output 705 (wire #90). Speed request is dependent on truck voltage and reach model. • Sending a speed request to the pump transistor regulator. Oil is fed through direction A (Y12) valve. Left Sideshift Sideshift allows the operator to move the fork carriage to the right or left in relation to the mast. • Enabling the sideshift solenoid (Y16) on the reach carriage from output 709 (wire #95). The speed request signal to the pump transistor regulator provides the PWM frequency rate to pulse the pump motor. to the sideshift (Y16) valve. to the sideshift (Y16) valve. © BT Prime-Mover Inc. The control handle interface card encodes the digital signal sensed at HM205 to an analog voltage level of approximately 2. and returns to the hydraulic tank. Return Service Manual 2001-03-15 389 . The amount of sideshift is 2 or 4 inches (50 or 100 mm) depending on the baseleg opening (BLO). The truck voltage and reach model is configured by Pump Type Parameter 14.

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 P R Fork Tilt Up Schematic LEGEND PRESSURE OIL RETURN OIL ELECTRIC POSITIVE ELECTRIC NEGATIVE 390 Return Service Manual 2001-03-15 .

The oil flows from the front port of the cylinder.94 volts at HM109 and sends to main electronic (A5) card input 508 (wire #84). to the rear port of the tilt cylinder. The main electronic (A5) card responds by: • Enabling voltage to the direction B solenoid coil (Y13) from output 706 (wire #91).11. The speed request signal to the pump transistor regulator provides the PWM frequency rate to pulse the pump motor. The control handle interface card encodes the digital signal sensed at HM203 to an analog voltage level of approximately 2.0 6000 Hydraulic System Version no 000 C-code T-code RTX35/RTX45 1.F-code Section PS S6. Speed request is dependent on truck voltage and reach model. driving the piston outward. Oil is fed through direction B (Y13) valve. pressing the tilt up button (S211) causes voltage to be sensed at HM203 on the control handle interface card. With the key switch ON and the brake pedal and/or right foot pedal depressed. Fork Tilt Up Fork tilt allows the operator to raise or lower the tips of the forks. to the direction B (Y13) valve. returning to the hydraulic tank. • Sending a speed request to the pump transistor regulator. • Enabling the tilt solenoid (Y17) on the reach carriage from output 710 (wire #94). to the tilt (Y17) valve. The truck voltage and reach model is configured by Pump Type Parameter 14. Standard fork tilt is 4o up and 3o down. © BT Prime-Mover Inc. Return Service Manual 2001-03-15 391 .

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 P R Fork Tilt Down Schematic LEGEND PRESSURE OIL RETURN OIL ELECTRIC POSITIVE ELECTRIC NEGATIVE 392 Return Service Manual 2001-03-15 .F-code Section C-code PS S6.

• Enabling the tilt solenoid (Y17) on the reach carriage from output 710 (wire #94). The main electronic (A5) card responds by: • Enabling voltage to the direction A solenoid coil (Y12) from output 705 (wire #90). pressing the tilt down button (S212) causes voltage to be sensed at HM204 on the control handle interface card. The truck voltage and reach model is configured by Pump Type Parameter 14. to the tilt (Y17) valve.F-code Section PS S6. driving the piston inward. returning to the hydraulic tank. Speed request is dependent on truck voltage and reach model. • Sending a speed request to the pump transistor regulator. Fork Tilt Down Fork tilt allows the operator to raise or lower the tips of the forks.41 volts at HM109 and sends to main electronic (A5) card input 508 (wire #84). Oil is fed through direction A (Y12) valve. The control handle interface card encodes the digital signal sensed at HM204 to an analog voltage level of approximately 4.12. Return Service Manual 2001-03-15 393 . to the direction A (Y12) valve. © BT Prime-Mover Inc. Standard fork tilt is 4o up and 3o down. The oil flows from the rear port of the cylinder. to the front port of the tilt cylinder. With the key switch ON and the brake pedal and/or right foot pedal depressed.0 6000 Hydraulic System Version no 000 C-code T-code RTX35/RTX45 1. The speed request signal to the pump transistor regulator provides the PWM frequency rate to pulse the pump motor.

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 3 Cylinder Free lift 4 Cylinder Reach/retract 5 Cylinder Tilt 6 Cylinder Sideshift 11 Valve Staging velocity fuse 13 Valve Free lift velocity fuse 14 Valve Relief A2 Pump transistor regulator Pump Motor A5 Electronic card Main Card A71 Electronic card Signal Conditioning Module F Filter Main filter M3 Motor Pump motor P 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 .

Lower of Forks Y10 Valve Lift/lower Y11 Valve Dump valve coil 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 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 Proportional Valve.

RTX35 Hydraulic Schematic 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 .0 Hydraulic System 6000 Version no T-code 000 RTX35/RTX45 2.F-code Section C-code PS S6.

Return Service Manual 2001-03-15 TILT CYLINDER SIDESHIFT CYLINDER 397 .F-code Section PS S6.0 6000 Hydraulic System Version no C-code T-code 000 RTX35/RTX45 3. RTX45 Hydraulic Schematic FREELIFT VALVE FREELIFT CYLINDER STAGING CYLINDER STAGING CYLINDER STAGING VALVE Y10 Y10 RELIEF VALVE M Y13 Y12 P R Y11 F T P P C2 C1 C3 T C1 C2 C4 Y15 Y17 S1 B A Y16 CV 300 PSI REACH CYLINDERS © BT Prime-Mover Inc.

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.

5. Drain hydraulic reservoir completely. away from any possible contaminating elements that could enter the hydraulic system during the changing process. To make the proper oil/ lubricant selection see “Oil and Grease Specifications” on page 81. drain as much oil as possible from the hydraulic lines and cylinders. should not be harmful to the operation of the truck. See “Bleeding Hydraulic System” on page 401. Be sure the truck is in a clean area. Hydraulic Fluid Selection Before adding or changing hydraulic fluid. 2.F-code Section PS S6. determine the environment and usage of the truck. Also. operate the lift/lower and auxiliary functions for approximately 2 minutes to purge the system. Bleed entire hydraulic system before placing truck into service. The remainder of the original hydraulic fluid left in the system. Changing Hydraulic System Fluid 1. 7. 6. Check for possible hydraulic leaks.1 6112 Hydraulic Fluid Version no 000 C-code T-code RTX35/RTX45 Hydraulic Fluid 1. Return Service Manual 2001-03-15 399 . and tilt is fully down. With lift system running. 4. © BT Prime-Mover Inc. Check reservoir oil level. 3. Check that the carriage is fully lowered. 2. Fill hydraulic reservoir with proper fluid. reach retracted. (approximately 5%).

400 Return Service Manual 2001-03-15 . 9. 7. Turn key switch OFF and disconnect battery connector. Remove top console and open motor compartment door. 5. Turn key switch OFF and disconnect battery connector. 11. 4. Operate lift until air in the system is heard. 3. Reconnect battery connector and turn key switch ON. 2. 10. Remove female half of diagnostic fitting and hose. 8. 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). 6.1 Hydraulic Fluid 6112 Version no T-code 000 RTX35/RTX45 3. Lower the carriage fully. Remove drainage tube and replace diagnostic fitting.F-code Section C-code PS S6. remove reservoir. Dispose of old hydraulic fluid according to local regulations for hazardous materials. If it is necessary to flush the reservoir. tilt forks down completely and retract reach mechanism fully. System Draining 1.

6. The reservoir holds 5 gallons (19 liters) of fluid. If reservoir was removed for flushing. Be sure to use the proper grade of fluid. 4. Install top console and secure motor compartment door. Fill hydraulic reservoir through breather cap/fill hole. Return Service Manual 2001-03-15 401 .1 6112 Hydraulic Fluid Version no 000 C-code T-code RTX35/RTX45 4. Bleed hydraulic system. See paragraph 5 below. 3. © BT Prime-Mover Inc. Turn key switch OFF and disconnect battery connector. 2. Install hydraulic filter. Reconnect battery connector and turn key switch ON. 2. 5. Elevate forks 2 to 3 inches (50 to 75 mm) off the floor. 5. System Refilling 1. Bleeding Hydraulic System When bleeding the hydraulic system to remove any trapped air: • Change hydraulic hose • Disconnect hydraulic fitting • Remove hydraulic cylinder • Remove hydraulic pump (see “Hydraulic Pump” on page 409). • Remove hydraulic reservoir • Notice that the load is bouncing 1.F-code Section PS S6. install reservoir.

6. Use an Allen wrench to loosen (but do NOT remove) the bleed screw at the top of the freelift cylinder. Repeat step 3 for each of the two staging cylinders. Fully extend and retract the reach mechanism several times. 4.1 Hydraulic Fluid 6112 Version no T-code 000 RTX35/RTX45 CAUTION Use caution. Thoroughly clean up any spilled hydraulic fluid.F-code Section C-code PS S6. 7. 9. If truck is equipped with tilt. shift the carriage all the way to the left and right several times. The mast may drop when bleeding the cylinder. If truck is equipped with sideshift. Check hydraulic reservoir level and refill as necessary. 12. Lower forks all the way down to the floor. Hold a rag close to and beneath the bleed screw to keep hydraulic fluid from spraying out. Reconnect battery connector and turn key switch ON. securely tighten the bleed screw. 11. 5. 10. 8. 402 Return Service Manual 2001-03-15 . tilt the carriage all the way forward and backward several times. When hydraulic fluid starts flowing from the bleed screw hole. 3.

5. Removal 1. Return Service Manual 2001-03-15 403 . hydraulic (RTX35) 2 Tank. Remove lift pump and motor. hydraulic (RTX45) 1.F-code Section PS S6. See “Top Console” on page 96. 3. Lower carriage fully and retract reach mechanism fully. 2. Drain hydraulic system. Remove top console. Turn key switch OFF and disconnect battery connector. © BT Prime-Mover Inc. See “Hydraulic Fluid” on page 399. Description 1 Tank. 4. Remove drive motor and brake assembly.1 6112 Hydraulic Tank Version no C-code T-code 000 RTX35/RTX45 Hydraulic Tank 1 2 Item No. 6.

Installation 1. Install hydraulic filter. 6. Disconnect hydraulic hose to the mast. 9. Plug the end to prevent contamination. 4. tilt chassis end of reservoir up. Remove hydraulic filter adapter Align Hose 2. Angle mast end of reservoir down and push forward to the frame. Pull reservoir back. 404 Return Service Manual 2001-03-15 . Let the chassis end of the reservoir drop straight down at this point. See “Bleeding Hydraulic System” on page 401. Bleed hydraulic system. 10. Reconnect battery connector. 8. Install hydraulic filter adapter.F-code Section C-code PS S6. 10. Install lift pump and motor assembly. Connect hoses to reservoir. 7. 2. Reconnect battery connector. To remove reservoir. Once the front of the reservoir has cleared the front chassis frame. Install top console. Install drive motor and brake assembly. Test operate truck. Fill hydraulic reservoir. 11. Turn key switch OFF and disconnect battery connector. Disconnect hydraulic hose to the control valve. 9. 5. 3. lift the reservoir out. away from the mast.1 Hydraulic Tank 6112 Version no T-code 000 RTX35/RTX45 7. 8. Plug ends to prevent contamination.

filter 4 Washer 11 U-gasket 5 Plate 12 Gasket. Return Description Item No. 2 3. 4 9 5.2 6131 Hydraulic Filter and Adapter Version no T-code 001 RTX35/RTX45 Hydraulic Filter and Adapter 7 13 11 8 1. tank 6 Gasket 13 Cap.F-code Section C-code PS S6. © BT Prime-Mover Inc. 6 12 10 Item No. Description 1 Screw 8 O-ring 2 Washer 9 Ring 3 Screw 10 Element. filter 7 Filter assembly Service Manual 2001-03-15 405 .

Removal NOTE! It is recommended that the hydraulic fluid be drained from the hydraulic tank prior to replacing the filter. 2. Install cap and filter assembly in hydraulic tank. Test operate truck.2. 1. Snap filter onto blue cover (13). Installation 1.1. 3. Check hydraulic fluid level and refill as needed. 7. Replace top console. Remove blue cover (13) on the filter adapter collar. 1. 6. Hydraulic Filter 1. Remove filter attached to the bottom of the blue cover by pulling straight down to snap it out of the latch. 406 Return Service Manual 2001-03-15 . 3.2 6131 Hydraulic Filter and Adapter Version no T-code 001 RTX35/RTX45 1. Turn key switch OFF and disconnect battery connector. 5. 4.F-code Section C-code PS S6. Return to service. Lower carriage fully to ensure all hydraulic pressure is relieved. 5. 4. 2. Reconnect battery connector. Remove top console (see page 96).

Installation 1. Reconnect battery connector. Return Service Manual 2001-03-15 407 . Hydraulic Filter Adapter 2. Install cap and filter. Bleed hydraulic system. Turn key switch OFF and disconnect battery connector. Check fill level fluid in the hydraulic tank.1.4 inch lb (50 N•m). 2. See “Top Console” on page 96. Test operate truck. 2. 10. Reconnect battery connector.F-code Section C-code PS S6. Removal 1. Clean all parts thoroughly. 8. See “Bleeding Hydraulic System” on page 401. Torque four mounting screws to 44. 2. Clean the mating surface of hydraulic tank. 3. Install top console.2. Align collar mounting holes with the hydraulic tank holes.2 6131 Hydraulic Filter and Adapter Version no 001 T-code RTX35/RTX45 2. 5. Turn key switch OFF and disconnect battery connector. 9. Remove blue cap and filter. Remove top console. 4. 7. © BT Prime-Mover Inc. 3. Remove four mounting screws attaching collar assembly to the plastic hydraulic tank. 6. 4.

2 6131 Hydraulic Filter and Adapter Version no T-code 001 RTX35/RTX45 408 Return Service Manual 2001-03-15 .F-code Section C-code 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 5 10 8 7 6 19 3 3 5 6 18 12 11 7 8 5 17 13 14 8 7 6 16 5 15 2 1 © BT Prime-Mover Inc.F-code Section PS S6. Return Service Manual 2001-03-15 409 .

3 Hydraulic Pump 6141 Version no T-code 000 RTX35/RTX45 Item No. Remove capscrews (19) and washers (18). Removal Remove hydraulic pump from pump motor. back-up 16 Body 7 Seal. driven 2 Pump Assembly 12 Flange. and spacer (4) to insure that the dual pump will be reassembled in the same manner. Secure unit in vise (use light clamping pressure on the ears of the front cover) with shaft end down. Description 1 Screw 11 Gear. 410 Return Service Manual 2001-03-15 . driven 6 Seal. dowel 15 Gear. covers (12. 1. Thoroughly clean outside of dual pump and air dry. Pump Disassembly CAUTION Overhaul pump only in a clean.) 2. drive 5 Pin. (See “Removal” on page 111. plate 17 End. 16). dust-free location. 2. drive 1. using clean tools and equipment. 17). cap 8 Bearing 18 Washer 9 Body 19 Screw 10 Gear. scribe a match mark on the replaced part.F-code Section C-code PS S6. Dirt or grit will damage the highly machined surfaces and will result in leakage or premature failure of the pump. mounting 3 O-ring 13 Seal. Description Item No. If the bodies or covers are replaced during overhaul. Scribe match mark on the bodies (9. shaft 4 Spacer 14 Gear. 3.

Separate body (16) from spacer (4).3 6141 Hydraulic Pump Version no 000 C-code T-code RTX35/RTX45 4. drive gear (10). take special note of the wear patterns on the bearing blocks (8) and body (16). The back static seal (3) may remain either with the body or the cover. and driven gear (15). 10. 8. Remove spacer (4). 7. Remove and discard back static seal (3). Remove and discard back static seal (3). Dowel pins (5) and the front static seal (3) may remain with either the body (16) or back cover (17). and driven gear (11). 5. Separate body (9) from front cover (12). drive gear (14). Return Service Manual 2001-03-15 411 . The bearing block will have somewhat heavier wear patterns on the inlet side. 9. Bearing Block Outlet Side (Discharge Pressure) Inlet Side (Suction) NOTE! During disassembly.F-code Section PS S6. Lift out the rear bearing block (8). 6. The large port whether in the body (16) or the rear cover (17) corresponds to the inlet side of the pump. Remove and discard front static seal (3). The bearing block will have somewhat heavier wear patterns on the inlet side. take special note of the wear patterns on the bearing blocks (8) and body (9). Lift out the rear bearing block (8). The inlet side of the body can be identified by the gear contact pattern in the gear bore. NOTE! During disassembly. Relate these patterns to the inlet and outlet side of the pump. The inlet side of the body can be identified by the gear contact pattern in the gear bore. Invert body (16) and lift out front bearing block (8). Separate rear cover (17) from body (16). The large port whether in the body (9) or the front cover (12) corresponds to the inlet side of the pump. Dowel pins (5) may remain with spacer (4). Relate these patterns to the inlet and outlet side of the pump. The back static seal (3) may remain either with the body or the cover. © BT Prime-Mover Inc.

12. Remove shaft seal (4) by prying it out with a large screwdriver. 13. 412 Return Service Manual 2001-03-15 . Invert front cover (12) with shaft seal up. CAUTION Care should be taken not to damage (gouge) the shaft seal bore because this will result in shaft seal leakage. Dowel pins (5) and the front static seal (3) may remain with either the body (9) or front cover (13).3 Hydraulic Pump 6141 Version no T-code 000 RTX35/RTX45 11. Invert body (9) and lift out front bearing block (8).F-code Section C-code PS S6. Remove and discard front static seal (3).

5. Wash all parts and dry thoroughly. If gear contact wear on low pressure side (inlet) exceeds 0. Remove anti extrusion seal (6) and pressure loading seal (7) from each bearing block and discard. Inspect bushings in each bearing block (8). replace pump. Inspect front and rear bearing blocks (8). replace pump. NOTE! A somewhat heavier wear pattern is normal on the low pressure (inlet) side of the bearing blocks (8). 2.F-code Section PS S6.3 6141 Hydraulic Pump Version no C-code T-code 000 RTX35/RTX45 3. lightly wipe and remove burr’s with suitable de-burring tool. Replace if scoring or uneven wear is observed.005 (0. 8 7 6 © BT Prime-Mover Inc. Replace bearing block if bushings are heavily scored or burned.127 mm) depth. If faces or journals are scored or worn. Inspect bodies for wear and scoring. Inspect gear journals and faces. Return Service Manual 2001-03-15 413 . If the body is usable. 3. Parts Inspection 1. There should be no heavy scoring on this area. 4. 6.

Drive Shaft Installation Tool (Bullet) 3. Pump Reassembly 1. Press seal until it is 0. Pack the area between the double lip of the seal with Lubriplate or equivalent grease. Face of Pilot Diameter Arbor press 0.0 mm) Seal Pressing Tool Front Cover (12) Shaft Seal (13) NOTE! The installation of new parts contained in the seal kit is recommended at each overhaul of the pump. Clamp front cover into vise so the seal ring groove is up.0 mm) below front surface. Install new shaft seal (13). Apply Lubriplate or equivalent to outer surface of drive shaft installation tool.15” (4.157 inch (4.3 Hydraulic Pump 6141 Version no T-code 000 RTX35/RTX45 4.F-code Section C-code PS S6. Shaft Seal 2. and 14. Apply a small amount of grease to the seal groove and install a new seal ring (3) into the groove. Seal kit parts consists of items 3. 7. 6. Place the front cover (12) on a flat plate with the shaft seal bore up. Insert tool (Bullet) into shaft seal from seal ring groove side of front cover Lubricate 414 Return Service Manual 2001-03-15 .

3 6141 Hydraulic Pump Version no 000 C-code T-code RTX35/RTX45 . Set the body (9) on the front cover (12). Return Service Manual 2001-03-15 415 . Insert the bearing block in the body. making sure that they are positioned properly. 5. Install a new load seal (7) and anti-extrusion seal (6) in the groove. Install spacer (4) matching the scribe marks. Place a small amount of grease in the seal groove on the rear bearing block (8). 7. Ensure the outside of the “W” seal is exposed to the discharge pressure. Install a new load seal (7) and anti-extrusion seal (6) in the groove. Apply a small amount of grease to the seal groove and install a new seal ring (3) into the groove. 11. matching the scribe marks on the body and front cover. If tool is not available. making sure that the load seal (7) and anti-extrusion seal (6) are positioned properly. Insert dowel pins (5) into the mating holes on the front cover (12). 8. Apply a small amount of grease to the dowel pins (5) and install into the body (9). 9. Place a small amount of grease in the seal groove on the front bearing block (8). Apply a small amount of grease to the dowel pins (5) and install into the spacer (4). making sure that the load seal (7) and anti-extrusion seal (6) are positioned properly. grease assemble being very careful not to cut seal (13). Remove spacer from vise and turn it around and place in vise.010 inch (0. Shaded area represents the “W” seal 4.F-code Section PS S6. Place a small amount of grease in the seal groove on the back bearing block (8). © BT Prime-Mover Inc. 10. Ensure the outside of the “W” seal is exposed to the discharge pressure. Apply a small amount of grease to the seal groove and install a new seal ring (3) into the groove. Outlet Side (Discharge Pressure) Inlet Side (Suction) 6. Install drive gear (10) and driven gear (11). Install a new load seal (7) and anti-extrusion seal (6) in the groove. Clamp spacer (4) into vise so the seal ring groove is up.25 mm). NOTE! Drive shaft installation tool wall thickness should be approximately 0. Insert the bearing block in the body.

Mount pump on truck and operate for two minutes at minimum pressure and one-quarter engine speed. With truck at idle speed. Increase discharge pressure to relief setting with control valve. No shaft seal leakage sufficient to form a drop is permissible. Testing 1. Torque to 42-46 ft-lbs (57-62 N•m). 12. 13. 416 Return Service Manual 2001-03-15 . Hold for five seconds and release. 2. 3.3 Hydraulic Pump 6141 Version no T-code 000 RTX35/RTX45 Insure outside of “W” seal is exposed to the discharge pressure. Repeat step 2 for three minutes at full pump speed.F-code Section C-code PS S6. 14. matching the scribe marks on the body (16) and rear cover (17). check pump and hydraulic system for leaks. Apply a small amount of grease to the seal groove in the rear cover (17). No external leakage is permissible. Install a new seal ring (3) into the groove. 5. Insert washers (18) and capscrew (19). Continue cycle for two minutes. Set the rear cover (17) onto the body (16). Repeat step 2 for three minutes at one-half pump speed. 4. Check that drive shaft turns with adjustable wrench without evidence of mechanical bind. 5.

58 mm) © BT Prime-Mover Inc. Installation 1. and Y13. Loosen hose clamp to remove return hose from reservoir. Disconnect the electrical wires from Y10.64 mm) wrench to loosen fittings on two smaller hoses. 7. Remove motor compartment rear door. 2. Apply thread locking compound to three mounting bolts.58 mm) wrench. Functions To Pump Y11 Dump Valve 4.F-code Section PS S6.58 mm) . Y12. To Reservoir WARNING Take precautions to prevent fluid from getting into the drive motor and/or brake assembly when removing fittings from control valve. 3. 8. Lower Y12 DIRA Y13 DIRB C-code T-code RTX35/RTX45 Control Valve 1. 6. Turn key switch OFF and disconnect battery connector.4 6211 Control Valve Version no 000 To Mast Y10 Lift and Prop. Mounting Bolt (one shown) 2. 5. Remove top console. Tighten using a 1/2 inch (13 mm) socket. with a 1-1/8 inch (28. Use a 13/16 inch (20. Loosen fittings on two large hoses. remove 3 bolts securing the control valve to bracket. To Aux. 3. Return Service Manual 2001-03-15 417 .Return hose to mast 1-1/8 inch (28. Removal 1. 2. Y11. toward the lift motor. Using a 1/2 inch (13 mm) socket.Control valve to reservoir . Attach hoses to control valve in the following order: .Control valve to lift pump 1-1/8 inch (28.

Install 90 degree fitting in the top port of control valve. Lower Y12 DIRA Y13 DIRB . If the reservoir needs to be replaced. tighten before installing the top hose. 418 Return Service Manual 2001-03-15 . Torque nut to 480 + 25 in. Install motor compartment rear door. then install remaining small hose. Hose with 90 degree fitting goes on the bottom.Two small hoses 13/16 inch (20. Remove return hose at reservoir. For large hoses. Install top console. lbs. Functions To Pump 6. 4. Connect the electrical wires from Y10. Y11 Dump Valve NOTE! To service either the drive motor or pump motor.64 mm) on the front of control valve. Y12. control valve may be removed from the bracket (leaving all hoses attached) and laid up over the reservoir. 5. and Y13. Y11. Lay hose over control valve and let the loose end drop into the operator compartment. (54 N•m).F-code Section C-code PS S6. 7. To Reservoir To Aux.4 Control Valve 6211 Version no T-code 000 RTX35/RTX45 To Mast Y10 Lift and Prop. finger tighten fittings until both ends are attached. leave the control valve on the bracket.

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 1 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.F-code Section PS S6. Return Service Manual 2001-03-15 419 .

seal (for item # 43) 25 Spring 43 Valve.F-code Section C-code PS S6. dampener ** 14 USIT-ring 4b Seal 29 Plug ** 18 Nut 29a Plug ** 20 Seal 30 Screw ** 31 Seal 17 Screw 35 Screw. seal (for item # 44) 26 Spring 44 Valve. check Kit. 15.4 Control Valve 6211 Version no T-code 000 RTX35/RTX45 Item No. 27 Sleeve 45 Spring ** 28 Ball 46 Ball. poppet. seal (for item # 40) 23 Guide spring 41 Valve. They are not serviceable individually. 29a. seal (for item # 41) 24 Piston 42 Body Kit. check Kit.O. Service Manual 2001-03-15 . 45. adjusting 32 Nut 18 Nut 36 Screw. control 2 Plug 3 O-ring 3 O-ring 13 Screw ** 4a O-ring 4 Insert 15 Spring ** 4b Seal 4a O-ring 16 Insert. Description Item No. manifold 21 Disc 39 Coil 22 Spring 40 Valve. 4 way 3 position Kit. 48. seal 38 Valve assembly. check ** 47 Plug ** 48 Plug ** 49 Plug ** 420 Return Seal Kit (Contains items below) Item No. valve mounting 33 Seal 19 Screw 37 Washer. Description Description 1 Valve assembly. 46. 16. 29. N. 30. flat 34 O-ring 20 Ring. 47. and 49 are shown for reference only. Individual Valve Seal Kits Proportional Pre-Pressure Relief Valve Kit (Contains items below) DBV Kit (Contains items below) ** Items 13.

Perform any procedures in a clean environment. Torque two screws to 15 ft-lb (20 N•m). Some spillage of hydraulic oil will occur. Proportional Pre-Pressure Reducing Valve. Replace if necessary. 3. it is advisable that the valve assembly be removed from the truck. Remove O-ring seal (3). 5. The SWR14 valve will separate from lift control valve assembly (1). The mast carriage must be fully lowered. © BT Prime-Mover Inc. 3. Hot oil under pressure may be present. and resealing. Inspect insert (4) and seals (4a and 4b). 4b): 1. 3. 4a. Valve Assembly SWR14 (Item 38) 1. 3. replacing piece parts. 2. Screw valve insert (4) out of block.F-code Section PS S6. Make sure all parts are cleaned before disassembly and kept clean during assembly. Install outer seal (20). Check piston in valve insert for smooth operation.2.4 6211 Control Valve Version no 000 C-code T-code RTX35/RTX45 3.1. Reverse procedure to assemble. 4. Make sure piston in valve insert operates smoothly when assembled. 6. Screw insert with seals into valve block. 2. Mount solenoid to valve block with three screws. Remove three screws and lift off twin solenoid block (2) from valve block. Inspect O-rings and replace if necessary. Repair WARNING When disassembling. 4. Remove two screws (36) and washers (37). Return Service Manual 2001-03-15 421 . (Items 3.

3. Use a light grease when assembling items 24 through 28. a calibrated pressure gauge capable of measuring 300 psi (2068 kPa) at mid-range is needed. Do not damage surface of dampening piston (24) or bore of valve seat.4. Setting Lift/Auxiliary Pressure Relief with a Rated Load Relief Pressure Test Port (beneath reservoir hose) NOTE! To set the system pressure. Items 17 and 18 can remain intact. The relief pressure test port is on the side of the control valve. near solenoid Y10. Turn adjuster screw until the load can be lifted. Check pressure setting with a pressure gauge. 422 Return Service Manual 2001-03-15 . Reverse procedure to assemble. 3. Inspect seal (20) for damage and replace if necessary. Pull out inner parts (21 to 28). to the right of hydraulic lines to reservoir and pump. During assembly make sure that the dampening piston operates smoothly. The pressure at rated load should be the truck capacity weight +10%. Be sure locknut is secure when adjustment is complete. Lift a rated load (maximum capacity listed on the specification plate plus 10%).3.4 Control Valve 6211 Version no T-code 000 RTX35/RTX45 3. The lift/auxiliary pressure relief adjusting screw is located on top of the main control valve. Remove screw (19). Relief Valve Adjusting Screw 2. 1.F-code Section C-code PS S6. 4. Turn adjuster screw counter-clockwise to reduce pressure and clockwise to increase pressure. 3. Pressure Limiting Valve Assembly (Items 17 to 28) 1. 4. Loosen locknut (18) so adjuster screw (17) can be turned. 2.

Refer to paragraph 3. Torque screw to 6 ft-lb (8 N•m). Loosen locknut (18) and remove adjuster screw (17). Loosen sealed locknut (32) so adjusting screw (35) can be turned. and 34) 1. that to the increase NOTE! If the lowering speed is to fast. 3. Adjust screw counter-clockwise lowering rate of speed.F-code Section PS S6. 14. insert (16) for damage or 4. Remove screw (30) and pull out spring (45) with check ball (46). Check damping contamination. The spring (15) is inserted inside screw. Return Service Manual 2001-03-15 423 . 5. Hydraulic Lowering Rate Adjustment 1.4 6211 Control Valve Version no 000 C-code T-code RTX35/RTX45 3. 5. tighten sealed locknut (32).5.1 for items 3. 32. Inspect for contamination or damage. 20. Install seal (14) and assemble. 31.6. 18. Remove screw (13). Recondition Seal Kit for Lift/ Lower Valve (Items 3. Remove screw (19) and replace seal (20). Replace locknut. The maximum lowering rate for the RTX35 with a rated load is 80 fpm and 95 fpm for the RTX45. 4a. 33. it will cause the safety valves on the lift cylinder to close and/or cause the columns to miss stage. 3. 2. 4b. 4. 6. After adjustment is complete. and 4b. 3. Adjust screw clockwise to decrease lowering rate of speed. 4a. Take care that the spring (15) stays inside screw (13). 2. 7. © BT Prime-Mover Inc.

12. To replace O-rings (34). Remove plug (29a) and replace seal (20). 424 Return Service Manual 2001-03-15 . Remove opposite screw (49) and replace seal (20).4 Control Valve 6211 Version no T-code 000 RTX35/RTX45 8. Screw plug in two turns.F-code Section C-code PS S6. 11. 13. 9. Remove plug (29) and replace seal (20). 15. Replace seal (31). The maximum torque value of screw (30) is 6 ft-lb (8 N•m). 10. refer to Valve Assembly SWR 14. Install plug and tighten items 29a and 48. Remove plug (47) and replace seal (33). Screw plug in two turns. Replace locknut. Remove plug (48) and replace seal (20). Install plug. Loosen locknut (32) and remove adjustment screw (35). Ensure during assembly that spring (45) and ball (46) are installed as shown in the illustration on page 419. 14. Install screw and tighten items 29 and 49.

seal 10 Piston 3 Cylinder tube. 2 Port 12 Rod. 1 Port 11 Ring. retainer 4 Cylinder tube.5 6610 Staging Cylinder. Description 1 Screw 9 Ring. 3 Stage 7 3 1 6 8 5 2 4 9 10 11 12 13 16 15 9 14 Item No.F-code PS Section C-code S6. 3 Stage Version no T-code 000 RTX35/RTX45 Staging Cylinder. wear 2 Washer. cylinder 5 Plugger assembly 13 O-ring 6 Spring 14 Bearing 7 Plug 15 Seal. Return Description Item No. rod 8 O-ring 16 Wiper Service Manual 2001-03-15 425 . © BT Prime-Mover Inc.

Clean exterior of lift cylinder. 1. 2.5 6610 Staging Cylinder. 3 Stage Version no T-code 000 RTX35/RTX45 1. If both sides are not blocked. Removal 1. and then only with effective chip-guarding and personal protective equipment. Lift mast so inner column is raised approximately 12 inches (305 mm). Disassembly 1. and wear ring (9) from bearing (14). 4. Fully extend cylinders to inspect cylinder rod (12) for gouges or pits. then the cylinder must be removed for repair. Remove bolts from the top end of the staging cylinder rods. Securely block the mast. using 4 x 4 inch (102 x 102 mm) blocks under each side of inner columns. WARNING When blocking the mast columns to prevent lowering. always block both sides of the column. 2.2. If gouges or pits are detected. 426 Return Service Manual 2001-03-15 . truck could tip on its side. WARNING Compressed air used for cleaning MUST be reduced to less than 30 psi (206 kPa). Lower cylinder rods hydraulically. Park truck on a level surface and apply the brake. Use care NOT to damage the inside of the bearing. rod wiper (16). 5. Remove and discard all seals. rod seal (15).1.F-code Section C-code PS S6. Remove cylinder rod (12) from cylinder tube. 3. Staging Cylinder Repair 1.

and electric cables. unless cylinder was removed for rod repair. The “lip” of the wiper must face outward. Assembly 1. seals. chains. Install lifting gear. and rod wiper (16) in gland (14). It is not necessary to replace wear ring (9). Install new wear ring (9). hoses. 2. 1.F-code PS Section C-code S6.5 6610 Staging Cylinder.4. Return Service Manual 2001-03-15 427 . Installation 1. Test for proper operation. 3 Stage Version no 000 T-code RTX35/RTX45 1. © BT Prime-Mover Inc.3.

3 Stage Version no T-code 000 RTX35/RTX45 428 Return Service Manual 2001-03-15 .F-code Section C-code PS S6.5 6610 Staging Cylinder.

seal 429 .6 6620 Freelift Cylinder. 2 Screw 10K O-ring 3 Tube cylinder 11K Back-up ring 4 Ring. 1 7K Return Description K Rod cylinder Bearing Kit. 3 Stage Version no T-code 000 RTX35/RTX45 Freelift Cylinder. seal 8 © BT Prime-Mover Inc.F-code PS Section C-code S6. retainer 12 5 Plunger assembly 13K Ring. 3 Stage K 2 1 9 3 15 8 14 13 7 12 6 11 5 10 4 Seal Kit Contains Items Marked with “K” Item No. guide 6 Spring 14K Seal Ring. guide 15K Wiper Service Manual Piston 2001-03-15 9 Description Washer. Item No.

meaning there are NO seals on the lower end of cylinder rod.F-code Section C-code PS S6. 2. Lower cylinder so chains. 3. 4. Disconnect battery. Fully extend cylinder to inspect cylinder rod (9) for gouges or pits. The lift cylinder can be resealed without removal from truck. Remove chains. 5. WARNING When blocking mast columns to prevent lowering. then cylinder must be removed for repair.6 6620 Freelift Cylinder. 1. If gouges or pits are detected. Freelift Cylinder Repair 1. Removal 1.1. and electric cables are loose. hoses. Securely block carriage/reach to prevent lowering. the truck could tip over on its side. and electric cables from lifting gear. Make sure all parts are cleaned before disassembly and kept clean during assembly. hoses. NOTE! Perform procedures in a clean environment. Otherwise. Park truck on a level surface and apply brake. Lift carriage/reach approximately 6 inches (152 mm). 430 Return Service Manual 2001-03-15 . always block both sides of the column. 3 Stage Version no T-code 000 RTX35/RTX45 The lift cylinders are positive displacement type.

Return Service Manual 2001-03-15 431 . 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. 3 Stage Version no 000 T-code RTX35/RTX45 6. Remove lifting gear from cylinder rod.6 6620 Freelift Cylinder. 7.F-code PS Section C-code S6. © BT Prime-Mover Inc. Clean exterior of lift cylinder.

6 6620 Freelift Cylinder.F-code Section C-code PS S6. Install lifting gear. 1. seals. Assembly 1. Remove and discard packing. and bearing retainer from bearing (12). 2. 3 Stage Version no T-code 000 RTX35/RTX45 1. Install a new bearing. 2. The “lip” of the wiper must face outward. unless the rod was removed for repair. hoses. chains.4. and rod wiper in gland. back-up ring. and electric cables. rod wiper.2. 1.3. Disassembly 1. Remove bearing (12) from cylinder tube (3). O-ring. 432 Return Service Manual 2001-03-15 . Installation 1. It is not necessary to replace wear ring (7). Test for proper operation. Use care NOT to damage inside of bearing (12). Connect battery. 3.

7 6650 Reach Cylinder (RTX35) Version no 001 Section T-code RTX35/RTX45 Reach Cylinder (RTX35) K 6 23 7 8 22 9 10 11 12 20 19 18 17 16 15 13 14 21 Seal Kit Contains Items Marked with “K” 1 2 5 1 4 3 Forks Direction © BT Prime-Mover Inc. Return Service Manual 2001-03-15 433 .F-code PS C-code S6.

7. Raise reach assembly above full freelift. Removal 1. Block and chain reach mechanism to prevent movement of reach mechanism. cylinder 23 Grease Fitting Wiper K Kit. back-up 5 Left reach cylinder assembly 13 Nut 21K Seal. Relieve pressure on reach cylinders. seal 8K Retainer 16K 1. Extend reach about 1/2 to 3/4 of total reach. set 22 O-Ring 7 Left tube cylinder 15 Yoke. roll 9K Ring. 2. clevis 10K 3 Pin. 5. 6. guide 2 Pin. Remove reach cylinder from truck. Remove hoses from reach cylinder. 3. Item No. rod 6 Right tube cylinder 14 Screw. 8.F-code Section C-code PS S6. 434 Return Service Manual 2001-03-15 . clevis 4 Item No.7 6650 Reach Cylinder (RTX35) Version no T-code 001 RTX35/RTX45 Item No. guide Right reach cylinder assembly 12 Rod assembly 20K Ring. 4. Park truck on a level surface and apply brake. Description Description 1 Pin. Remove front cylinder mounting pins (3). Description 17 Bearing Ring. sealing 18K Seal rod 11K O-Ring 19K Ring. Remove rear cylinder mounting pins (2).

1. 7. Remove and discard all seals and rod wiper (16). Disassembly NOTE! Perform procedures in a clean environment.7 6650 Reach Cylinder (RTX35) Version no 001 T-code RTX35/RTX45 2. Put base end of cylinder in a vise equipped with soft jaws.F-code PS Section C-code S6. Before disassembly. It will not be necessary to remove bearings unless they are found to be unfit for further service. Remove rod assembly (12). WARNING Compressed air used for cleaning MUST be reduced to less than 30 psi (206 kPa). Remove bearing retainer (8) and bearing (22) by rotating bearing from cylinder tube (6 or 7) with a spanner wrench. Be sure all hydraulic fluid has been removed from cylinder. clean the exterior of reach cylinder in a cleaning solution to remove all contamination. 2. 4. and then only with effective chip-guarding and personal protective equipment. Stroking piston rod will help force fluid out. 6. 5. 3. © BT Prime-Mover Inc. Make sure all parts are cleaned before disassembly and kept clean during assembly. Return Service Manual 2001-03-15 435 . Inspect mounting bearings (22) located at the base end of cylinders.

or evidence of unusual wear. 3. Look for gouges. scratches. Inspection WARNING Compressed air used for cleaning MUST be reduced to less than 30 psi (206 kPa). Carefully clean all parts in a cleaning solution and position parts on a clean work surface. Check cylinder bore for any damage.7 6650 Reach Cylinder (RTX35) Version no T-code 001 RTX35/RTX45 3. Check rod assembly (12) for damage. corrosion. 2. and then only with effective chip-guarding and personal protective equipment. Parts with deep gouges or pitted surfaces will require replacement. 1. Deeper damage will require replacement of piston rod assembly (12).F-code Section C-code PS S6. Minor surface damage can be repaired by the use of fine abrasion cloth or stoning. Make sure threads on rod are free of damage. Be extremely careful not to remove chrome plating. 436 Return Service Manual 2001-03-15 .

Return Service Manual 2001-03-15 437 . Use care so the seals are not nicked or cut upon installation. The “lip” of the wiper must face outward. Check installation by making sure piston rod assembly moves smoothly within tube assembly without binding. 5. Install new O-rings and rod wiper (16) in bearing assembly (17). 3. 2. 8. Install bearing assembly into cylinder tube.7 6650 Reach Cylinder (RTX35) T-code RTX35/RTX45 4. If necessary.F-code PS Version no 001 Section C-code S6. © BT Prime-Mover Inc. Apply clean hydraulic fluid to piston rod assembly. 4. Install rod assembly (12). back-up ring (20). Coat the inside of cylinder tube and bearing assembly with clean fluid. Install retainer (8). replace rod assembly (12) with new. Assembly 1. 7. and O-rings (21) on bearing (17). 6. Install new bearing seals (18 & 19). Carefully slide bearing assembly (17) onto cylinder rod assembly (12). Be sure rod end does not cut or nick wiper or packing upon installation.

5. 2. Connect correct hydraulic hoses to reach cylinders. Connect battery.7 6650 Reach Cylinder (RTX35) Version no T-code 001 RTX35/RTX45 5. CAUTION DO NOT use your hands to check for hydraulic leakage. Installation 1. After running the hydraulic system. 438 Return Service Manual 2001-03-15 . Use a piece of cardboard or paper to search for leaks. 8. Lower reach assembly. Raise reach assembly to full freelift height. check and fill the hydraulic tank with new clean oil. Install reach cylinder rear mounting pins (2). Check operation of the whole hydraulic system. 7.F-code Section C-code PS S6. Install reach cylinder front mounting pins (3). Keep hands and body away from pinholes and nozzles which eject fluids under high pressure. Secure mounting pins with roll pins. 6. Tighten all connections before applying pressure. Fill hydraulic tank with new clean oil. Remove blocking and chains. 4. Relieve pressure before disconnecting hydraulic or other lines. Escaping fluid under pressure can penetrate the skin causing serious injury. 3. Operate reach to remove air from hydraulic hoses. Secure mounting pins with roll pins.

F-code PS Section C-code S6. Return Service Manual 2001-03-15 439 .7 6650 Reach Cylinder (RTX45) Version no T-code 001 RTX35/RTX45 Reach Cylinder (RTX45) K 11 12 28 13 14 27 15 16 17 25 24 23 22 21 20 18 19 Seal Kit Contains Items Marked with “K” 26 5 4 6 7 10 1 9 3 2 5 4 8 7 6 Forks Direction © BT Prime-Mover Inc.

7 6650 Reach Cylinder (RTX45) Version no T-code 001 RTX35/RTX45 Item No. Park truck on a level surface and apply brake. 2. Relieve pressure on reach cylinders. rod 4 Screw 14K Ring. Remove reach cylinder from truck. 5. washers (5 and 6) and cotter pins (7) securing front cylinder mounting pins in position. guide 5 Lockwasher 15K Ring. 3. 6. Remove screws (4). cotter 17 Rod assembly 27 Bearing 8 Pin 18 Nut 28 Fitting. 7. 4. Description 1 Spacer 11 Right tube cylinder 21K Wiper 2 Right reach cylinder assembly 12 Left tube cylinder 3 Left reach cylinder assembly 13K Retainer 23K Seal. Removal 1. Raise reach assembly above full freelift. washers (5 and 6) and cotter pins (7) securing rear cylinder mounting pins in position. flat 16K O-ring 26K O-Ring 7 Pin. set K Kit. cylinder 22 Bearing 1. Extend reach about 1/2 to 3/4 of total reach. Block and chain reach mechanism to prevent movement of reach mechanism. Seal 10 Pin 20 Yoke. sealing 25K Ring. guide 24K Ring.F-code Section C-code PS S6. Remove screws (4). Description Description Item No. grease 9 Spacer 19 Screw. Remove front cylinder mounting pins (8). Item No. 8. Remove rear cylinder mounting pins (10). 440 Return Service Manual 2001-03-15 . Remove hoses from reach cylinder. back-up 6 Washer.

5. Remove bearing retainer (13) and bearing (22) by rotating bearing from cylinder tube (11 or 12) with a spanner wrench. and then only with effective chip-guarding and personal protective equipment. 7. 6. 3. WARNING Compressed air used for cleaning MUST be reduced to less than 30 psi (206 kPa). Disassembly NOTE! Perform procedures in a clean environment. Be sure all hydraulic fluid has been removed from the cylinder. © BT Prime-Mover Inc. Make sure all parts are cleaned before disassembly and kept clean during assembly. Return Service Manual 2001-03-15 441 .7 6650 Reach Cylinder (RTX45) Version no 001 T-code RTX35/RTX45 2. 2. 1. 4. Stroking piston rod will help force fluid out. It will not be necessary to remove bearings unless they are found to be unfit for further service. Remove rod assembly (17). Inspect mounting bearings (27) located at the base end of cylinders. Remove and discard all seals and rod wiper (21). Before disassembly. clean the exterior of reach cylinder in a cleaning solution to remove all contamination. Put base end of cylinder in a vise equipped with soft jaws.F-code PS Section C-code S6.

F-code Section C-code PS S6. 3. Carefully clean all parts in a cleaning solution and position them on a clean work surface. Check rod assembly (17) for damage. Make sure threads on rod are free of damage. Deeper damage will require replacement of piston rod assembly. 1. Check cylinder bore for any damage. Look for gouges. Inspection WARNING Compressed air used for cleaning MUST be reduced to less than 30 psi (206 kPa). scratches. Minor surface damage can be repaired by the use of fine abrasion cloth or stoning.7 6650 Reach Cylinder (RTX45) Version no T-code 001 RTX35/RTX45 3. Parts with deep gouges or pitted surfaces will require replacement. Be extremely careful to not remove chrome plating. and then only with effective chip-guarding and personal protective equipment. or evidence of unusual wear. 442 Return Service Manual 2001-03-15 . corrosion. 2.

Carefully slide bearing assembly (22) onto cylinder rod assembly (17). 3. Return Service Manual Install retainer (13). 2. 7. If necessary. Be sure rod end does not cut or nick wiper or packing upon installation.F-code PS Version no 001 Section C-code S6. Install piston and cylinder rod assembly into cylinder tube (11 or 12). 4. back-up ring (25). Assembly 1. The “lip” of the wiper must face outward. and O-rings (26) on bearing assembly. Use care so seals are not nicked or cut upon installation. Check installation by making sure piston rod assembly moves smoothly within tube assembly without binding. Install rod assembly (17).7 6650 Reach Cylinder (RTX45) T-code RTX35/RTX45 4. 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. 6. 5. Coat the inside of cylinder tube and bearing assembly with clean fluid. Install bearing assembly into cylinder tube. Apply clean hydraulic fluid to piston rod assembly. 9. 8. replace rod assembly (17) with new. 2001-03-15 443 . © BT Prime-Mover Inc. Install new bearing seals (23 & 24). Install new rod wiper (21) in bearing assembly.

washers (5 and 6) and screws (4). Relieve pressure before disconnecting hydraulic or other lines. 6. Tighten all connections before applying pressure. 7. Secure mounting pins in position with cotter pins (7).7 6650 Reach Cylinder (RTX45) Version no T-code 001 RTX35/RTX45 5. CAUTION DO NOT use your hands to check for hydraulic leakage. 2. Secure mounting pins in position with cotter pins (7). 3. check and fill hydraulic tank with new clean oil.F-code Section C-code PS S6. Check operation of the whole hydraulic system. Install reach cylinder front mounting pins (8). 8. Installation 1. Operate reach to remove air from hydraulic hoses. washers (5 and 6) and screws (4). Connect correct hydraulic hoses to reach cylinders. 444 Return Service Manual 2001-03-15 . Fill hydraulic tank with new clean oil. Raise reach assembly to full freelift height. Connect battery. Escaping fluid under pressure can penetrate the skin causing serious injury. 5. Lower reach assembly. Install reach cylinder rear mounting pins (10). 4. Keep hands and body away from pinholes and nozzles which eject fluids under high pressure. Use a piece of cardboard or paper to search for leaks. Remove blocking and chains. After running the hydraulic system.

1 Tilt cylinder assembly 6 Seal 11 O-ring 2 Bushing 7 Bearing. cap 9 O-ring 14 Tube. Inc. back-up 3 Retainer. Return Item No.F-code Section PS C-code S6. Description 445 . cylinder Service Manual Description 2001-03-15 Item No. back-up 13 Retainer 4 Screw.8 6660 Tilt Cylinder (RTX35) Version no T-code 001 RTX35/RTX45 Tilt Cylinder (RTX35) 13 14 11 7 5 8 9 12 10 6 1 2 3 4 © BT Prime-Mover. cylinder 8 Ring. cylinder 12 Ring. cylinder 5 Wiper 10 Rod. Description Item No.

Remove strap (3) and cap screws (4) that secure the cylinder to the fork frame. 7. Remove tilt cylinder (1) from truck. Park truck on a level surface and apply the brake. Relieve pressure on tilt cylinder (1). 446 Return Service Manual 2001-03-15 . 6. 3. 4. 2.F-code Section PS S6. Pivot carriage/reach upward and block to prevent the fork frame from lowering. Raise reach approximately 12 inches (305 mm) and block so reach will not lower. Remove hydraulic hoses from tilt cylinder (1).8 Tilt Cylinder (RTX35) Version no T-code 001 RTX35/RTX45 C-code 6660 1. Removal 1. 5.

Remove bearing retainer (13) and cylinder bearing (7) from the cylinder tube. © BT Prime-Mover. clean the exterior of tilt cylinder (1) in a cleaning solution to remove all contamination. Before disassembly. 8. Be sure all hydraulic fluid has been removed from the cylinder. NOTE! Perform procedures in a clean environment. Return Service Manual 2001-03-15 447 . Disassembly WARNING Compressed air used for cleaning MUST be reduced to less than 30 psi (206 kPa). and piston seals. 6. 3. 5.8 6660 Tilt Cylinder (RTX35) T-code RTX35/RTX45 2. Make sure all parts are cleaned before disassembly and kept clean during assembly. and then only with effective chip-guarding and personal protective equipment. 1. Inc. 11. 9. Put the base end of the cylinder in a vise equipped with soft jaws. Stroking the piston rod will help force the fluid out. 6. It will not be necessary to remove bushings unless they are found to be unfit for further service.F-code PS Version no 001 Section C-code S6. Remove and discard all seals and rod wiper (5. 4. rod (10). seals. rings. 2. and 12). 7. Inspect mounting bushings (2) located at both ends of the cylinder. Remove bearing assembly.

Deeper damage will require replacement of the piston rod assembly. scratches. Inspection WARNING Compressed air used for cleaning MUST be reduced to less than 30 psi (206 kPa). Minor surface damage can be repaired by the use of fine abrasion cloth or stoning. or evidence of unusual wear. Check piston rod (10) for damage. 2. 1.8 Tilt Cylinder (RTX35) Version no T-code 001 RTX35/RTX45 C-code 6660 3. Be extremely careful not to remove the chrome plating. Carefully clean all parts in a cleaning solution and position parts on a clean work surface. and then only with effective chip-guarding and personal protective equipment. Check cylinder bore for any damage. Parts with deep gouges or pitted surfaces will require replacement. Look for gouges. corrosion.F-code Section PS S6. 448 Return Service Manual 2001-03-15 . 3. 4. Check threaded section of the cylinder tube to be sure the threads have not been damaged.

back-up ring. 10. Install new packing and rod wipers in the bearing assembly. Be sure rod end does not cut or nick wiper or packing upon installation. Install new bearing seals. Install new piston seals on the piston. Install bearing assembly into cylinder barrel. Inc. Install piston and rod into cylinder barrel. Install piston on the rod. 5. and retainer (13) on the bearing assembly. Return Service Manual 2001-03-15 449 . 9.8 6660 Tilt Cylinder (RTX35) T-code RTX35/RTX45 4. Use care so seals are not nicked or cut upon installation. 2. Carefully slide bearing assembly on piston rod. © BT Prime-Mover. 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. Assembly 1. 3. 7. The “lip” of the wiper must face outward. Install cylinder bearing (7) and bearing retainer (13). 8. 4. Coat the inside of cylinder barrel and bearing assembly with clean fluid.F-code PS Version no 001 Section C-code S6. Apply clean hydraulic fluid to piston rod assembly. 6. Check installation by making sure piston rod assembly moves fairly easy within barrel assembly without binding.

F-code Section PS S6.8 Tilt Cylinder (RTX35) Version no T-code 001 RTX35/RTX45 C-code 6660 5. Secure with four cap screws (4). 8. Connect battery. 6. Tighten all connections before applying pressure. WARNING DO NOT use your hands to check for hydraulic leakage. Keep hands and body away from pinholes and nozzles which eject fluids under high pressure. 4. Properly connect correct hydraulic hoses to the front and rear of tilt cylinder. Relieve pressure before disconnecting hydraulic or other lines. 7. Escaping fluid under pressure can penetrate the skin causing serious injury. Fill hydraulic tank with new clean oil. Install mounting straps (3). Installation 1. 5. Use a piece of cardboard or paper to search for leaks. check and fill the hydraulic tank with new clean oil. Remove blocking and chains. 3. Operate tilt to remove air from hydraulic hoses and check operation of the whole hydraulic system. 2. Install cylinder on reach front frame. After running the hydraulic system. 450 Return Service Manual 2001-03-15 .

cylinder 2 Bushing 7 Seal 12 O-ring 3 Retainer. cylinder 8 Bearing. Inc.F-code Section PS C-code S6. back-up 14 Retainer 5 Screw. back-up 4 Lockwasher 9 Ring.8 6660 Tilt Cylinder (RTX45) Version no T-code 001 RTX35/RTX45 Tilt Cylinder (RTX45) 14 15 13 12 9 8 6 11 10 7 5 4 1 2 3 © BT Prime-Mover. Return Item No. 1 Tilt cylinder assembly 6 Wiper 11 Rod. Description Item No. cap 10 O-ring 15 Tube. cylinder 13 Ring. Description 451 . cylinder Service Manual Description 2001-03-15 Item No.

Remove hydraulic hoses from tilt cylinder (1). 4. 5. Remove cylinder retainers (3). 452 Return Service Manual 2001-03-15 . Park truck on a level surface and apply brake. Raise reach approximately 12 inches (305 mm) and block so reach will not lower. 3.F-code Section PS S6.8 Tilt Cylinder (RTX45) Version no T-code 001 RTX35/RTX45 C-code 6660 1. Removal 1. 6. 2. Remove tilt cylinder (1) from truck. Pivot carriage/reach upward and block to prevent carriage/reach from lowering. 7. Relieve pressure on tilt cylinder (1). and cap screws (5) that secure cylinder to carriage/ reach. lockwashers (4).

5. Before disassembly. Disassembly WARNING Compressed air used for cleaning MUST be reduced to less than 30 psi (206 kPa). 7. Be sure all hydraulic fluid has been removed from cylinder. Put base end of cylinder in a vise equipped with soft jaws. 1. Remove and discard all seals and rod wiper (6. Remove bearing retainer (14) and cylinder bearing (8) from cylinder tube. 7. © BT Prime-Mover. rod (11). 3. Return Service Manual 2001-03-15 453 . 2.F-code PS Version no 001 Section C-code S6. 9. It will not be necessary to remove them unless they are found to be unfit for further service. and 13). seals. 12. Stroking piston rod will help force fluid out. rings. Remove bearing assembly. 6. Make sure all parts are cleaned before disassembly and kept clean during assembly. and piston seals. 4. clean the exterior of tilt cylinder (1) in a cleaning solution to remove all contamination. Inc. and then only with effective chip-guarding and personal protective equipment. 10. Inspect mounting bushings (2) located at both ends of cylinder.8 6660 Tilt Cylinder (RTX45) T-code RTX35/RTX45 2. NOTE! Perform procedures in a clean environment.

Look for gouges.8 Tilt Cylinder (RTX45) Version no T-code 001 RTX35/RTX45 C-code 6660 3. scratches. 1. Check cylinder bore for any damage. Check piston rod (11) for damage. Be extremely careful to not remove the chrome plating. and then only with effective chip-guarding and personal protective equipment. or evidence of unusual wear. Parts with deep gouges or pitted surfaces will require replacement. Check threaded section of cylinder tube to be sure threads have not been damaged. corrosion. 454 Return Service Manual 2001-03-15 . Inspection WARNING Compressed air used for cleaning MUST be reduced to less than 30 psi (206 kPa). 4.F-code Section PS S6. Carefully clean all parts in a cleaning solution and position them on a clean work surface. Minor surface damage can be repaired by the use of fine abrasion cloth or stoning. 2. 3. Deeper damage will require replacement of piston rod assembly.

Check installation by making sure piston rod assembly moves fairly easy within the barrel assembly without binding. Install cylinder bearing (8) and bearing retainer (14). Use care so seals are not nicked or cut upon installation. 7. © BT Prime-Mover. 6. Install bearing assembly into cylinder barrel. Install piston on rod. 5. 9. Install new bearing seals and back-up ring on bearing assembly. Install piston and rod into cylinder barrel. Apply clean hydraulic fluid to piston rod assembly. Assembly 1. 8. Inc. Coat the inside of cylinder barrel and bearing assembly with clean fluid. The “lip” of the wiper must face outward.8 6660 Tilt Cylinder (RTX45) T-code RTX35/RTX45 4. 10. Install new piston seals on piston. Carefully slide bearing assembly on piston rod. 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. 2. 4. Install new packing and rod wipers in bearing assembly. Return Service Manual 2001-03-15 455 .F-code PS Version no 001 Section C-code S6. 3. Be sure rod end does not cut or nick wiper or packing upon installation.

Keep hands and body away from pinholes and nozzles which eject fluids under high pressure.F-code Section PS S6. Remove blocking and chains. Secure with four lockwashers (4) and cap screws (5). Install cylinder on reach front frame.8 Tilt Cylinder (RTX45) Version no T-code 001 RTX35/RTX45 C-code 6660 5. 4. Use a piece of cardboard or paper to search for leaks. Install cylinder retainers (3). Fill hydraulic tank with new clean oil. 8. Tighten all connections before applying pressure. 6. 7. check and fill hydraulic tank with new clean oil. Installation 1. Escaping fluid under pressure can penetrate the skin causing serious injury. Operate tilt to remove air from hydraulic hoses and check operation of the whole hydraulic system. 456 Return Service Manual 2001-03-15 . Connect battery. 5. Properly connect correct hydraulic hoses to the front and rear of tilt cylinder. WARNING DO NOT use your hands to check for hydraulic leakage. 2. After running the hydraulic system. Relieve pressure before disconnecting hydraulic or other lines. 3.

F-code PS Section C-code S7. Return 4 5 17 19 Service Manual 2001-03-15 39 457 . 3 Stage (RTX35) Version no T-code 000 RTX35/RTX45 Mast. 3 Stage (RTX35) 33 27 32 34 5 6 34 35 8 2 28 29 30 31 28 3 4 1 5 10 9 6 3 1 7 4 11 22 14 12 13 15 3 26 14 21 20 15 4 3 23 6 18 5 38 36 16 6 37 36 17 40 25 24 © BT Prime-Mover Inc.0 7110 Mast.

cap 11 Freelift cylinder assembly 25 Screw. cap 39 Shaft.F-code Section PS S7. hydraulic 30 Bearing. and electrical 13 Pin.0 Mast. inner 4 Pin. hydraulic. button head 22 Sheave 36 Spacer 9 Column. 3 Stage (RTX35) Version no T-code 000 RTX35/RTX45 Item No. shim Return Service Manual 2001-03-15 . Intermediate 32 Lockwasher 5 Shim 19 Bracket 33 Screw. inner 23 Screw. Staging lift 16 Line. 458 C-code 7110 Description Item No. cap 31 Race. Description Item No. roller 3 Pin. grease 7 Staging cylinder assembly 21 Lockwasher 35 Shaft 8 Screw. chain 2 Chain. hose 10 Chain. cap 37 Sheave. outer 40 Sheave. cotter 17 Screw. cotter 27 Shaft 14 Nut 28 Washer. Description 1 Anchor. flat 38 Screw. jam 29 Sheave. cap 6 Bearing 20 Screw. anchor 26 Column. chain 15 Nut. chain 18 Column. sheave 12 Pin. cap 34 Fitting. Free lift 24 Washer.

Thoroughly clean off all outside dirt around the mast roller bearings. 3 Stage (RTX35) T-code RTX35/RTX45 1. Return Service Manual 2001-03-15 459 . 8. Lower carriage down through the inner column to expose bearings. Remove shims as required if tight spots are encountered where an assembler cannot move the carriage smoothly. Remove battery from truck. Determine amount of shims required. Check bearing shimming as carriage is raised. If the truck is not blocked. Install under bearings. Hydraulically lift up inner column enough to remove reach carriage assembly.F-code PS Version no 000 Section C-code S7. Attach a hoist to the top of carriage assembly. it could tip on its side. Park the truck on a level surface and make sure all wheels are blocked to prevent accidental movement. Pry carriage to one side and slip shims between bearings and web on the column. Turn key switch OFF and disconnect battery connector. Shimming Carriage with Mast on Truck WARNING Block all wheels to prevent truck from rolling. electrical cable. and hydraulic hoses. 1. always block both sides of the column. Raise carriage up through the inner column as far as it will go under normal operation. Divide shims as equally as possible between the two bearings. 2. Remove bearings to install shims behind the bearings.0 7110 Mast. 7. Add shims by hand until no more can be added. This will allow removal of lift chain anchor pins. 6. Hoist to loosen lift chains. Check for excessive bearing clearance with the © BT Prime-Mover Inc. 4. 3. WARNING When blocking the mast columns to prevent lowering. 5. Jack truck up (see “Safe Jacking Procedure” on page 64).

chains are to be free of twists and adjusted for equal tension with adjusting nuts (wheel nuts) and locknuts (jam nuts) torqued to 200 ft-lb (271 N•m).030 inch (0. Check operation first with no load.030 inch (0.F-code Section PS S7. 3 Stage (RTX35) Version no T-code 000 RTX35/RTX45 C-code 7110 carriage in the fully lowered position.76 mm). 9. Pry carriage to one side and check with a 0. Remove hoist from carriage and test operation of unit. Maximum clearance must not exceed 0.030 inch (0. Check for excessive bearing clearance with the carriage in fully raised position.0 Mast. lift chain anchor pins.03125 inch (0.030 inch (0.8 mm) 10.76 mm). 460 Return Service Manual 2001-03-15 .76 mm) shim. Pry the carriage to one side and check with a 0. Lower carriage to install hydraulic hoses. When installing lift chains. Chains are to be centered on the sheave within 0.76 mm) shim. Maximum clearance must not exceed 0. and electrical cable. then with a capacity rated load.

8. always block both sides of the column. Return Service Manual 2001-03-15 461 . 4.F-code PS Version no 000 Section C-code S7. Disconnect electric wiring harness located by the emergency disconnect. and hydraulic hoses. © BT Prime-Mover Inc. electrical cable. 6. Park the truck on a level surface and make sure all wheels are blocked to prevent accidental movement. Hydraulically lift up inner column enough to remove reach carriage assembly. Hoist to loosen lift chains. If truck is equipped with a light and/or fan package. Attach a hoist to the top of carriage assembly. 2. Disconnect two hydraulic supply lines located by the emergency disconnect and cap.0 7110 Mast. Disconnect hydraulic supply line which is located in the lower left corner of the battery box and cap. Three Stage Mast 2. Plate 7. Bolts WARNING When blocking the mast columns to prevent lowering. This will allow removal of lift chain anchor pins. 9. If the truck is not blocked. 1. 10. 3 Stage (RTX35) T-code RTX35/RTX45 2. it could tip on its side. Remove battery from truck. Jack truck up (see “Safe Jacking Procedure” on page 64). 1+ 01/2 5. Tighten enough to remove all slack in chains.1. Turn key switch OFF and disconnect battery connector. Connect a hoist to the top tie bars of mast. Remove two side mounting plates at the pivot points on mast. disconnect harness located at the base of overhead guard post. Removal WARNING Block all wheels to prevent truck from rolling. Remove two mast bolts located in the middle of the battery box. 3.

2. 8. Pull intermediate column straight forward until it stops (hits bearings) and then pull 90 degrees straight up from the outer column.2. Remove staging cylinder assemblies by pushing intermediate column forward. 2. 9. two cotter pins. NOTE! Lift cylinder can be repaired at this time. 12. if needed. Remove cap screws from the top of intermediate column. Pull inner column straight forward until it stops (hits bearings) and then 90 degrees straight up from intermediate column.F-code Section PS S7. lift chain. Disassembly 1. 4. Remove two bolts at the base of overhead guard post. 462 Return Service Manual 2001-03-15 . 3. NOTE! Lift cylinder can be repaired at this time. Pull straight up to remove freelift cylinder assembly. 5. Lift mast enough to clear chassis and lay mast on the floor. 7. 6. Thoroughly clean all parts. Remove freelift chain anchor. if needed. and two cylinder anchor pins from inner column.0 Mast. Lower mast assembly to a horizontal position before work can begin. and electrical cable from the mast. 3 Stage (RTX35) Version no T-code 000 RTX35/RTX45 C-code 7110 11. Remove chain sheaves and cable sheaves from all columns. Remove lift chain anchors. attachment hydraulic hoses. Remove mast bearings and shim washers from all columns.

Assemble intermediate column in outer column.030 inch (0. Thoroughly clean all parts and air dry. Install shims under the bearings. Check bearing shimming as column is extended. Pry column to one side and check with a 0. Check for excessive bearing clearance with columns in the fully extended position. Maximum clearance must not exceed 0. Assemble inner column in intermediate column. Install mast roller bearing on both intermediate and outer columns.030 inch (0. © BT Prime-Mover Inc.F-code PS Version no 000 Section C-code S7. Determine amount of shims required. Determine amount of shims required. Maximum clearance must not exceed 0.76 mm) shim. 4. Assembly WARNING Compressed air used for cleaning MUST be reduced to less than 30 psi (206 kPa). Extend intermediate column through the outer column as far as it will go under normal operation. Pry inner column to one side and slip shims between bearing and web on mast. 8. 3.3. 3 Stage (RTX35) T-code RTX35/RTX45 2. 2. Pry inner column to one side and slip shims between bearing and web on the mast.030 inch (0. Return Service Manual 2001-03-15 463 .76 mm).0 7110 Mast. 7. 6. Add shims by hand until no more can be added. and then only with effective chip-guarding and personal protective equipment. Remove shims as required if tight spots are encountered where an assembler cannot roll the mast by hand. Pry column to one side and check with a 0. Divide shims as equally as possible between the two bearings. 1. 5. Add shims by hand until no more can be added. Slide columns together.76 mm) shim. Check for excessive clearance with columns in fully closed position.030 inch (0. Slide columns together.76 mm).

Pry column to one side and check with a 0. Install shims under bearings.5 mm). Grease roller bearings. Extend inner column through the intermediate column as far as it will go under normal operation. Press roller bearings in lift chain sheaves.5 mm) shim.060 inch (1. 15.76 mm) shim.F-code Section PS S7. Check for excessive bearing clearance with columns in the fully extended position. Slide pins through sheaves and secure pins with two (2) cap screws and lockwashers. 11.030 inch (0. Maximum clearance must not exceed 0. Maximum clearance must not exceed 0. Check bearing shimming as the column is extended. 3 Stage (RTX35) Version no T-code 000 RTX35/RTX45 C-code 7110 9. Pry column to one side and check with a 0. Install staging lift cylinder assembly in outer column lower end. Install shim washers on either side of lift chain sheaves and install in intermediate column. Thread a wheel nut on each anchor and secure with a jam nut.030 inch (0. Grease bearing and install spacers on either side of bearing. Push intermediate and outer columns together. Complete this for both chain sheave pins. Install a cap screw in intermediate column to secure staging lift cylinder. 16. then slide inner races in roller bearings. 464 Return Service Manual 2001-03-15 . Secure sheave with one cap screw and lockwasher.76 mm). Divide shims as equally as possible between the two bearings. Check for excessive clearance with columns in the fully closed position. 14. 10. Install a bearing in the electrical sheave.0 Mast. 13. Install electrical sheave in the proper location on intermediate column. 12.060 inch (1. Remove shims as required if tight spots are encountered where an assembler cannot roll the mast by hand. Install lift chain anchors through outer column. 17.

Make sure chain and sheaves are properly aligned. Hydraulically lift up inner column enough to install reach carriage assembly. 8. 4. Adjust lift chains. 20. Install and connect battery. Bleed any air from cylinders. Install two bolts at the base of overhead guard post. 21. After chain pins have been installed. Install two bolts in middle of the battery box. Installation 1. Retighten jam nut and torque. 6. 11. Loosen jam nut and tighten staging chains equally until the top of the rails are level in the fully lowered position. 3 Stage (RTX35) Version no 000 T-code RTX35/RTX45 18. 2. Lubricate grease fittings using a standard lube gun (see “Oil and Grease Specifications” on page 81). Connect all electrical connectors. Test operations of mast and unit. Connect hydraulic hoses to lift cylinders. 2.F-code PS Section C-code S7. Torque to 400 ft-lb (543 N•m). Freelift chains should be adjusted in the fully lowered position. Install mast using a hoist. Install side mounting plates. Torque mounting plate bolts to 85 ft-lb (115 N•m). Install freelift cylinder assembly on inner column.4. 9. Torque to 25 ft-lb (34 N•m). Secure with four cap screws and nuts. Adjust chains until the top of forks are 2. Grease all chain sheaves.0 7110 Mast.0 inches (50 mm) off the floor. 7. 19. © BT Prime-Mover Inc. 5. Return Service Manual 2001-03-15 465 . run lift chain over chain sheaves. Install lift chain on chain anchors and secure with chain pins. 10. 3. Connect hydraulic lines to lift cylinder.

3 Stage (RTX45) 28 29 24 25 30 8 2 26 27 31 5 24 6 3 9 4 1 5 10 6 3 1 7 4 11 18 12 13 14 37 3 15 4 19 14 15 22 3 38 17 4 16 23 5 5 6 6 20 32 33 32 21 35 34 466 Return 36 Service Manual 2001-03-15 .0 Mast.F-code Section C-code PS S7. 3 Stage (RTX45) 7110 Version no T-code 000 RTX35/RTX45 Mast.

outer 35 Washer. anchor 25 Sheave. cap 36 Sheave. hydraulic. shim 10 Chain.0 7110 Mast. Intermediate 31 Shaft 6 Bearing 19 Bracket 32 Spacer 7 Staging cylinder assembly 20 Screw. Description Item No. chain 14 Nut 27 Race. cap 4 Pin. cotter 26 Bearing. roller © BT Prime-Mover Inc. chain 17 Screw. jam 28 Lockwasher 3 Pin.F-code PS Version no 000 Item No. cap 33 Sheave. 3 Stage (RTX45) 467 . Return Service Manual 2001-03-15 C-code S7. inner 22 Column. cotter 16 Line. grease 5 Shim 18 Column. cap 30 Fitting. inner 2 Chain. shim 37 Manifold 12 Pin. Description Item No. hydraulic 29 Screw. Free lift 23 Screw. Section T-code RTX35/RTX45 Description 1 Anchor. sheave 34 Screw. and electrical 11 Freelift cylinder assembly 24 Washer. hose 8 Screw. cap 9 Column. Staging lift 15 Nut. chain 38 Screw 13 Pin. button head 21 Shaft.

3. as required. Install shims under bearings. the truck could tip on its side. Check bearing shimming as the carriage is raised. and hydraulic hoses.F-code Section PS S7. 2. Hoist to loosen lift chains. Shimming Carriage with Mast on Truck WARNING Block all wheels to prevent truck from rolling. 8. 7. Raise carriage through the inner column as far as it will go under normal operation. 3 Stage (RTX45) Version no T-code 000 RTX35/RTX45 C-code 7110 1. Hydraulically lift up inner column enough to remove reach carriage assembly. Add shims by hand until no more can be added. Attach a hoist to the top of carriage. Thoroughly clean off all outside dirt around mast roller bearings. Jack truck up (see “Safe Jacking Procedure” on page 64). Remove shims. 6. 4. Pry carriage to one side and slip shims between bearings and web on the column. Divide shims as equally as possible between the two bearings. Lower carriage through inner column far enough to expose bearings. always block both sides of the column. Park the truck on a level surface and make sure all wheels are blocked to prevent accidental movement. If not.0 Mast. Determine amount of shims required. This will allow removal of lift chain anchor pins. electrical cable. 5. Remove bearings to install shims behind bearings. if tight spots are encountered where an assembler cannot move the carriage smoothly. WARNING When blocking mast the columns to prevent lowering. Check for excessive bearing clearance with the 468 Return Service Manual 2001-03-15 . Turn key switch OFF and disconnect battery connector. 1. Remove battery from truck.

Pry carriage to one side and check with a 0. Lower carriage to install hydraulic hoses.76 mm).8 mm).030 inch (0.030 inch (0. Remove hoist from the carriage. Check operation first with no load. © BT Prime-Mover Inc. 10. Chains are to be centered on the sheave within 0.0 7110 Mast. Maximum clearance must not exceed 0. Adjusting nuts (wheel nuts) and locknuts (jam nuts) should be torqued to 200 ft-lb (271 N•m). When installing lift chains. 9.76 mm).76 mm) shim. 3 Stage (RTX45) T-code RTX35/RTX45 carriage in the fully lowered position. Maximum clearance must not exceed 0. chains are to be free of twists and adjusted for equal tension. Return Service Manual 2001-03-15 469 . then with a capacity rated load.F-code PS Version no 000 Section C-code S7.030 inch (0.76 mm) shim. Pry carriage to one side and check with a 0. Test operation of unit.030 inch (0. lift chain anchor pins. Check for excessive bearing clearance with carriage in the fully raised position.03125 inch (0. and electrical cable.

+ 01/21 - 6. 9. Attach a hoist to the top of carriage assembly. 1. Plate 7. Remove two side mounting plates at the pivot points on mast. 4. 8. If the truck is not blocked. Disconnect two hydraulic supply lines located near the emergency disconnect switch and cap. Bolts WARNING When blocking the mast columns to prevent lowering.1. Hoist to loosen lift chains. Read and follow correct operating procedures for your jack or hoist. Service Manual 2001-03-15 . Disconnect hydraulic supply line located in lower left corner of battery box and cap. Removal WARNING Block all wheels to prevent truck from rolling. 5. Park the truck on a level surface and make sure all wheels are blocked to prevent accidental movement. electrical cable. 3 Stage (RTX45) Version no T-code 000 RTX35/RTX45 7110 2. it could tip on its side. Bolts 470 Return 10. 3.0 Mast. If truck is equipped with a light and/or fan package. disconnect harness located at the base of overhead guard post. This will allow removal of lift chain anchor pins. Connect a hoist to the top tie bars of mast and tighten enough to remove all slack in the chains. Remove two mast bolts located in the middle of the battery box.F-code Section C-code PS S7. always block both sides of the column. Hydraulically lift up inner column enough to remove reach carriage assembly. 2. Disconnect electric wiring harness located near the emergency disconnect switch. and hydraulic hoses. Remove battery from truck. Three Stage Mast 2. Turn key switch OFF and disconnect battery connector.

0 7110 Mast. Disassembly 1. Remove freelift chain anchor. © BT Prime-Mover Inc. if needed. 2. 9. 2. two cotter pins. 7. 3 Stage (RTX45) T-code RTX35/RTX45 11. Lift mast enough to clear chassis. and two cylinder anchor pins from inner column. 4. lift chain.F-code PS Version no 000 Section C-code S7. 2001-03-15 471 . Lower mast assembly to a horizontal position before work can begin. 12. Return Service Manual Thoroughly clean all parts. Remove cap screws from the top of intermediate column. 6. 8. attachment hydraulic hoses. Lay mast flat on floor.2. Remove freelift cylinder assembly by pulling straight up. NOTE! Lift cylinder can be repaired at this time. Remove mast bearings and shim washers from all columns. Remove two bolts at base of overhead guard post. 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. Remove staging cylinder assemblies by pushing the intermediate column forward. Pull intermediate column straight forward until it stops (hits bearings) and then pull 90 degrees straight up from the outer column. if needed. and electrical cable from mast. 3. NOTE! Lift cylinder can be repaired at this time. Remove lift chain anchors.

1. Divide shims as equally as possible between two bearings. Assemble inner column in the intermediate column. Slide columns together. Remove shims as required if tight spots are encountered where an assembler cannot roll the mast by hand. Thoroughly clean all parts and air dry. Assembly WARNING Compressed air used for cleaning MUST be reduced to less than 30 psi (206 kPa). Check bearing shimming as column is extended. 5. Extend intermediate column through the outer column as far as it will go under normal operation. 7.F-code Section PS S7.030 inch (0. Determine the amount of shims required.76 mm) shim.3. Determine the amount of shims required. 6. in the outer 4. Pry the inner column to one side and slip shims between the bearing and web on the mast. Pry column to one side and check with a 0. Check for excessive clearance with the columns in the fully closed position.76 mm) shim. Check for excessive bearing clearance with the columns in the fully extended position. Slide columns together.76 mm). 8. Pry column to one side and check with a 0.030 inch (0. Assemble intermediate column column.030 inch (0. and then only with effective chip-guarding and personal protective equipment.0 Mast.76 mm).030 inch (0. 3 Stage (RTX45) Version no T-code 000 RTX35/RTX45 C-code 7110 2. Pry inner column to one side and slip shims between bearing 472 Return Service Manual 2001-03-15 . Maximum clearance must not exceed 0. Install mast roller bearing on both the intermediate and outer columns. Maximum clearance must not exceed 0. Install shims under bearings. Add shims by hand until no more can be added. 2. 3.

Secure with one cap screw and lockwasher. 10.76 mm) shim. Complete this to both chain sheave pins. Pry the column to one side and check with a 0. 16. 12. Grease bearing and install spacers on either side of bearing. 15. Press roller bearings in the lift chain sheaves. Divide shims as equally as possible between two bearings. Install shim washers on either side of the lift chain sheaves. Install staging lift cylinder assembly in the intermediate column lower end. 14. 11. Remove shims as required if tight spots are encountered where an assembler cannot roll the mast by hand.060 inch (1. Check for excessive clearance with the columns in the fully closed position. 9.030 inch (0. Install a cap screw in the intermediate column to secure the staging lift cylinder. Extend inner column through the intermediate column as far as it will go under normal operation. Maximum clearance must not exceed 0. 13. Install electrical sheave in the proper location on the intermediate column. Add shims by hand until no more can be added. Grease roller bearings. Push intermediate and outer columns together. 3 Stage (RTX45) T-code RTX35/RTX45 and web on the mast.F-code PS Version no 000 Section C-code S7. © BT Prime-Mover Inc.76 mm). Pry column to one side and check with a 0. Check for excessive bearing clearance with the columns in the fully extended position. Return Service Manual 2001-03-15 473 .5 mm).0 7110 Mast. Install in the intermediate column.060 inch (1. Install shims under the bearings. Check bearing shimming as the column is extended.030 inch (0.5 mm) shim. Install a bearing in the electrical sheave. Slide pins through the sheaves and secure pins with two (2) cap screws and lockwashers. then slide the inner races into the roller bearings. Maximum clearance must not exceed 0.

0 Mast. Hydraulically lift up inner column enough to install reach carriage assembly. Make sure chain and sheaves are properly aligned. Torque mounting plate bolts to 85 ft-lb (115 N•m). 18. run the lift chain over the chain sheaves. Connect all electrical connectors. 20. Grease all chain sheaves. Carriage chains should be adjusted in the fully lowered position. Secure with chain pins. 2. Bleed any air from the cylinders. Install lift chain anchors through the outer column. Connect hydraulic hoses to lift cylinders. Install two bolts in the middle of the battery box. 7. 5. Adjust chains until the top of forks are 2. 4. Install lift chain on the chain anchors. Connect hydraulic lines to the lift cylinder. 8. Install freelift cylinder assembly on the inner column. Install side mounting plates. Retighten jam nut and torque. Torque to 25 ft-lb (34 N•m). Lubricate grease fittings using a standard lube gun (see “Oil and Grease Specifications” on page 81). Install mast using a hoist. Thread a wheel nut on each anchor and secure with a jam nut. 10. Installation 1. 19. 9. 3.4. Install two bolts at base of overhead guard post. 2. 3 Stage (RTX45) Version no T-code 000 RTX35/RTX45 C-code 7110 17. Secure with four cap screws and nuts.F-code Section PS S7. 474 Return Service Manual 2001-03-15 . 6. Torque to 400 ft-lb (543 N•m). 21. After chain pins have been installed.0 inch (50 mm) off the floor. Loosen jam nut and tighten chains equally until top of rails are level in the fully lowered position. Adjust lift chains.

© BT Prime-Mover Inc. Test operations of mast and truck.0 7110 Mast. Install and connect battery. Return Service Manual 2001-03-15 475 .F-code PS Version no 000 Section C-code S7. 3 Stage (RTX45) T-code RTX35/RTX45 11.

4 mm) before lift frame raises slightly. Safe. rust and corrosion. Lift chain tension is correct if lift chains can be forced sideways approximately 0. 3. Lift Chain Inspection After every 100 hours of truck operation. When performing inspection. 1. The chain system on the mast was designed for efficient. 2. reliable transmission of lifting force from the hydraulic cylinder to the forks. When operating in unfamiliar corrosive environment. Lift Chain Adjustment 1. uninterrupted use of the truck depends on proper care and maintenance of lift chains. Lift Chain Maintenance Unsatisfactory chain performance can be traced directly to inadequate maintenance. inspect chains every 50 hours. Highly stressed precision chains require periodic maintenance to deliver maximum service life.5 to 1 inch (12. Inspect chains every 50 hours when operating in unfamiliar corrosive environment.7 to 25. 476 Return Service Manual 2001-03-15 .0 7110 Version no T-code 000 RTX35/RTX45 Lift Chain Lift chains are very important components of the truck.F-code Section C-code PS Lift Chain S7. protruding or turned pins. 2. Tighten adjusting nuts until both chains are free of twist and of equal tension. observe the following chain conditions: chain wear. After 100 hours of truck operation. lift chains should be inspected and lubricated. Retighten locking nut on chain anchors. lift chains should be inspected and lubricated. and chain side wear. cracked plates. 3. Loosen locking nuts on chain anchors.

Chain Wear Scale Chain wear can be measured by using a wear scale or a steel tape. During inspection. the external surface of the lift chains must be protected with a film of oil. Rust and Corrosion Lift chains are highly stressed precision components.2.) When checking chain wear. the joints gradually wear.0 Version no 000 C-code 7110 Lift Chain T-code RTX35/RTX45 3. 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. New Chain Stretched Chain 3. Discard chains when elognated 3%. When 16 pitches measures 12. NOTE! Do not steam clean or degrease new lift chains. Return Service Manual 2001-03-15 477 . Outside plates are susceptible to stress-corrosion cracking. If lift chains are heavily rusted or corroded.1. It is very important that maintenance is performed throughout the chain service life. one foot of chain contains 16 pitches (links). Stress-corrosion Cracking NOTE! In all cases. carefully examine the external lift chain surfaces for the presence of an oily film. oil lift chains every 100 hours and more frequent under adverse conditions.375 inches (314 mm). remove them from the mast to thoroughly inspect for cracked plates. Under normal operating conditions. Corrosion will cause a major reduction in the load-carrying capacity of the lift chain or roller chain because corrosion causes sideplate cracking. Replace all © BT Prime-Mover Inc. (For example. NOTE! Do not repair chains by cutting out the worn section and splicing in a new piece. It is extremely important to protect the lift chain from corrosion. Wear As the chain flexes on and off the sheaves. measure a segment of chain that operates over a sheave. Lift chain lubricant serves both as a joint lubricant and corrosion inhibitor. whether in service or in storage.F-code Section PS S7. replace chains.

0 7110 Version no T-code 000 RTX35/RTX45 lift chains on the truck if the plates are cracked. 3. the plates may crack causing the chains to eventually break (load’s higher than the truck’s capacity).3. Ultimate Strength Failure This type of failure is caused by overload in excess of the truck design load. After many repeated heavy loads. Fatigue cracks are almost always found through the pitch holes perpendicular to the pitch line. increase internal friction. replace all lift chains on truck. Tight joints resist flexure. 478 Return Service Manual 2001-03-15 . Cracked Plates Fatigue failure is the most common cause of plate cracking. increasing chain tension required to lift a given load. Broken Plate Caused by Overload All joints in roller chain or lift chain should flex freely. Increased tension accelerates wear and fatigue problems. If cracks are present.F-code Section C-code PS Lift Chain S7. Lubricate the chains when reinstalled on the truck.

Return Service Manual • Bent pins or plates • Rusty joints • Peened plate edges • Oily rusty chains with bent or peened components 2001-03-15 479 .0 Version no 000 C-code 7110 Lift Chain T-code RTX35/RTX45 In roller chain. Tight joints in lift chains can be caused by the following: © BT Prime-Mover Inc. Tap bushing plates inward to remedy a plate “walking” problem. Tight joints prevent proper flexing of roller chain Bent or peened plates on lift chains can cause tight joints and prevent flexing. The majority of roller chains with tight joints have been run with little or no lube. If plate “walking” persists. replace lift chain. This type of link plate displacement is accelerated by poor lubrication. Replace chains if rusty. tight joints are usually caused by rust or inside plates moving outward on bushings.F-code Section PS S7.

causing chain failure. NOTE! Pins have turned 90o. If the chain is allowed to operate in this condition. unusually heavy loads or chain sliding past a guide in the mast. Turned pins can be quickly spotted because the flats on the “V” head are no longer in line.4. 3. Do not attempt to repair the chain by driving the pins back into the chain. 480 Return Service Manual 2001-03-15 . Protruding or Turned Pins Heavily loaded chains operating with little lube cause wear between the pin and plates (pin and bushing in roller chain).0 7110 Version no T-code 000 RTX35/RTX45 Peening of plate’s edges may be caused by worn sheaves. Chains with turned or protruding pins should be replaced. the torque in the joint can turn pins in the press-fit outside plate. the pins slowly work out of the chain. In some extreme cases.F-code Section C-code PS Lift Chain S7.

Anchors with worn or broken fingers should be replaced.F-code Section PS S7. load is not spread uniformly between the plates.6. Chain Side Wear A wear pattern on pin heads and outside plates indicates misalignment. Anchors should be adjusted to eliminate twisting or other misalignment in the chain. 3. breakage.0 Version no 000 C-code 7110 Lift Chain T-code RTX35/RTX45 Protruding Pins MA0633. This condition damages chain and sheaves as well as increasing internal wear in the chain system. and misalignment. Chain Anchors and Sheaves An inspection of the chain system includes a close look at the chain anchors and sheaves. When chain is misaligned. 3. Prolonged operation will result in premature failure.ill Turned Pins Out-of-line flats on “V” heads indicate that pins have turned in place.5. © BT Prime-Mover Inc. Return Service Manual 2001-03-15 481 . Check chain anchors for wear.ill MA0000.

F-code Section C-code PS Lift Chain S7. Heavy flange wear indicates chain misalignment. but oil must flow into the live bearing surface for maximum wear life. 4. Applying oil to the external surface will prevent rust. The oil must penetrate chain joint to prevent wear. Maintaining an oil film on all chain surface will cause the following: • Minimize joint wear (chain stretch) • Prevent corrosion • Reduce possibility of pin turning • Minimize tight joints in roller chain • Promote smooth. Do not use dry film lubes on lift chain.0 7110 Version no T-code 000 RTX35/RTX45 Sheaves with badly worn flanges and outside diameter should be replaced. Like all bearing surfaces. Hard working. Lift Chain Lubrication Lubrication of the lift chain in field maintenance is a very important duty. heavily loaded chains cannot be expected to give satisfactory wear life without scheduled periodic relubrication. quiet chain action • Lower chain tension by reducing internal wear in the chain system Heavy motor oil is an excellent chain lubricant (even used oil drained from truck engines is adequate for lubricating exposed lift chains). Lubricate the entire length of all strands every 100 hours (50 hours in corrosive environment). Brush chains with heavy motor oil (#40 weight oil) to lubricate lift chain rather than #10 weight oil or automatic transmission fluid. 482 Return Service Manual 2001-03-15 . a film of oil between mating parts is required to prevent rapid wear.

Flood the chain with oil over its entire length.0 Version no 000 C-code 7110 Lift Chain T-code RTX35/RTX45 Lubricate Lubricate Apply oil to chains with a narrow paint brush.F-code Section PS S7. Return Service Manual 2001-03-15 483 . A plastic liquid detergent bottle makes a handy lube applicator. Trucks in severe service (or parked outside) may require more frequent relube to maintain an oil film on all chain surfaces. The best estimate of lube period is 100 hours (or 4 weeks) actual truck operating time. © BT Prime-Mover Inc.

Replace all chains as a set. 4. 3. Do not degrease or paint new chains. Replace anchors and anchor pins when installing new chains. Lift Chain Replacement 1.F-code Section C-code PS Lift Chain S7.0 7110 Version no T-code 000 RTX35/RTX45 5. 484 Return Service Manual 2001-03-15 . All chains should be replaced if any strand has wear elongation of 3% or if any of the conditions listed in “Lift Chain Inspection” on page 476 are evident during inspection. 2.

Return Description Item No. roller 10 Screw. chain 2 Ring. © BT Prime-Mover Inc. hydraulic and electrical 4 Race 9 Shaft 5 Bearing. grease 6 Sheave. sheave 3 Shim 8 Sheave. set Service Manual 2001-03-15 485 . retainer 7 Head.1 7170 Lifting Gear (Crosshead) (RTX35) Version no T-code 000 RTX35/RTX45 Lifting Gear (Crosshead) (RTX35) 1 2 3 4 5 6 8 3 7 9 3 10 6 5 4 3 2 1 Freelift Cylinder Item No.F-code Section C-code PS S7. Description 1 Fitting.

and electric cables are loose. Lower freelift cylinder so chains. and electric cables from lifting gear sheaves (6 and 8). WARNING Compressed air used for cleaning MUST be reduced to less than 30 psi (206 kPa). Lifting Gear Repair 1. Loosen set screw (10) at the base of sheave head (7). Securely block carriage/reach to prevent lowering. 1. 486 Return Service Manual 2001-03-15 . the truck could tip over on its side. Park truck on a level surface and apply brake. hoses.1 7170 Lifting Gear (Crosshead) (RTX35) Version no T-code 000 RTX35/RTX45 The lifting gear is located on the top of the freelift cylinder. Turn key switch OFF and disconnect battery connector. 3. always block both sides of the column. Park the truck on a level surface and make sure all wheels are blocked to prevent accidental movement. 2. 6. WARNING When blocking mast columns to prevent lowering. 8. Remove battery from truck. 7. Otherwise. and then only with effective chip-guarding and personal protective equipment. 4. Removal WARNING Block all wheels to prevent truck from rolling. 5. hoses. Lift lifting gear assembly off the freelift cylinder rod. 1.1.F-code Section C-code PS S7. Remove chains. Lift carriage/reach approximately 6 inches (152 mm). Turn key switch OFF and disconnect battery connector. Clean lifting gear.

Install one shim (3). Repeat steps 1 and 2 for the opposite side. 1. Install a grease fitting (1) in each end of the shaft (9). Disassembly 1. through the hydraulic/electric sheave (8). one chain sheave with bearing assembly (6. and a retaining ring (2) on shaft (9). Slide shim (3). Remove retaining ring (2) from one end of the lifting gear assembly. 3. chain sheave (6) and the second shim (3) off the shaft (9). 2. 5. Lube sheave head.2. 3. 5. Secure shaft in position with a set screw (10). bearing roller and race (5 and 4).F-code Section C-code PS S7. Return Service Manual 2001-03-15 487 . a second shim (3).1 7170 Lifting Gear (Crosshead) (RTX35) Version no 000 T-code RTX35/RTX45 1. © BT Prime-Mover Inc. 4. 2. Remove shaft (9) from sheave head (7) releasing the hydraulic/electric sheave (8). 6.3. Loosen set screw (10) in the side of the sheave head (7). Repeat step 4 for the opposite side. 4. Assembly 1. 5. 4). Place hydraulic/electric sheave (8) into the sheave head. Insert shaft (9) into sheave head (7).

Remove blocking and test for proper operation. 3. Place lifting gear assembly on top of freelift cylinder. 2.4. Grease chain sheaves. Connect battery. Install chains. hoses. 488 Return Service Manual 2001-03-15 .1 7170 Lifting Gear (Crosshead) (RTX35) Version no T-code 000 RTX35/RTX45 1. Installation 1. Tighten set screw (10) in the base of sheave head (7) to secure the lifting gear to the cylinder.F-code Section C-code PS S7. and electric cables. 4. 5.

F-code Section C-code PS S7. roller 10 Screw. set Service Manual 2001-03-15 489 . grease 6 Sheave. Return Description Item No. chain 2 Ring. © BT Prime-Mover Inc. Description 1 Fitting. retainer 7 Head. sheave 3 Shim 8 Sheave. hydraulic and electrical 4 Race 9 Shaft 5 Bearing.1 7170 Lifting Gear (Crosshead) (RTX45) Version no T-code 000 RTX35/RTX45 Lifting Gear (Crosshead) (RTX45) 1 2 3 4 5 6 3 8 7 9 3 10 6 5 4 3 2 1 Freelift Cylinder Item No.

Lift carriage/reach approximately 6 inches (152 mm). always block both sides of the column. 6. 5. 1. Otherwise. and electric cables are loose. and electric cables from lifting gear sheaves (6 and 8). 7. Park the truck on a level surface and make sure all wheels are blocked to prevent accidental movement. Lower freelift cylinder so chains. the truck could tip over on its side. 8. WARNING When blocking mast columns to prevent lowering. and then only with effective chip-guarding and personal protective equipment. 3. Removal WARNING Block all wheels to prevent truck from rolling. Securely block carriage/reach to prevent lowering. Park truck on a level surface and apply brake. Loosen set screw (10) at the base of sheave head (7). Remove chains. Turn key switch OFF and disconnect battery connector. Clean lifting gear. hoses. is located on the top of the freelift cylinder.1. Remove battery from truck. Turn key switch OFF and disconnect battery connector. Lifting Gear Repair 1.1 7170 Lifting Gear (Crosshead) (RTX45) Version no T-code 000 RTX35/RTX45 The lifting gear. 490 Return Service Manual 2001-03-15 . WARNING Compressed air used for cleaning MUST be reduced to less than 30 psi (206 kPa).F-code Section C-code PS S7. 1. 2. Lift the lifting gear assembly off freelift cylinder rod. hoses. 4.

bearing roller and race (5 and 4). Assembly 1. 2. Remove shaft (9) from sheave head (7) releasing the hydraulic/electric sheave (8). 1. Loosen set screw (10) in the side of sheave head (7). 1. hoses. through the hydraulic/electric sheave (8). Repeat step 4 for the opposite side. 3. 4. Install a grease fitting (1) in each end of the shaft (9). one chain sheave with bearing assembly (6. a second shim (3). Remove retaining ring (2) from one end of the lifting gear assembly.F-code Section C-code PS S7. © BT Prime-Mover Inc.4.3. Repeat steps 1 and 2 for the opposite side. 3. Installation 1. Return Service Manual 2001-03-15 491 . 3. Install chains. Tighten set screw (10) in the base of the sheave head (7) to secure the lifting gear to the cylinder. Place lifting gear assembly on the top of the freelift cylinder. and electric cables. chain sheave (6) and the second shim (3) off shaft (9). 4).1 7170 Lifting Gear (Crosshead) (RTX45) Version no 000 T-code RTX35/RTX45 1. and a retaining ring (2) on the shaft (9). 4. 5. Lube sheave head. Install one shim (3). Disassembly 1. Secure shaft in position with a set screw (10). Place hydraulic/electric sheave (8) into the sheave head. Insert shaft (9) into the sheave head (7). Grease chain sheaves. 5.2. 6. Slide shim (3). 5. 2. 2.

492 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 4. Remove blocking and test for proper operation. 5. Connect battery.

F-code Section PS S7. Return Service Manual 2001-03-15 493 .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 5 4 29 3 “X” 9 7 28 10 8 6 27 13 11 12 © BT Prime-Mover Inc.

Description 1 Screw 11 Hook. cylinder cap 2 Bracket 12 Pad. Description Item No. upper 14 Cap. 494 Return Description Item No. cylinder 25 Rod 6 Bolt. right 24 Seal 5 Frame 15 Body. lower hook 18 O-ring 28 Screw 9 Washer. lower hook 20 Bushing Service Manual 2001-03-15 . lower hook 23 Seal 4 Pad. left cylinder 3 Support 13 Plate. flow 10 Washer. lower hook 16 Seal 26 Cylinder 7 Bolt.2 Sideshifter 7211 Version no T-code 000 RTX35/RTX45 Item No. stop 17 Piston 27 Washer 8 Set screw. lower 21 Ring.F-code Section C-code PS S7. stop bolt 19 Ring 29 Restrictor. lower 22 Cap.

Lift sideshift unit onto the truck’s carriage using a lifting device with a minimum capacity of 1000 lbs (454 kg). Remove cylinder retaining caps (21). Apply grease to the fork carriage frame where the lower pads slide. Torque securing bolts (6) to 65 ft-lb (90 N•m). bringing the plastic pad (12) in contact with the underside of the truck carriage. 7.1. Tighten fittings to 56 ft-lb (80 N•m). 2. 8. Install fork stop bolt (7) with washer (9. 4. Lift lower hook (11). 1. Remove safety screw (28) located between the lower hook mounting bolts (6). Mount forks in the notches on the upper bar of the sideshift carriage. Return Service Manual 2001-03-15 495 .2 Version no 000 C-code 7211 Sideshifter T-code RTX35/RTX45 1. Tighten set screw (8) to 21 ft-lb (30 N•m) torque. 10) into the lower bar of the sideshift carriage. 5.F-code Section PS S7. 3. 11. 9. Install safety screw (28) into the hole with the set screw (8). Loosen two lower hook securing bolts (6). Make sure centering lug (X) on cylinder support (3) fits completely in the center notch of the truck carriage. Remove lower pads (12) from sideshift assembly. Grease lower pads and return to the sideshift unit. Torque safety screw to 70 ft-lb (100 N•m). Mounting Instructions 1. 6. Connect hydraulic fittings to the sideshift cylinder. © BT Prime-Mover Inc. Installation NOTE! Clean the fork carriage and inspect to be sure it is free of damage or grooves before installing the sideshift carriage. 10.

F-code Section C-code PS S7. 496 Return Service Manual 2001-03-15 . Operation Always operate the truck controls in a smooth manner. NOTE! Following assembly. 3. check the operation of the sideshift unit by sideshifting first without a load. NOTE! In a dirty environment or rough operations. Refer to the scheduled maintenance chart on page 67 for service tasks and intervals. Sideshift the unit several times to insure there are no leaks. Maintenance Maintenance on the sideshift unit should be performed on a regular basis to receive the best performance from the unit. it is necessary to inspect the sideshift unit more frequently. Check sideshift unit for smooth operation with no interference. then with a load.2 Sideshifter 7211 Version no T-code 000 RTX35/RTX45 12. as well as cause damage to the overall system. 2. Sudden movements of the sideshift at high lifts can compromise the stability of the truck.

Loosen lower hook mounting bolts (6) and set screws (8) until lower hooks (11) are completely lowered.1. Cap the ends of the hoses to prevent contamination of the hydraulic system. 4. Detach hoses from sideshift cylinder. Remove safety screws (28). 4. 5. See paragraph 3. Install sideshift carriage on the truck.F-code Section PS S7.5 mm) or less at any point on the round surface. Carriage Removal 1. Lubricate the upper pads with grease. 2. Lift the upper pads (4) from the cylinder support bracket (3). See “Mounting Instructions” on page 495. 3.1 above. Return Service Manual 2001-03-15 497 . Remove fork stop bolt (7) from sideshift carriage. 2. Remove forks. Lift sideshift unit from the truck’s carriage using a lifting device with a minimum capacity of 1000 lbs (454 kg).0625 inch (1. The upper pad (4) should be replaced if the pad is worn to 0. 1. Upper Pad Replacement Always replace all of the upper pads at the same time to ensure even wear and proper movement. 3. NOTE! Be sure the pressure is relieved from the hydraulic system before detaching the hoses from the sideshift cylinder.2 Version no 000 C-code 7211 Sideshifter T-code RTX35/RTX45 3. Be sure the centering pins on each pad are seated in the notches in the support bracket. 3. © BT Prime-Mover Inc. Remove sideshift carriage from the truck. Install new pads on the cylinder support bracket.2. 5.

Remove blocking spacer and lower sideshift carriage to fork carriage. Lower Pad Replacement Replace the lower pads (12) if the pad is worn to 0. Detach hoses from sideshift cylinder. bringing plastic pad (12) in contact with underside of truck carriage. 6. Remove lower pads (12) using a screwdriver. The sideshift carriage does not need to be removed to replace the lower pads. 11.2 Sideshifter 7211 Version no T-code 000 RTX35/RTX45 3. 2. Remove safety screws (28). Tighten set screw (8) to 21 ft-lb (30 N•m) torque. 5. Lubricate lower pads with grease. 12. Be sure they are seated. 8. 7. 9. Lift lower hook (11). Loosen lower hook mounting bolts (6) and set screws (8) until lower hooks are completely lowered.20 inch (5 mm) or less at any point. Lift lower part of sideshift carriage away from fork carriage (leave the top of the sideshift attached to fork carriage). It is recommended to replace the lower hook plates (13) each time the lower pads are replaced. 1. Remove fork stop bolt (7) from sideshift carriage. NOTE! Be sure the pressure is relieved from the hydraulic system before detaching the hoses from the sideshift cylinder. Cap the ends of the hoses to prevent contamination of the hydraulic system. 498 Return Service Manual 2001-03-15 . Securely block sideshift carriage away from the fork carriage with a 3 inch (70 mm) spacer. 3. then place new pads into lower hook (11).F-code Section C-code PS S7. 4. Torque securing bolts (6) to 65 ft-lb (90 N•m). 10.3. Remove forks.

Tighten fittings to 56 ft-lb (80 N•m). © BT Prime-Mover Inc. 16. Mount forks in the notches on the upper bar of sideshift carriage. Connect hydraulic fittings to the sideshift cylinder.F-code Section PS S7. check operation of sideshift unit by sideshifting first without a load. NOTE! Following assembly. 10) into lower bar of the sideshift carriage. then with a load. Check the sideshift unit for smooth operation with no interference. 17. Install fork stop bolt (7) with washer (9. Install safety screw (28) into the hole with the set screw (8). 14. 15.2 Version no 000 C-code 7211 Sideshifter T-code RTX35/RTX45 13. Return Service Manual 2001-03-15 499 . Torque safety screw to 70 ft-lb (100 N•m). Sideshift the unit several times to insure there are no leaks.

slowly removing the cap.F-code Section C-code PS S7. See “Mounting Instructions” on page 495. See 2. Remove cylinder from cylinder support. follow the correct mounting sequence.4. Cylinder 1. Secure cylinder in cylinder support (3) using brackets (2) and screws (1). 7. Remove sideshift carriage from “Carriage Removal” on page 497. 4.2 Sideshifter 7211 Version no T-code 000 RTX35/RTX45 3. 5. Loosen locking screws (1). Use a wrench to turn the cap (22) until the ring (21) comes out. Turn the ring. 3. Lift cylinder assembly (26) from the support. NOTE! When replacing the seals. a minimal amount of scoring may be removed by polishing with a fine emery cloth. 6. Remove brackets (2). 500 Return Service Manual 2001-03-15 . Check that the seal passes through the recess (press the seals through the recess with a screwdriver). truck. NOTE! If the cylinder rod (25) becomes scored. The bracket slots should be facing upwards. Reassemble cylinder. Deep scoring requires that the cylinder (26) be replaced. Secure body of the cylinder in a vice equipped with soft jaws. Install sideshift carriage on truck.

If necessary. 7. Check that lower hook pads (12) are not too tight against truck fork carriage. Very Slow Sideshifting 1.2 Version no 000 C-code 7211 Sideshifter T-code RTX35/RTX45 4.5 liters per minute) and should be a minimum of 1 gallon per minute (4 liters per minute). Check hydraulic lines and cylinder for leaks. No Sideshifting 1. 4.5 liters per minute) and should be a minimum of 1 gallon per minute (4 liters per minute). 6.1. 3. Check relationship of lower hook (11) to truck carriage. Check upper and lower pads (4. 2. Average working pressure should be 1000 psi (6894 kPa). Check carriage frame for damage. Remove flow restrictor (29).2. Troubleshooting Below are three symptoms and the corrective actions to be taken for each.F-code Section PS S7. Return Service Manual 2001-03-15 501 . enlarge the hole in flow restrictor disk. 2. Check for leaks in the hydraulic circuit or cylinder. Check carriage frame for damage. Recommended oil flow is 2 gallons per minute (7. Replace as necessary. 3. Check oil level in hydraulic tank. Check that input pressure is not greater than 3200 psi (22060 kPa). Check that input pressure is not greater than 3200 psi (22060 kPa). Recommended oil flow is 2 gallons per minute (7. Average working pressure should be 1000 psi (6894 kPa). 4. © BT Prime-Mover Inc. 12) for wear. 4. 5. 4.

2.2 Sideshifter 7211 Version no T-code 000 RTX35/RTX45 4.3. Bleed hydraulic system if necessary. 502 Return Service Manual 2001-03-15 . Irregular Sideshifting 1.F-code Section C-code PS S7. 12) for wear. Check upper and lower pads (4. Check hydraulic system to be sure there is no air. Replace as necessary.

Single (RTX35) Version no T-code 001 RTX35/RTX45 Reach.F-code Section PS C-code S7.3 7241 Reach. Maintenance The only maintenance required on the reach mechanism is the normal Planned Maintenance per the schedule (see page 67). Single (RTX35) 1. Return Service Manual 2001-03-15 503 . 19 18 20 7 6 5 8 4 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 7 17 1 33 27 35 28 29 32 37 7 31 32 30 © BT Prime-Mover Inc.

socket head 3 Frame.3 7241 Reach. lock 27 Washer. Description 1 Screw. cap 7 Fitting. roll 34 Screw. cap 38 Screw. Single (RTX35) Version no T-code 001 RTX35/RTX45 Item No. inner 25 Pin 41 Clamp 10 Control valve 26 Arm. forward 33 Bushing 2 Pin 18 Pin. left 21 Bar. flat head lock 46 Bearing 15 Screw 31 Cap 47 Reach cylinder assembly 16 Manifold 32 Bearing 48 Tilt cylinder assembly Return Service Manual 2001-03-15 . flat 43 Bracket 12 Cover. valve 28 Nut. jam 44 Nut 13 Clamp. rear 19 Pin 35 Bumper 4 Screw. right 42 Washer.F-code Section C-code PS S7. Description Item No. fork 37 Shim 6 Bushing 22 Screw. poly 29 Set. 504 Description Item No. cap 17 Frame. flat head 20 Bushing 36 Shim 5 Arm. grease 23 Washer 39 Manifold 8 Bushing 24 Washer 40 Screw 9 Arm. bearing 14 Cover 30 Screw. bearing 45 Cap. flat 11 Screw.

2. Remove cap screw (1) at the front frame (17). backrest. Remove front frame (17) from inner arm (9) rollers (46). Reach Repair 2. Remove load page 532. Park truck on a level surface.F-code PS Version no 001 Section C-code S7. Removal NOTE! The reach can be repaired without removal from the mast. 2. 4. 1.1. Remove forks. Return Service Manual 2001-03-15 505 . WARNING Block all wheels to prevent truck from rolling.1. Disassembly 2. See “Removal” on 3. Drive pins (25) to the outside by hitting with a soft hammer. Park the truck on a level surface and make sure all wheels are blocked to prevent accidental movement.3 7241 Reach.1. 2. Disconnect hydraulic hoses from tilt and sideshift cylinders from the input side of junction block. Securely block reach so it will not retract. Remove battery from truck. © BT Prime-Mover Inc. Front Frame Removal 1. Jack truck up (see “Safe Jacking Procedure” on page 64). 5. Secure front frame with a hoist to prevent movement before removing cap screw (1) and pins (25). 4.1. 5. Turn key switch OFF and disconnect battery connector. Single (RTX35) T-code RTX35/RTX45 2. Extend reach approximately half way. Cap hoses with plugs to prevent contamination. 3.

2. and rollers (32) from outer arms. Remove outside bearing (29). Remove right outer arm (26). Outer Arm Removal 1. 4. 7.1.1.1. Secure inner arms to prevent movement when roll pins are removed from inner frame. 3. 2.3. 2.4. 5. Drive pins (2) out by hitting with a soft hammer. 4. Remove inner arms (9). Remove rear frame. 3. 7. Rear Frame Removal 1. 6. 5. Inner Arm Removal 1. NOTE! Connect a hoist to the rear frame to prevent it from dropping when the channel is raised. Remove screws (30). Disconnect electrical cable. 5. Plug to prevent contamination. Raise inner mast channel.F-code Section C-code PS S7. Remove reach cylinder rod end pins from inner frame. Repeat steps 1 thru 3 to remove left outer arm (5). Remove lift chain anchors from rear frame. 506 Return Service Manual 2001-03-15 . Disconnect hydraulic lines from manifold block. Single (RTX35) Version no T-code 001 RTX35/RTX45 2.2. 2. Lower rear frame. 4. 6. 3. Disconnect hydraulic hoses. Lift rear frame (3) until all tension is removed from lift chains. Drive pins out of reach cylinder rod end pins. 2. Remove cap screws (1) at rear frame (3).3 7241 Reach. Remove nut (28) and washer (27). Plug to prevent contamination. caps (31).

2. 2. 1. 2. Connect hydraulic hoses.1. Return Service Manual 2001-03-15 507 . NOTE! Adjust frame rollers so there is 0.030 inch (0 to 0. 2. rollers. Remove lock pins from rear frame. Install shims (37) and rollers (32). and wear strips for damage or wear.1. 3.F-code PS Version no 001 Section C-code S7. Rear Frame Installation NOTE! Install same number of shims as removed for initial adjustment. rollers. Lower inner mast channel onto rear frame rollers (32). Plug to prevent contamination. washers. Remove rollers (32). pins. Disconnect hydraulic hoses.2. 2.2. 2. 9. 2.76 mm) side movement of the rear frame at tightest part of the inner mast channel. Reach Cylinder Removal WARNING Block reach to keep it from collapsing. 3. Install locking pins.000 to 0. 1. Assembly Install new bearing. Repair reach cylinders as needed. Keep track of shims (37) to each roller and roller to pin location. © BT Prime-Mover Inc. 4. Clean and inspect all bearing. Remove cylinder tube mounting pins. and pins as needed. Single (RTX35) T-code RTX35/RTX45 8.3 7241 Reach.2. Reach Cylinder Installation 1. 2.5. Install rear frame pins.

6. 6. Torque nut to 295 ft-lb (405 N•m). Install rollers (32). Torque to 85 ft-lb (115 N•m). Install roll pins into the cylinder rod pins. Install a new bearing (8) in each side arm. 5. Connect tilt cylinder hoses. Connect hydraulic hoses. Arms should pivot freely with some drag. 2. rollers (46). Install washer (27) and nut (28) and tighten. Install washers (24). 4. Installation” on page 509. Install pins (2) in the rear frame and inner arms (9). 3. Single (RTX35) Version no T-code 001 RTX35/RTX45 3. 2.2. Outer Arm Installation 1. Install cap screw (1) and tighten. 2. 3. See “Front Frame 7. Connect hydraulic hoses to the reach cylinder. 8. Inner Arm Installation 1. 4.3. 7. Install lift chain anchors. Install upper end of inner arms (9) into rear frame (3). Grease all fittings on reach. Test for proper operation of reach. Install front frame (17). Install forks and load backrest.3 7241 Reach. Install pins in the rod end of the reach cylinder. 508 Return Service Manual 2001-03-15 . and cap (45). Install outer arms (5 and 26) on the center stud of inner arm (9). Install bearing (29) in outer arms (5 and 26). caps (31) and screws (30) on outer arms (5 and 26).F-code Section C-code PS S7. 8.4. 5. 4. Connect electrical cable. Arms should pivot freely with some drag. 2. 9.2. Check for side clearance. 5.

Install cap screw (1). Adjust reach cylinder rods so the reach assembly extends in time. Install front frame (17) onto inner arm (9) rollers (46). The RTX35 reach uses rectangular bumpers (35) attached to each side and at the bottom of the carriage/reach rear frame. Return Service Manual 2001-03-15 509 . These bumpers are attached with socket head screws (34). cracking. Front Frame Installation 1. Fully retract reach assembly.1. 3. 4. 2. or deformation must be replaced. There should be no splitting. cracking. If the reach assembly does © BT Prime-Mover Inc. Verify that the (3) reach retract bumpers (35) are in good condition.F-code PS Section C-code S7. The reach assembly must retract evenly to all three retract bumpers (35).125 inch (3 mm) shim (36) behind each reach retract bumper (35). 4.3 7241 Reach.2. Install a 0. Install washer (23) and pivot shaft (25) in bushing in outer arm. 2. Fully extend the reach assembly. splitting. Carriage Bumpers The carriage/reach retract bumpers assure that the carriage remains square with the truck in its nested position. Reconnect hydraulic hoses to the tilt and sideshift cylinders at junction box. 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. 3. Bumpers that show signs of wear. 3. CAUTION The cylinder rod should never be adjusted where the rod end touches the inner arm assembly. Single (RTX35) Version no 001 T-code RTX35/RTX45 2.5. 3. Loosen reach rod jam nuts. Reach Adjustment 1.

measure from the face of the inner column to the backside of fork hanger carriage (21). The jam nuts must be inspected for tightness at every Planned Maintenance visit to insure proper operation of the reach assembly. Repeat steps 2 through 4 until proper retraction is achieved. (Example: Extended measurement of 25. Note this measurement.75 and 23 inches (578 and 584 mm).75 inches (654 mm) minus retracted measurement of 2. The pins and bushings for the inner arms should be inspected if the amount of threads are excessively less or greater than the three threads.F-code Section C-code PS S7.0625 inch (1. 6. CAUTION The piston threads must be cleaned and have Loctite® applied whenever the reach assembly is readjusted. When measurement is correct. Adjust cylinder rods so that the overall reach stroke is between 22. use a 0.125 inch (3 mm) shim (36) accordingly to achieve proper retraction to all three reach bumpers. Single (RTX35) Version no T-code 001 RTX35/RTX45 not retract to all bumpers evenly. 9. With the reach fully retracted. 5. there should be approximately three full threads showing above the jam nuts at the clevis end of reach cylinders. 510 Return Service Manual 2001-03-15 . BT Prime-Mover specifications allow a maximum overall reach stroke between 22. CAUTION The cylinder rod should never be adjusted where the rod end touches the inner arm assembly.75 inches (70 mm) equals an overall reach stroke of 23 inches (584 mm)).5 mm) or 0. Subtract the retracted measurement from the extended measurement. 7. This is your overall reach stroke.3 7241 Reach. 8.75 and 23 inches (578 and 584 mm).

clean rod threads and apply Loctite 242® thread locking compound. If carriage becomes loose within inner columns.1. 5. If carriage hangs up in the column during lowering. © BT Prime-Mover Inc. When proper adjustment is achieved. The carriage must be removed to access these bearings. Lock down jam nuts. 5. 3. a suitable bearing puller may be required for removal. one or more of the roller bearings may be damaged or worn and requires replacement. Repeat step 2 for the other three bearings. Single (RTX35) T-code RTX35/RTX45 10. Remove carriage/reach. The lower bearings are shimmed at the factory so that no play exists between the carriage and inner columns. Return Service Manual 2001-03-15 511 . 4. The carriage bearing should slide off the shaft with hand pressure. lower roller bearings may require additional shims. Removal 1.3 7241 Reach. Fork Carriage Pivot Pins RTX35 reach trucks use a pin (18) and roll pin (19) combination for the fork carriage pivot pin. If necessary. If possible. maintain an equal amount of shim thickness on each side. Carriage Roller Bearings Two roller bearings (32) are located within the mast assembly on either side. 2.F-code PS Version no 001 Section C-code S7.

5. See “Shimming Carriage with Mast on Truck” on page 459. 4. Return truck to service.F-code Section C-code PS S7. Install new bearing on shaft. 2. Installation 1. Test lift/lower functions of the carriage. Repeat step 1 for the other three bearings.3 7241 Reach. 512 Return Service Manual 2001-03-15 . 3.2. Reinstall carriage/reach. Single (RTX35) Version no T-code 001 RTX35/RTX45 5.

F-code Section PS C-code S7. Single (RTX45) Version no T-code 001 RTX35/RTX45 Reach. Return Service Manual 2001-03-15 1 513 . Single (RTX45) 1.3 7241 Reach. Maintenance The only maintenance required on the reach mechanism is the normal Planned Maintenance per the schedule (see page 67). 42 45 43 46 41 47 48 44 60 49 51 52 59 58 50 57 56 55 53 54 6 5 12 13 14 7 4 1 8 2 9 3 10 38 37 36 35 34 20 33 21 22 6 27 25 26 5 11 3 5 32 22 39 28 36 40 30 29 24 23 22 19 20 21 17 16 18 9 35 31 6 8 7 15 5 2 3 © BT Prime-Mover Inc.

Description 1 Screw 21 Lockwasher 41 Solenoid valve 2 Cap. Single (RTX45) Version no T-code 001 RTX35/RTX45 Item No. pivot 54 Bumper 15 Arm. left 24 Pin 44 Bearing 5 Fitting. thrust 38 Screw 58 Cylinder. bearing 22 Flat Washer 42 Frame.3 7241 Reach. retainer 8 Bearing. wear 31 Frame. 514 Description Item No. bearing 57 Plate. back 51 Screw 12 Screw 32 Screw 52 Lockwasher 13 Shaft-half 33 Lockwasher 53 Spacer 14 Shaft-half 34 Pin. inner 30 Solenoid valve 50 Nut 11 Plug. cylinder Return Service Manual 2001-03-15 .F-code Section C-code PS S7. carriage 3 Bearing 23 Pin. tilt 19 Spacer 39 Guide. thrust 28 Spacer 48 Shaft 9 Shim 29 Screw 49 Frame. hose 59 Bearing 20 Screw 40 Screw 60 Bracket. mast guide 56 Screw 17 Lockwasher 37 Cap. Description Item No. right 35 Shim 55 Screw 16 Nut 36 Bearing. fork 10 Arm. grease 25 Bearing 45 Spacer 6 Bearing 26 Reach cylinder 46 Screw 7 Bearing 27 Pin 47 Ring. wear 18 Bearing. cotter 43 Screw 4 Arm.

2. 4.F-code PS Section C-code S7. and bearing (7) from the center stud of outer arms (4 and 15). Remove thrust bearing (18). Remove screw (12) and half shafts (13 and 14) from the front frame (42).2. 5.3 7241 Reach. 2. © BT Prime-Mover Inc. 2. Disconnect battery. 2. Reach Repair NOTE! The reach can be repaired without removal from the mast. Remove nut (16) and lockwasher (17). Single (RTX45) Version no 001 T-code RTX35/RTX45 2.1. 5. Remove shims (9). 2. bearing caps (2). 3. Remove forks.1. backrest. Remove right outer arm (15). Repeat steps 1 thru 3 to remove left outer arm (4). Outer Arm Removal 1. and bearing (3) from outer arms (4 and 15). Disassembly 2. Cap hoses with plugs to prevent contamination. Remove load page 532.1. 6. Remove front frame (42) from inner arm (10) rollers (3). Remove screws (1). 1. Front Frame Removal 1. Extend the reach approximately half way.1. Return Service Manual 2001-03-15 515 . thrust bearing (8). 4. Securely block reach so it will not retract. Disconnect hydraulic hoses from the tilt and sideshift cylinders from the input side of the solenoid valve. Jack truck up (see “Safe Jacking Procedure” on page 64). 3. See “Removal” on 3.

Remove cap screw (32) and washer (33) at the rear frame (31).F-code Section C-code PS S7.3. Drive pins (34) out by hitting with a soft hammer. and wear strips for damage or wear. 4. Single (RTX45) Version no T-code 001 RTX35/RTX45 2.4. Disconnect hydraulic hoses. Remove rollers (36).1. Rear Frame Removal 1. Clean and inspect all bearing. NOTE! Connect a hoist to rear frame to prevent it from dropping when the channel is raised. 8. Remove screws (20) and washer (22). Disconnect electrical cable. 9. 2.1. Remove reach cylinder rod end pins (24) from the inner frame (10). Inner Arm Removal 1. Drive cotter pins (23) out of the reach cylinder rod end pins. Plug to prevent contamination. Disconnect lift chain from the chain anchors on the rear frame. rollers. 7. 516 Return Service Manual 2001-03-15 . Keep track of shims (35) to each roller and roller to pin location. 2. 5. Raise inner mast channel. 3. Disconnect hydraulic lines from manifold block (30). Lower rear frame. 4. 3. Remove inner arms (10). washers. 2. Plug to prevent contamination. Lift rear frame (31) until all tension is removed from the lift chains. 6. pins. 5. 7. 6. Remove rear frame out the bottom of the mast.3 7241 Reach.

3 7241 Reach. washers (21 and 22). 2. Connect hydraulic hoses. 2. 2. 2. Remove screws (20) and cotter pins from rear frame.2. Connect electrical cable.F-code PS Section C-code S7. Install rear frame pins (27). Return Service Manual 2001-03-15 517 .1. Rear Frame Installation NOTE! Install same number of shims as removed for initial adjustment. 2. Lower inner mast channel onto rear frame rollers (36). 1.000 to 0. Plug to prevent contamination. Disconnect hydraulic hoses. NOTE! Adjust frame rollers so there is 0.2. © BT Prime-Mover Inc. Reach Cylinder Installation 1. Install cotter pins (23). 4. Repair reach cylinders as needed. Connect hydraulic hoses to reach cylinder. 1.76 mm) side movement of the rear frame at the tightest part of the inner mast channel. 3. 2. and pins as needed. 3.1. Reach Cylinder Removal WARNING Block reach to keep it from collapsing. 3. and screws (20). Assembly Install new bearing.2.2. Single (RTX45) Version no 001 T-code RTX35/RTX45 2.030 inch (0 to 0. Install shims (35) and rollers (36). 4. Remove cylinder tube mounting pins (27).5. rollers.

bearing cap (2) and screw (1) on the arms (4 and 15). Check for side clearance. Install upper end of inner arms (10) into rear frame (31). Install bearing (18).F-code Section C-code PS S7. Inner Arm Installation 1. Install bearing (3). 5. Install forks and load backrest. See paragraph 2.2. 2. Install half shafts (13 and 14) and screw (12) attaching front frame to outer arm. 2. Arms should pivot freely with some drag. Install lift chain anchors. Torque to 85 ft-lb (115 N•m). 7. 6. 5.2. Install outer arms (4 and 15) through the center hole of inner arm (10).4.3 7241 Reach.5.2. Install rollers (3) and cap screw (11). Install pins (34) in rear frame (31) and inner arms (10). Single (RTX45) Version no T-code 001 RTX35/RTX45 5. 2. Install front frame (42). washer (17). thrust bearing (8). 518 Return Service Manual 2001-03-15 .2. Arms should pivot freely with some drag. Connect tilt cylinder hoses. Grease all fittings on reach. 8.5 below. 6. Install washer (33) and cap screw (32) and tighten. 3. Install front frame (42) onto inner arm (10) rollers (3). 2. 3. Outer Arm Installation 1. 2. 4. Connect hydraulic hoses to reach cylinder (26). Front Frame Installation 1. 2. 9. Torque nut to 295 ft-lb (405 N•m). 4. Install bearing (7). and nut (16). and shims (9) on the center stud of outer arms (4 and 15).3. Test for proper operation of reach. Install bearing (6) in inner arm (10).

This is the surface the inner scissor arm roller travels against. 2.F-code PS Section C-code S7. Unbolt two flat head screws (56) at the top and bottom of reach wear strip (57). Return Service Manual 2001-03-15 519 . 3.1. Partially extend the carriage so that the end of the inner scissor arm (10) is midway down the track.2. 2. 4. 3. Removal 1. Installation 1. Reconnect battery connector. © BT Prime-Mover Inc. Grease and wedge the new reach wear strip (57) between bearing (3) and track. Install top and bottom flat head screws (56). 3. exposing the top and the bottom of the reach wear strip (57). 4. Reach Carriage Wear Strip A wear strip (57) is used on the RTX45 reach truck.3 7241 Reach. Single (RTX45) Version no 001 T-code RTX35/RTX45 3. Turn key switch OFF and disconnect battery connector. 3. Reconnect hydraulic hoses to tilt and sideshift cylinders from the input side of solenoid valve. The wear strip is located on the back of the reach carriage front frame (42). Place a block on each side of the carriage between the scissor’s lower back bearings and the carriage’s bottom support plate. Remove blocking from the scissor mechanism. 3.

If possible. The carriage must be removed to access these bearings. If the carriage becomes loose within the inner columns.F-code Section C-code PS S7. a suitable bearing puller may be required for removal. Carriage Roller Bearings The upper carriage roller bearing is accessible when the carriage is elevated. The carriage bearing should slide off the shaft with hand pressure. 6.1. If the carriage hangs up in the columns during lowering. Single (RTX45) Version no T-code 001 RTX35/RTX45 4. 6. Remove socket head cap screw (38) and washer (37) on the end of bearing (36). Fork Carriage Pivot Pins RTX45 reach trucks use a shaft (48) with a retainer ring (47). Carriage Bumpers The carriage bumpers assure that the carriage remains square with the truck in its nested position. If necessary. the lower roller bearings may require additional shims. 2. one or more of the roller bearings may be damaged or worn and requires replacement. 5. The lower bearings are shimmed at the factory so that no play exists between the carriage and the inner columns. 3. Two other roller bearings are located within the mast assembly on either side. Removal 1. maintain an equal amount of shim thickness on each side.3 7241 Reach. Remove carriage/reach. The RTX45 reach uses rectangular bumpers (54) attached to the chassis side (back side) of the front frame (42). 520 Return Service Manual 2001-03-15 . The shaft is attached to the reach carriage front frame with a screw (46) and nut (50).

2. 4. Return Service Manual 2001-03-15 521 . Installation 1.F-code PS Version no 001 Section C-code S7. Return truck to service. See “Shimming Carriage with Mast on Truck” on page 459. Install new bearing on shaft. 3. Test lift/lower functions of the carriage. © BT Prime-Mover Inc.3 7241 Reach. Single (RTX45) T-code RTX35/RTX45 6. 2. Fasten cap screw (38) and washer (37) in place. Reinstall carriage/reach. Apply thread locking compound to socket head cap screw (38).

3 7241 Reach. Single (RTX45) Version no T-code 001 RTX35/RTX45 522 Return Service Manual 2001-03-15 .F-code Section C-code PS S7.

F-code Section PS S9. lift height 523 . 1 © BT Prime-Mover Inc.0 9311 Height Indication Version no 000 C-code T-code RTX35/RTX45 Height Indication 1 +1/21 0 Item No. Return Service Manual 2001-03-15 Description Indicator.

broken cable wire. The character window (1) shows the fork height. Error code 13 should disappear. Error Code 13 To clear error code 13 (Height counter error): See “Height Indicator Error” on page 336. A and B. Check continuity for disconnected or broken electrical wire. The pulse sensor sends pulses to the main electronic card. This gives information to the main electronic card on whether the forks are moved up or down. 2. turn key switch OFF and disconnect battery connector.F-code Section PS S9. The pulse sensor has two channels. which give signals at 90 degrees to each other. or faulty terminal connection and repair as necessary. Reconnect battery connector and turn key switch ON. General A height indicator is fitted to trucks with high lifting heights. 3. Before checking wires. If error code 13 fails to disappear continue to check for faulty wires. Operation The measurement in the staging zone starts when the reference switch (S45) is activated and sends a signal to the main electronic card. Error code 13 only appears if current is not flowing to the height indicator. The height indicator shows the current position of the forks within the staging zone. based on information from the sensing device (pulse sensor) mounted on the mast.0 Height Indication Version no T-code 000 RTX35/RTX45 C-code 9311 1. 524 Return Service Manual 2001-03-15 .

Return Description Item No. bottom 10 Washer 17 Nut 4 Spring 11 Screw 18 Screw 5 Roller 12 Arm 19 Cable 6 Bearing 13 Screw 7 Ring. © BT Prime-Mover Inc. locking 15 Device. Description 1 Support 8 Ring. Description Item No. snap 14 Setscrew Service Manual 2001-03-15 525 . sensing 2 Cover 9 Bearing 16 Screw 3 Anchor.F-code PS Section C-code S9.0 9311 Height Indicator (RTX35) Version no T-code 000 RTX35/RTX45 Height Indicator (RTX35) 13 17 18 1 14 10 16 11 12 15 7 6 8 19 5 9 2 Wiring Harness 4 3 Item No.

1. 1.2. 3. Remove spring (4) and anchor (3) from cable (19). Remove screws (16) and cover (2). Remove cable from the pulley. 1. Worn or cables with deteriorated cable coatings will result in less accurate lift height readings. To replace the pulse sensor (15). Wrap cable once around the pulley wheel. Stretch the cable (19) tight and reinstall the bottom anchor bolt. Repair 1. 2. Install a new cable (19) on the top anchor. Remove cable (19) from the top anchor. Attach spring (14) and bottom anchor (3) to the cable (19). Removal 1. 3. Installation 1.1.2. Unplug wiring harness at the sensing unit.2. Reverse the procedure to reinstall pulse sensor. Remove screws (13) and arm (12). 526 Return Service Manual 2001-03-15 . Cable NOTE! Keep cable in good condition.0 9311 Height Indicator (RTX35) Version no T-code 000 RTX35/RTX45 1. 2. remove bolt from the bottom anchor (3) relieving spring tension. Pulse sensor 1. loosen setscrew (14) and remove pulse sensor.2. To replace cable (19).1. 2. 4. 3.F-code Section C-code PS S9.

1. and bearing (6). retaining rings (7 and 8). Remove bearing (9).3. Reverse procedure to reinstall. To replace roller (5). 4. remove cover (2). Remove screw (11) and roller. © BT Prime-Mover Inc. pulse sensor. 2. Return Service Manual 2001-03-15 527 . Pulley 1.3. Removal 1. and cable (19).0 9311 Height Indicator (RTX35) Version no 000 T-code RTX35/RTX45 1.F-code PS Section C-code S9. 3.

sensing 2 Cover 9 Mount. Description 1 Support 8 Ring. set Service Manual 2001-03-15 . locking 15 Device.F-code Section C-code PS S9. retainer 14 Screw. bearing 16 Screw 3 Anchor.0 9311 Height Indicator (RTX45) Version no T-code 000 RTX35/RTX45 Height Indicator (RTX45) 17 18 16 5 6 8 10 11 1 13 14 15 19 2 12 7 9 Wiring Connector 4 3 20 Item No. 528 Return Description Item No. Description Item No. bottom 10 Washer 17 Nut 4 Spring 11 Screw 18 Screw 5 Roller 12 Arm 19 Cable 6 Bearing 13 Screw 20 Screw 7 Ring.

remove bolt from the bottom anchor (3) relieving spring tension. 3. 1. 2. 1.2.2. Install a new cable (19) on the top anchor. Remove cable from pulley.1. Repair 1. Unplug wiring harness at the sensing unit. Remove screws (13) and arm (12). To replace cable (19). 3.2.2. 4. Removal 1. Remove cable (19) from the top anchor. Wrap the cable once around the pulley wheel. 2. Installation 1. Cable NOTE! Keep cable in good condition.0 9311 Height Indicator (RTX45) T-code RTX35/RTX45 1. © BT Prime-Mover Inc. Remove screws (16) and cover (2). Reverse procedure to reinstall pulse sensor. Pulse sensor 1. Stretch cable (19) tight and reinstall the bottom anchor bolt. 3. Attach spring (14) and bottom anchor (3) to cable (19). Return Service Manual 2001-03-15 529 .F-code PS Version no 000 Section C-code S9.1. Remove spring (4) and anchor (3) from cable (19). Loosen setscrew (14) and remove pulse sensor (15). Worn or cables with deteriorated cable coatings will result in less accurate lift height readings. 1. 2.

F-code Section C-code PS S9. To replace roller (5). 3. 2.3. Pulley 1. and cable (19). 530 Return Service Manual 2001-03-15 . Remove screw (11) and roller. remove cover (2). Remove bearing (9). and bearing (6). Reverse procedure to reinstall. Removal 1.1. 4. retaining rings (7 and 8). pulse sensor.3.0 9311 Height Indicator (RTX45) Version no T-code 000 RTX35/RTX45 1.

Return Service Manual Description 1 Backrest 2 Screw.F-code Section PS S9. cap 3 Washer. © BT Prime-Mover Inc. flat 2001-03-15 531 .1 9501 Load Backrest Version no C-code T-code 001 RTX35/RTX45 Load Backrest 1 3 2 Item No.

Reconnect battery connector. Insert mounting screws (2) and tighten. Repeat steps 2 and 3 for the opposite side. 5. aligning mounting holes. be sure to retrieve two shims that go between the backrest and front fork frame. slide shims between frame and backrest.1 Load Backrest 9501 Version no T-code 001 RTX35/RTX45 1. Return truck to service. If truck has sideshift. 6. Turn key switch OFF and disconnect battery connector. All BT Prime-Mover trucks are shipped with the extension installed. Removal of extension could result in injury or product damage. 2. Turn key switch OFF and disconnect battery connector. 4. Lift backrest off the front fork frame. Remove battery from truck. Use a 3/4 inch (19 mm) socket to remove four screws (2) (two on each side). Park the truck on a level surface and make sure all wheels are blocked to prevent accidental movement. For units with sideshift. Park truck on a level surface. 532 Return Service Manual 2001-03-15 . 1. Removal WARNING The load backrest extension also serves as a fork stop. 2.F-code Section C-code PS S9. 3. 4. 5. WARNING Block all wheels to prevent truck from rolling. Place load backrest on front fork frame. 2. Installation 1. 3.

. . . . . . . . . . . . . . . . . . . 531 Back-up Alarm . . . . . . . . . . . 285 Retainer Plates . . . . . . 515 Carriage/Reach Bumpers. Location . . . RTX35 . . . . Wear Strip . . . . . . . . . . . . . . . . . 41 Alarm Back-up . . . . . . . .Index A Carriage/Reach . 180 Armature & Coil . . . . . . . . 103 Codes Error . . . . . . . . . . . . . . . . . Retract . . . . . . . . . . . . . . . . 37 © BT Prime-Mover Inc. . . . . . . Caster . . . 37 Steering . . . . . . . . 125 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Drive . . . . . . . . . . . . . . . Reach. . . . . . . . . . . . . . . . . . . . . . . . . . . . .512. . . . 505 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reach. 1 Components Control Handle . 513 Assembly . . . . 177 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Mast . . . . . . . . . . . . . . . . . 503 Adjustment . . . . . . . . . . . . . .497 Removal . . . . . 123 Adjustment . .497 Troubleshooting . . . . . . . . 517 Disassembly .511. . . . . . . . . . . . . . . . 515 Maintenance . . . . . . . . . . . . . . . . . . 201 Clipboard . . . . . . . . . . . . . . . . . Retract C Cable. . 127 Braking Caster Assembly . . . . . 285 Maintenance . . . . . . . . . . . . 513 Repair . . . . . . . . . . . . . . Standard . . . . . . 327 Carriage Bumpers . . . . . . . . . . . . . . . 520 Bumpers. . . . . . . 33 Applications. . . . . . . 37 Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . 106 Rollers . . . . . . . . . . . . . . . . . 286 Installation . . . . . . . . . 292 Applications. . . . . . . . . . . . . . 181 Friction Plate . . . . . . . . . . 509 Adjustment Points . . . . . . . 519 Roller Bearings Installation . . . . . . . . . . . . . . . . 287 Cleaning Exterior . . . . . . . . . . . . . . . . . . . . . 520 Reach. . . . Height Indicator RTX35 . . . . . . . . . . . 199 Bumpers Carriage . . . . . . . . 292 Travel . . . . . . . . . . . . . . . . . 177 Brake Pedal . . . . 507 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Prohibited . . . . . . . . 33 Aux. . . . . . . . . . . . . . . . . . . 106 Storage . . . . . . . . . . . . . . . . . . . . . . . . 520 Sideshifter . . . . . . . . . . . 124. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182 Installation . . . . . . . . . . . . . 288 Inspection and Care . 521 Removal . . . . . . . 295 History Record . . . . . . 179 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Return 533 . . 201 Electromagnetic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 493 Pad Replacementl . . 529 Card Main Electronic . . . . . . . . . . . . . . . . . . . . 336 Codes. . . . . . . . . . . 308 B Backrest. . . . . . . . . . . . . 288 Bleeding Hydraulic System . . . 526 RTX45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RTX45 . . . . . . . . . 285 Charging . 509 Caster Brake Adjustment . . . . . . . . . . . . . . . . . 509 Assembly . . 401 Brake Adjustment. . . . . . . . 286 Removal . . Power Hook-Up . . . . . . 292 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339 Warning/Caution . . . . . . . . 505 Carriage. 128 Bearing Replacement . . . . . . . . . . 287 Connector . . . 503 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .501 Carriage. . . . . . . . . . Intended . . . . . . . . . . . . . . . . . . . . . Load . . 37 Components. 201 Caster . . . . . .

120 Installation . . . 421 Conversion Formulas . . . . . . . . . . . . . . 13 Warning . . . . . . . . . . . . . . . . . . . . . . 1 Danger . . . . . . . . . . . . . . . . . . . . . . . . . . Left . . . . . . . . . . . . . 436 Installation . . . . . . . . . .454 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429 Assembly . . . . . . . . . . . . . . . . . 444 Removal . . . . . . . . . . . . . . . . . . . . . . . . . .446 Tilt. . . . . . . . . . . 120 Control Valve . . . . 299 Inspection . 315 Removal . . . . . . 442 Installation .456 Removal . . RTX35 . . . . . . . . . . . . . 93 Dimensional Data RTX35 . . . . . . . . . . . . 427 Removal . . . . . . . . 500 Staging . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Operator Compartment Panel. . . 97 Drive Motor . . . . . . . . . . . . . . . . . . . 36 Decals . . . . 34 RTX45 . . . . . . . . . . . . . . . . . . . . . . . . . . 141 Electrical Components. . . . . . . . . 438 Removal . . . . . . . . . . . . . . . . . . . . . . . . 417 Repair . . . . . . . . . . . . .Index Contactor Battery Cut-out Installation . . . 437 Disassembly . . . . . 101 Motor Compartment Door . . . . . . . . . . . . 52 Cover Main Electronic Card Panel . . . . . . . . . 121 Removal . . . . . . . . 441 Inspection . 87 Emergency Disconnect Switch . 313 Removal . . . . . . . . . . . . . . . . . . . 432 Disassembly . . . . . . . . . . . . . . . . . . . . . . . 13 Note . . . . . . . .447 Inspection . . . . . . . . . . . . . . . 364 E Electrical Compartment Fan . Location . . . . . . . . 426 Installation . . . . . . 435 Inspection . 107. . . . . . . . . . . 440 Sideshifter . . . . . . . . . . . . . . 221 Electrical Schematics . .453 Inspection . . . . . . . . . . . 430 Reach. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 445 Assembly . . . . . . . .455 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RTX45 . . . . 309 Tip Inspection . . . . . . . . . . . . . . . . . . . . . . Return 534 . . . . . . . . . . . . . . . . . . . . . . . . . . 299 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271 Electrical Troubleshooting . . . . . . . . . . . .449 Disassembly . . . . . . . 35 Door. . 98 Top Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364 Motor Speed Sensor . . . . . 13 Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RTX35 . . . . . . . . . . . . . . . . . . . . . 96 Cylinder Freelift . . . . . . . 426 Tilt. . 433 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425 Assembly . . 273 Electrical Symbols . . . . . . 427 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313 Testing Resistance . . . . . . . . . . 133 Definition Caution . . . . . . . . .448 Installation . . . . . . . . . . . . . . . . . . 439 Assembly . . . . . . . . . . . . . . 432 Removal . . . . . . . . Motor Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RTX45 . . . . . . . 299 © BT Prime-Mover Inc. . .450 Removal . . . . . . . . 165 Motor Direction Sensor . . 268 Electrical Functions . . . .452 D Data Plate . . 315 Lift Bypass Installation . . . . . . . . . Left 100 Side Panel. . 309 Control Handle . . 434 Reach. . . . . 13 Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 451 Assembly . . . . . . . . . . . . . . . . . . . . . 443 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432 Installation . . . . . . 300 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . 67 Maintenance. . .Index K Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . Hydraulic . . . . . Control . . . . . . . . . . Bleeding . . . . . . . . . . . . . . . . . . . 100 Left Side Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Truck Torque Specifications . . . . . . . . 290 Working . 305 G Gear Steering Motor . . . . . . . Battery . . . . 488 Removal . . . . . . . . . . . . 489 Assembly . 487 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Guard Overhead . . . . . . . . . . . . . . . . . . . . . . 102 Fuses . . . . . . . RTX45 . . . . . . . 120 Height Indicator RTX35 . . . 324 Installation . . . 525 RTX45 . 394 Hydraulic System. . . 491 Removal . . . . 487 Installation . . . . . . . . . . . . 85 Glossary . . . . . . . . . . . . 129 Fasteners . . Planned . . . . . . . . . 485 Assembly . . . 490 Lights Overhead Guard . 405 Floor Board . . . . . . 40 M Main Electronic Card . . . . . . . 505 Lifting Gear. . . . . . . . . . . . . . . . . . . 324 Removal . . . . . . . . . . 286 Introduction . . . . . . . . . . . . . . . . . . . . . . 79 Lubrication Points . . . . . . . . 291 Load Backrest . . . . . . 405 Hydraulic Pump . . . 43 Designations . . . . . . RTX35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 491 Installation . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 339–344 F Fan Electrical Compartment . . . . . . . . . . . . . . . . . . 401 Hydraulic Troubleshooting . . . . . . . . . . . . . . . . . . . . . Battery . . . . . . . . . 46 Strength Identification . . 92 I Inspection and Care. . . . . . . . . . . . . . . . . . . 139 General Troubleshooting . . . 531 Installation . . . . . . . . . . . . . . . . . 289 Warning . . . . 293 Hydraulic Filter . . . . . . 131 H Handle Interface Module . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Maintenance Schedule . . . . . . . . . . . . . . . . . . 486. . . . . . . 327 Maintenance . . . . . . . . . . . . . 528 Horn . . . . Return 535 297 297 298 297 . 65 Lubrication Chart . . . . . . . 532 Lubricants Cold Storage . . . . . . . . . . . . . . L Left Operator Compartment Panel . . . . . . . . . . . . . . . . . . . 409 Hydraulic System List of Symbols . . . . . . . . . . . . . . . . 286 © BT Prime-Mover Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Stage Mast . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324 Lifting Gear. . . 98 Lift Chain. . . . . . . . . . . 476 Lift Limit Override Switch . . . . . . . . . . . . . 532 Removal . . . . . . . . . . . . . . . . . . . 27 Key Switch . . . . . . . . . . . . . . . . 51 Filter. . . . . . . . . . . . . . 496 Maintenance Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 491 Disassembly . 45 Torque Values . . . . . . . . . . . . . . . . . . . 119 Handle. . . . . . . . . 72 Sideshifter . . . . . . . . 141 Operator . . . . . . . . . . . .

. . . . . . . . . . . . . Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 Pump . Pump Motor . 106 Platform Switch . . . . . . . . . . . . . . . . . . . 364 Drive . . . . . 100 Panel. . . . Operator Fan . . . . . . . 143 Operating Environment . . . . 364 Installation . . . . . . . . . . . . . . . . . . . . . . 503 Repair . . . . . . . . . . . . . . . . . . . . Battery . . . . . . . . Main Electronic Card . . . . .Index Maintenance. Left Operator Compartment . . . . . Battery Retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overhead Light Switch . . . . . . . . . . . 15 Jacking Procedure . . . . . . . Introduction . .511. . . . . 364 Steering . . . . . . . . . . Return 536 . . . . . . . . . 107. . . 302 Installation . . . . . . . . . . . 520 Plate. . . . . . Fork Carriage . . . . . Pulse Sensor. . . . . . . . 110 Speed Sensor . . . . . . . . . . . . . . 505 Reach Carriage. . . . Overhead Guard . . . . . . . . Pump. . . . . . . 145 Direction Sensor . . . . Installation . . . . 517 Disassembly . . . . . . . . . . . . 98 Panel. . . . . . . . . . . . . . . . . . . 345 362 527 530 526 529 110 409 R Reach Carriage. . . . . . . . 520 Rollers. . Handle Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 509 Assembly . . . . . . . . . Installation . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Stage Lift Chain . . . . 507 Disassembly . . . . . . . . . . . . . . . . 106 RV2 Adjustment Procedure . . . . . . . 143 Troubleshooting . . . . . . . . . . . . . . . . . . . 358 Safety Battery . . . . . . . . . . . . . Operator Fan Switch . . . . . . . . . . . . . Height Indicator RTX35 . . . . . . . . . . . . . . . . . . . . . . . . . . Overhead Guard Lights . . . . . . 513 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Mast Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301 Adjustment . . . . . . . . . . . .365 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic . 36 Plates. . . . . . Pulley. . . . . . . . . . . . RTX45 . . . . . . . 476 Module. . . . . . . . . . . . . . . . . . . . . 64 Welding . . . . . 503 Adjustment . . 144 Primary Sources . . . . . . . . 19 Electrostatic Discharge . . . . . . . . . 515 Maintenance . . . . . . . . . . . 505 Maintenance . . . . 101 Pivot Pins. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 Motor Compartment Door . . . . . . . . Height Indicator RTX35 . . . . . . . . . . . . . 304 Removal . . . . . . . . 119 Motor Brush Performance . . . 519 Roller Bearings Carriage Installation . . . . . . . . . . . . . . . . . . 303 Mast. . . . . . . . . . . . . . . . . . . . . . . . . . . . RTX45 . . . .364 © BT Prime-Mover Inc. . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 129 325 325 325 131 289 325 325 325 Programming Parameters . . . . . . . . . . . . . . 358 Removal . . . Left Side . . . . 165 General . . RTX45 . . . . . . 511. 23 General . .512. . . . . . . . . 521 Removal . . . . . . . . . . . 515 Reach Wear Strip . . . . Proximity Sensor Steer Stop . . . . . . . . . . . . . . . . . . . . . . . . RTX35 . . . 24 Sensor Drive Motor Direction . . . . . . 97 O Operator Compartment Floor . . 357 Installation . . . . . . . . . . . . . . . 513 Assembly . . . 354 S P Panel. . .

. . . . . . . . . . . . . . . . . . . . . . . 364 Installation . . . 363 Removal . . . 137 Storage. . . . . . . . . . . . . . . . . . . . . . 288 Switches Emergency Disconnect . . . . . . . . . Steer . . . . . . . . . . 373 Lifting . . . . . . . . . . . . . . . . . . 362 Wheel Direction . . Low Speed . . . 364 Steer Stop Proximity . . . . . . . . . . . . . . . . . . . . . . . 96 Transmission . . . . . . . . . . . . 379 Lowering . . . . . . . . . . . . . . . . . . . . Ordinance . . . . . . . . . . . . . . . . . . . 79 Truck Specifications . 365 Removal . . . . . . . . . . . . . . . . . . . . . . 65 Truck Lubrication Points . . . . . . . . . . . . Left . . . . . 292 Troubleshooting General Instructions . . . . . . . . 501 Troubleshooting Guidelines Electrical . . . 297. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301 Operator Fan . . . . . . . . 496 Operation . . . 51 V Valve © BT Prime-Mover Inc. . . . . . . . . 377 Retract. . . 375 Low Speed Extend . . . . . . . . . . . . . . . . . High Speed . . . . . . . . . . 115 Repair Leakage. . . 529 Sideshifter Carriage . . . . . . . . . . . . Battery . . . . . . . . . . . . . . 324 Mast Switch . . . . . . . . . 217 Technical Service Data . . . . . . . . . . . . . . . . . . . 359 Steer Tachometer . . 358 Installation . . . . 495 Maintenance . . . . . 323. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Truck Torque Specifications . . . 387 Top Console . . . . . . . . . . . . . . . 59 Specification Plate . . . . . . . . . . . . Warning . . . . . . . . T Tachometer. . . . . . . . 215 Steer Stop Proximity Sensor . . . . . 500 Installation . . . . . . . 526 RTX45 . . . . . . . . . . . . . . . . . . . . . . . . 381 Hydraulic Control Handle Interface 369 Hydraulic Supply . . . . . . . . . . . . . . . . . . . . . . . . . . Right . . 385 Retract. . . . . . 357 Staging . . . . . . . . . . 357 Work Light . . . . . . . . . . Danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Staging Switch . 169 Fluid Changing . . . . . . . . . . . . . . . . . . . . 362 Installation . . . 383 Sideshift. . . . . . . 363 Steering Bearing . . . . . . . . Down . . . . . . . . . . . . . . . . 92 Truck Installation Cold Storage Conditioning . . . . . . . . 301. . . Oil and Grease . . . . . . . . . . . . . . . . . 360 Sensor. . . Return 537 13 13 14 14 13 . . . . 85 Sideshifter . . . . 497 Removal . . . . 217 Wheel . . . . . . . . . . . . . . . . . . . . . . . .174 Leakage. . . . . . . . . 493 Pad Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Prohibitory . . . . . . 36 Specifications. . . . . Lower Cover . . 219 Motor . . . . . . . . . . .175 Travel Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . Ordering . . . . . . . . . . . Top Cover . . . . . . . . . . . . . . . 297 Lift Limit Override . . . . . . . . . 87 Hydraulic . . . .173 Wheel Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359 Removal . . . . . . . . . . . . 325 Symbols Caution . . . . . . . . . . . . . . 325 Platform Switch . . . . . . . . . . . . . . . . . . 299 Key Switch . . . . . . . . 497 Cylinder . . . . . . . . . . . . . . . . . . . . . . . . 393 High Speed Extend . . . . . . . . . . . .Index Drive Motor Speed . 325 Overhead Light . . . 496 Spare Parts. . . 362 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358 Test/Inspection . . . . . . . . . . . . . . . . 389 Sideshift. . . . . . . . . . . . . . . . . . . 55 Theory of Operation Fork Tilt. . . . Pulse RTX35 . . . . . . . . . . . .

361 Removal . . . . . . . . . . . . . . . . . . . . . 361 Wheels Caster . . . . . . . . . . . . . . . 360 Adjustment . . . . . . . . . . .211 Tandem . . . . . 325 Removal . . . . . . . . . Pressure Setting . . . . . . . . . . . . . . 215 Wheel Direction Sensor . . . Pressure Limiting. . . . . . . 325 Working Lights . . . . Return 538 . . . . . . . . . 203 Load Single . . 417 423 422 421 422 423 421 W Warning Lights . . . . . . . . . . . . . 325 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repair . . . . . . . . . . . . 197 Caster. . Repair . . . . . . . . . . . Reach Carriage . . . . . . . . . . . . Seal Kit . . . . . . . SWR14. . . . . . . . . . . . . . . . . . . . . . Repair . . . . . . . .207 Work Light Switch . . .Index Control . . . . 291 © BT Prime-Mover Inc. . . Pressure Reducing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336–?? Wear Strip. . . . . . . 290 Warning/Caution Codes . . . with brake . . . . . . . . . . . . . Lowering Rate Adjustment . . 519 Wheel Steering . . . .

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Back Cover BT Prime-Mover.A. Highway 38. Inc.S. Iowa 52761-8800 U.. Tel (563) 262-7700 • Fax (563) 262-7600 Return . 3305 N. Muscatine.