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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

Chassis

0000

Drive Motor

1000

Drive Gear / Transmission

2000

Brake / Wheel System

3000

Steering System

4000

Electrical System

5000

Hydraulic / Pneumatic System

6000

Operating Function-lifting Mast / Cylinders

7000

Peripheral / Installation Equipment

8000

Options / Attachments

9000

Service Manual

2001-03-15

F-code

Section

C-code

BT Prime-Mover Standard Codes


Version no

T-code

000

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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 ................................................................................... 320
Micro Switches ............................................................................................
General ....................................................................................................
Lift Limit Override Switch (S33) ...............................................................
Optional Light and Fan Switches (S96, S97 and S99) ............................

323
323
324
325

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


Removal ...................................................................................................
Installation ................................................................................................
Connectivity to Truck ...............................................................................
Display .....................................................................................................
Warning/Caution codes ...........................................................................
Error codes ..............................................................................................
Parameters ..............................................................................................
Running time ............................................................................................
Programming Parameters ........................................................................
RV2 Adjustment Procedure .....................................................................
Adjustment Procedures for
Setting Brake Switch and Brake Transducer ...........................................

327
327
327
328
334
336
339
344
344
345
354

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


General ....................................................................................................
Platform (Right Foot) Switch (S23) ..........................................................
Staging Switch (S45) ...............................................................................
Wheel Direction Sensor ...........................................................................
Steer Stop Proximity Sensor A and Sensor B .........................................
Drive Motor Speed/Direction Sensors .....................................................

357
357
357
358
360
362
364

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


Operation .................................................................................................
RTX35 Hydraulic Schematic ....................................................................
RTX45 Hydraulic Schematic ....................................................................

367
367
396
397

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


Hydraulic Fluid Selection .........................................................................
Changing Hydraulic System Fluid ............................................................
System Draining ......................................................................................
System Refilling .......................................................................................
Bleeding Hydraulic System ......................................................................

399
399
399
400
401
401

355

Hydraulic Tank ............................................................................................ 403


Removal ................................................................................................... 403
Installation ................................................................................................ 404

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Table of Contents
Hydraulic Filter and Adapter ..................................................................... 405
Hydraulic Filter ......................................................................................... 406
Hydraulic Filter Adapter .......................................................................... 407
Hydraulic Pump ..........................................................................................
Removal ...................................................................................................
Pump Disassembly ..................................................................................
Parts Inspection .......................................................................................
Pump Reassembly ...................................................................................
Testing .....................................................................................................

409
410
410
413
414
416

Control Valve ...............................................................................................


Removal ..................................................................................................
Installation ................................................................................................
Repair ......................................................................................................

417
417
417
421

Staging Cylinder, 3 Stage ........................................................................... 425


Staging Cylinder Repair ........................................................................... 426
Freelift Cylinder, 3 Stage ........................................................................... 429
Freelift Cylinder Repair ............................................................................ 430
Reach Cylinder (RTX35) .............................................................................
Removal ...................................................................................................
Disassembly ............................................................................................
Inspection ................................................................................................
Assembly .................................................................................................
Installation ................................................................................................

433
434
435
436
437
438

Reach Cylinder (RTX45) .............................................................................


Removal ...................................................................................................
Disassembly ............................................................................................
Inspection ................................................................................................
Assembly .................................................................................................
Installation ................................................................................................

439
440
441
442
443
444

Tilt Cylinder (RTX35) ...................................................................................


Removal ...................................................................................................
Disassembly ............................................................................................
Inspection ................................................................................................
Assembly .................................................................................................
Installation ................................................................................................

445
446
447
448
449
450

Tilt Cylinder (RTX45) ................................................................................... 451


Removal ................................................................................................... 452

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10

Table of Contents
Disassembly ............................................................................................
Inspection ................................................................................................
Assembly .................................................................................................
Installation ................................................................................................

453
454
455
456

Mast, 3 Stage (RTX35) ................................................................................. 457


Shimming Carriage with Mast on Truck ................................................... 459
Three Stage Mast .................................................................................... 461
Mast, 3 Stage (RTX45) ................................................................................. 466
Shimming Carriage with Mast on Truck ................................................... 468
Three Stage Mast .................................................................................... 470
Lift Chain ......................................................................................................
Lift Chain Adjustment ...............................................................................
Lift Chain Maintenance ............................................................................
Lift Chain Inspection ................................................................................
Lift Chain Lubrication ...............................................................................
Lift Chain Replacement ...........................................................................

476
476
476
476
482
484

Lifting Gear (Crosshead) (RTX35) ............................................................. 485


Lifting Gear Repair ................................................................................... 486
Lifting Gear (Crosshead) (RTX45) ............................................................. 489
Lifting Gear Repair ................................................................................... 490
Sideshifter ....................................................................................................
Mounting Instructions ...............................................................................
Operation .................................................................................................
Maintenance ............................................................................................
Troubleshooting .......................................................................................

493
495
496
496
501

Reach, Single (RTX35) ................................................................................


Maintenance ............................................................................................
Reach Repair ...........................................................................................
Carriage Bumpers ....................................................................................
Fork Carriage Pivot Pins ..........................................................................
Carriage Roller Bearings .........................................................................

503
503
505
509
511
511

Reach, Single (RTX45) ................................................................................


Maintenance ............................................................................................
Reach Repair ...........................................................................................
Reach Carriage Wear Strip ......................................................................
Fork Carriage Pivot Pins ..........................................................................
Carriage Bumpers ....................................................................................

513
513
515
519
520
520

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Table of Contents
Carriage Roller Bearings ......................................................................... 520
Height Indication .........................................................................................
General ....................................................................................................
Operation .................................................................................................
Error Code 13 ..........................................................................................

523
524
524
524

Height Indicator (RTX35) ............................................................................ 525


Pulse sensor ............................................................................................ 526
Height Indicator (RTX45) ............................................................................ 528
Pulse sensor ............................................................................................ 529
Load Backrest ............................................................................................. 531
Removal ................................................................................................... 532
Installation ................................................................................................ 532

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Section

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Warning Symbols
Version no

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Warning Symbols
Always follow the warnings given in this Instruction Manual
and on the truck to avoid accidents and incidents from
occurring.

1. Warning Levels
Warning texts are given in four levels and provide information
on the risks, describe the consequences, and instruct how to
avoid accidents.
DANGER
Warns that an accident will occur if the instructions are not
followed.
The consequences are serious personal injury or possibly
death, and/or extremely large material damage.

WARNING
Warns that an accident can occur if the instructions are not
followed.
The consequences are serious personal injury or possibly
death, and/or large material damage.

CAUTION
Warns that an accident can occur if the instructions are not
followed.
The consequences are personal injury and/or material
damage.

NOTE!
Marks the risk of an accident or breakdown if the
instructions are not followed.

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Service Manual

2001-03-15

13

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Section

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PS
Prohibitory Symbols
Version no

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001

Prohibitory Symbols

NO SMOKING
If smoking occurs in situations where a restriction against
smoking is stated, a serious accident can occur.

OPEN FLAMES PROHIBITED


If open flames are used in situations where open flames are
prohibited, a serious accident can occur.

GENERAL PROHIBITION
If the prohibition is ignored, a serious accident can occur.

1. Ordinance Symbols

SAFETY SHOES
When the directive for safety shoes is given, safety shoes
shall always be worn to avoid personal injury.

PROTECTIVE GLASSES
When the directive for protective glasses is given,
protective glasses shall always be worn to avoid personal
injury.

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Section

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Safety
Version no

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Safety
1. General Safety
Do NOT operate or work on this truck unless trained,
qualified, and authorized to do so and have read the
Operators Manual.

Know the trucks controls and what they do.

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


way unsafe.

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Service Manual

2001-03-15

15

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Section

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PS
Safety
Version no

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001

Operate this truck only from the operators position.

Before working on this truck, always turn the key switch to


OFF and disconnect the trucks battery connector (unless this
manual tells otherwise).

Do NOT wear watches, rings, or jewelry when working on the


truck.

Follow the scheduled


inspection steps.

16

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Service Manual

lubrication,

maintenance,

and

2001-03-15

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Safety
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001

Follow exactly the safety and repair instructions in this


manual. Do NOT take shortcuts.

BT

Do NOT use an open flame near the truck.

Do NOT use gasoline or other flammable liquids for cleaning


parts.

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


spilled on the floor.

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Service Manual

2001-03-15

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Section

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PS
Safety
Version no

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001

Always operate and park this truck indoors.

Do NOT wash this truck with a hose.

Do NOT add to or modify this truck without written approval


from BT Prime-Mover, Inc.

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2001-03-15

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Section

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Battery Safety
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Battery Safety
WARNING As a battery is being charged, an
explosive gas mixture forms within and
around each cell. If the area is not properly
ventilated, this explosive gas can remain
in or around the battery for several hours
after charging. Be sure there are no open
flames or sparks in the charging area. An
open flame or spark can ignite this gas,
resulting in serious damage or injury.
WARNING Battery electrolyte is a solution of sulfuric
acid and water. Battery acid causes burns.
Should any electrolyte come in contact
with your clothing or skin, flush the area
immediately with cold water. Should the
solution get on your face or in your eyes,
flush the area with cold water and get
medical help immediately.
Read, understand, and follow procedures, recommendations
and specifications in the battery and battery charger
manufacturers manuals.

Wear personal protective equipment to protect eyes, face,


and skin when checking, handling, or filling batteries. This
equipment includes goggles or face shield, rubber gloves
(with or without arm shields), and a rubber apron.

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Service Manual

2001-03-15

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Battery Safety
Version no

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001

Make sure a shower and eyewash station are nearby in case


there is an accident.

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


open flame, or use anything that gives off sparks near a
battery.

Keep the charger area well-ventilated to avoid hydrogen gas


concentration.

Turn the key switch off before disconnecting the battery from
the truck at the battery connector. Do NOT break live circuits
at the battery terminals. A spark often occurs at the point
where a live circuit is broken.

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Battery Safety
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001

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


short circuit or explosion could result.

Keep batteries clean. Corrosion causes shorts to the frame


and possibly sparks.
Keep plugs, terminals, cables, and receptacles in good
condition to avoid shorts and sparks.

Keep filler plugs firmly in place at all times except when the
electrolyte level is checked, when water is added to the cells,
or when the specific gravity is checked.
Make sure vent holes in filler plugs are open to allow gas to
escape from the cells.

Vent Hole

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2001-03-15

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Battery Safety
Version no

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001

Do NOT allow cleaning solution, dirt, or any foreign matter to


enter the cell.
Make sure to install the correct size battery. A smaller or
lighter weight battery could seriously affect truck stability. See
the trucks specification (data) plate for more information.

Never plug a battery charger into the trucks battery


connector. 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.

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Static Safety
Version no

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

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2001-03-15

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Welding Safety
Version no

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001

Welding Safety
WARNING Flame cutting or welding on powder coat
painted surfaces may produce potentially
harmful fumes, smoke and vapors. Prior to
performing flame cutting or welding
operations, it is recommended that the
coating be removed in the vicinity where
the operation(s) will be performed.
WARNING Coating removal may be by mechanical
methods, chemical methods or a
combination of methods. Flame cutting
and/or welding operations should be
carried out only in well ventilated areas
using local exhaust if necessary.
Before working on this truck, make sure that:
Fire protection equipment is nearby.
Know where the nearest eyewash station is.

CAUTION Disconnect battery before attempting to


inspect, service, or repair the truck.
Check for shorts to frame. If any shorts are detected,
remove them before proceeding with the welding
operation.
Clean the area to be welded.
Protect all truck components from heat, weld spatter and
debris.

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Welding Safety
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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.

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2001-03-15

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PS
Welding Safety
Version no

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001

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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.
1+01/2

An Operators Manual is sent with every BT Prime-Mover


truck when it is manufactured. If the Operators Manual is
missing from the truck, a new manual may be obtained by
contacting:
BT Prime-Mover, Inc.
3305 N. Highway 38
Muscatine, Iowa 52761-8800
(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

BT Prime-Mover Inc.

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SUBJECT

MACHINE INFORMATION

PLANNED MAINTENANCE

SERVICE INSTRUCTIONS

OPTIONS

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Introduction, Service Manual
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Contents, Section M
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Contents, Section M
1. Machine Information

BT Prime-Mover Inc.

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M1.0

GENERAL PRODUCT INFORMATION

M2.0

TECHNICAL SERVICE DATA

M3.0

ORDERING SPARE PARTS

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Contents, Section M
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General Product Information
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RTX35/RTX45

General Product Information


1. Truck Presentation

1+01/2

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 operators line of sight for
proper operation of truck. The terms right-hand and left-hand
used indicate the right and left side of the truck as viewed
from the operators line of sight for proper operation of truck.

Left Side

Rear

Forward

Right Side

BT Prime-Mover Inc.

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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.

+1
1/2
0

Open
back
compartment

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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 trucks lifting capacity, lifting height, and weight can be
found on the trucks 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.

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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

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1.7. RTX45 Dimensions


The following diagram shows external dimensions for the
RTX45 truck in its standard design.
Dimensions shown in parentheses are metric, others are inches.
6
(17 9.5
65)
5.5 (139)
8.0 (203) 32.0 (812)
to
to
30 (762), 36 (914), 42 (1066),
50.0
(1270)
29.5
(749)
48 (1219)
1.75 (44) x 4.0 (101) Forks

40.5 31.0
1028) (787)

5.5 (139)
74.6
(1894)

B
7.7 (195)

A
46.0 (1168)

95.0
(2413)

22.0 (558)
C

48.0
(1219)
+4
11.75
(298)
Step
Height

OALH

-3

3.0
(76)

2.0
(50)

Battery
Roller 7.0 (177)
Height

16.4
(416)

5.0
(127)

60.0
(1524)

9.1
(231)

Free Lift

10% Empty and 6% Loaded Gradient Performance

BT Prime-Mover Inc.

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1.8. Data Plate


The illustration below shows the data plate used on the truck.

Model

Truck Serial Number

1
Battery Wt.
Maximum (Lbs.)

Battery Wt.
Minimum (Lbs.)

Use UL Class
Battery Type

6
Type

Max. Amp Hr.

14
Hour Rate

Attachment

Mast Serial Number

10

Inches
B

Truck Wt.
Less Batt. (Lbs.)

DC Voltage

Cap. (Lbs.)

11

12

Max
Back Tilt

13
B

THIS FORKLIFT TRUCK MEETS OR EXCEEDS DESIGN SPECIFICATIONS OF


ANSI/ASME B56.1 IN EFFECT ON THE DATE OF MANUFACTURE.

BT Prime-Mover, Inc.
Muscatine, IA 52761

310574-000

Legend
1
2
3
4
5
6
7
8
9
10
11
12
13
14

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Truck model number


Truck serial number
Weight less battery
Maximum battery weight
Minimum battery weight
Truck voltage DC
Battery type UL class
Battery maximum AMP hours
Hour rate
Truck type
Mast serial number
Attachment
Maximum degree rear tilt
Truck capacity

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2. Main Components
1

Hydraulic valve:
The valves are located to provide easy access.

Battery:
24/36V with different capacities and weights.

Battery connector:
The truck is connected to the battery through the battery connector.
When charging the battery, do not connect the battery charger to the
battery connector at the truck chassis.

Hydraulic unit:
Pump motor and pump are an integrated unit.

Drive unit with brake:


Drive motor, gears, drive wheel, and electrical brake combined in the
drive unit.

Electrical steering:
A servo steer motor drives a gear ring enabling the drive unit to be
rotated through 180 degrees (90 degrees in either direction).

Data plate:
See Data Plate on page 36.

Cover:
Removable to provide access for servicing.

Pedal:
Brake pedal.

10 Control console:
The operator controls are located either on the console cover or on
the control handle. The steering wheel, instrument panel, and
switches (key switch, emergency stop, and light/fan cluster) are on
the console cover. The hydraulic functions (lift, reach, and auxiliary),
horn, and travel speed and direction are controlled through the control
handle. The orientation of the controls permit operation in a 45 degree
or side stance configuration.
11 Instrument panel (Operator Display):
Provides information on the trucks running hours, time display, error
codes, parking brake, and battery status.
12 Mast:
The mast is a clear view model.
13 Electronics:
The electronics are in a protected compartment.
14 Control circuit fuse (F50):
10A, BT part number 25275-12
15 Steering circuit fuse (F51):
30A, BT part number 25275-13
16 Drive motor fuse (F1):
250A, BT part number 305656-000

BT Prime-Mover Inc.

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17 Pump motor fuse (F3):


RTX35 425A, 24V BT part number 305656-002
RTX35 355A, 36V BT part number 305656-001
RTX45 500A, 36V BT part number 305656-004
18 Right foot pedal
An operator must keep all of his or her body in the operators
compartment at all times. The area of the operators compartment in
the RTX35/45 is designed so that an operator can do so. A red
triangle (reminder light) will be displayed on the instrument panel if the
right foot pedal is not depressed. This feature reinforces that the
operator must take advantage of the area of the operators
compartment and keep all of his or her body in the compartment.
19 Emergency stop
The emergency stop switch will stop all control and power functions.
20 Lift height indicator fuse (F52):
1/4A, BT part number 25275-11
21 12 volt sensor feed fuse (F53):
1/4A, BT part number 25275-11
22 Display power fuse (F54):
1/4A, BT part number 25275-11
23 Relay1 fuse (F55):
10A, BT part number 25275-12
24 Fuse (AF1):
10A, BT part number 25275-12
25 Fuse (AF2):
10A, BT part number 25275-12
26 Auxiliary power circuit fuse (AF3):
2A, BT part number 25275-15

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12
19

11
16
17

10
8
1+ 01/2

5
4
6
7
9
18

13

14
15
20
21
22
23
24
25
26

Main Components of Truck

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3. Grease Point Location

1+ 01/2

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4. Mast Adjustment Points

+1 1
0/2

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Inch (SAE) and Metric Fasteners

10

10

1. Introduction
Threaded fasteners such as bolts, nuts, cap screws, and
studs are made to specifications that describe the mechanical
strength and hardness of the fastener. A fastener used in a
design application is selected in accordance with its
specifications. Fasteners that are similar cannot be used as
direct replacements.
Service persons must use replacement fasteners that have
the same specifications as the original. Fasteners made to
each specification have identification marks for that
specification. This specification is commonly called grade
for SAE standards and property for metric standards. This
section describes the identification of some common
fasteners.
The metric system used is described as SI (International
System of Units, also called SI in all languages). The SI
system of measurement is described in ISO Standard 1000,
1973.

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2. Nomenclature, Threads
The thread design is specified by a series of numbers and
letters for inch and metric fasteners (see figure below). The
diameter of the shank of the fastener is shown first in the
series, e.g. M12=12 mm, M20=20 mm (1/2=1/2 inch, 3/4=3/4
inch).

The number of threads per inch is normally not shown for inch
nomenclature and only the UNC (Unified National Coarse) or
UNF (Unified National Fine) is shown. This number of threads
per inch is not shown because a UNC or UNF fastener has a
standard number of threads per inch for a specific diameter.
The length of a shank is often indicated as part of the
description of a fastener. This length is shown in inches for
inch fasteners and in millimeters for metric fasteners.
A cap screw will have the following description:
INCH

METRIC

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


A
B
C
D

M12 x 1.75 x 50
A
B
C

A = SHANK DIAMETER
B = NUMBER OF THREADS PER UNIT
OF LENGTH
C = TYPE OF THREAD
D = SHANK LENGTH

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A = THREAD SIZE
B = PITCH
C = LENGTH

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3. Strength Identification
The most common property classes for metric fasteners are
8.8 and 10.9. The property class is marked with a number on
the head of the cap screw or on a nut. Property classes less
than 8.8 are often not marked. Grades for inch bolts go from 2
to 8. Grade 2 fasteners normally do not have marks. The
following tables show the marks that identify the grades and
property classes for different fasteners.
When fasteners must be replaced, new
CAUTION fasteners must be of same strength or
greater than original fasteners. The new
fasteners must also be the correct size.
NOTE! Identification marks are according to bolt
strength. The higher the number, or increase
in number of marks, indicates increased bolt
strength.

BT Prime-Mover Inc.

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Table 1. Bolt and Screw Designations

Types of
Fasteners

Inch Fasteners

Metric Fasteners

Strength Levels: SAE Grades

Strength Levels: Property Classes

* Markings Not Required


2

5.2

Hex Head Bolts


& Cap Screws

4.6*

4.8*

5.8*

8.8

4.6

4.8

5.8

8.8

9.8

10.9

12.9

9.8

10.9

12.9

Markings
for size
M5 and
Larger

Hex Head
Flange Screws

Same As Above
5

12 Point
Flange Screws
Markings Not Required

8.8

12.9

8.8

12.9

Hex Socket Head


Cap Screws
5.1

4.8*

9.8

4.8

9.8

SEMS

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Table 2. 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

4.6*
5.2*

8*

5.8*

4.8

4.6

5*

4.8*

8.8

5.8

9.8

10.9

9.8

10.9

8.8

12.9
Markings
for size
M5 and
Larger

12.9

8.1
or

Studs

Optional Geometric Symbols for


Size M5 through M11 ONLY.

Hex Nuts

Hex Slotted Nuts

Hex Flange Nuts

BT Prime-Mover Inc.

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10

12

10

12

10

12

8
or

or

Markings Not Required

10

12

10

12

10

12

10

12

Markings Not Required

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Table 3. Torque Nut Designations

Types of
Fasteners

Inch Fasteners
Strength Levels: SAE Grades

Metric Fasteners
Strength Levels: Property Classes

10

10

or
All Metal Prevailing Torque
Nuts

G
9

10

or
All Metal Prevailing Torque
Flange Nuts

10

or

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Table 4. Torque Nut with Nylon Insert Designations

Types of
Fasteners

Metric Fasteners

Inch Fasteners

Strength Levels: Property Classes

Strength Levels: SAE Grades

10

10

or

Nylon Insert Prevailing Torque


Nuts

Markings Not Required

or
or

Markings Not Required

10

10

or

Nylon Insert Prevailing Torque


Flange Nuts

BT Prime-Mover Inc.

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Table 5. Fastener Torque Values

Size and Pitch

Property, Class
8.8*

Property, Class
10.9**

Property, Class
12.9***

Nm

in-lbs

Nm

in-lbs

Nm

in-lbs

5-6
8-10
20-25

44-53
71-88
177-221

7-8
12-14
30-35

62-71
106-124
------------

8-10
14-16
------------

71-88
124-142
------------

Nm

ft-lb

Nm

ft-lb

Nm

ft-lb

M8 x 1.25
M10 x 1.5

-----------40-45

-----------30-33

-----------60-65

22-26
44-48

34-40
70-75

26-30
52-55

M12 x 1.75
M14 x 2

70-80
110-125

30-33
52-59

100-110
155-180

74-81
114-133

115-130
180-210

85-96
133-155

M16 x 2
M20 x 2.5

170-190
340-380

125-140
251-280

240-270
450-500

177-199
332-369

280-320
550-600

207-236
406-443

M24 x 3

580-650

428-479

800-900

590-664

900-1050

664-774

M30 x 3.5

1150-1300

848-959

1600-1800

1180-1328

1850-2100

1364-1549

M36 x 4

2000-2250

1479-1660

2800-3150

2065-2323

3250-3700

2397-2729

M5 x 0.8
M6 x 1
M8 x 1.25

Property class 8.8, Protective Treatment CMHC


Specification H (zinc phosphate), applies also to
internally threaded fasteners made of property
class 8 material.

** Property class 10.9, Protective Treatment CMHC


Specification H (zinc phosphate), applies also to
internally threaded fasteners made of property
class 10 material.
*** Property class 12.9, Protective Treatment CMHC
Specification H (zinc phosphate), applies also to
internally threaded fasteners of property class 12
material.

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Truck Torque Specifications


Description
Clipboard clip screws

31 in-lb (3.5 Nm)

Pump motor electrical power cable nuts

100-200 in-lb (11.2-13.6 Nm)

Transmission mounting bolts

90 ft-lb (122 Nm) Loctite 242

Drive wheel nuts

65 ft-lb (88 Nm)

Control handle shaft set screw

30 ft-lb (42 Nm)

Overhead guard mounting bolts

200 ft-lb (271 Nm)

Steering motor mounting bolt

35 in-lb (3.95 Nm) Loctite 242

Steering motor gear mounting bolt

88 in-lb (10 Nm)

Pump motor terminals

140 in-lb (15.82 Nm)

Pump motor pole piece screws

250-300 in-lb (28-33 Nm)

Drive axle bolts

81 ft-lb (110 Nm) Loctite 242

Lower transmission cover bolts

18 ft-lb (25 Nm)

Steering gear ring bolts

19 ft-lb (25 Nm)

Drive tire axle nut

95 ft-lb (130 Nm)

Steering wheel E-clip setscrew

5 in-lb (0.56 Nm) Loctite 242

Hydraulic collar mounting bolts

44.4 in-lb (50 Nm)

Hydraulic pump rear cover bolts

42-46 ft-lb (57-62 Nm)

Control valve hose clamp nuts

480 + 25 in-lb (54 Nm)

Control valve assembly SWR14 mounting screws

15 ft-lb (20 Nm)

Control valve lift/lower recondition seal kit screw and


block screws

6 ft-lb (8 Nm)

Lift chain adjusting nuts and locknuts

200 ft-lb (271 Nm)

Mast mounting plate bolts

85 ft-lb (115 Nm)

Battery box bolts

400 ft-lb (543 Nm)

Overhead guard post base bolts

25 ft-lb (34 Nm)

Sideshifter lower hook bolt

65 ft-lb (90 Nm)

Sideshifter lower hook set screw

21 ft-lb (30 Nm)

Sideshifter safety screw

70 ft-lb (100 Nm)

Sideshifter cylinder hydraulic fittings

56 ft-lb (80 Nm)

Single reach inner arm capscrew

85 ft-lb (115 Nm)

Single reach outer arm nut

295 ft-lb (405 Nm)

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4. Conversion of Metric and English


Units
AREA
Multiply

By

To Get

Multiply

By

To Get

inches

6.451

centimeters (cm)

centimeters

0.155

inches (in)

feet

0.093

meters (m)

meters

10.764

feet (ft)

LINEAR
Multiply

By

To Get

Multiply

By

To Get

inches

25.4

millimeters(mm)

millimeter

0.039

inches (in.)

feet

0.305

meters (m)

meter

3.280

feet (ft)

yards

0.914

meters (m)

meter

1.094

yards (yd)

miles

1.609

kilometers (km)

kilometer

0.621

miles (mi)

MASS
Multiply

By

To Get

Multiply

By

To Get

ounces (oz)

28.49

grams (g)

grams

0.035

ounces (oz)

pounds (lb)

0.454

kilograms (kg)

kilograms

2.205

pounds (lb)

tons (2000 lb)

907.18

kilograms (kg)

kilograms

0.001

tons (2000 lb)

tons (2000 lb)

0.907

metric ton (t)

metric ton

1.102

tons (2000 lb)

POWER
Multiply

By

To Get

Multiply

By

To Get

horsepower

0.746

kilowatts (kW)

kilowatts

1.34

horsepower
(hp)

PRESSURE

52

Multiply

By

To Get

Multiply

By

To Get

pounds/in

6.895

kilopascal (kPa)

kilopascals

0.145

pounds/in
(psi)

pounds/in

0.007

megapascal (MPa)

megapascals

145.04

pounds/in
(psi)

Return

Service Manual

2001-03-15

F-code

Section

C-code

M1.1
Inch (SAE) and Metric Fasteners
Version no

T-code

001

TEMPERATURE
Multiply

By

To Get

Multiply

By

To Get

(Fahrenheit
-32)

0.56

Celsius (C)

(Celsius x 1.8)

+32

Fahrenheit (F)

By

To Get

TORQUE
Multiply

By

To Get

Multiply

inch pound

0.113

Newton meter (Nm) Newton meter

8.851

inch pounds
in-lbs

feet pound

1.356

Newton meter (Nm) Newton meter

0.738

foot pounds
ft-lb

VELOCITY
Multiply

By

To Get

Multiply

By

To Get

miles/hour

1.609

kilometer/hour
(km/h)

kilometer/hour

0.621

miles/hour
(mph)

VOLUME
Multiply

By

To Get

Multiply

By

To Get

inches

16.387

centimeters (cm)

centimeters

0.061

inches (in)

inches

0.016

liters

liters

61.024

inches (in)

quarts, U.S.

0.946

liters

liters

1.057

quarts, U.S.
(qt)

quarts, U.S.

0.83

quarts, Imp. (qt)

quarts, Imp.

1.205

quarts, U.S.
(qt)

gallons, U.S.

3.785

liters

liters

0.264

gallons, U.S.
(gal)

gallons, U.S.

0.83

gallons, Imp. (gal)

gallons, Imp.

1.205

gallons, U.S.
(gal)

ounces

29.57

milliliters (ml)

milliliters

0.034

ounces (oz)

BT Prime-Mover Inc.

Return

Service Manual

2001-03-15

53

F-code

Section

C-code

M1.1
Inch (SAE) and Metric Fasteners
Version no

T-code

001

54

Return

Service Manual

2001-03-15

F-code

PS

Section

C-code

M2.0
Technical Service Data

Version no

T-code

000

RTX35/RTX45

Technical Service Data


NOTE! When the battery is fully charged,
performance may vary due to motor and
system efficiency tolerance. Technical
service data represents nominal values
obtained under typical operating conditions.
Specifications are subject to change without
notice.

MODEL
RTX35
(192 inch mast)

RTX45
(210 inch mast)

Series - DC

Series - DC

DRIVE MOTOR
Type
Power

5 hp/3.725 kw (24 volt drive motor)


6.25 hp/4.66 kw (36 volt drive motor)
16hp/11.9 kw (36 volt lift motor)

Duty factory

1 hour continuous

1 hour continuous

Minimum brush length

0.8 inch (20 mm)

0.8 inch (20 mm)

Minimum commutator
diameter

2.90 inches (74 mm)

2.90 inches (74 mm)

Minimum brush spring


tension

6.4 oz. (180 grams)

6.4 oz. (180 grams)

Vertical motor
spiral-bevel output

Vertical motor
spiral-bevel output

Gear ratio

17.57

17.57

Oil volume

1 gallons (3.79 liters)

1 gallons (3.79 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.

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Service Manual

2001-03-15

55

F-code

Section

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PS
M2.0
Technical Service Data
Version no

T-code

000

RTX35/RTX45

MODEL
RTX35
(192 inch mast)

RTX45
(210 inch mast)

Drive wheel

13.5 x 5.5 x 10.0 inches


(343 x 140 x 254 mm)

13.5 x 5.5 x 10.0 inches


(343 x 140 x 254 mm)

Drive wheel weight without


load with battery, lbs. (kg)

1600 lb battery
14.5 BC - 6735 (3054)
2000 lb battery
16.5 BC - 4315 (1959)

2000 lb battery
16.5 BC - 4750 (2156)
2400 lb battery
21 BC - 4910 (2229)

Drive wheel weight with rated


load and battery, lbs. (kg)

1600 lb battery
14.5 BC - 3240 (1471)
2000 lb battery
16.5 BC - 3430 (1557)

2000 lb battery
16.5 BC - 3780 (1716)
2400 lb battery
21 BC - 4025 (1827)

95 ft-lb
(130 Nm)

95 ft-lb
(130 Nm)

5.0 x 3.6 inches


(127 x 91 mm)

5.0 x 3.6 inches


(127 x 91 mm)

1600 lb battery
14.5 BC - 6860 (3114
2000 lb battery
16.5 BC - 7145 (3244)

2000 lb battery
16.5 BC - 8595 (3902)
2400 lb battery
21 BC - 8690 (3945)

300 Amp
400 Amp

Not Applicable (N/A)


425 Amp

WHEELS

Torque axle nut


Load wheel
Load wheel weight with rated
load, 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 - 2250 empty-1450 loaded


36V - 2100 empty-1500 loaded
36 volt
11.6 HP with 20% duty cycle

20% on
5 minute cycles

Minimum brush length

0.8 inch (20 mm)

0.62 inch (16 mm)

Minimum commutator
diameter

2.90 inches (74 mm)

2.80 inches (72 mm)

Minimum brush spring


tension

6.4 oz (180 grams)

40 oz (1120 grams)

Pressure at rated load

2450 psi (16890 kPa)

2450 psi (16890 kPa)

56

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2001-03-15

F-code

Section

PS

C-code

M2.0
Technical Service Data

Version no

000

T-code

RTX35/RTX45

MODEL
RTX35
(192 inch mast)

RTX45
(210 inch mast)

11 cc upper/4 cc lower
16 cc upper/4 cc lower
8 cc upper/4 cc lower

N/A
23 cc upper/4 cc lower
11 cc upper/4 cc lower

5 gallons
(19 liters)

5 gallons
(19 liters)

Sunoco TH
ATF
Texaco 15

Sunoco TH
ATF
Texaco 15

250 Amp

250 Amp

425 Amp
355 Amp

N/A
500 Amp

10 Amp

10 Amp

14.4 x 38.8 x 32.0 inches


(366 x 986 x 813 mm)
16.4 x 38.8 x 32.0 inches
(417 x 986 x 813 mm)

16.4 x 38.8 x 32.0 inches


(417 x 986 x 813 mm)
20.9 x 38.8 x 32.0 inches
(531 x 986 x 813 mm)

1020 Amp hours


1000 Amp hours
875 Amp hours

N/A
1000 Amp hours
875 Amp hours

14.5 inches (368 mm)


1600 lb (726 kg)
(2300 lb / 1044 kg)
16.5 inches (419 mm)
2000 lb (908 kg)
(2300 lb / 1044 kg)

16.5 inches (419 mm)


2000 lb (908 kg)
(2300 lb / 1044 kg)
21.0 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. Amp-hrs.)


24 volt
E
EE
Weight Minimum
(Maximum)

BT Prime-Mover Inc.

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Service Manual

2001-03-15

57

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PS
M2.0
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

6.0 mph (9.65 kph)


6.5 mph (10.46 kph)

N/A
6.5 mph (10.46 kph)

With rated load and hot motor


24 volt
36 volt

5.5 mph (8.85 kph)


6.0 mph (9.65 kph)

N/A
6.0 mph (9.65 kph)

24 volt
36 volt

57 fpm (17.37 m/min.)


80 fpm (24.4 m/min.)

N/A
95 fpm (29 m/min.)

24 volt
36 volt

34 fpm (10.4 m/min.)


60 fpm (18.3 m/min.)

N/A
60 fpm (18.3 m/min.)

Lower without load,


electrical valve

80 fpm (24.4 m/min.)

90 fpm (27.5 m/min.)

Lower with rated load,


electrical valve

80 fpm (24.4 m/min.)

95 fpm (29 m/min.)

24 volt
36 volt

95 Amps
80 Amps

N/A
90 Amps

24 volt
36 volt

115 Amps
95 Amps

N/A
105 Amps

DRIVING SPEEDS

LIFTING/LOWERING TIME
Lift without load

Lift with rated load

CURRENT READINGS
Driving without load

Driving with rated load

Lifting without load


24 volt
36 volt, type E
36 volt, type EE
Lifting with rated load
24 volt
36 volt, type E
36 volt, 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

F-code

PS
Version no

Section

C-code

M3.0
Ordering Spare Parts
T-code

000

Ordering Spare Parts


1. Locate the fault on the truck.
2. Identify truck model, serial number, and battery voltage.
3. Locate the page with the exploded diagram and find the
item number for the part required.
4. Locate the item number in the table. Select the column
for the actual truck model and serial number. 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,


component
parts
may
not
be
interchangeable. If an incorrect part is
used, the truck may malfunction.
5. Note the part number.
6. Call your local BT Prime-Mover Dealer and indicate
the part number.
7. If the model, serial number, or the article number
cannot be found on the truck, call your local BT PrimeMover Dealer for assistance.

BT Prime-Mover Inc.

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Service Manual

2001-03-15

59

F-code

Section

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PS
M3.0
Ordering Spare Parts
Version no

T-code

000

60

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2001-03-15

F-code

PS
Version no

Section

C-code

P
Contents, Section P
T-code

001

Contents, Section P
1. Planned Maintenance

BT Prime-Mover Inc.

Return

P1.0

INTRODUCTION, MAINTENANCE

P2.0

SERVICE SCHEDULE

P3.0

LUBRICATION CHART

P4.0

OIL AND GREASE SPECIFICATIONS

Service Manual

2001-03-15

61

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Section

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PS
P
Contents, Section P
Version no

T-code

001

62

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F-code

PS

Section

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P1.0
Introduction, Maintenance

Version no

T-code

000

Introduction, 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 years
operation of a truck. These schedules are based on hourly
usage and can be adapted to suit most normal one shift
patterns. The following hourly usage figures have been used
when calculating the schedule:
Single shift, 30 hours per week usage
Double shift, 60 hours per week usage
Triple shift, 90 hours per week usage
The schedules are intended only as a guide, not as a rigid
structure. Operators of trucks may wish to adapt to local
requirements; but it is emphasized that the schedules
represent minimum manufacturer requirements, and all items
should be included in a service program to ensure minimum
downtime and a high safety status of the equipment. When
operating under abnormal or severe conditions, perform
these services more often to keep the unit in good operating
condition.
- Use only spare parts approved by BT Prime-Mover.
- Always clean the equipment and carry out a full safety
check after service.

BT Prime-Mover Inc.

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2001-03-15

63

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PS
P1.0
Introduction, Maintenance
Version no

T-code

000

1. Safe Jacking Procedure


To perform maintenance that requires the truck to be lifted
from the floor, observe the proper safety precautions as
follows:
Stop block
Pivot plate

1. Lower the forks completely. Remove any load.


2. Turn key switch OFF and disconnect battery
connector.
3. If possible, stabilize the top of the mast with an
overhead chain hoist.
4. Before jacking the truck, check the stop block on
pivot plate to make sure it is good. If the block is
excessively worn or missing, take the truck out of
service. Install stop block on pivot plate, if
necessary.
WARNING Use extreme care whenever the truck is
jacked up for any reason. Never block the
truck between the mast column and floor.
Use a suitable hoist to stabilize the mast.
Keep hands and feet clear from beneath
truck while jacking. Use jack stands or
solid blocks to support the truck, do not
rely on jacks.
5. Place the jack under the designated jacking points.

Jack only in these areas

1.1. Elevate Rear of Truck


1. Place the jack in the designated jacking position.
2. Jack the rear of the truck so the drive tire is off the
floor no more than 3 inches (76 mm).
3. Block truck in place.

1.1. Elevate Either Side of Truck


1. Place the jack in the designated jacking position.
2. Jack the side of the truck so that the load wheel is
off the floor no more than 0.50 inch (12.7 mm).
3. Block truck in place.

64

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F-code

PS

Section

C-code

P1.0
Introduction, Maintenance

Version no

T-code

000

2. Lubricants
2.1. Cold Storage Conditioning
BT Prime-Mover reach trucks are recommended to operate
in temperatures between 32 F (0 C) and 115 F (46 C) in
their standard design. Cold storage conditioning is available
for continuous operation in -5 F (-15 C) temperatures or for
in and out applications to -13 F (-25 C). A freezer
conditioning package is available for applications with
continuous operation to -31 F (-35 C).
If the truck is to be used in a cold storage application, it will be
equipped with cold storage components and cold storage
fluids in the hydraulic tank and the drive unit when delivered
from the factory.

2.2. Electrical Component Cold Storage


Conditioning
To prevent moisture contamination in the electrical system,
trucks equipped with cold storage or freezer conditioning
packages have electrical compound applied to all electrical
connections during assembly. Compound is applied to the
front and backside of each individual electrical lug and around
the base of the plug to the power amplifiers. During
scheduled maintenance, it is recommended that all electrical
connections be inspected and the electrical compound
replenished if necessary.

BT Prime-Mover Inc.

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2001-03-15

65

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PS
P1.0
Introduction, Maintenance
Version no

T-code

000

66

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2001-03-15

F-code

Section

PS

P2.0
Service Schedule

Version no

C-code

T-code

001

RTX35/RTX45

Service Schedule
1. Planned Maintenance Schedule
ITEM
0000
0000.1
0000.2
0000.3
0000.4
0000.5
0640
0640.1
0640.2
0640.3
1700
1700.1
1700.2
1700.3
1700.4
1700.5
1700.6

1700.7

2550
2550.1
3300
3300.1

WORK REQUIRED
Interval in Hours
Interval in Days/Weeks/Months
Chassis
Check that the truck identification
plate is legible
Check for damage and cracks
Retighten the truck body bolts
(to the chassis)
Check the cover screws
Replace any unreadable or
damaged decals.
Operator Controls
Check that the travel direction/
speed control is operational
Check that the horn button is
operational
Check that the lift pot and
auxiliary buttons are operational
Motors
Check for arcing due to poor
connections
All connections tight
Clean motor of dirt and dust
Check torque of motor bolts
Check for abnormal noise in
motor bearings
Blow carbon, copper, and plastic
particle accumulations from the
motor using compressed air.
Check electrical armature (See
Armature Electrical Check on
page 157.)
Drive Gear
Check for oil leakage
Brake
Clean dust and debris

BT Prime-Mover Inc.

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Service Manual

8
1d

30
1w

120
1m

240
2m

360
3m

720
6m

1440
12 m

4320
36 m

X
X
X
X
X

X
X
X

X
X
X

X
X
X
X

2001-03-15

67

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PS
P2.0
Service Schedule
Version no

T-code

001

RTX35/RTX45

ITEM
3300.2
3300.3
3300.4
3500
3500.1
3500.2
3500.3
3500.4
4100
4100.1
4100.2
5110
5110.1
5110.2
5110.3
5110.4
5200
5200.1
5300
5300.1
5300.2
5300.3
5300.4

5300.5
5400
5400.1
5400.2
68

Return

WORK REQUIRED
Interval in Hours
Interval in Days/Weeks/Months
Check brake shoes for wear
Check correct clearance of
electrical brake and brake shoes
Check brake operation
Wheels
Remove all string, wrapping and
debris
Check all wheels for wear
Grease load wheel bearings
Grease caster and caster
wheels
Steering Wheel
Check fasteners
Check ease of steering
Battery
Electrolyte level, 0.5 inch (13 mm)
above cell plates
All connections: battery and
battery and charger plugs
All cell and link covers intact
Check battery specific gravity
Instrument Panel
Check battery indicator and hour
meter for correct operation
Electrical Control System
Check key switch
Check brake micro switch
Check control wiring harness for
proper routing
Examine negative cable and
wires from battery to the main
electronic card (A5).
Check that the red emergency
stop switch is operational
Electrical Panel
Cleaning and mounting to
chassis
Tightening of connections

8
1d

30
1w

120
1m

240
2m

360
3m

720
6m

1440
12 m
X

4320
36 m

X
X
X
X
X
X

X
X
X
X
X
X
X

X
X
X
X

Service Manual

X
X
2001-03-15

F-code

Section

PS

P2.0
Service Schedule

Version no

T-code

001

ITEM
5400.3
5400.4
5400.5
5400.6

5710
5710.1
6000
6000.1
6000.2
6000.3
6000.4
6000.5
7100
7100.1
7100.2
7100.3
7100.4
7100.5
7100.6
7100.7
7100.8
7100.9
7200
7200.1
7200.2
7200.3

RTX35/RTX45

WORK REQUIRED
Interval in Hours
Interval in Days/Weeks/Months
Check contactor tips
Check contactor tips for free
movements
Check all cable insulation for
damage
Check power safety control
system on the transistor regulator
(refer to page 319).
Electronic Card
Check for connections in harness
connectors
Hydraulic System
Check hoses and connections
for leakage
Check hoses for wear and
damage
Check oil tank for cracks, leaks
and mounting
Check correct oil level
Change hydraulic oil and filter
Mast
Check for damage and cracks
Retighten mast mounting bolts
Check clearance of the rollers
Check lateral play of inner section
Check for wear on lift chains and
chain rollers
Check adjustment of lift chains
Clean & lube lift chains
Clean & lube mast rails
Lube chain sheaves
Sideshifter
Check torque of lower hook
mounting bolts
Inspect hydraulic hoses for wear
Inspect cylinder and fittings for
wear or leaks

BT Prime-Mover Inc.

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C-code

Service Manual

8
1d

30
1w

120
1m

240
2m

360
3m

720
6m
X
X

1440
12 m

4320
36 m

X
X

X
X
X
X
X
X
X
X
X
X

X
X
X

X
X
X
X

X
X
X

2001-03-15

69

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C-code

PS
P2.0
Service Schedule
Version no

T-code

001

RTX35/RTX45

ITEM
7200.4
7200.5
7200.6
7200.7
7310
7310.1
7310.2
7400.
7400.1
7400.2
7400.3
7400.4
7400.5
7400.6
7400.7

70

Return

WORK REQUIRED
Interval in Hours
Interval in Days/Weeks/Months
Grease lower hook where pads
slide
Check thickness of upper pads
Check thickness of lower pads
Replace upper and lower pads
Lift Cylinder
Check for leakage
Check mounting
Lifting Device
Check clearance of fork carriage
Check fork carriage for
damage and cracks
Check forks for wear and cracks
Check reach attachment for
damage and cracks
Check reach attachment for
proper reach stoke and timing.
Check reach attachment for
damaged retract bumpers
Lube all grease fittings on reach
attachment

8
1d

Service Manual

30
1w

120
1m
X

240
2m

360
3m
X

720
6m

1440
12 m

4320
36 m

X
X
X
X
X
X
X
X
X
X
X
X

2001-03-15

F-code

Section

PS

P2.0
Service Schedule

Version no

C-code

T-code

001

RTX35/RTX45

7310

7100
0640
0840

6000

5200
5400
4100

5300

1700

7200

1+ 01/2

5710

7400

3300
2550
5100

3500
0000

3300 (RTX35 HAS NO BRAKE ON CASTER WHEEL


BRAKE ON TOP OF DRIVE MOTOR ONLY)

Planned Maintenance Schedule


BT Prime-Mover Inc.

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Service Manual

2001-03-15

71

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Section

C-code

PS
P2.0
Service Schedule
Version no

T-code

001

RTX35/RTX45

2. Planned Maintenance Procedures


This section describes how to perform the services listed in
the Schedule of Planned Maintenance Operations. As with
the Schedule, this section is subdivided into service
intervals.

2.1. Services Performed Daily or Every 8


Operating Hours
The daily inspection is to be made by the operator prior to
each operating shift. It is the operator's responsibility to report
any problems with the truck to the appropriate personnel. The
truck should not be operated until it has been inspected and
repaired by a qualified technician. The operator is ultimately
responsible for the safe operation of the truck.
2.1.1. Battery Discharge Indicator with slow down
The battery discharge indicator indicates the current charge
status of the trucks battery. (See Parameter 13 Battery
Type Adjustment on page 347.)
1

Full charge battery

1/2

Half charged battery

Discharged battery

The battery discharge indicator has an integrated cut-out


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

72

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Section

PS

P2.0
Service Schedule

Version no

001

C-code

T-code

RTX35/RTX45

2.1.3. Frame/Sheet Metal


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

2.2. Services Performed Monthly or Every


120 Operating Hours
The monthly planned maintenance service should be
performed by a qualified technician.
2.2.1. Inspection
All of the services and inspections listed for the daily
inspection should be performed at this time. The inspection
procedure should be more thorough. Minor deficiencies
should be corrected.
2.2.2. Transmission
Inspect for oil leakage.
2.2.3. 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.

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2.2.4. Battery
Contact your battery dealer for specific instructions on care
and maintenance of the battery.
An average battery will have a specific gravity of 1.170 at the
80% discharged level. However, there are many different
batteries on the market. Only the battery manufacturer can
accurately determine the fully charged and 80% charged
levels. Contact the battery manufacturer for this information.
2.2.5. Electrical Connections
All electrical connections should be checked that they are
clean and tight. Plug-in connectors should be unplugged and
plugged back in to clean the terminals. If the truck is equipped
with any of the cold storage, freezer use, or corrosive
environment application packages, the di-electric compound
in the plug-in connectors should be renewed.
2.2.6. Contactor Tips (NOT Sealed)
Inspect contactor tips for arcing, pitting, or burning. Minor
pitting of the tips is not a problem. However, if the tips are
pitted through the tip to the copper bar, the tips should be
replaced. DO NOT file tips. Replace tips only in complete
sets. Some contactors have concealed tips or are fully sealed
so that tips cannot be replaced.
2.2.7. Motor Brushes
The drive motor is equipped with a brush wear sensor which
will indicate when the brushes need replacing. Minimum
brush lengths are given in the specifications section of this
manual. As a rule of thumb, the brushes should be replaced if
the brush spring is within 0.0625 inch (1.6 mm) of touching
the brush holder.
2.2.8. Drive Motor
Blow out the drive motor fan and vents. Check for any signs
of oil on the drive motor fan and air vents. Check for any
damage to the fan or air vents.
WARNING Compressed air used for cleaning MUST
be reduced to less than 30 psi (206 kPa),
and then only with effective chip-guarding
and personal protective equipment worn.

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2.2.9. Hydraulic Reservoir


Check the fluid level in the hydraulic reservoir.
2.2.10. 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. The total number of grease fittings
depends on the truck options when built. A truck with a cold
storage, freezer use, or corrosive environment application
package will have more grease fittings than a standard truck.
Look for flush-type grease fittings on the load wheel axles.
Regular fittings may be found on the transmission mounting
bearing and the mast chain sheave shafts.
2.2.11. Pivot Points
There are some pivot points and other items that need to be
lubricated but do not have grease fittings. Lubricate these
non-greasable wear points with a drip oil can using 10 wt.
machine oil.

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2.3. Services Performed Every 480 or 960


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

2.4. Services Performed Annually or Every


1440 Operating Hours
The annual planned maintenance service will take a longer
period of time to complete than does the monthly service.
This would be a good time to arrange other repairs that have
been noted on the monthly service.
2.4.1. Inspection
All of the services and inspections listed for the daily and
monthly inspection should be thoroughly performed at this
time. All deficiencies should be corrected.

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2.4.2. Transmission
The transmission fluid should be drained once a year. The
drain port is located on the lower portion of the side cover
opposite the drive tire. Remove the bolt to drain the
transmission fluid. Flush the transmission case. Pour clean
solution into the fill port accessed from battery compartment.
With drive tire off the floor, allow solution to run out of drain
port while transmission is running. Stop flushing when the
solution runs clean. Allow the solution to drain well before
replacing the drain plug bolt. Replace the drain plug bolt.
Refill the transmission with the proper clean oil before
operating the truck.
2.4.3. Battery
At approximately 1500 hours, contact an authorized battery
dealer to determine the overall condition of the battery.
Determine if the battery needs to be washed down. This can
only be done by properly equipped and trained personnel.
2.4.4. Hydraulic System
The hydraulic system should be drained, flushed and refilled,
and the pressure relief valve setting should be checked and
adjusted. This will maintain proper lubrication properties
within the system.
WARNING Before siphoning oil from reservoir, make
certain siphon is clean.
To drain the reservoir, remove the reservoir filter assembly.
Siphon oil from the reservoir and purge the oil out of hydraulic
system. Fill the reservoir with proper clean oil. Operate the
raise and lower function several times to purge air from
system. Check the oil level. Put a rated truck capacity load on
the forks and adjust pressure relief valve, if necessary, so
that truck will lift a rated load.

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2.4.5. Brakes
Follow procedures for brake removal before inspecting.
Remove the brake assembly and inspect the friction disc for
wear. The friction disc should be replaced once thickness is
0.25 inch (6 mm) or less. The armature and magnetic coil
should be adjusted if machine will not meet stopping and
holding specifications. The air gap should not exceed 0.014
inch (0.36 mm) and should remain within 0.003 inch (0.076
mm) throughout the circumference.
2.4.6. Lift and Carriage Chains.
Lift and carriage chains should be checked every 720 hours.
A chain gauge should be used to check stretch of the links.
To adjust inner rails, loosen jam nut and tighten chains
equally until the top of the rails are level in the fully lowered
position. Retighten jam nut and torque. Carriage chains
should be adjusted in the fully lowered position with the forks
level. Adjust chains until the top of the forks are 2.0 inches
(50.8 mm) off of the floor.

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Lubrication Chart
Interval/Running Hours
Pos. No.

Service Point

1
2
3
4
5
6

360 h

Wheel bearings
Mast beam
Lifting chains
Hydraulic system
Steering bearings
Drive gear

720 h

1440 h

L
L
L
C
C
L= Lubrication

C = Check

O
L
O

Lubricant
(See Approved
Oils and Grease
on page 81.)
A
A
D
B
A
C

O = Oil change

2
3

+
1/21 0

5
1
1
Truck Lubrication Points
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Oil and Grease Specifications


1. Approved Oils and Grease
Specification

Lubricant

Standard and
Corrosion
Continuous
Operation
Above
23 F (-5 C)

Cold Storage

Freezer

Continuous Operation
To 5 F (-15 C)
Intermittent Operation
To -13 F (-25 C)

Continuous
Operation
To
31 F (-35 C)

Application
area

Bearings and
bushings
Hydraulic
system

Grease

Mystik JT-6

Mystik JT-6

Mobiltemp
SHC 32

Hydraulic oil

Sunoco TH

ATF

Texaco 15

SAE 80

SAE 80

ATF

Gears

# 10 W 40

# 10 W 40

# 10 W 40

Chains
Mast rails,
Reach,
Sideshift
Mast rails,
Reach,
Sideshift

Transmission
oil
Motor Oil

Grease

Molykote
200025 *

Molykote 200025

Molykote
200025

Grease

49670-00 *

49670-00

49670-00

* Refer to section 10000 of Parts Book for special lubricants.

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B
+
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C
A
A

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Contents, Section S
1. Service Instructions
NO

FUNCTION GROUP

C-CODE

TROUBLESHOOTING GUIDELINES
0

CHASSIS

0000

MOTORS

1000

DRIVE GEAR / TRANSMISSION

2000

BRAKE / WHEEL SYSTEM

3000

STEERING SYSTEM

4000

ELECTRICAL / PNEUMATIC SYSTEM

5000

HYDRAULIC SYSTEM / CYLINDERS

6000

LIFTING MAST

7000

PERIPHERAL / INSTALLATION
EQUIPMENT

8000

OPTIONS / ATTACHMENTS

9000

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Troubleshooting Guidelines
1. General
Troubleshooting can be broken down into two sections: (1)
mechanical and (2) electrical circuits. Electrical circuits can
be further broken down into control circuit and power circuit.
Many hours of troubleshooting time can be saved by knowing
the exact operational symptoms. If the proper switch operates
for the chosen direction and speed, the problem can be found
in the controller or the power circuit of that function.
Voltage tests are made with the negative lead of the
voltmeter connected to battery negative if the negative lead is
connected to a negative terminal on the electrical panel. First,
verify the negative connection to the battery by touching the
positive meter lead to the positive battery post. The battery
voltage must be at least 25.2 volts for a 24 volt system. If the
battery voltage is below 22 volts (no load), the controller may
not operate properly. The battery voltage must be at least
37.8 volts for a 36 volt system. If the battery voltage is below
33 volts (no load), the controller may not operate properly.
Charge the battery before starting the troubleshooting
procedures.
When testing voltage, the positive side of any component
refers to the terminal on that component that is closest
electrically to the battery positive terminal. The negative
side of any component refers to the terminal on that
component that is farthest electrically from the battery
positive terminal. It is possible, and in many cases desirable,
to measure battery voltage on the negative side of a
component.
Rear direction refers to travel in the direction of the truck
with the forks trailing. Forward direction refers to travel with
the forks first.
After the final test is completed, the truck should be repaired
and operating properly. If it is not, then verify test results and
possibly re-evaluate the failure symptoms. If the truck is still
not repaired, then call your local authorized BT Prime-Mover
Dealer for assistance.

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The following information is required when placing a service


call:
Truck model and serial number
Service hour meter
Actual battery voltage at open circuit
Actual battery voltage at open circuit at hydraulic operation
under full load
Operating symptoms
Exact results of the testing performed
Perform the following steps before starting all troubleshooting
procedures:
1. Inspect truck for physical damage or mechanical
malfunction. Contactors must be free to move and the tips
must not be welded or burnt.
2. Check for ground faults from the electrical system to the
frame with an ohmmeter. A minimum of 20,000 ohms
resistance from the frame to any and all wiring is
acceptable.
3. Check that the battery is fully charged and connected.
4. Operate the truck in all modes to determine the exact
symptoms. DO NOT forget that these systems are
designed to prevent operation in the event of improper
operating procedures.

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2. Electrical
Many problems are caused by a faulty or dirty battery. Make
sure the battery is clean. Check the electrolyte level and state
of charge.
CAUTION Be sure to block the truck whenever a
troubleshooting procedure requires turning
key switch (S17) ON. This will avoid
accidents caused by unexpected truck
travel.
CAUTION Unless otherwise directed, disconnect the
battery connector when checking electrical
circuits or components with an ohmmeter.
Electrical current can damage the
ohmmeter.
For error code listings see pages 336 and 340. For
programming parameters see page 345. Visually inspect all
wiring and electrical components for the following:
Loose connections or connectors
Loose or broken terminals
Damaged terminals, blocks, or strips
Broken wiring and shorted conditions (especially those that
are close to metal edges or surfaces)
Proper connections from the main electronics card (A5) to
and from the battery
Use an ohmmeter to check for wiring continuity.

2.1. Shorts to Frame Test


Shorts to frame is an industry term for unintentional current
leakage paths between normally isolated electrical circuits
and their metal enclosures.
Shorts to frame may be metallic connections, such as a wire
conductor contacting metal through worn insulation. More
often, shorts to frame are resistive leakage paths caused by
contamination and/or moisture.

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These leakage paths can result in unwanted electrical noise


on the metallic truck structure, and may result in improper
operation.
Shorts to frame can be caused by the following:
Accumulation of dirt
Battery electrolyte leakage
Motor brush dust
Motor brush leads touching 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,
including:
Batteries
Motors
Cables, wiring, and harnesses
Heat sinks
Bus bars
Solenoids
Contactors
Terminal strips
Switches
Power panel insulation
Circuit card mounts
To test for shorts to frame:
1. Turn the key switch OFF and disconnect the battery
connector.
2. To test the battery for shorts to case, connect a 12-volt
test light to the battery case from battery B+, and then to
the battery case from battery B-. If the light comes on at
all, even momentarily, there is a problem with the battery,
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either external contamination or internal damage. DO


NOT continue until this condition is corrected. Your
meter may be damaged if proceeding before correcting
this condition. Install another battery in the truck and
repeat this procedure from step 1. If the test light does not
come on, continue to the next step.
3. With the battery disconnected from the truck, use a digital
volt/ohm/ammeter on the ampere function to measure the
leakage current from the battery case to battery B+ and
from the battery case to battery B-. Begin measuring at
the highest Ampere scale and work toward the lowest. A
reading of more than 0.001 ampere (1 mA) indicates a
short. DO NOT continue until this condition is
corrected. Your meter may be damaged if proceeding
before correcting this condition. Install another battery in
the truck and repeat this procedure from step 1. If the
current is less than 0.0002 ampere (0.2 mA), go to step 4.
If the current is greater than 0.0002 ampere (0.2 mA) and
less than 0.001 ampere (1 mA), remove the battery from
the truck, then continue with step 4. Ensure the battery
case does not touch the truck frame during the remaining
tests.
4. With the battery disconnected (or removed and
disconnected) from the truck, use a digital ohmmeter to
measure the resistance from the truck frame to truck B+,
to truck B- (NOT battery B+ and B-), and to all fuses and
motors. A reading of less than 1000 ohms indicates a
short. DO NOT continue until this condition is
corrected. Your meter may be damaged if proceeding
before correcting this condition.
a. To identify the cause of the short to frame,
disconnect circuit components until the low
resistance condition disappears. Do not reconnect
components one at a time, but leave them
disconnected until the low resistance reading
disappears. Prevent disconnected terminals or
connectors from touching truck frame or other
conductive surfaces.
b. The most likely areas to check include:
- Motors
- Heat sinks
- Power cables
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- Power circuit components


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


leakage current. Repeat step 6.
d. Reconnect all other components previously
disconnected, measuring current between steps. If
a reading is more than 0.001 ampere (1 mA) when
reconnecting a component, that component or its
wiring is defective. Repair/replace as appropriate.
7. After all components are reconnected, and a reading is
less than 0.001 ampere (1 mA) there is no short to frame
condition with the truck or the battery. If the battery was
previously removed from the truck, reinstall the battery.

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3. Hydraulic
NOTE! Proper care and cleanliness should be
observed when servicing the truck to ensure
that the oil does not become contaminated
with dirt or other foreign material.
Contaminants drawn into the pump may
cause the pump to stick, score, or fail.
If the hydraulic pump assembly does not operate properly,
preliminary checks should be made of the following: For error
code listings see pages 336 and 340. For programming
parameters see page 345.
Proper oil level
All electrical connections tight
Battery fully charged
CAUTION After elevating or reaching the carriage for
troubleshooting, be sure to use blocks to
secure the carriage.
Use extreme care when blocking the mast
for any reason. Never remove a block when
it is supporting the mast.
Lower the carriage fully and retract the reach mechanism
fully.
If the truck is equipped with tilt, set the forks level, not tilted
either up or down.
If the truck is equipped with sideshift, center the forks
horizontally.
When checking voltage at solenoids, make sure hydraulic
lines and components are fully installed.
Whenever possible, keep the key switch OFF and the
battery connector disconnected.

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4. Definitions
Auxiliary Function. A hydraulic function other than lift/lower.
The truck includes: reach/retract; tilt; and sideshift. Some
auxiliary functions, or aux functions are optional features on
the truck.
Continuity. A continuous and uninterrupted path between
two or more locations in an electrical circuit, typically having a
resistance of less than 1 ohm.
Brake Pedal Switch. The switch in the truck that must be
closed to allow reach truck operation. It is activated by the
operator stepping on the foot pedal thus engaging the brake
pedal. Travel is prohibited when the brake is applied.
High Speed Travel Limit. A reduced speed initiated when
the truck is driven while the carriage is elevated above a
certain mast height. This is a safety feature that limits the
speed of travel with an elevated mast and helps prevent
unstable load conditions.
Mast Assembly. The elevating section of the truck, which
bolts to the chassis section adjacent to the battery. The mast
assembly consists of column sections, carriage assembly, lift
cylinders, lift chains, etc.
Mast Switch. A switch on the mast that is actuated when the
carriage is above a certain height on the mast. It is used to
activate the speed limit feature to limit travel speed when the
carriage is elevated.
Open Circuit. A lack of a continuous path between two or
more electrical connections. Generally, when such a circuit is
tested, it will have a resistance greater than ten megohms.
Overtemperature (Power Amplifier). Overtemperature
of
the motor power amplifier is from 185o F (85o C) and above.
At overtemperature the drive current limit is linearly
decreased from full set current down to zero. Plug current is
not reduced to provide full vehicle braking under all thermal
conditions.
Pulse Width Modulation. Pulse Width Modulation (PWM),
also called chopping, controls the speed of the motor by
switching the battery voltage to the motor on and off very
quickly.

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Short Circuit or Short. A short circuit is an unspecified


path in a circuit that provides unwanted full or partial
continuity between two or more locations in an electrical
circuit.
Example: Two insulated wires are physically next to
each other and the insulation has been worn off each
of the wires. Because the conductors inside each wire
are now touching each other, there is a short circuit.
Example: A power cable from the battery to a junction
post in the reach truck has had the insulation worn
away. Because the wire conductors are touching the
frame, there is a short circuit of the battery cable.
Chassis. The body section of the truck that contains the
battery, motors, drive unit, controls, and handle. The mast
assembly bolts to the truck, which is adjacent to the battery.
Undertemperature. When the power amplifier is operating at
less than 13o F (25o C), the current limit is cut back
resulting in reduced travel speed.

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Chassis
1. General
t

The chassis has several panels and covers that are


removable. During operation of the reach truck, all panels and
covers must be secured to the chassis. The purpose of bolton panels and covers is for easier access to components
when servicing the truck.
Clip Board
Top
Console
Left Side
Panel

Contactor
Plate/Bracket

Floor
Board

Motor
Compartment
Door

Left Operator
Compartment
Panel

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2. Top Console
The top console is a one piece unit. It covers the motor
compartment, the drive and pump transistor regulators, and
contactors. The operator display, key switch, emergency
disconnect switch, and optional push-button switches are
mounted in the top console.

2.1. Removal
1. Park truck on a level surface and block.
2. Turn keyswitch OFF and disconnect the battery
connector.
3. Remove hardware securing the top console to the
frame.
4. Lift the cover up enough to disconnect the wiring
harness connections to the key switch, emergency
disconnect switch, optional push-button switches,
and the operator display.
5. Lift the top console off the steering wheel and
control handle, removing it from the truck.

2.2. Installation
1. Place the top console over the steering wheel and
control handle.
2. Attach the harness connections to the operator
display, the key switch, the emergency disconnect
switch, and the optional push-button switches.
3. Align the bolt holes in the cover with the ones in the
frame.
4. Secure cover to the frame.
5. Reconnect battery connector.
6. Return truck to service.

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3. Motor Compartment Door


3.1. Removal
1. Use an Allen wrench to turn the latch screw
clockwise one quarter turn.
2. Open the door fully. Lift upward to release the door
from the hinge pins and set aside.

3.2. Installation
1. Set the door in place so the hinge pins are securely
mounted in the panel hinge.
CAUTION Do not force the Allen head screw past one
quarter turn or the latch can become loose.
2. Close the door. Tighten the latch screw count.

BT Prime-Mover Inc.

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2001-03-15

97

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C-code

PS
Chassis

S0.1

0340

Version no

T-code

001

RTX35/RTX45

4. Left Side Panel (Exterior)


Removal of the left side panel allows for easier access to
components that affect traction and lift functions. The drive
motor may be removed with the side cover on, however, it is
a more difficult and time consuming task.

4.1. Removal
1. Park truck on a level surface and block.
2. Turn keyswitch OFF and disconnect the battery
connector.
3. Remove top console (see page 96).
4. Remove motor compartment door (see page 97).
5. Remove three flanged nuts using a 0.59 inch (15
mm) socket. Two are located under the control
console by the hydraulic tank. The third flanged nut
can be accessed through the left side of the battery
box or by removal of the operators compartment
left side panel.
6. Remove 0.511 inch (13 mm) bolt at the rear of the
panel, located by drive motor.
7.

Remove four bolts securing the overhead guard


post. Disconnect wiring harness at the post if
applicable.

NOTE! Be sure the wire assemblies are pushed up,


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

Pull the left side panel outward and set aside.

CAUTION The left side panel is heavy. Help may be


required to remove it from the truck.

98

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PS

S0.1

Version no

001

C-code

0340
Chassis

T-code

RTX35/RTX45

4.2. Installation
1. Lift left side panel up to align the three studs on the
panel with the holes in the frame.

CAUTION The left side panel is heavy. Help may be


required to remove it from the truck.
2. Install four bolts securing the overhead guard post.
Reconnect the wiring harness at the post if
applicable.
NOTE! Be sure the wire assemblies are pushed up,
into the overhead guard post before the bolts
are installed. This will prevent damage to the
wires if the post shifts as the bolts are
replaced.
3. Install 0.511 inch (13 mm) bolt at the rear of the
panel located by the drive motor.
4. Install three flanged nuts using a 0.59 inch (15 mm)
socket. Two are located under the control console
by the hydraulic tank. The third flanged nut can be
accessed through the left side of the battery box.
5. Install motor compartment door.
6. Install top console.
7. Reconnect battery connector.
8. Return truck to service.

BT Prime-Mover Inc.

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2001-03-15

99

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PS
Chassis

S0.1

0340

Version no

T-code

001

RTX35/RTX45

5. Left Operator Compartment Panel


5.1. Removal
1. Park truck on a level surface and block.
2. Turn keyswitch OFF and disconnect the battery
connector.
3. Loosen bolt, near the brake pedal, about 1/2 way
using a 0.511 inch (13 mm) wrench.
4. Remove 0.393 inch (10 mm) nut at the top of the
panel near the motor compartment door.
5. Remove bolt securing the top of the panel at the
front of the operator compartment (toward the
battery).
6. Lift panel up and set aside.

5.2. Installation
1. Slide left compartment panel into position.
2. Install bolt at the top of the panel.
3. Tighten bolt near the brake pedal.

100

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Section

PS

S0.1

Version no

001

C-code

0340
Chassis

T-code

RTX35/RTX45

6. 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.

6.1. Removal
1. Park truck on a level surface and block.
2. Turn keyswitch OFF and disconnect the battery
connector.
3. Remove two Allen head screws at the top of the
main electronic card panel.
4. Loosen two lower Allen head screws if access to
the main electronic card is required. If the operator
compartment floor is to be removed, remove the
two screws at the bottom of the main electronic
card panel.
5. Tilt panel in, toward the operator compartment. Lift
the main electronic card panel out and set to the
side.

6.2. Installation
1. Place slots along the lower edge of the main
electronic card panel over the bottom two retaining
screws.
2. Install two top screws, then tighten the two lower
screws.
3. Reconnect battery connector and return truck to
service.

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101

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Chassis

S0.1

0340

Version no

T-code

001

RTX35/RTX45

7. Floor Board
7.1. Removal
1. Park truck on a level surface and block.
2. Turn keyswitch OFF and disconnect battery
connector.
3. Remove main electronic card panel.

CAUTION Pinch point, keep fingers clear of the floor


board cutout while holding down the left
foot (brake) pedal.
4. Push down on left foot (brake) pedal with one
hand. Remove floor board by pulling up and
pivoting plate toward motor compartment. Release
left foot pedal as the floor board pivots up.

CAUTION Disconnect wire connections to the right


foot pedal switch (S23) prior to removal of
the floor board.
5. With floor board raised, disconnect wires from right
foot switch (S23). Remove floor board and set it to
one side.

7.2. Installation
1. Truck must be properly blocked at this time.
2. Reconnect wires to the right foot switch. Push
down on the left (brake) pedal with one hand and
install the floor board by pushing down and pivoting
the plate away from the motor compartment.
Release brake pedal as the floor board pivots
down.
3. Install main electronic card panel.

102

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Section

PS

S0.1

Version no

001

C-code

0340
Chassis

T-code

RTX35/RTX45

8. Clipboard
The clipboard is located on the top console near the steering
wheel.
+
1 1/2
0

8.1. Removal
1. Loosen top console to gain access to the clip
mounting hardware.
2. Remove screw, small flat washer, compression
spring, and large flat washer from each clip shaft.
Clip

Large
Flat
Washer

3. Lift clip from the top console.

8.2. Installation
1. Raise top console to allow reach of clipboard
mounting holes from underside of the cover.
Compression
Spring

Small Flat
Washer

2. Insert console through the holes in the top console.


3. 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. Secure both screws into the clip. Torque to 31 inlbs (3.5 Nm).

Compression
Spring (2)

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Large Flat
Washer (2)

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2001-03-15

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Chassis

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RTX35/RTX45

104

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Section

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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

Bearing

Roller, battery

Shaft, battery

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.

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2001-03-15

105

F-code

Section

C-code

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

T-code

001

RTX35/RTX45
f

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.

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Description

Item No.

Description

16

Stop, steering

23

Sleeve

17

Screw, cap

24

O-ring

18

Screw, cap

25

Screw, cap

19

Ring, retainer

26

Drive motor assembly

20

Ring, retainer

27

Brake assembly

21

Bearing

28

Sensor assembly

22

Ring, seal

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S0.3
Mounting Points

0451

Version no

T-code

001

RTX35/RTX45

1.1. Removal
WARNING There is no brake on truck when drive motor
is removed from transmission assembly.
Block all wheels to prevent truck from
rolling.
1. Park the truck on a level surface and make sure all
wheels are blocked to prevent accidental
movement.
2. Turn key switch OFF and disconnect battery
connector.
3. Remove top console, motor compartment door,
and left side panel to allow access to drive motor.
4. Remove four power cables. An 11/16 inch (17 mm)
wrench is required to loosen terminal nuts for the
field and armature connections. Note cable
numbers and terminal locations for use in
reassembly.
5. Disconnect the drive motor brush sensor, two
speed/directional sensors, temperature sensor,
and brake assembly connectors.
6. Using an 9/16 inch (13 mm) socket, remove the six
drive motor mounting bolts (25). A 24 inch (609
mm) extension is helpful to access the two bolts
behind the drive motor.
7. Attach a lifting tool to lift the drive motor. (Using two
eye bolts screwed into the top of the brake
assembly (two empty holes used for the brake
manual release screws), attach a piece of chain
(about 20 inches (508 mm) long) with a S hook at
each end to each of the eye bolts.)
8. Attach a hoist to the lifting tool attached to the top
of the brake assembly.
9. Gently lift the drive motor out of the transmission.
(It may be necessary to rock the drive motor gently
to loosen it from the transmission.)
10. Cap top of the transmission
contamination of transmission fluid.
108

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to

prevent

2001-03-15

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S0.3
0451
Mounting Points

Version no

001

C-code

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RTX35/RTX45

1.2. Installation
1. Remove cap from the top of transmission.
2. Lower drive motor straight down onto transmission.
The drive motor terminals and brush motor sensor
should be facing out.
3. Remove chain, S hooks, and eye bolts from brake
assembly.
4. Apply Loctite 242 to drive motor mounting bolts.
A magnet may be handy to help start the back bolt
or to retrieve a bolt if dropped behind the drive
motor.
5. Using an 9/16 inch (13 mm) socket tighten drive
motor mounting bolts (25).
6. Be sure to draw motor down evenly to allow the
gear on the motor shaft to properly mesh with the
transmission.
7. Attach brake electrical connection (R3).
8. Attach brush wear indicator connections.
9. Install drive motor power cables to terminal posts.
10. Add washers and nuts to terminal posts. Be sure
nuts are tight using an 11/16 inch (17 mm) wrench
for the armature and field connections.
11. Reconnect brush wear sensor, temperature
sensor, and two speed/directional sensor
connections.

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S0.3
Mounting Points

0451

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RTX35/RTX45

2. Pump Motor

1
2

3
4
5
6

Item
No.

Description

Item
No.

Description

Item
No.

Description

Lift Pump Assembly

Bracket, pump mounting

Washer, flat

Screw

Screw

Shock, mount

The pump motor and lift pump should be removed and


installed as a single unit.

110

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0451
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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.

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Mounting Points

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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 Nm). Use a second wrench on the stud
terminal securing nut to avoid twisting the stud.

112

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Mounting Points

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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.

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S0.3
Mounting Points

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3. Transmission

18
17
16

15
14
13
12
10

11

Item
No.

114

Description

Item
No.

Description

Item
No.

Description

Plate, stop

11

Screw, flat head

15

Screw, EE

Plate, target

12

Cap, plug

16

Stop, steering

Transmission
assembly

13

Gasket, EE

17

Screw, cap

10

Drive wheel
assembly

14

Plate, EE

18

Screw, cap

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S0.3
0451
Mounting Points

Version no

001

C-code

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RTX35/RTX45

3.1. Fluid Changing Procedure


1. Remove drain plug (item 28, page 169) from drive
unit and drain all the fluid.
2. Reinstall drain plug.
3. Refill using the proper grade fluid. The capacity of
the drive unit is 1 gallon (3.785 liters).
4. The fluid level of the drive unit may be checked by
removing the fill level plug (item 35, page 169).

CAUTION Incorrect selection of fluid, for a particular


application, may cause damage. No
warranty will be paid on component
damage resulting from incorrect fluid
selection.

3.2. Removal
1. Park the truck on a level surface.
2. Turn key switch OFF and disconnect battery
connector.
3. Jack the rear of truck (see Safe Jacking
Procedure on page 64).
4. Drain transmission fluid. See paragraph 3.1 above.
5. Remove drive tire. See Removal on page 183.
6. Place drive tire face down on the floor. Slide it
under the transmission to act as a cradle to keep
the transmission upright when it is unbolted from
truck frame. There should be an 1 inch (25.4 mm)
gap between the tire and the transmission before
the transmission is unbolted.
7. Using an 3/4 inch (19 mm) socket remove six bolts
(18) that secure the transmission to truck frame.
Remove drive motor before removing the
transmission (see page 108).

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Mounting Points

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8. Tap transmission with a rubber mallet to break it


loose from the frame. The transmission will drop
down, into the recess in the back of the drive tire.
9. Using a hoist, lift the truck high enough to slide the
transmission, in the tire cradle, out from
underneath the truck.

3.3. Installation
1. Place transmission in drive tire and slide
transmission, in the tire cradle, beneath the truck.
Using a hoist, lower the truck frame onto the
transmission. Be careful not to pinch hands
between the transmission and the truck frame.
2. Line grease fittings up with the indentations in the
frame.
3. The half-moon shaped piece mounted to the top
surface of the transmission should be toward the
left so that the sensors will read the wheel position
correctly.
4. Guide the transmission, with one hand through the
hole in the truck frame, while lowering the frame
onto the transmission. Install drive motor (see
page 109).
5. Clean and apply Loctite 242 to the transmission
mounting bolts (18). Using a 3/4 inch (19 mm)
wrench to help get the bolts started straight.
6. The transmission will draw tight to the truck frame
mounting surface as the bolts are tightened.
Transmission mounting bolts (18) should be
torqued to 90 ft-lbs (122 Nm).
7. Add transmission fluid. (See Fluid Changing
Procedure on page 115.)
8. Install drive wheel. Lubricate wheel nut. Secure
drive wheel with wheel nut. Torque wheel nut to 65
ft-lb (88 Nm).
9. Lower truck and remove blocks.
10. Reconnect battery connector.
116

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PS

S0.4
0640
Driver Controls

Version no

C-code

T-code

001

RTX35/RTX45

Driver Controls

Drive Handle Assembly


17
8

16
15

9
10

3
4

11

14

12

13

31

6
7

18

28
7

27

19
18
22

29

20

30
26 25 24 23

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117

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PS
S0.4
Driver Controls

0640

Version no

T-code

001

RTX35/RTX45

Item
No.

118

Return

Item
No.

Description

Description

Handle, control

17

Button, auxiliary

Handle, left hand

18

Switch, push button

Handle, right hand

19

Heater (cold storage)

Insulator, heat shrink

20

Shaft

Screw

21

Bearing

Screw

22

Screw

Screw

23

Spring

Screw, set

24

Screw, set

Screw, set

25

Spacer

10

Knob, left

26

Potentiometer

11

Spring

27

Tie, wire

12

Bracket

28

Housing, connector

13

Potentiometer

29

Pin, connector

14

Card assembly (cold storage)

30

Cable assembly

15

Actuator, button

31

Insulator, heat shrink

16

Spring

Service Manual

2001-03-15

F-code

Section

PS

S0.4
0640
Driver Controls

Version no

001

C-code

T-code

RTX35/RTX45

1. Handle Interface Module


The handle interface module is located on the contactor plate/
bracket, beneath and to the left of the base of the control
handle. The module processes digital inputs from the control
handle auxiliary function switches. It then forwards analog
outputs to the main electronic card, requesting activation of
solenoids and the hydraulic system.
Inputs from the travel and lift lower controls are analog. They
pass through the handle interface module with no processing,
to the main electronic card where they are acted upon.

1.1. Removal
1. Turn key switch OFF and disconnect battery
connector.
2. Remove top console (see page 96).
3. Disconnect wiring harnesses to the control handle
and main electronic card.
4. Remove two thread forming screws securing the
interface module to the bracket.
5. Remove interface module from truck.

1.2. Installation
1. Position handle interface module at the contactor
plate/bracket, aligning mounting holes.
2. Install two thread forming screws to secure module
to bracket.
Screw

3. Connect wiring harnesses from main electronic


card and control handle.
4. Install top console.
5. Test the operation of truck. Return truck to service.
Handle
Interface
Module

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S0.4
Driver Controls

0640

Version no

T-code

001

RTX35/RTX45

2. Control Handle
The control handle is the operators means of controlling
travel, lift/lower, and auxiliary functions. The control handle
assembly is located in the middle of the top console, to the
right of the steering wheel.

Lift/lower
Knob

Item
No.

Allen head
screw

Keep 14 of
cable off of the
control handle
straight

Description

Item
No.

Description

Handle, control

Screw

Pin, dowel

Plate, keeper

Support, travel

Module, interface

Screw, set

Screw

2.1. Removal
5
6

2
4

1. Turn key switch OFF and disconnect battery


connector.
2. Remove top console (see page 96).

7
CAUTION Be sure to observe proper precautions
against electrostatic discharge (see Static
Safety on page 23).
3. Unplug control handle wiring harness from the
handle interface module (7).
4. Cut any tie-straps that secure the wiring harness.
5. Loosen Allen head screw (4) that secures the
control handle assembly to its support travel
bracket (3).
6. Slide the control handle assembly to the left, out of
its support bracket.

120

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0640
Driver Controls

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RTX35/RTX45

2.2. Installation
1. Insert the shaft of the control handle assembly into
the support bracket (3).
2. Apply thread-locking compound to the threads of
the Allen head screw (4).
3. Hold the control handle in place.
4. Align the hole in the shaft with the set screw hole.
Torque the set screw to 30 ft-lb (42 Nm).
CAUTION To ensure long handle cable life, proper
wire routing is necessary. Make sure 14
inches (355 mm) of the cable off of the
control handle is kept straight.
5. Route the control handle wiring harness up and
plug it into the Handle Interface Module (7).
6. Secure the control handle wiring harness in place
with tie-straps. Ensure the cable extends out of the
handle as straight as possible to avoid kinking.
7. Reinstall top console.
8. Reconnect battery connector and turn key switch
ON.

2.3. Recalibration
Recalibration of the control handle is necessary whenever
error codes 30, 38 or 33 appear on the operator display.
To clear error code 30 (Control Handle Calibration Error
1): Key OFF the truck. Press and hold SW1 on the main
electronic card. Key ON truck until truck powers-up and the
display turns on. Release SW1 to prepare the main electronic
card for calibration of the control handle.
To clear error code 38 (Accelerator Pot Span Calibration
Error): With both foot pedals released, move the control
handle forward and backward the full range of travel until the
code 38 disappears. This calibrates the handle travel and
limit positions.

BT Prime-Mover Inc.

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Service Manual

2001-03-15

121

F-code

Section

C-code

PS
S0.4
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, rotate the lift/lower thumb
knob to both ends of travel (full lift and full lower) until the
code 33 disappears.

Control
Handle
Function

Control
Handle
Interface
Card
Input Pin

Travel

Notes:

HM210

Control Handle
Interface Card
Approximate Input
Voltage (measured
with respect to HM213)
Min. 0.6V Rev
Nom. 1.4V
Max. 2.2V Fwd

Control Handle
Interface Card
Output Pin
(measured with
respect to HM110)
HM105

Control Handle
Interface Card
Nominal Output
Voltage
Min. 0.6V Rev
Nom. 1.4V
Max. 2.2V Fwd

Wire #

The control handle interface card decodes and conditions the


digital signals from the control handle for use by the main
electronic (A5) card. Analog signals (travel and lift/lower) from
the control handle are relayed unchanged to the main
electronic card. The following table shows the relationship of
the selected control handle function to the output of the
control handle interface card.

50

Main Electronic
Card (A5) Input
Pin (measured
with respect to
510)
505

Main
Electronic
Card (A5)
Nominal Input
Voltage
Min. 0.6V Rev
Nom. 1.4V
Max. 2.2V Fwd

1.

Voltages at the main electronic card inputs greater than 6.75 volts and less than 0.6 volts indicate shorted or
open signal wires for travel and lift/lower.

2.

The center and travel limits of the travel and lift/lower potentiometers are learned. Therefore, the voltages listed
are a rough approximation.

When the readings are within the parameters listed, the


control handle is calibrated and the truck is ready for normal
operation.

122

Return

Service Manual

2001-03-15

F-code

Section

PS

C-code

S0.5
0642
Brake Pedal (RTX35)

Version no

T-code

000

RTX35/RTX45

Brake Pedal (RTX35)


12

2
1

2
5

8
4
3
8
9

13
14

10
11

Item
No.

Description

Item
No.

Pedal, brake

Bumper

11

Screw

Bearing, flanged

Plate

12

Mat, pedal

Bumper

Screw

13

Nut, twin

Bracket, brake

Screw

14

Switch, brake

Spring, return

10

Potentiometer

15

Screw

BT Prime-Mover, Inc.

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15

Service Manual

Description

2001-03-15

Item
No.

Description

123

F-code

Section

PS
S0.5
Brake Pedal (RTX35)
Version no

T-code

000

RTX35/RTX45

C-code

0642

1. Pedal Removal
1. Park truck on a flat surface.
2. Disconnect battery at the battery connector. Check
to make sure the battery retainer plates are in
place.
3. Jack the rear of the truck (see Safe Jacking
Procedure on page 64).
4. Remove the main electronics card panel (see
page 101).

CAUTION Pinch point, keep fingers clear of the floor


board cutout while holding down the left
foot brake pedal.
CAUTION Disconnect the wire connections to the right
foot pedal switch prior to removal of the
floor board.
5. Remove the floor board.
6. Remove screws (11) holding the brake
potentiometer (10) and remove wires from the
brake switch (14).
7. Loosen four mounting bolts holding the brake
pedal assembly to the frame. Remove the brake
pedal assembly from the truck to service.

124

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Service Manual

2001-03-15

F-code

PS
Version no

000

Section

C-code

S0.5
0642
Brake Pedal (RTX35)
T-code

RTX35/RTX45

2. Pedal Bearing Replacement


1. To replace the bearing assemblies on the brake
pedal (1), remove the brake pedal return spring (5).
2. Remove flange bearing mounting screws (8) on
both bearings.
3. Loosen set screws on the bearing collars and slide
bearing assemblies back.
4. Remove brake pedal assembly from bracket (4)
and remove bearings (2).
5. Install bearings (2) on the brake pedal shaft (1).
6. Install brake pedal assembly into the bracket (4).
7. Slide bearings forward, engaging them in the
bracket. Install bearing mounting screws (8).
8. Install the brake pedal return spring (5).

3. Pedal Adjustment
1. See Adjustment Procedures for Setting Brake
Switch and Brake Transducer on page 355.
2. When replacing bumper (6), it should be threaded
down until the stop makes contact with bracket (4).

BT Prime-Mover, Inc.

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Service Manual

2001-03-15

125

F-code

Section

PS
S0.5
Brake Pedal (RTX45)
Version no

T-code

000

RTX35/RTX45

C-code

0642

Brake Pedal (RTX45)


12

6
2
1

17

16

5
4
3
8

13

14

7
10
11

15

126

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Service Manual

2001-03-15

F-code

PS
Version no

000

C-code

S0.5
0642
Brake Pedal (RTX45)
T-code

RTX35/RTX45

Item
No.

Description

Item
No.

Pedal, brake

Plate

13

Nut, twin

Bearing, flanged

Screw

14

Switch, brake

Bumper

Screw

15

Screw

Bracket, brake

10

Potentiometer

16

Cable, brake

Spring, return

11

Screw

17

Pin with cotter pin

Bumper

12

Mat, pedal

Description

Item
No.

Section

Description

1. Pedal Removal
1. Park truck on a flat surface.
2. Disconnect battery at the battery connector. Check
to make sure battery retainer plates are in place.
3. Jack the rear of the truck (see Safe Jacking
Procedure on page 64).
4. Remove the main electronics card panel (see
page 101).

CAUTION Pinch point, keep fingers clear of the floor


board cutout while holding down the left
foot brake pedal.
CAUTION Disconnect the wire connections to the right
foot pedal switch prior to removal of the
floor board.
5. Remove the floor board.
6. Remove screws (11) holding the brake
potentiometer (10) and remove the wires from the
brake switch (14). Remove brake cable pin with
cotter pin (17).
7. Loosen mounting bolts holding the brake pedal (1)
assembly to the frame. Remove the brake pedal
assembly from the truck to service.

BT Prime-Mover, Inc.

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Service Manual

2001-03-15

127

F-code

Section

PS
S0.5
Brake Pedal (RTX45)
Version no

T-code

000

RTX35/RTX45

C-code

0642

2. Pedal Bearing Replacement


1. To replace bearing assemblies on brake pedal (1),
remove the brake pedal return spring (5).
2. Remove flange bearing mounting screws (8) on
both bearings.
3. Loosen set screws on the bearing collars and slide
bearing assemblies back.
4. Remove brake pedal assembly from the bracket
(4) and remove the bearings (2).
5. Install bearings (2) on the brake pedal (1) shaft.
6. Install brake pedal assembly into the bracket (4).
7. Slide bearings forward, engaging them in the
bracket. Install the bearing mounting screws (8).
8. Install the brake cable pin with cotter pin (17) and
brake pedal return spring (5).

3. Pedal Adjustment
1. See Adjustment Procedures for Setting Brake
Switch and Brake Transducer on page 355.
2. When replacing the bumper (6), it should be
threaded down until the stop makes contact with
the bracket (4).

128

Return

Service Manual

2001-03-15

F-code

Section

PS

S0.6
0681
Internal Fittings

Version no

001

C-code

T-code

RTX35/RTX45

Internal Fittings
1. Operator Fan
The operator fan/overhead light is located in the compartment
on the left side of the overhead guard. The operator fan/
overhead light is an option, therefore, it may not be on your
particular truck. There are separate switches for the operator
fan and the overhead light. These switches are located to the
right of the key switch on the top console.
1

2
3

3
4
13

14

6
7
8

12
11
10

BT Prime-Mover Inc.

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Service Manual

2001-03-15

129

F-code

Section

C-code

PS
S0.6
Internal Fittings

0681

Version no

T-code

001

RTX35/RTX45

Item
No.

Description

Item
No.

Description

Screw

Nut

Screw

Screw

Nut, clip

10

Console

Bracket, hanger

11

Louver

Plate, filler

12

Shroud

Washer, flat

13

Tie, wire

Lockwasher

14

Fan motor

1.1. Removal
1. Turn key switch OFF and disconnect battery
connector.
2. From the top of the overhead guard, remove four
screws (1) securing the light/fan assembly.
3. Lower the light/fan assembly enough to disconnect
it from the harness.
4. Remove the light/fan assembly from the truck.
5. Repair or replacement of the fan is achieved by
removing the four screws (9) in the sides of the
light/fan console assembly to detach the hanger
bracket (4) from the top of the console (10).

1.2. Installation
1. Reassemble the light/fan console assembly. Be
sure the clip nuts (3) are positioned over the
mounting holes for attachment to the overhead
guard.
2. Reconnect the harness connections.
3. Install the mounting screws (1) through the top of
the overhead guard to secure the assembly.
4. Reconnect battery connector.
5. Test the operation of the light assembly, then
return truck to service.
130

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Service Manual

2001-03-15

F-code

Section

PS

S0.7

Version no

001

C-code

0811
Guards

T-code

RTX35/RTX45

Guards
4

1. Overhead Guard

Item
No.
3
5

Description

Overhead guard

Bolt

Screw, cap

Nut

Post, overhead guard

Remove of the overhead guard is not recommended.


Checking tightness of the mounting bolts (2) is recommended
on a regular basis. Overhead guard mounting bolts should be
torqued to 200 ft-lb (271 Nm).

BT Prime-Mover Inc.

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Service Manual

2001-03-15

131

F-code

Section

C-code

PS
Guards

S0.7

0811

Version no

T-code

001

RTX35/RTX45

132

Return

Service Manual

2001-03-15

F-code

Section

PS

S0.8

Version no

001

C-code

0851
Decals

T-code

RTX35/RTX45

Decals
Remove and replace any decals that are damaged. Replace
any missing decals. Remove a damaged decal by using a
sharp edge to peel the decal from the surface. Use caution
not to scratch or damage the paint on the truck when
removing the decal.
Using the required cleaning solution, thoroughly clean the
surface of the truck before applying a new decal. Allow the
surface to completely dry, be sure that there is no residue.
Touch up the paint in the area of the decal, as required.

1. Decal with Protective Sheet


To install this style, peel off the backing, place the decal into
position, and press the decal into place. Do not wrinkle the
decal. Rub over the protective over-sheet with a firm, straight,
plastic edge to remove air bubbles and any wrinkles. Peel off
the over-sheet.

2. Decal without Protective Sheet


To install this style, peel off the backing, place the decal into
position, and press the decal into place. Do not wrinkle the
decal. Smooth the decal into place using clean fingers. Be
sure all the edges are secured to the surface.

BT Prime-Mover Inc.

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Service Manual

2001-03-15

133

F-code

Section

C-code

PS
Decals

S0.8

0851

Version no

T-code

001

RTX35/RTX45

12
KEEP HANDS CLEAR

11

10

+1/21
0

8
7

Model

Serial Number

Cap. (Lbs.)

TruckBatt.
Wt. (Lbs.)
Less

Battery Wt., Max. (Lbs.)Battery Wt., Min. (Lbs.)

DC Volt age

UseULType
Class
Battery

Type Mast Serial Number

BInches C

Max. Amp. Hours


Max. Tilt
Attachment Back

Truck as ratedat factory conforms torequirements of Part III of ASMEB561-1993


306040-000

C
B

BTPrime-Mover, Inc.
Muscatine, IA 52761

5
3
4

134

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Service Manual

2001-03-15

F-code

Section

PS

S0.8

Version no

001

Item
No.

BT Prime-Mover Inc.

Return

Description

Item
No.

T-code

RTX35/RTX45

Description

Decal, WARNING

Decal, RTX45

Decal, WARNING

Decal, RTX35

Decal, BT Prime-Mover Logo

Decal, special oil

Box, Manual

10

Decal, travel control

Plate, UL

11

Decal WARNING

Plate, Data

12

Decal, Reverse Steering

Service Manual

2001-03-15

C-code

0851
Decals

135

F-code

Section

C-code

PS
Decals

S0.8

0851

Version no

T-code

001

RTX35/RTX45

136

Return

Service Manual

2001-03-15

F-code

Section

PS

S1.0
1730
Steering Motor

Version no

001

C-code

T-code

RTX35/RTX45

Steering Motor
The steering motor is located in the lower right section of the
motor compartment, nearest the motor compartment door. It
is to the right of the drive motor and beneath the control
valve.

1. Removal
WARNING Block all wheels to prevent truck from
rolling.
1. Park truck on a level surface. Block truck to
prevent accidental movement.
2. Turn key switch OFF and disconnect battery
connector.
3. Remove motor compartment door to access the
steering motor (see page 97).
4. Disconnect steering motor from the main electrical
harness.
5. Use an 13/64 inch (5 mm) Allen wrench to remove
four bolts securing the steering motor to the truck
frame. The rubber gasket should remain on each
bolt.

Spacer

6. Gently lift the motor upward. Rock it a little to


unseat it if necessary.
O-Rings

BT Prime-Mover Inc.

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Service Manual

7. Be sure the two O-rings stay on the bottom of the


steering motor. The black rubber spacer under the
steering motor is to reduce noise. Be sure to keep
the spacer with the steering motor for reassembly.

2001-03-15

137

F-code

Section

C-code

PS
S1.0
Steering Motor

1730

Version no

T-code

001

RTX35/RTX45

2. Installation
1. Make sure the rubber spacer and two O-rings are
on the end of the steering motor.
2. Apply a little grease so the motor will slide into the
frame without cutting the O-rings.
3. Apply black graphite grease to the gear to help
prevent excessive wear.
4. Place the electrical connectors toward the lift
motor. Insert the steering motor into the truck
frame.
5. Apply Loctite 242 to the mounting bolt threads.
Install the four bolts with rubber grommets. Using
an 0.203 inch (5 mm) Allen wrench torque to 35 inlbs (3.95 Nm).
6. Reconnect the electrical harness connections.
7. Install the motor compartment door.
8. Remove blocks from truck. Reconnect the battery
connector.
9. Test truck for proper operation.
10. Return truck to service.

138

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Service Manual

2001-03-15

F-code

Section

PS

S1.0
1730
Steering Motor

Version no

001

C-code

T-code

RTX35/RTX45

3. Steering Motor Gear Replacement


3.1. Removal
1. Remove steering motor following the procedure on
page 137.
2. Loosen bolt attaching steering gear to the steering
motor shaft.
3. Remove steering gear from the motor shaft.

3.2. Installation
1. Slide steering gear onto the steering motor shaft.
2. Install mounting bolt in the steering gear.
3. Torque gear mounting bolt to 88 in-lbs (10 Nm).
4. Return steering motor to the truck following the
installation procedure on page 138.

BT Prime-Mover Inc.

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Service Manual

2001-03-15

139

F-code

Section

C-code

PS
S1.0
Steering Motor

1730

Version no

T-code

001

RTX35/RTX45

140

Return

Service Manual

2001-03-15

F-code

Section

PS

S1.1

Version no

001

C-code

1740
Fan Motor

T-code

RTX35/RTX45

Fan Motor
The main fan motor in the truck cools the upper electrical
compartment. An optional operator cooling fan is also
available.

1. Upper Electrical Compartment Fan


The upper electrical compartment fan is located in the front of
the truck section. This fan vents heat out of the upper
electrical compartment toward the mast. It is standard
equipment on all reach trucks.

1.1. Removal
1. Turn key switch OFF and disconnect battery
connector.
2. Remove top console (see page 96).
3. Disconnect electrical connections from the fan to
the main wiring harness.
4. Remove four nuts (1) from upper electrical
compartment side.
5. Remove four screws (2) from the mast side of the
truck compartment.
6. Remove the fan assembly from truck.
1

1.2. Installation
1. Install fan assembly by inserting four screws (2)
through the truck frame from the mast side.
2. Install four nuts (1) from the electrical compartment
side.
3. Connect electrical connections to the main wiring
harness.
4. Install top console.
5. Reconnect battery and return truck to service.

BT Prime-Mover Inc.

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Service Manual

2001-03-15

141

F-code

Section

C-code

PS
Fan Motor

S1.1

1740

Version no

T-code

001

RTX35/RTX45

2. Operator Fan
The operator fan is located in the compartment with the
overhead light on the left side of the overhead guard. The
operator fan/overhead light is an option, therefore, it may not
be on your particular truck. To service the operator fan, see
Internal Fittings on page 129.

142

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Service Manual

2001-03-15

F-code

Section

C-code

PS
S1.2
1700
Motor Maintenance Schedule/Troubleshooting
Version no

000

T-code

RTX35/RTX45

Motor Maintenance
Schedule/Troubleshooting
1. General Information
A routine maintenance schedule with recorded findings is the
best way to reduce costly shut-downs and repair of
equipment during operating hours. The goal of any
maintenance program, long-life and trouble-free operations is
related to the time spent making inspections and correcting
minor problems as they occur. The drive motor and pump
motor are both equipped with brush sensors. When brushes
are in need of replacement, a warning code C-17 will show on
the dash display.

2. Operating Conditions
Operating environment of reach truck motors varies
widely: The following recommendations should be applied as
actual conditions dictate.
Normal Service:

Basically an eight hour day of indoor


material handling.

Severe Service:

Extended operating hours, or constant


usage.

Extreme Service:

yChemical Processing
yFreezer operation
yProcessing plants (poultry, meat)

BT Prime-Mover Inc.

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Service Manual

2001-03-15

143

F-code

Section

C-code

PS
S1.2
1700
Motor Maintenance Schedule/Troubleshooting
Version no

T-code

000

RTX35/RTX45

3. Troubleshooting
When a motor has trouble in operation, a reasonable decision
has to be made as to the proper corrective course of action. A
review of the many troubleshooting guides has been
conducted and have been reduced to a few which seem to be
the most effective Symptom/Cause relationships and listed
on tables 1 and 2.

144

Return

Table 1

Unsatisfactory brush performance.

Table 2

Primary sources of unsatisfactory brush


performance.

Service Manual

2001-03-15

F-code

Section

C-code

PS
S1.2
1700
Motor Maintenance Schedule/Troubleshooting
Version no

000

T-code

RTX35/RTX45

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.
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.

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Service Manual

2001-03-15

145

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

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Service Manual

See Glowing at Brush Face

2001-03-15

F-code

Section

C-code

PS
S1.2
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.

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Service Manual

2001-03-15

7-13-23-24

147

F-code

Section

C-code

PS
S1.2
1700
Motor Maintenance Schedule/Troubleshooting
Version no

T-code

000

RTX35/RTX45

Table 2. Primary Sources of Unsatisfactory Brush Performance


Preparation and Care of Machine
1.

Poor preparation of commutator surface

2.

High mica

3.

Feather-edge mica

4.

Bar edges not chamfered after undercutting

5.

Need for periodic cleaning

6.

Clogged ventilating ducts


Machine Adjustment

7.

Brushes in wrong position

8.

Unequal brush spacing

9.

Poor alignment of brush holders

10.

Incorrect brush angle

11.

Incorrect spring tension

12.

Interpoles improperly adjusted

13.

Series field improperly adjusted


Mechanical Fault in Machine

148

Return

14.

Brushes tight in holders

15.

Brushes too loose in holders

16.

Brush holders loose at mounting

17.

Commutator loose

18.

Loose pole pieces or pole-face shoes

19.

Loose or worn bearings

20.

Unequal air gaps

21.

Unequal pole spacing

22.

Dynamic unbalance

23.

Variable angular velocity


Service Manual

2001-03-15

F-code

Section

C-code

PS
S1.2
1700
Motor Maintenance Schedule/Troubleshooting
Version no

000

T-code

RTX35/RTX45

Table 2. Primary Sources of Unsatisfactory Brush Performance


24.

Commutator too small


Electrical Fault in Machine

25.

Open or high resistance connection at commutator

26.

Poor connection at shunt terminal

27.

Short circuit in field or armature winding

28.

Ground in field or armature winding

29.

Reversed polarity on main pole or interpole


Machine Design

30.

Commutating zone too narrow

31.

Commutating zone too wide

32.

Brushes too thin

33.

Brushes too thick

34.

Magnetic saturation of interpoles

35.

High bar-to-bar voltage

36.

High ratio of brush contact to commutator surface area

37.

Insufficient cross connection of armature coils


Load or Service Condition

BT Prime-Mover Inc.

Return

38.

Overload

39.

Rapid change of load

40.

Reversing operation of non-interpole machine

41.

Plugging

42.

Dynamic braking

43.

Low average current density in brushes

44.

Contaminated atmosphere

45.

Contact poisons

46.

Oil on commutator or oil mist in air

47.

Abrasive dust in air


Service Manual

2001-03-15

149

F-code

Section

C-code

PS
S1.2
1700
Motor Maintenance Schedule/Troubleshooting
Version no

T-code

000

RTX35/RTX45

Table 2. Primary Sources of Unsatisfactory Brush Performance


48.

Humidity too high

49.

Humidity too low

50.

Silicone contamination
Disturbing External Condition

150

Return

51.

Loose or unstable foundation

52.

External source of vibration

53.

External short circuit or very heavy load surge

54.

Commutation factor too high

55.

Commutation factor too low

56.

Contact drop of brushes too high

57.

Contact drop of brushes too low

58.

Coefficient of friction too high

59.

Lack of film forming properties in brush

60.

Lack of polishing action in brush

61.

Brushes too abrasive

62.

Lack of carrying capacity

Service Manual

2001-03-15

F-code

Section

PS

C-code

S1.3
1750
Pump Motor (RTX35)

Version no

T-code

000

RTX35

Pump Motor (RTX35)


3

18
8

13
17

16

11
9

10

14

ROTATION

Item
No.

C.C.W.C.E.

Motor assembly

10

Holder, brush

Frame & field assembly

11

Lead assembly

Armature & fan assembly

12

Bearing

Fan, drive end

13

Washer, wave

End head, drive

14

End head, commutator

Spring, brush

15

Fan, commutator end

Bearing

16

Hardware, fan

Brush

17

Shroud, fan

Spring

18

Hardware, shroud

Counterclockwise
when viewed from
commutator end.

BT Prime-Mover Inc.

Return

15

12

Description

Service Manual

2001-03-15

Item
No.

Description

151

F-code

Section

PS
S1.3
Pump Motor (RTX35)
Version no

T-code

000

RTX35

C-code

1750

1. Component Repair
1.1. Motor Disassembly
1. Remove pump motor from truck (see page 111).
2. Use a brush hook to reach into the motor and lift
the brush springs (9). Pull the brushes (8) out of
the brush holders. Either position brushes outside
the motor or remove brush retaining screws, and
remove brushes (8) from the motor.
3. Scribe or center punch locating marks in the end
head and frame. Although locating marks are not
always necessary, they can save time when the
motor does not have locating pins.
4. Remove commutator end head retaining screws.
Most motors have a slip fit bearing at the
commutator end, and end head can be removed
with very little trouble.
5. Remove drive end head retaining screws if
necessary. Some of the smaller pump motors
retain the drive end head with the motor through
bolts. Separate armature (3) and drive end head
(5) as an assembly from the frame and field coil
assembly.
6. Separate armature (3) from the drive end head (5),
by pressing the armature out of the drive end
bearing. Remove bearing with a puller, protecting
the end of the armature shaft with a nut or a thick
flat washer.
CAUTION Use caution and DO NOT damage
armature during removal. If shaft, coupling,
or spline is damaged when removing the
drive end head, the armature or the drive
spline must usually be replaced.
7. Separate bearing (6) from end head (4). On larger
motors, the bearing is retained with a snap ring.
Remove the snap ring. Press the bearing out of the
end head.

152

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2001-03-15

F-code

PS
Version no

000

Section

C-code

S1.3
1750
Pump Motor (RTX35)
T-code

RTX35

8. The ventilation fans (4) are cast aluminum. Once


the fans have been pressed onto the armature,
they must be heated to be removed without
damage.
Install a puller and apply slight pressure against the
fan. Use a small propane torch to heat the area of
the fan around the shaft. When the fan becomes
loose on the shaft, as evidenced by the puller
becoming loose, remove as quickly as possible.
9. When the fan (4) is reassembled on the shaft,
make sure it is a tight fit. Use Loctite Retaining
Compound 40 or equivalent on the inside of the
fan hub when reassembling fan.
10. After the motor has been separated into all its
major subassemblies, the components should be
cleaned and inspected for wear or damage.
Use Loctite on
this area of shaft

BT Prime-Mover Inc.

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Service Manual

2001-03-15

153

F-code

Section

PS
S1.3
Pump Motor (RTX35)
Version no

T-code

000

RTX35

C-code

1750

2. Motor Inspection
A good planned maintenance program will save many hours
of future down time on a piece of equipment. Maintenance
schedules should consist of periodic routine inspections of
motors, battery and wiring circuitry.

2.1. External Motor


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

154

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Service Manual

2001-03-15

F-code

Section

PS

C-code

S1.3
1750
Pump Motor (RTX35)

Version no

T-code

000

RTX35

2.2. Brush and Commutator


The most important part of any planned maintenance
schedule is the brush and commutator inspection. By
recognizing undesirable commutator and/or brush conditions,
corrective action can be taken before a major component is
damaged beyond serviceability.
Brush and commutator inspection can usually be
accomplished be removing the cover band (if equipped) from
the commutator end of the motor. The brushes and
commutator should be inspected for even wear and good
communication. Good commutation will be indicated by a
dark brownish, polished commutator and an evenly polished
brush wearing surface. If the commutator appears rough,
pitted, scored or has signs of burning or heavy arcing
between the commutator bars, the motor should be removed
for servicing.
For a detailed inspection of the commutator, the motor should
be disassembled. With the armature supported on both
bearing journals, check run-out of commutator with a dial
gauge. Total indicated run-out should not exceed 0.003 inch
(0.0762 mm) or 0.001 inch (0.0254 mm) bar to bar. If the
readings fall outside this limit, commutator must be turned
and reundercut. After the commutator has been undercut, the
armature should be placed in lathe and the commutator lightly
sanded with No. 00 sandpaper. This will remove any burrs left
from the undercutting operation. Clean commutator with dry
compressed air and recheck commutator run-out.
mica

segments

GOOD UNDERCUT
0.04 inch deep
mica
segments mica
segments

BAD UNDERCUT
Brushes should be inspected for uneven wear and signs of
overheating such as discolored brush shunts and brush
springs. See Table 1. Unsatisfactory Brush Performance on
BT Prime-Mover Inc.

Return

Service Manual

2001-03-15

155

F-code

Section

PS
S1.3
Pump Motor (RTX35)
Version no

T-code

000

RTX35

C-code

1750

page 145. Check the brush holders for physical damage and
make sure they are not loose on the end head or the brush
holder plate. Check the brush springs for correct alignment on
the brush. A brush spring that does not apply equal pressure
on the center of the brush will cause the brush to wear
unevenly. Check for correct clearance and freedom of brush
movement in the holder. If any of the brushes are worn to the
point that replacement is necessary, the complete brush set
should be replaced. Do not replace just one or two brushes.
When brush service is required on the motor, lift brush spring
over holding bracket before removing brush. See drawing
below:

Put Spring In This


Position For Brush Removal

Do not substitute brushes. The brushes are matched to the


motor type and application to provide the best service.
Substituting brushes of the wrong grade can cause
commutator damage or excessive brush wear.
After the installation of new brushes, the motor should be
operated at 12 Volts, no load and brushes seated to the
commutator with a dressing Minimum commutator diameter

156

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2001-03-15

F-code

PS
Version no

000

Section

C-code

S1.3
1750
Pump Motor (RTX35)
T-code

RTX35

before armature needs to be replaced is specified on original


manufacturers test specification.

2.3. Bearings
After the motor has been disassembled, it is recommended
that new bearings are installed. Bearings may have been
damaged during removal. Although the bearings may appear
and feel good, the bearing races could be brinelled and fail
within a relatively short period of service.

2.4. Armature Electrical Check


Before the armature is reassembled into the motor, the
following test should be performed.
1. Check armature for grounded circuits by placing
one test lead of a Dielectric Breakdown Tester on
the commutator and the other lead at the armature
shaft. If the test light comes on, the armature is
grounded.
2. For short circuit connection, one armature is tested
on a growler using a hacksaw plate to locate any
shorted windings.
3. All motor armatures are wave wound and can be
short circuit tested. For helpful maintenance guides
for proper servicing of motors, see page 67.

BT Prime-Mover Inc.

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Service Manual

2001-03-15

157

F-code

Section

PS
S1.3
Pump Motor (RTX35)
Version no

T-code

000

RTX35

C-code

1750

2.5. Frame & Field Service


Recommendation
Motors disassembled for servicing should also include a
complete inspection of the frame and field assembly. It is not
uncommon that the frame and field of a motor becomes
exceptionally dirty after many hours of operation. This may
result in a grounding condition due to dirt, grease and other
foreign materials. Clean the complete frame and field in a
cleaning solution. After cleaning, the frame and field must be
oven-cured for one hour at 300F (148C). Add a coat of WS200 PT George Varnish for proper insulation protection. This
is a Class H water soluble varnish. A similar air-dry varnish
may also be used providing it has a Class H thermal
specification.
If new field coils are installed the cross-over connection
should be brazed for a good sound connection and to prevent
breakage due to vibration. It is not recommend that
connections be soldered. Motor terminals should be torqued
to 140 in-lbs (15.82 Nm). Pole piece screws should be
torqued to 250-300 in-lbs (28-33 Nm).
NOTE! Do not use a torch for the crossover
connection. The insulation of the field coils is
easily damaged by this method.
A high capacity resistance power unit with a plier-type
handpiece may be used for brazing field connections.

158

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2001-03-15

F-code

PS
Version no

000

Section

C-code

S1.3
1750
Pump Motor (RTX35)
T-code

RTX35

2.6. Assembly/Testing
Refer to the following drawing whenever a bearing is installed
into an end head or shaft.
Press Ram

Pipe Same Size


As Inner Race

Bearings
Inner Race

End Head
Armature
Shaft

Snap Ring

1. Press against the race that is absorbing the


pressure.
2. Use a new bearing when servicing a motor.
3. After assembly, the motor should be tested per the
original motor manufacturer.
WARNING Do not run motor NO LOAD at full motor
voltage.
4. In the event no dynamometer is available for
testing, the motor should be tested against a NO
LOAD POINT outlined on the specification.
5. Reinstall pump motor on truck (see page 112).

BT Prime-Mover Inc.

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Service Manual

2001-03-15

159

F-code

Section

PS
S1.3
Pump Motor (RTX35)
Version no

T-code

000

RTX35

160

Return

C-code

1750

Service Manual

2001-03-15

F-code

PS

Section

C-code

S1.4
1750
Pump Motor (RTX 45)

Version no

T-code

000

RTX45

Pump Motor (RTX 45)

1
6

15
12
11
14

10

8
9

13

Item
No.

Description

Item
No.

Description

ROTATION
1

Ring, retainer

Plate assembly, brush

C.C.W.C.E.

Bearing

10

Kit, lead assembly

Counterclockwise
when viewed from
commutator end.

End head, drive

11

Bearing

Fan

12

Washer, wave

Armature & fan Assembly

13

End head, commutator

Kit, field coil

14

Band, cover (optional)

Brush

15

Indicator kit, brush wear

Spring, brush

BT Prime-Mover Inc.

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Service Manual

2001-03-15

161

F-code

Section

PS
S1.4
Pump Motor (RTX 45)
Version no

T-code

000

RTX45

C-code

1750

1. Component Repair
1.1. Motor Disassembly
1. Remove pump motor from truck (see page 111).
2. Remove cover band (14) from the commutator end
of the motor.
3. Use a brush hook to reach into the motor and lift
the brush springs (8). Pull the brushes (7) out of
the brush holders. Either position the brushes
outside the motor or remove the brush retaining
screws, and remove the brushes (7) from the
motor.
4. Scribe or center punch locating marks in the end
head and the frame. Although locating marks are
not always necessary, they can save time when
the motor does not have locating pins.
5. Remove the commutator end head retaining
screws. Most motors have a slip fit bearing at the
commutator end, and the end head can be
removed with very little trouble.
6. Remove the drive end head retaining screws if
necessary. Some of the smaller pump motors
retain the drive end head with the motor through
bolts. Separate the armature (12) and drive end
head (3) as an assembly from the frame and field
coil assembly.

CAUTION Use caution and DO NOT damage the


armature during removal. If the shaft,
coupling, or spline is damaged when
removing the drive end head, the armature
or the drive spline usually must be
replaced.
7. Separate the armature (12) from the drive end
head (3), by pressing the armature out of the drive
end bearing. Remove the bearing with a puller,
protecting the end of the armature shaft with a nut
or a thick flat washer.

162

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2001-03-15

F-code

PS
Version no

000

Section

C-code

S1.4
1750
Pump Motor (RTX 45)
T-code

RTX45

8. Separate the bearing (2) from the end head (3). On


larger motors, the bearing is retained with a snap
ring. Remove the snap ring. Then press the
bearing out of the end head.
9. The ventilation fans (4) are cast aluminum. Once
these fans have been pressed onto the armature,
they must be heated to be removed without
damage.
Install a puller and apply slight pressure against the
fan. Use a small propane torch to heat the area of
the fan around the shaft. When the fan becomes
loose on the shaft, as evidenced by the puller
becoming loose, remove as quickly as possible.
10. When the fan (4) is reassembled on the shaft,
make sure it is a tight fit. Use Loctite Retaining
Compound 40 or equivalent on the inside of the
fan hub when reassembling fan.
11. After the motor has been separated into all its
major subassemblies, the components should be
cleaned and inspected for wear or damage.
Use Loctite on
this area of shaft

BT Prime-Mover Inc.

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Service Manual

2001-03-15

163

F-code

Section

PS
S1.4
Pump Motor (RTX 45)
Version no

T-code

000

RTX45

C-code

1750

2. Motor Inspection
See Motor Inspection on page 154.

164

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Service Manual

2001-03-15

F-code

Section

PS

S1.5

Version no

C-code

1760
Drive Motor

T-code

000

RTX35/RTX45

Drive Motor
5

3
1

4
2

10
6

12

11

9
8

13
Item
No.

Description

Item
No

Description

Item
No

Description

Kit, field coil

Brush

10

Indicator kit, brush


wear

Key

Spring, brush

11

Ring, retainer

Armature and fan


assembly

Plate assembly, brush

12

Bearing

Fan

Kit, lead assembly

13

End head, commutator

End head, drive

BT Prime-Mover Inc.

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Service Manual

2001-03-15

165

F-code

Section

C-code

PS
S1.5
Drive Motor

1760

Version no

T-code

000

RTX35/RTX45

1. Motor Disassembly
1. Remove drive motor from truck (see page 108).
2. For EE motors, remove the head band from the
commutator end of the motor.
3. Use a brush hook to reach into the motor and lift
the brush springs (7). Pull the brushes (6) out of
the brush holders. Either position the brushes
outside the motor or remove the brush retaining
screws and remove the brushes from the motor.
4. Scribe or center punch locating marks in the end
head and the frame. Although locating marks are
not always necessary because of locating pins in
some motors, they can save a lot of time when the
motor does not have locating pins.
5. Remove the commutator end head retaining
screws. Most motors have a slip fit bearing (12) at
the commutator end, and the end head can be
removed with very little trouble.
6. Remove the drive end head retaining screws, if
necessary. Separate the armature (3) and drive
end head (5) as an assembly from the frame and
field coil assembly.
CAUTION Use caution and DO NOT damage the
armature during removal. If the shaft,
coupling, or spline is damaged when
removing the drive end head, the armature
or the drive spline usually must be
replaced.
7. Separate the armature (3) from the drive end head
(5), by pressing the armature out of the drive end
bearing.
8. Remove retainer (11) from the commutator end
head (13). Press bearing (12) out of the
commutator end head.
9. After the motor has been separated into all its
major subassemblies, the components should be
cleaned and inspected for wear or damage.

166

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Service Manual

2001-03-15

F-code

Section

PS

S1.5

Version no

000

C-code

1760
Drive Motor

T-code

RTX35/RTX45

2. Motor Inspection
See Motor Inspection on page 154.

BT Prime-Mover Inc.

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Service Manual

2001-03-15

167

F-code

Section

C-code

PS
S1.5
Drive Motor

1760

Version no

T-code

000

RTX35/RTX45

168

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Service Manual

2001-03-15

F-code

Section

PS

S2.0
2550
Transmission.

Version no

C-code

T-code

000

RTX35/RTX45

Transmission.
Before disassembly of parts, thoroughly clean the outside of
the assembly with cleaning solution or other non-corrosive
cleaning fluid and air dry parts

31
30

8
10

29

40
9
39

11
12
38

35
41

32
13
24

20

14
19

17

33
36
16

15
37

22

21

26
27

18
23
25

BT Prime-Mover Inc.

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34

Service Manual

2001-03-15

28

169

F-code

Section

C-code

PS
S2.0
Transmission.

2550

Version no

T-code

000

RTX35/RTX45

Item
No.

170

Return

Item
No.

Description

Description

Transmission assembly

22

Screw

Gear, ring

23

Bearing

Kit, spare parts (Bearing)

24

Washer

Kit, spare parts (Sealing)

25

Spacer

Kit, spare parts (Helical gear)

26

Ring, sealing

Kit, spare parts (Wheel shaft)

27

Ring, locking

Kit, spare parts (Bevel gear)

28

Plug, drain

Gear, wheel

29

Nut (not part of item #1)

Gear, wheel

30

Washer, locking (not part of item #1)

10

Nut

31

Washer (not part of item #1)

11

Bearing

32

Screw

12

Kit, shim

33

Gear, bevel

13

Kit, shim

34

Screw

14

Bearing

35

Plug, fill

15

O-ring

36

Keeper

16

Screw

37

Cover

17

Axle

38

Case

18

Washer, copper

39

Bearing

19

Bearing

40

Screw

20

Kit, shim

41

O-ring

21

Cover ring

Service Manual

2001-03-15

F-code

Section

PS

S2.0
2550
Transmission.

Version no

C-code

T-code

000

RTX35/RTX45

1. Axle Sealing Ring


Replace the axle sealing ring when there is oil leakage from
the drive axle.

1.1. Disassembly
1. Remove transmission
page 115).

from

the

truck

(see

2. Remove copper washer (18) from drain plug (28).


3. Remove bolts (34) from lower case cover (37).
Remove lower case cover (37). Remove O-ring
(15) from cover.
4. Loosen drive axle bolts (16). Remove bolts (16)
and keeper washer (36).
5. Using a brass punch and hammer, knock out the
drive axle (17).
NOTE! To avoid bearing damaging during removal,
use a split bearing puller.
6. Using a puller, remove bearing (23) from drive axle
(17).
NOTE! The seal ring (26) may remain in the
transmission case (38).
7. Remove seal ring (26)
transmission case (38).

BT Prime-Mover Inc.

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Service Manual

2001-03-15

from

axle

(17)

or

171

F-code

Section

C-code

PS
S2.0
Transmission.

2550

Version no

T-code

000

RTX35/RTX45

1.2. Assembly
1. Place drive axle outer bearing (23) in the
transmission case (38).
.

NOTE! Use care when pressing the new seal ring into
place so the seal is seated correctly in the
gear housing.
2. Press new seal ring (26) into transmission case
(38).
3. Press drive axle (17) into the transmission case.
Be sure the spacer (25) is aligned with the axle
(17) and that the splines on the drive axle (17) are
aligned with the splines in the bevel gear (33).
4. Place keeper washer (36) onto the drive axle end
and install new bolts (16). Use Loctite 242 on
bolts (16). Torque axle bolts (16) to 81 ft-lb (110
Nm).
5. Install a new O-ring (15) on the lower cover (37).
Install lower cover (37). Lubricate new bolts (34).
Secure lower cover (37) with new bolts (34).
Torque bolts (34) to 18 ft-lb (25 Nm). Make sure
O-ring (15) is not damaged during installation.
6. Install a new copper washer (18) on drain plug
(28). Install drain plug (28) in the transmission. Fill
transmission with oil (see Approved Oils and
Grease on page 81). Install fill level plug (35) in
the transmission case.
7. Install transmission on truck (see page 116).

172

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2001-03-15

F-code

Section

PS

S2.0
2550
Transmission.

Version no

000

C-code

T-code

RTX35/RTX45

2. Leakage
When there is leakage from the transmission top cover,
proceed as follows:

2.1. Top Cover


1. Remove transmission from truck.
2. Remove bolts (32) securing steering gear ring (2)
to the transmission case (38).
3. Remove steering gear ring (2) from the
transmission case (38). Carefully clean the sealing
surfaces of steering gear ring and transmission
case.
4. Apply sealant, type Loctite 515, to the
transmission case (38), following the instructions
given on the sealant container.
5. Install steering gear ring (2). Lubricate bolts (32)
and install on the steering gear ring. Torque bolts
(32) to 19 ft-lb (25 Nm).
6. Install a new copper washer (18) on drain plug
(28). Install drain plug (28) in transmission. Fill
transmission with oil. Install fill level plug (35) in the
transmission case.
7. Install transmission on truck.

BT Prime-Mover Inc.

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2001-03-15

173

F-code

Section

C-code

PS
S2.0
Transmission.

2550

Version no

T-code

000

RTX35/RTX45

2.2. Lower Cover


When there is leakage from the transmission lower cover,
proceed as follows:
1. Drain transmission oil by removing drain plug (28).
Remove washer (18) from drain plug (28).
2. Remove bolts (34) from the cover (37). Remove
lower cover (37) from the transmission case (38).
Remove O-ring (15) from the cover (37).
3. Install a new O-ring (15) on the cover (37). Install
the cover (37). Lubricate the new bolts (34).
Secure lower cover (37) with new bolts (34).
Torque bolts (34) to 18 ft-lb (25 Nm). Make sure
O-ring (15) is not damaged during installation.
4. Install a new copper washer (18) on drain plug
(28). Install drain plug (28) in the transmission. Fill
the transmission with oil. Install fill level plug (35) in
the transmission case.

174

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Service Manual

2001-03-15

F-code

Section

PS

S2.0
2550
Transmission.

Version no

000

C-code

T-code

RTX35/RTX45

3. Wheel Bolt
1. Drain transmission oil by removing drain plug (28).
2. Remove transmission from truck.
3. Remove drive axle from the transmission case.
4. Press or knock out the damaged bolt from the drive
axle rim.
NOTE! Always install a new drive axle seal during
assembly.
5. Smooth away any burring around the bolt hole.
Press or knock new bolt into place.
6. Install drive axle into the transmission case (see
page 172).
7. Install transmission on truck.

BT Prime-Mover Inc.

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Service Manual

2001-03-15

175

F-code

Section

C-code

PS
S2.0
Transmission.

2550

Version no

T-code

000

RTX35/RTX45

176

Return

Service Manual

2001-03-15

F-code

Section

PS

C-code

S3.0
3371
Electromagnetic Brake

Version no

T-code

001

RTX35/RTX45

Electromagnetic Brake
13

11

Item
No.

10
2

7
4

12
5

Description

Brake assembly

Coil

Armature

Hub

Plate, friction

Plate, mounting

Spacer, Adjustable

Spring

Screw, socket head

10

Washer

11

Screw, socket head

12

Screw

13

Spacer

1. Removal
WARNING Block all wheels to prevent truck from
rolling.
1. Park the truck on a level surface and make sure all
wheels are blocked to prevent accidental
movement.

2. Turn key switch OFF and disconnect battery


connector.
3. Remove top console, motor compartment door,
and left side panel to allow access to
electromagnetic brake.

BT Prime-Mover Inc.

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2001-03-15

177

F-code

Section

C-code

PS
S3.0
3371
Electromagnetic Brake
Version no

T-code

001

RTX35/RTX45

WARNING The two manual release screws (11) must


be fully tightened before removing the
three brake retaining screws (9). Screws
(11) are used as a tool for braking. Size of
screw is 8 mm x 1.25 thread x 37.5 mm.
Refer to Section 3000 of the Parts Book
for part number of screw (11).
4. Fully tighten two manual release screws (11).
5. Remove three screws (9) which hold brake parts
and set aside. Avoid moving the adjustable
spacers (7) if possible, thus maintaining correct
axial air gap when reassembled.
6. Electrically disconnect the brake assembly. Lift
upward to remove the armature (3) and coil (2)
from the top of the drive motor.
7. Slide the friction plate (5) off the hub (4) spline and
away from the mounting plate (6).
8. Remove brake hub (4) from motor shaft.
9. Remove mounting plate (6) from the electric drive
motor if drive motor is to be replaced. If only the
brake is being changed, mounting plate may be
reused for the new brake assembly.

178

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2001-03-15

F-code

PS
Version no

001

Section

C-code

S3.0
3371
Electromagnetic Brake
T-code

RTX35/RTX45

2. Installation
WARNING Block all wheels to prevent truck from
rolling.
1. Be sure truck is securely blocked with key switch
OFF and battery disconnected.
WARNING The magnetic coil (2) and armature (3) are
under pressure. DO NOT remove the
retaining screws (9) without the manual
release screws (11) securely in place.
WARNING The two manual release screws (11) must
be fully tightened before removing the
three brake retaining screws (9). Screws
(11) are used as a tool for braking. Size of
screw is 8 mm x 1.25 thread x 37.5 mm.
Refer to Section 3000 of the Parts Book
for part number of screw (11).
2. Fully tighten two manual release screws (11) .
3. Remove three retaining screws (9) which hold
brake parts and set aside, ensuring all parts are
clean and dry. Avoid moving the adjustable
spacers (7) if possible, thus maintaining correct
axial air gap when reassembled. The mounting
plate is secured to drive motor with retaining screw
(9).
4. Secure brake hub (4) to motor shaft. It should not
interfere with mounting plate (6).
5. Slide friction plate (5) onto the hub spline and up to
the mounting plate (6).
6. Place armature (3) and coil (2) of the brake over
the mounting plate (6) and line up screws (9).
Carefully secure in place.
7. Once brake is fully secured in position, remove
manual release screws (11) and set aside.
8. Check air gap and adjust if necessary. For
adjustment procedures see Adjustments on
page 180.
BT Prime-Mover Inc.

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2001-03-15

179

F-code

Section

C-code

PS
S3.0
3371
Electromagnetic Brake
Version no

T-code

001

RTX35/RTX45

9. After making adjustments, check that the brake will


release when power is applied.

3. Adjustments
NOTE! Do not remove retaining screws (9).
Adjustment is carried out by using a 9/16 inch
(14 mm) open end wrench and a 1/4 inch (6
mm) socket key.
1. Turn Allen head retaining screws (9) counterclockwise to loosen one at a time, to allow
adjustment of threaded spacers (7).
2. Using a 9/16 inch (14 mm) wrench, the brass nut
on the threaded spacers (7) can now be threaded
in or out of the magnet. This changes the relative
position of the armature and end plate, thus
changing the air gap.
Turn the brass nut to the left (clockwise) to
increase the air gap. Turn the brass nut to the right
(counter-clockwise) to decrease the air gap.
NOTE! Be sure to tighten the Allen head retaining
screw (9) before checking the air gap. The
gap should be checked on each side of the
brass nut to assure consistency in the setting.
3. The air gap should be set to 0.008 inch to 0.014
inch (0.20 to 0.36 mm) and be within 0.003 inch
(0.08 mm) throughout the entire circumference.

180

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Service Manual

2001-03-15

F-code

PS

Section

C-code

S3.0
3371
Electromagnetic Brake

Version no

001

T-code

RTX35/RTX45

4. 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. Electromagnetic Brake, Armature


and Magnetic Coil
5.1. Removal
WARNING Block all wheels to prevent truck from
rolling.
1. Park the truck on a level surface and make sure all
wheels are blocked to prevent accidental
movement.
2. Turn key switch OFF and disconnect battery
connector.
3. Remove top console, motor compartment door,
and left side panel to allow access to
electromagnetic brake.
WARNING The magnetic coil (2) and armature (3) are
under pressure. Do not remove retaining
screws (9) without the manual release
screws (11) securely in place.
4. Fully tighten two manual release screws (11).
5. Remove three brake retaining screws (9).
6. Electrically disconnect brake assembly and lift
upwards to remove.

BT Prime-Mover Inc.

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Service Manual

2001-03-15

181

F-code

Section

C-code

PS
S3.0
3371
Electromagnetic Brake
Version no

T-code

001

RTX35/RTX45

5.2. Installation
NOTE! Make certain brake friction plate (5) and
armature (3) are clean and free of fluid.
1. Set armature (3) and magnetic coil (2) on the base
plate (6).
2. Align and tighten three brake retaining screws (9).
3. Remove two manual release screws (11) and
electrically connect the brake.
4. Set the air gap to 0.008 inch to 0.014 inch (0.20 to
0.36 mm) and be within 0.003 inch (0.08 mm)
throughout the entire circumference.
5. To test operation of the brake, connect battery, turn
key switch ON, and depress brake pedal. This will
allow the truck to operate.

6. Brake Friction Plate


6.1. Inspection
The brake friction plate should be replaced when the
thickness is 0.2344 inch (6 mm) or less.

6.2. Replacement
If the brake friction plate needs replaced, remove and install
new plate.

182

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2001-03-15

F-code

Section

PS

S3.1

Version no

C-code

3531
Drive Wheel

T-code

000

RTX35/RTX45

Drive Wheel
3
4

Item
No.

Description

Item
No.

Description

Tire

Nut

Wheel, drive

Washer, spherical

1. Removal
NOTE! Replace drive wheel when traction problems
develop.
1. Park truck on a level surface.
2. Turn key switch to OFF and disconnect battery at
the battery connector. Check to make sure battery
retainer plates are in place.
3. Jack the rear of the truck (see Safe Jacking
Procedure on page 64).
4. Remove seven wheel retaining nuts (3) and
spherical washers (4). Pull tire (1) and drive wheel
(2) from the transmission drive axle hub.
BT Prime-Mover Inc.

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2001-03-15

183

F-code

Section

C-code

PS
S3.1
Drive Wheel

3531

Version no

T-code

000

RTX35/RTX45

5. Press tire (1) from drive wheel (2).

2. Installation
1. Press drive tire on wheel hub. This is usually done
while pressing off the old tire. Press hub to the
center of the tire (1).
2. Install drive tire assembly on the transmission axle
hub. Torque drive tire retaining nuts to 95 ft-lb (130
Nm).

184

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2001-03-15

F-code

Section

PS

S3.1

Version no

000

C-code

3531
Drive Wheel

T-code

RTX35/RTX45

3. Tire Pressing Procedure


Outside of Hub
and Tire Assembly

New Tire

Worn Tire

Circular Ram
Press Table

1. Check the inside surface of the metal insert on the


new tire. Remove any scaling or rust with
sandpaper. Clean the inside of the metal insert and
lubricate it with a soap solution.
2. Place a circular ram on the press table. The length
of the ram must be longer than the width of the old
tire to allow complete removal of 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.
3. If the outside edge of the hub is not flush with the
edge of the metal insert in the old tire, measure
how far the hub is recessed inside the tire. The
new tire must be placed in the same position the
old tire was installed on the hub. 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.
4. Position hub assembly with the old tire on the top
of the circular ram so the outside of the wheel is
positioned upward. The outside edge of the hub
has a chamfer to help guide the new tire onto the
wheel. The chamfered edge must always be the
leading edge when a tire is pressed onto the hub.
5. Center hub assembly on top of the ram and make
sure that they mate squarely.
6. Position new tire with its chamfered insert facing
the hub. Align new tire and hub so that they are
concentric.

BT Prime-Mover Inc.

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Service Manual

2001-03-15

185

F-code

Section

C-code

PS
S3.1
Drive Wheel

3531

Version no

T-code

000

RTX35/RTX45

CAUTION Misalignment of the tire and hub while the


tire is being pressed onto the hub can
cause damage to the hub. For this reason,
chamfers have been provided on the
outside edge of the hub and on the end of
the inside diameter of the tires metal insert.
The chamfers help to center the hub and
tire during the pressing operation and
reduce the possibility of misalignment. To
prevent damage, the hub must be installed
on the circular ram with its chamfered side
up.
NOTE! If the new tire does not press on with a
minimum of 5 tons (5080.235 kg) force,
replace the hub.
7. Begin pressing new tire onto hub and old tire off
the hub. Run the press slowly for the first few
inches of travel, because this is the critical stage of
the operation. If the tire begins to cock to one side,
stop the press and realign the tire. A sharp jar with
a soft-headed mallet will usually realign the tire on
the hub.
8. Release the press. Remove wheel, tire assembly,
and old tire from the press table. Inspect wheel and
tire assembly.
9. Install wheel assembly following the procedure for
the specific type of wheel.

186

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Service Manual

2001-03-15

F-code

Section

C-code

PS
S3.2
3541
Non-Braking Caster Assembly
Version no

001

T-code

RTX35

Non-Braking Caster Assembly


1

3
6
4
7
8
9

17

10
11
12
19
20

18

13

14
17
15
16

BT Prime-Mover, Inc.

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Service Manual

2001-03-15

187

F-code

Section

C-code

PS
S3.2
3541
Non-Braking Caster Assembly
Version no

T-code

001

RTX35

Item
No.

188

Return

Description

Item
No.

Description

Item
No.

Description

Locknut

Spring

15

Caster assembly

Lockwasher

Screw, set

16

Block

Ring, Nilos

10

Nut

17

Fitting, grease

Bearing

11

Screw, cap

18

Bushing

Screw, cap

12

Nut

19

Washer

Nut

13

Pivot, caster

20

Screw, cap

Guide, spring

14

Bearing, thrust

Service Manual

2001-03-15

F-code

Section

C-code

PS
S3.2
3541
Non-Braking Caster Assembly
Version no

001

T-code

RTX35

1. Caster Pivot
1.1. Removal
1. Park truck on a level surface.
2. Turn key switch OFF and disconnect battery
connector. Check to make sure the battery retainer
plates are in place.
3. Jack the rear of the truck (see Safe Jacking
Procedure on page 64).
4. Remove main electronic card panel. See Main
Electronic Card Panel on page 101.
5. Remove floor board.
WARNING Secure caster pivot before removing
mounting bolts (20). Serious injury could
occur if failure to comply with this
requirement.
6. Turn and secure transmission to access the
mounting bolts (20).
NOTE! For models with a brake on the caster wheels,
the cable linkage must be disconnected
before removal of the brake pedal.
7. Bend lockwasher (2) tab down and remove locknut
(1).
8. Remove Nilos ring (3) and bearing (4).
9. Remove caster assembly.
10. Remove mounting bolts (20
11. Loosen nuts (5) to release spring tension.
12. Remove caster pivot (13). Inspect and replace
bushings and bearings as needed.

BT Prime-Mover, Inc.

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Service Manual

2001-03-15

189

F-code

Section

C-code

PS
S3.2
3541
Non-Braking Caster Assembly
Version no

T-code

001

RTX35

1.2. Installation
1. Install pivot block (16) closest to the battery
compartment first.
2. Install rear pivot block (16) on caster pivot (13).
3. Maneuver caster pivot (13) in place between the
frame.
4. Install caster assembly in the caster pivot (13).
NOTE! Make certain Nilos ring and lockwasher are in
the correct position.
5. Tighten locknut (1) while turning the caster wheel
assembly until tight, then back off 1/4 turn.
6. Bend the tab on lockwasher (2) up to secure the
locknut (1).
7. Install brake pedal.
NOTE! For models with a brake on the caster wheels,
the cable linkage must be installed.
8. Set spring tension and stops. See Caster Springs
on page 193.
9. Install floor board.
10. Install main electronic card panel.
11. Test truck operation, then return to service.

190

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2001-03-15

F-code

Section

C-code

PS
S3.2
3541
Non-Braking Caster Assembly
Version no

001

T-code

RTX35

2. Thrust Bearing
2.1. Removal
1. Park truck on a level surface.
2. Turn key switch OFF and disconnect battery
connector. Check to make sure the battery retainer
plates are in place.
3. Jack the rear of the truck.
4. Remove main electronic card panel.
5. Remove floor board.
NOTE! For models with brakes on the caster wheels,
remove the brake arm.
6. Bend the tab down on the lockwasher (2).
7. Remove locknut (1), lockwasher (2) and Nilos ring
(3).
8. Inspect and replace bearings as needed.

BT Prime-Mover, Inc.

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2001-03-15

191

F-code

Section

C-code

PS
S3.2
3541
Non-Braking Caster Assembly
Version no

T-code

001

RTX35

2.2. Installation
1. The truck must be properly blocked at this time.
2. Install the race (4) in the caster pivot and the thrust
bearing (14) on the caster assembly.
3. Install caster assembly in the caster pivot (13).
4. Install bearing (4), Nilos ring (3), lockwasher (2)
and locknut (1).
5. Tighten locknut (1) while turning the caster wheel
assembly until tight, then back off 1/4 turn.
6. Bend the lockwasher tab (2) up to secure the
locknut (1).
NOTE! For models with brakes on the caster wheels,
install the brake arm.
7. Test caster operation.

192

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2001-03-15

F-code

Section

C-code

PS
S3.2
3541
Non-Braking Caster Assembly
Version no

001

T-code

RTX35

3. Caster Springs
3.1. Adjustment
1. Park truck on a level surface.

5.375-5.50 inches

2. Turn key switch OFF, disconnect


connector, and securely block the truck.

battery

3. Remove main electronic card panel.


4. Measure from the top of the spring spacer to the
caster pivot plate. The measurement range should
be within 5.375-5.50 inches (136.5-139.7 mm).
5. To change the adjustment, loosen the jam nuts (6)
and tighten or loosen the bolts (5).

3.2. Removal
New Free Length
is 7 inches (178 mm)

1. Park truck on a level surface.


2. Turn key switch OFF and disconnect battery
connector. Check to make sure the battery retainer
plates are in place.
3. Jack the rear of the truck.
4. Remove main electronic card panel.
5. Remove the floor board.
6. Loosen the jam nuts (6) and release all spring
tension with the adjusting bolts (5). Remove the
bolts (5).
7. Remove the jam nut (12). Loosen the stop bolt (11)
to allow the caster pivot to rest on the frame stop.

Worn Free Length


is 6.5 inches (165 mm)
or Less.

BT Prime-Mover, Inc.

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Service Manual

8. The springs must be removed from the side.

2001-03-15

193

F-code

Section

C-code

PS
S3.2
3541
Non-Braking Caster Assembly
Version no

T-code

001

RTX35

3.3. Installation
5

1. Install caster springs.

11
5.375-5.50 inches

2. Install adjusting bolts (5).


3. Lower the truck to the floor and remove the hoist.

9
10
12

4. Tighten adjusting bolts (5) until there is 5.375-5.50


inches (136.5-137.9 mm) between the top of the
spring spacer and the caster pivot plate.
5. Adjust the bottom stop bolt (9) to 0.125 inch (3 mm)
clearance on the stop.

CAUTION Failure to determine battery compartment


size, battery weight, and mast height can
result in serious injury.
6. Adjust the top stop bolts (11). The recommended
dimension between the stop bolts and the stop
block is 0.25 inch (6.35 mm). Refer to the following
table to determine if the maximum dimension for
the truck can be increased.
Mast Height
Compartment Size / Minimum
Battery Weight

192 inches
(4877 mm)

210 inches
(5334 mm)

240 inches
(6096 mm)

270 inches
(6858 mm)

14.5 inches (368 mm) / 1600 lb (726 kg)


minimum battery weight
16.5 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
(9.53 mm)
0.375 inch
(9.53 mm)
0.375 inch
(9.53 mm)
N/A

0.375 inch
(9.53 mm)
0.375 inch
(9.53 mm)
0.375 inch
(9.53 mm)
N/A

0.375 inch
(9.53 mm)
0.375 inch
(9.53 mm)
0.375 inch
(9.53 mm)
N/A

0.375 inch
(9.53 mm)
0.375 inch
(9.53 mm)
0.375 inch
(9.53 mm)
N/A

7. Install the floor board.


8. Install main electronic card panel.
9. Test truck operation.

194

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2001-03-15

F-code

Section

C-code

PS
S3.2
3541
Non-Braking Caster Assembly
Version no

001

T-code

RTX35

4. Caster Stops

4.1. Adjustment
5.375-5.50
inches

11

1. Park truck on a level surface. Turn key switch OFF


and disconnect battery connector. Securely block
the truck.

2. Remove main electronic card panel.


10

3. Remove floor board.

12

4. Measure from the top of the spring spacer to the


caster pivot plate. The measurement range should
be within 5.375-5.50 inches (136.5-139.7 mm).
Adjust the caster spring if necessary.
NOTE! The stop bolts must NOT be touching the stop
blocks when measuring spring compression.
5. Adjust the bottom stop bolt (9) to 0.125 inch (3 mm)
clearance on the stop.

CAUTION Failure to determine battery compartment


size, battery weight, and mast height can
result in serious injury.
6. Adjust the top stop bolts (11). The recommended
dimension between the stop bolts and the stop
block is 0.25 inch (6.35 mm). Refer to the previous
table to determine if the maximum dimension for
the truck can be increased.
7. Secure the jam nuts (12).
8. Install the floor board.
9. Install main electronic card panel.
10. Test truck operation, then return to service.

BT Prime-Mover, Inc.

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Service Manual

2001-03-15

195

F-code

Section

C-code

PS
S3.2
3541
Non-Braking Caster Assembly
Version no

T-code

001

RTX35

196

Return

Service Manual

2001-03-15

F-code

Section

C-code

PS
S3.3
3542
Non-Braking Caster Wheels
Version no

T-code

000

RTX35

Non-Braking Caster Wheels


1

2
1
3
4
4

Item
No.

Description

Item
No.

Description

Wheel, caster

Lockwasher

Bracket, caster

Locknut

Ring, Nilos

Fitting, grease

Bearing

Cap, wheel

1. Removal
NOTE! Replace caster wheel when caster spring can
no longer be adjusted. (See Caster Springs
on page 193.)
1. Park truck on a level surface.
2. Turn key switch to OFF and disconnect battery at
the battery connector. Check to make sure the
battery retainer plates are in place.
3. Jack the rear of truck (see Safe Jacking
Procedure on page 64).
4. Remove wheel cap (8).
5. Bend lockwasher (5) tab down and remove locknut
(6).
BT Prime-Mover Inc.

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2001-03-15

197

F-code

Section

C-code

PS
S3.3
3542
Non-Braking Caster Wheels
Version no

T-code

000

RTX35

6. Remove caster wheel assembly.


7. Inspect and replace the race and bearing (4) as
needed.

2. Installation
1. Install Nilos ring (3) on the axle.
2. Install caster wheel assembly.
3. Install Nilos ring (3), lockwasher (5) and locknut
(6).
4. While turning the caster wheel, tighten locknut (6)
until the wheel becomes tight.
5. Back off locknut (6) until the caster wheel turns
freely. The locknut (6) and lockwasher (5) tab
should be aligned.
6. Bend lockwasher (5) tab to secure locknut (6).
7. Grease as needed.
8. Replace wheel cap (8).

198

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2001-03-15

F-code

PS
Version no

001

Section

C-code

S3.4
3543
Braking Caster Assembly
T-code

RTX45

Braking Caster Assembly


1

2
3
5
4
25

26

23

24
23

7
9
17

21

22

10
11
12

20

19

13

18

14

16

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15

17

Service Manual

2001-03-15

199

F-code

Section

C-code

PS
S3.4
3543
Braking Caster Assembly
Version no

T-code

001

RTX45

Item
No.

200

Return

Description

Item
No.

Description

Item
No.

Description

Locknut

10

Nut

19

Washer

Lockwasher

11

Screw, cap

20

Screw, cap

Ring, Nilos

12

Nut

21

Shaft

Bearing

13

Pivot, caster

22

Bracket

Screw, cap

14

Bearing, thrust

23

Bearing, flanged

Nut

15

Caster assembly

24

Pin, roll

Guide, spring

16

Block

25

Pivot

Spring

17

Fitting, grease

26

Screw, cap

Screw, set

18

Bushing

Service Manual

2001-03-15

F-code

PS

Section

C-code

S3.4
3543
Braking Caster Assembly

Version no

001

T-code

RTX45

1. Removal
NOTE! For models with a brake on the caster wheels.

1.1. Caster Brake Adjustment


1. Park truck on a flat surface.
2. Disconnect battery at the battery connector. Check
to make sure the battery retainer plates are in
place.
3. Jack the rear of truck (see Safe Jacking
Procedure on page 64).
4. Remove main
page 101).

electronic

card

panel

(see

CAUTION Pinch point. Keep fingers clear of the floor


board cutout while holding down the left
foot brake pedal.
CAUTION Disconnect wire connections to the right
foot pedal switch prior to removal of floor
board.
5. Remove floor board.
6. Total travel of the left foot brake pedal from up to
down is 3.5 inches (89 mm). The pedal setpoint is
50 percent down or 1.8 inch (45.7 mm). This can
be felt by a change in force at the pedal by the
spring tension.
7. Loosen adjusting nuts of the cable end at the
caster assembly bell crank. Adjust the cable
threaded end to allow for more engagement
required by a worn brake. At the 50 percent pedal
up position, the caster wheels should stop rotating
due to the brakes making contact with the caster
wheel drums.
8. When the cable can no longer be adjusted for
caster braking, the brake must be adjusted at the
caster wheels.

Adjuster nuts

BT Prime-Mover Inc.

Return

Service Manual

2001-03-15

201

F-code

Section

C-code

PS
S3.4
3543
Braking Caster Assembly
Version no

T-code

001

RTX45

9.

Run the cable adjustment back to the original


position, full threads toward the caster assembly.

10. Remove only one caster wheel. Refer to caster


wheel removal, on page 204.
11. Remove brake assembly from caster wheel.
12. Adjust double nuts at the brake rod up or down by
tightening the brake arm. Check brake at 50
percent pedal up position. The caster wheel should
stop rotating due to the brake starting to make
contact with the drums.
13. Lock double nuts together.
14. Reassemble and test for proper brake operation.

Rod

Spring

Adjusting
nuts

202

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Service Manual

2001-03-15

F-code

Section

C-code

PS
S3.5
3544
Braking Caster Wheel Assembly
Version no

T-code

000

RTX45

Braking Caster Wheel Assembly


16

15

13
9

14
2

11

10

13
12

9
10
11

1
4
4

3
5

Item
No.

Description

Item
No.

Description

Item
No.

Description

Wheel, caster

Fitting, grease

13

Washer

Bracket, caster

Cap, wheel

14

Pivot, brake

Ring, Nilos

Ring, E

15

Spring

Bearing

10

Brake assembly

16

Plunger, brake

Lockwasher

11

Screw, cap

Locknut

12

Nut

BT Prime-Mover Inc.

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Service Manual

2001-03-15

203

F-code

Section

C-code

PS
S3.5
3544
Braking Caster Wheel Assembly
Version no

T-code

000

RTX45

1. Removal
NOTE! Replace caster wheel when caster spring can
no longer be adjusted. (See Caster Brake
Adjustment on page 201.)
1. Park truck on a level surface.
2. Turn key switch to OFF and disconnect battery at
the battery connector. Check to make sure the
battery retainer plates are in place.
3. Jack the rear of truck (see Safe Jacking
Procedure on page 64).
4. Remove wheel cap (8).
5. Bend down lockwasher (5) tab and remove locknut
(6).
6. Remove caster wheel assembly.
7. Inspect and replace the race and bearing (4) as
needed.
8. Remove E-ring (9) and cap screws (11) if brake
assembly is to be replaced, otherwise replace
brake shoes.
9. Remove nuts (12), washer (13), and slide brake
plunger (16) up to remove brake pivot (14) and
other washer (13).
10. Remove brake plunger (16) and spring (15).

204

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2001-03-15

F-code

Section

C-code

PS
S3.5
3544
Braking Caster Wheel Assembly
Version no

000

T-code

RTX45

2. Installation
1. Slide spring (15) in the caster bracket (2) and
install brake plunger (16).
2. Install washer (13) on the brake plunger (16). Then
slide the brake pivot (14) on the brake plunger (16),
against the washer (13).
3. Install a second washer (13) on the brake plunger
against the brake pivot (14). Secure assembly
together with a nut (12). Install a second nut (12) to
lock the first nut in place.
4. Install brake assembly (10) with cap screws (11).
5. Move brake pivot (14) around to install an E-ring
(9) on both brake assemblies (10).
6. Install Nilos ring (3) on the axle.
7. Install caster wheel assembly.
8. Install Nilos ring (3), lockwasher (5), and locknut
(6).
9. While turning caster wheel, tighten locknut (6) until
the wheel becomes tight.
10. Back off locknut (6) until the caster wheel turns
freely. The locknut (6) and lockwasher (5) tab
should be aligned.
11. Bend lockwasher (5) tab to secure locknut (6).
12. Grease as needed.
13. Replace wheel cap (8).

BT Prime-Mover Inc.

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Service Manual

2001-03-15

205

F-code

Section

C-code

PS
S3.5
3544
Braking Caster Wheel Assembly
Version no

T-code

000

RTX45

206

Return

Service Manual

2001-03-15

F-code

Section

PS

C-code

S3.6
3551
Tandem Load Wheels

Version no

T-code

000

RTX35/RTX45

Tandem Load Wheels


1

11
3

4
10
5

6
7
8

9
8
7
6

Item
No.

BT Prime-Mover Inc.

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Description

Item
No.

Description

Axle

Washer, 16 gauge

Toe box

Bearing

Plate, rocker

Wheel, load

Ring, retainer

10

Nut

Fitting, grease

11

Bolt, shoulder

Washer, 10 gauge

Service Manual

2001-03-15

207

F-code

Section

PS
S3.6
Tandem Load Wheels
Version no

T-code

000

RTX35/RTX45

C-code

3551

1. Removal
NOTE! Replace load wheels when traction problems
develop.
1. Park truck on a level surface.
2. Lower the carriage fully
3. Turn key switch to OFF. Disconnect the battery at
the battery connector. Check to make sure the
battery retainer plates are in place.
WARNING Block all wheels to prevent truck from
rolling.
4. Hoist truck so the load wheels are approximately 2
inches (50.8 mm) off the floor and securely block.
5. Remove retainer ring (4) from the axles.
6. Use a piece of rod or a punch to tap the axle (1)
back out through the wheels. Remove rocker plate
(3). Remove two washers (6 and 7) on each side of
the wheel (9). The axle is welded into the rocker
plate. Remove the load wheel (9) from the toe box
(2).
7. Inspect bearings (8).

208

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F-code

PS

Section

C-code

S3.6
3551
Tandem Load Wheels

Version no

000

T-code

RTX35/RTX45

2. Installation
1. Pack bearings with grease.
2. Install bearings (8) in the load wheel (9).
WARNING Install bearing shield and 10 gauge
washer (6) properly.
3. Install load wheel assembly in the toe box (2).
NOTE! Place a block behind the axle (1) to hold it in
place while assembling the rocker plate and
snap rings.
4. Install axle (1), washers (6 and 7) and rocker plate
(3).
5. Install retainer rings (4) to axle (1).
6. Grease as needed.
7. Remove blocking and lower truck to the floor.
8. Reconnect battery connector.
9. Test operate truck.
10. Return truck to service.

BT Prime-Mover Inc.

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Service Manual

2001-03-15

209

F-code

Section

PS
S3.6
Tandem Load Wheels
Version no

T-code

000

RTX35/RTX45

210

Return

C-code

3551

Service Manual

2001-03-15

F-code

PS

Section

C-code

S3.7
3555
Single Load Wheels

Version no

T-code

000

RTX35/RTX45

Single Load Wheels


1
10
2
3
4

11

4
3
7

9
Item No.

BT Prime-Mover Inc.

Return

Description

Item No.

Description

Toe box, right

Toe box, left

Washer, 10 gauge

Fitting, grease

Washer, 18 gauge

Nut

Bearing

10

Bolt, shoulder

Tire, load

11

Load wheel assembly

Wheel

Service Manual

2001-03-15

211

F-code

Section

PS
S3.7
Single Load Wheels
Version no

T-code

000

RTX35/RTX45

C-code

3555

1. Removal
NOTE! Replace load wheels when traction problems
develop.
1. Park truck on a level surface.
2. Lower carriage fully. Turn key switch to OFF.
Disconnect the battery at battery connector. Check
to make sure the battery retainer plates are in
place.
WARNING Block all wheels to prevent truck from
rolling.
3. Hoist truck so the load wheels are approximately 2
inches (50.8 mm) off the floor, and securely block.
4. Remove toe box retaining nuts (9) and bolts (10).
5. Remove axle nut (9).
6. Remove right toe box (1) and load wheel (6).
7. Grease as needed.
8. Press load tire (5) from wheel (6).
9. Inspect bearings and replace if necessary.
WARNING Be sure to install the bearing shield and 10
gauge washer (2) properly.

212

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2001-03-15

F-code

PS

Section

C-code

S3.7
3555
Single Load Wheels

Version no

000

T-code

RTX35/RTX45

2. Installation
1. Inspect and replace bearing (4) as needed.
2. Press new load tire (5) on wheel (6).
3. Install load wheel assembly (11) on toe box axle.
4. Install right toe box (1).
5. Install axle nut (9).
6. Install toe box assembly on the support arm. Apply
Loctite 242 to nuts (9) and bolts (10).
7. Remove blocking and lower truck to the floor.
8. Reconnect battery connector.
9. Test the operation of the load wheel and truck.
Return truck to service.

BT Prime-Mover Inc.

Return

Service Manual

2001-03-15

213

F-code

Section

PS
S3.7
Single Load Wheels
Version no

T-code

000

RTX35/RTX45

214

Return

C-code

3555

Service Manual

2001-03-15

F-code

Section

PS

S4.0
4110
Steering Wheel

Version no

T-code

001

Spring

RTX35/RTX45

Steering Wheel

E-Clip

Item
No.

Set screw

Coupler

C-code

1
2
3

Description

Item
No.

Description

Cap, spinner

10

Bracket

Nut

11

Spring

Washer

12

Ring, retainer

Spinner

13

Coupler

Wheel, steering

14

Tachometer

Spacer, steering

15

Screw

Bushing, flat

16

Washer, flat

Bushing, flanged

17

Support, steering

Screw

18

Screw

1. Removal

4
5

WARNING Block all wheels to prevent truck from


rolling.

6
18
17

11

8
9
7
12

16
10
15

13

1. Park truck on a level surface and block wheels.


2. Turn key switch OFF and disconnect battery
connector.
3. Remove top console. See Top Console on
page 96.
4. Release set screw in the coupler (13).

14

5. Lift up on spring (7) and remove E-clip (12).


6. Lift steering wheel (5) from bracket (10). Inspect
and replace bushings (7 and 8) as needed.

BT Prime-Mover Inc.

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Service Manual

2001-03-15

215

F-code

Section

C-code

PS
S4.0
Steering Wheel

4110

Version no

T-code

001

RTX35/RTX45

2. Installation
1. Place steering wheel in the mounting bracket (10).
2. Lift up on the spring (11) and install E-clip (12).
3. Apply Loctite 242 to setscrew. Tighten set screw
in the coupler (13) to 5 in-lbs (0.56 Nm).
4. Check steering wheel for ease of operation.
5. Test the operation of steering wheel and truck.
6. Replace top console.
7. Remove blocks and return truck to service.

216

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2001-03-15

F-code

Section

PS

S4.0

Version no

T-code

001

Spring

E-Clip

C-code

4110
Steer Tach

RTX35/RTX45

Steer Tach
The steer tach is attached to a bracket beneath the steering
wheel.
Item
No.

Set screw

Coupler

1
2
3

Description

Item
No.

Description

Cap, spinner

10

Bracket

Nut

11

Spring

Washer

12

Ring, retainer

Spinner

13

Coupler

Wheel, steering

14

Tachometer

Spacer, steering

15

Screw

Bushing, flat

16

Washer, flat

Bushing, flanged

17

Support, steering

Screw

18

Screw

1. Removal

WARNING Block all wheels to prevent truck from


rolling.

5
6

1. Park truck on a level surface and block wheels.

18
17

11

2. Turn key switch OFF and disconnect battery


connector.

7
12

3. Remove top console. See Top Console on


page 96.

8
9
16
10
15

13

14

4. Disconnect steer tach from the main electrical


harness.
5. Use an Allen wrench to loosen one set screw in the
flexible coupler (13). Lift up on spring (11) to
remove E-clip (12).
6. Remove remaining set screw and remove coupler
from the tach shaft.

BT Prime-Mover Inc.

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Service Manual

2001-03-15

217

F-code

Section

C-code

PS
S4.0
Steer Tach

4110

Version no

T-code

001

RTX35/RTX45

7. Use an Allen wrench to remove two screws (9)


securing steer tach (14) to the mounting bracket
(10).

2. Installation
1. Attach steering tach (14) to the underside of
mounting bracket (10) with two screws (9).
2. Attach flexible coupler (13) to the tach shaft.
3. Lift up on spring (11) to install E-clip (12).
4. Apply Loctite 242 to setscrew. Tighten set screw
in the coupler (13) to 5 in-lbs (0.56 Nm).
5. Reconnect the electrical harness.
6. Test to see that the steering functions properly.
7. Install top console (see page 96).
8. Remove blocks and return truck to service.

218

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Service Manual

2001-03-15

F-code

Section

PS

S4.1
4181
Steering Bearing

Version no

000

C-code

T-code

RTX35/RTX45

Steering Bearing
1
2

Item
No.

BT Prime-Mover Inc.

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Service Manual

Description

Bearing

Screw

Transmission assembly

2001-03-15

219

F-code

Section

C-code

PS
S4.1
Steering Bearing

4181

Version no

T-code

000

RTX35/RTX45

1. Removal
NOTE! The transmission and drive motor must be
removed from the truck to access the steering
bearing. (To remove drive motor see
page 108. and page 115 for removal of
transmission.)
1. Park truck on a level surface.
2. Turn key switch to OFF and disconnect the battery
at battery connector. Check to make sure the
battery retainer plates are in place.
3. Jack the rear of truck (see Safe Jacking
Procedure on page 64).
4. Remove the motor compartment door and left side
panel to access the motor compartment. (See
page 97 and page 98.)
5. Disconnect all electrical connections on the drive
motor and brake assembly.
6. Remove drive motor.
7. Remove transmission.
8. Remove mounting ring.
9. Remove fifteen bolts (11) retaining the steering
bearing (1).

2. Installation
1. Install new steer bearing (1).
2. Install
transmission
mounting
plate
and
transmission in the truck. Torque the six mounting
bolts to 90 ft-lb (122 Nm).
3. Install drive motor.
4. Connect all electrical connections.
5. Refill transmission as needed.
6. Test the steering and truck operation.

220

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2001-03-15

F-code

PS
Version no

001

Section

C-code

S5.0
5000
Electrical Functions
T-code

RTX35/RTX45

Electrical Functions
1. General
The braking, steering, and travel control systems on the
reach truck are electrically controlled and monitored. The lift/
lower and auxiliary function systems are electrically controlled
and hydraulically operated. See Electrical Schematics on
page 273 and Hydraulic System on page 367.
The control system of the reach truck consists of the following
components: control handle; control handle interface card;
main electronic card containing steer control; drive motor
transistor regulator; pump motor transistor regulator; steering
components; and brake. An operator instrument panel
displaying actual time, hourmeter/error code, parking brake
indicator, right foot switch indicator, and parameter set mode.
For a listing of error codes see pages 336 and 340. For a
listing of parameters see page 345. For information on the
fuses and their location see page 305.

1.1. Directional/Speed Control Handle


A5

+
1 1/2
0

BT Prime-Mover Inc.

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The directional/speed control handle is the operators input


interface to the truck. Five basic control functions available on
the control handle allow the operator to perform work with the
truck. The five functions include: travel; lift/lower; reach/
retract; tilt; and sideshift. These five functions can be further
broken down for more specialized control. Travel direction is
selected by moving the handle in the desired direction of
travel. A thumb controlled lever at the end of the control
handle selects lift or lower. Rotating the lever upward selects
lift and downward selects lower. Lift and lower speeds are
dependent upon the distance the lever is rotated in the
desired function direction.
There are two push buttons conveniently located under the
handle select reach or retract functions. Pushing the push
buttons in a particular sequence activates a high speed reach
Control Handle function. To extend the reach, push the push button located
(travel speed / forward on the handle. To retract the reach, push the push
direction)
button located rearward on the handle. To extend the reach in
high speed, push the retract button with extend button
activated. The reach will continue to extend, but at a higher

Service Manual

2001-03-15

221

F-code

Section

PS
S5.0
Electrical Functions
Version no

T-code

001

RTX35/RTX45

C-code

5000

speed. To retract the reach in high speed, push the extend


button with retract button activated. The reach will continue to
retract, but at a higher speed. A thumb controlled rocker
switch selects tilt up, tilt down, sideshift left, and sideshift
right. A horn push button is also located on the control
handle.

1.2. 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 digital signals from the control
handle include: reach; tilt; and sideshift. The digital signals
are decoded by converting the possible combinations of push
buttons to different analog voltage levels. The result is then
conditioned and passed to the main electronic card (A5) for
processing. The analog signals are from the travel and lift/
lower potentiometers. The control handle analog signals are
relayed unchanged to the main electronic card (A5).
A 7.35-Volt power supply on the handle interface card
provides the control handle potentiometer and push button
voltage. (The 7.35-Volt power supply is covered in 7.35-Volt
Power Supplies on page 251.) This supply is referenced to a
7.35-Volt power supply signal sent from the main electronic
card (A5). The handle interface card contains horn driver
circuitry activated when the horn push button is pushed. This
circuitry is designed to drive a high impedance horn input. A
green LED indicates the handle interface card power status.

1.3. Main Electronic Card


The
main
electronic
card
(A5)
contains
three
microprocessors. One microprocessor operates as a master
and the other two as slaves. The three microprocessors
share various digital and analog input functions. The
microprocessors monitor the state of switches, sensors,
control handle functions, system functions, and other input
devices. The master microprocessor makes decisions based
on the information received from its inputs and the two slave
processors. The results of the decisions are communicated to
the slaves. All three microprocessors share in control of
digital and analog outputs. Output devices controlled include:

222

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2001-03-15

F-code

PS
Version no

001

Section

C-code

S5.0
5000
Electrical Functions
T-code

RTX35/RTX45

solenoids; contactors; motor controllers; steer motor; and


brake, and optional equipment.
The main electronic card (A5) performs diagnostic tests at
start-up and during truck operation. The diagnostic tests
assist in repair by identifying problems and minimizing truck
downtime. For any identified problems, the operator is alerted
by a visible tool bar icon and error code numbers displaying
on the operator display. An audible alarm is sounded when
an error is detected. A history log records error codes by date
and time.
The main electronic card (A5) contains a clock/calendar chip
with an internal battery. The combination of chip and battery
allows clock and date settings to remain in memory when the
trucks battery is disconnected.

BT Prime-Mover Inc.

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Service Manual

2001-03-15

223

F-code

Section

C-code

PS
S5.0
Electrical Functions

5000

Version no

T-code

001

RTX35/RTX45

K10

K10

A1
3

A2
M1

F55

ARMATURE

B7

2
A1

15
ACC
RELAY

B+

A5

44

F1

S21
101

34

902

40

FIELD
1

K11

K13
M1

K11

K13
8

M
1

805

64

Y1

803

51

K11

802

52

K13

22
F51

F50
808
36V only
501
S48
43 111

A71
25

S108

21
S21

24

S17

49 102
22

809
901

Start Up Battery Connected

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

224

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2001-03-15

F-code

PS
Version no

001

Section

C-code

S5.0
5000
Electrical Functions
T-code

RTX35/RTX45

2. Start Up
With the battery connected to the reach truck, wire #1
connects battery voltage to the battery terminal of the main
contactor (K10), the control fuse (F50), the steer servo fuse
(F51), and the accessory fuse (F55). Control fuse F50 and
wire #21 connect voltage to the main electronic card (A5)
connector pin 808 (and connector pin 501 for 36V trucks), the
positive terminal of one section of the emergency disconnect
(S21) switch, and the control handle interface card. Steer
servo fuse (F51) and wire #25 connect battery positive to the
main electronic card (A5) connector pin 901 (steer servo).
Accessory fuse (F55) and wire #15 connect battery voltage to
the accessories relay(s). The main electronic card (A5), steer
servo, and control handle interface card are powered when
the battery is connected. Wire #40 is battery negative.

BT Prime-Mover Inc.

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2001-03-15

225

F-code

Section

C-code

PS
S5.0
Electrical Functions

5000

Version no

T-code

001

RTX35/RTX45

A2
K10

F3

K10

B+
A1
3

A2
M1

F55

B+

ARMATURE
2
FIELD

K11

B7

A1
15
ACC
RELAY

A5

44

F1

S21
101

34

902

40

K13

M1

1
K11

K13
8

M
1

805

64

Y1

803

51

K11

802

52

K13

22
F51

F50
808
36V only
501
S48
43 111

A71
25

S108

21
S21

24

S17

49 102
22

809
901

Start Up E- Stop Released/Key ON

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

226

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2001-03-15

F-code

PS
Version no

001

Section

C-code

S5.0
5000
Electrical Functions
T-code

RTX35/RTX45

Start Up E- Stop Released/Key ON


By closing the emergency disconnect switch (S21) and key
switch (S17), electricity flows through wire #22 to the main
electronic card (A5) input 809 and the normally closed brake
switch (S48), and main electronic card (A5) input 111. With
power at input 809, the main electronic card (A5) performs a
start-up diagnostic test and, if successful, applies power to
the cards outputs. Electricity also flows through wire #22 to
the drive transistor regulator (A1) connector pin 1 and to the
pump transistor regulator (A2) connector pin 1. The drive
transistor regulator (A1) performs an internal safety test. If the
test is successful, output at connector pin 7 wire #34 goes to
battery voltage. Wire #34 supplies an input to terminal 101 of
the main electronic card (A5). 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). K10 energizes and applies battery voltage to
the drive transistor regulator B+ terminal through fuse (F1)
and the pump transistor regulator B+ terminal through fuse
(F3). The main electronic card (A5) monitors the state of wire
#34 through input 101. If all tests are successful, the truck is
now powered and ready to begin operation.

BT Prime-Mover Inc.

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Service Manual

2001-03-15

227

F-code

Section

C-code

PS
S5.0
Electrical Functions

5000

Version no

T-code

001

RTX35/RTX45

A5

40
902 (0V)
F51

25

1
60
M6

901

Tx+ 303

A6
Rx+

Tx- 304

Rx-

903 +

M
61

904 -

62
503 IN U1

G
63

502 IN +

Steering Components

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

228

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F-code

PS
Version no

001

Section

C-code

S5.0
5000
Electrical Functions
T-code

RTX35/RTX45

3. Steering Components
3.1. Steering System
The steering system is electrically controlled. The input is a
tachometer (DC generator (U1) connected to the steering
wheel. The faster the steering wheel is turned, the higher the
voltage produced by the tachometer (U1). The direction of
tachometer (U1) rotation determines the polarity of the signal.
The tachometer (U1) is connected to the main electronic card
(A5) by wire #62 to input 503 (-) and by wire #63 to input 502
(+). The master processor on the main electronic card (A5)
processes the tachometer signal and communicates the
result to the steer slave processor. The steer slave processor
controls the steer chopper to obtain the appropriate output
voltage and polarity to drive the steer motor (M6). The steer
motor is connected to the main electronic card (A5) through
wire #60 output 903 (+) and wire #61 output 904 (-). Current
through the main electronic card (A5) connector pins 903 (+)
and 904 (-) determine the steer motor direction. Electrical
power for the steer motor is supplied through wire #1 to fuse
(F51) and through wire #25 to the main electronic card (A5) at
connector pin 901. The negative is wire #40 connected to the
main electronic card (A5) connector pin 902.
The main electronic card (A5) monitors the steer system. If a
fault is sensed in the steer tachometer, steer controller, steer
motor, or wiring, an error code will appear on the Operator
Display (A6) indicating the steering problem.
Three parameters can be modified to adjust the steering for
custom control. Parameter 1 adjusts speed sensitive steering
(reduced steering sensitivity at high speed). Parameter 2
adjusts steering sensitivity (tachometer response). Parameter
11 adjusts steer direction (forks trailing or forks first).
Turning the steering wheel clockwise directs B- current to the
steer motor through a series of steps:
The steer tachometer determines the rate and direction of
steer wheel rotations.
Turning the steer tachometer clockwise sends 0 to +2.9
volts (depending upon the rate of rotation of the steering
wheel) to the main electronic card (A5) at input 502 with
respect to connector pin 503.
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The main electronic card (A5) interprets the input from the
steer tachometer (depending upon the sensitivity setting
selected) and instructs the steer motor to rotate clockwise
(direction parameter 11 set to forward) by supplying Bvoltage through wire #60 from output 903 to the steer
motor with respect to wire #61, connector pin 904.
The drive wheel steers in a counter-clockwise direction
turning the forks of a moving, forks leading truck to the
right.
Turning the steering wheel counter-clockwise directs B+
current to the steer motor through a series of steps:
The steer tachometer determines the rate and direction of
steer wheel rotations.
Turning the steer tachometer counter-clockwise sends 0 to
-2.9 volts (depending upon the rate of rotation of the
steering wheel) to the main electronic card (A5) at input
502 with respect to connector pin 503.
The main electronic card (A5) interprets the input from the
steer tachometer (depending upon the sensitivity setting
selected) and instructs the steer motor to rotate
counterclockwise (direction parameter 11 set to forward)
by supplying B+ voltage through wire #60 from output 903
to the steer motor with respect to wire #61, connector pin
904.
The drive wheel steers in a clockwise direction turning the
forks of a moving, forks leading truck to the left.

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A5
F53

67
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)

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3.2. Wheel Direction Sensors


This diagram covers the channel A steering stop proximity
sensor (S66), channel B steering stop proximity sensor
(S67), fuse (F53), steering wheel position sensor (S65), and
main electronic card (A5). 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 three
sensors, Steer Wheel Position (S65), 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). S66 connector is grey in color and located in the
front. S67 connector is blue in color and located in the back.
The 12-Volt power supply is covered in 12-Volt Power
Supply on page 249, provides power to the Steering Stop A
sensor (S66), and Steering Stop B sensor (S67). The Steer
Wheel Position sensor (S65) requires battery voltage to
operate. S65 is connected to the main electronic card input
202 (Wire #57). S66 is connected to the main electronic card
input 204 (wire #58). S67 is connected to the main electronic
card input 203 (wire #59). As the drive wheel is steered
toward the electrical stops the sensors change state,
signaling the main electronic card (A5) to the drive wheel
position. When the sensors are in specific ON/OFF states,
signaling the electrical stop has been reached, the main
electronic card (A5) stops the steer request to the steer
controller. Continuing to steer in the same direction will not
steer the drive wheel any farther. Steering in the opposite
direction will allow the drive wheel to steer away from the
electrical stop.
The main electronic card (A5) monitors the steering sensors.
If the main electronic card (A5) detects all sensors ON or all
sensors OFF, an error code will display on the operator
display indicating a sensor problem. When a steering sensor
failure occurs, the steering electrical stops no longer function
and the stopping of the drive wheel steering relies on the
mechanical stop. Failure to replace a failed sensor could
result in mechanical stop failure and additional sensor
damage.

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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

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Failure Error

OFF

OFF

OFF

Failure Error

ON

ON

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4. Brake Release
Brake release occurs when the brake pedal is fully
depressed. The emergency switch (S21) ON, key switch
(S17) ON and the brake pedal fully depressed (down) causes
the brake switch (S48) to open removing the input to the main
electronic card (A5) terminal 111 (wire #43). The brake
potentiometer (R3) output goes to a higher voltage than when
the brake pedal is released (up). The main electronic card
(A5) senses the increase in voltage at terminal 511 (wire
#65). The main electronic card (A5) responds by turning on
output 805 (wire #64) sending current to the magnetic brake
coil (Y1). The energizing of the brake coil (Y1) causes the
brake pressure plate to move from the brake friction plate,
releasing the brake and allowing the truck to travel.

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

K10

K10
A5

A1
44

F1
3

A2

M1

B+

ARMATURE

B-

S21

7
2

A1

K13
8

22

40

29 504 +7.35V
50 505 +3.65V

K13

M1
K11

902

FIELD
K11

101

34

30 510 0V
M
1

805
65
R3

64

Y01

51

K11

52

K13

511
803

F50

802
808
36V only
S48
43

21

S108
S21

24

S17

49
22

501
111
102
809

Brake Release
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K10

K10

A1
F1

A2
M1
A1
FIELD
M1

K11

B7
10

ARMATURE
2

K11

B+

44

K13

11
6

34
36

22

37
35

M
1

902

40

611
609 -

A71
HM104
HM105

29 504 +7.35V
50 505 +3.65V

HM110

30 510 0V

HM111

64

Y1

51

K11

52

K13

805

R1
Blue/white stripe

HM215

Orange/black stripe

F50

101
610

K13
8

A5
S21

R3

65 511
803
802

HM210

Red/white stripe

HM213

808
36V only
S48
43

21

S108
S21

24

S17

501
111

49

102
22 809

S60
39

104

Travel Request, Forks First

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

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5. Travel Request, Forks First


CAUTION Releasing the brake pedal while on an
incline will cause the truck to move.
Forks first travel occurs when the brake pedal is depressed
and the control handle is moved toward the forks. With the
emergency switch (S21) ON, key switch (S17) ON, and the
brake pedal depressed, 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 control handle
interface card senses this increase in voltage at HM210. 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), closing the normally open (NO) contact tips and
opening the normally closed (NC) contact tips. The (forks
trailing) direction contactor (K13) remains in the de-energized
state. The electrical path created by the contact position of
K11 and K13 allows current to flow from the battery to the
motor terminal (A2) through the motor brushes and armature
to motor terminal (A1) through K11 (NO) the motor field K13
(NC) to drive transistor (A1) regulator terminal M- in a
direction to cause the drive motor to rotate counter-clockwise
and move the truck in the forks first direction.
A battery voltage potential is provided to the drive transistor
(A1) regulator terminal A. The main electronic card (A5) turns
on speed request output 610 (wire #36) to a level proportional
to the control handle travel request. This signal is sent to the
drive transistor (A1) regulator input pin 10. 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. Both speed
request and current limit signals range from 0 volts to
approximately 4.5 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). The drive
transistor (A1) regulator sends the amplified signal to the
drive motor commanding travel. The main electronic card
(A5) monitors the drive motor temperature limit. A drive
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temperature switch (S60), located on the motor and


connected to main electronic card (A5) input 104 (wire #39),
opens if the motor frame exceeds 257 F (125 C). The main
electronic card (A5) reduces the drive speed request and the
drive transistor regulator responds by reducing the
commanded motor speed.
Travel speed is proportional to directional/speed handle
movement. A reduction in maximum travel occurs for the
following conditions:
1. A steering sensor failure (S65, S66 or S67). (See Wheel
Direction Sensors on page 233.)
2. A drive motor over temperature condition (S60).
3. A steer controller over temperature (internal to the main
electronic card (A5).
4. The mast is extended above free lift height (S31). (See
page 252 and page 254.)
5. Mast switches (S31 and S45) sequence error. (See
page 252 and page 254.)
The main electronic card (A5) will request less speed from
the drive transistor regulator if any of these conditions occur
by reducing the speed request signal. Error codes will be
displayed for all conditions except number 5. When the truck
is traveling and the right foot pedal is not depressed, the
warning triangle on the operator display will flash signaling
the operator to depress the right foot pedal switch (S108).

A5

238

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The center and travel limits of the travel potentiometer are


learned during control handle calibration. Control handle
calibration is required by the display of certain error codes,
when a new control handle is installed or when the A5 card is
replaced (for calibration see page 121). To calibrate the
control handle, key off the truck. Make sure the throttle and
lift/lower pots are centered and the brake pedal and left foot
pedal are released (up). Press SW1 on the electronic card
(A5) and key ON the truck. When the display appears on the
dash display (A6) release SW1. Error code E38 should be
displayed. To clear code E38 move the control handle
through the full range of pot movement, truck travel forks first
and forks trailing. When this is completed error code E33
should be displayed. To clear error code E33, move the lift/
lower pot through the full range of pot movement, lift and
lower. When this is completed no error codes should be
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displayed and the control handle has been calibrated for truck
operation. If control handle calibration was not successful the
same or other codes may be displayed. Other codes could be
caused by incorrect calibrating procedure, a bad control
handle, a failed control handle interface card, a failed control
module (A5) or wiring.
The relationship between the drive transistor (A1) regulator
speed request voltage and travel potentiometer (R1) is an
approximate relationship and include the following:
The travel speed request voltage range is 0 to 5 volts. The
travel potentiometer (RI) voltage is approximately 0.6 to
2.2 volts with the center at approximately 1.4 volts.
Moving the control handle away from the operator causes
voltage to increase from 1.4 to 2.2 volts. For every 0.16
volt increase of the travel potentiometer (R1), the speed
request will increase approximately 1 volt.
The speed request voltage is from the main electronic card
(A5) terminal 610 through wire #36 to the drive transistor
(A1) regulator pin 10.
Wire #35, connecting the drive transistor (A1) regulator pin
6 and the main electronic card (A5) pin 609, is the common
reference for the speed request/current limit voltages.

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K10

K10

A1
44

F1
3

A2
M1

B+

ARMATURE
2

A1
FIELD

K11

M1

K11

B10

K13

11
6

34

22

101
610

37

M
1

902

40

611
609 -

A71
HM104

35

HM105

29 504 +7.35V
50 505 +3.65V

HM110

30 510 0V

HM111

64

Y1

51

K11

52

K13

805

R1
Blue/white stripe

HM215

Orange/black stripe

F50

S21

36

K13
8

A5

R3

65

511
803

HM210

Red/white stripe

HM213
802
808
36V only
S48
43

21

S108
S21

24

501
111

49

102
22 809

S17
S60

104
39

Travel Request, Forks Trailing

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

240

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6. Travel Request, Forks Trailing


CAUTION Releasing the brake pedal while on an
incline will cause the truck to move.
Forks trailing travel occurs when the brake pedal is
depressed and the control handle is moved from the forks.
With the emergency switch (S21), key switch (S17) ON and
the brake pedal depressed, 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. The control
handle interface card senses this decrease in voltage at
HM210. 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 802 (wire #52) and sending current in the forks trailing
direction to the direction contactor (K13), closing the normally
open (NO) contact tips and opening the normally closed (NC)
contact tips. The forks first wheel direction contactor (K11)
remains in the de-energized state. The electrical path created
by the contact position of K13 and K11 allows current to flow
from the battery to the motor terminal (A2) through the motor
brushes and armature to motor terminal (A1) through K13
(NO) the motor field K11 (NC) to drive transistor regulator
(A1) terminal M- in a direction to cause the drive motor to
rotate clockwise and move the truck in the forks tailing
direction.
A battery voltage potential is provided to the drive transistor
(A1) regulator terminal A. The main electronic card (A5) turns
on speed request output 610 (wire #36) to a level proportional
to the control handle travel request. This signal is sent to the
drive transistor (A1) regulator input pin 10. 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. Both speed
request and current limit signals range from 0 volts to
approximately 4.5 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). The drive
transistor (A1) regulator sends the amplified signal to the
drive motor commanding travel. The main electronic card
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(A5) monitors the drive motor temperature limit. A drive


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


displayed and the control handle has been calibrated for truck
operation. If control handle calibration was not successful the
same or other codes may be displayed. Other codes could be
caused by incorrect calibrating procedure, a bad control
handle, a failed control handle interface card, a failed control
module (A5) or wiring.
The relationship between the drive transistor (A1) regulator
speed request voltage and travel potentiometer (R1) is an
approximate relationship and include the following:
The travel speed request voltage range is 0 to 5 volts. The
travel potentiometer (RI) voltage is approximately 0.6 to
2.2 volts with the center at approximately 1.4 volts.
Moving the control handle away from the operator causes
voltage to increase from 1.4 to 2.2 volts. For every 0.16
volt increase of the travel potentiometer (R1), the speed
request will increase approximately 1 volt.
The speed request voltage is from the main electronic card
(A5) terminal 610 through wire #36 to the drive transistor
regulator (A1) pin 10.
Wire #35, connecting the drive transistor (A1) regulator pin
6 and the main electronic card (A5) pin 609, is the common
reference for the speed request/current limit voltages.

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K10

K10

A1
3

A2
M1

B+

K11

FIELD

M1
K13

11

37

M
1

609 611

A71
29

HM104

50

HM105
1

30

HM110
R1
22

40

610
35

6
8

902
103

36
10

K13

K11

101

34
38

2
A1

S21

B7

ARMATURE

A5

44

F1

504 +7.35V
505 +3.65V
510 0V

HM111
Blue/white stripe
Orange/black stripe
Red/white stripe

HM210

Y1

51

K11

52

K13

805

R3

HM215

64

511
65

803
802

HM213

F50
810 +
811 -

22
808
36V only
S48

21

S108
S21

24

S17

S
125

501
43
49

111
102

23
105

809
22

S
64

56

201

Plug Braking

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

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7. Plug Braking
CAUTION Releasing the brake pedal while on an
incline will cause the truck to move.
There are two methods of plug braking available on the reach
truck. The one is using the directional/speed control handle
and is detailed first. The second method is accomplished
through raising the brake pedal and is detailed second.

7.1. Directional/Speed Control Handle


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

7.2. Brake Pedal Method


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

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Knowing the drive motor direction, 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. The main electronic
card (A5) begins to ramp up speed request output 610 (wire
#36) from zero volts. This signal is sent to the drive transistor
regulator (A1) input pin 10 (wire #36). The drive transistor
regulator (A1) sends the amplified signal to the drive motor
commanding plugging. At approximately 0.5 volts speed
request the drive transistor regulator (A1) recognizes the
drive motor is plugging and the drive switches to plug brake
mode. The drive transistor regulator (A1) output pin 8 (wire
#38) signals the main electronic card (A5) input 103, lighting
LED 103, that the drive motor and drive transistor regulator
(A1) are in plug brake mode. The main electronic card (A5)
responds by setting speed request output 610 (wire #36) at
2.5 volts locking the system of the drive motor, the drive
transistor regulator (A1) and the main electronic card (A5)
into plug braking.
Speed request output 610 (wire #36) from the main electronic
card (A5) remains at 2.5 volts as long as the drive transistor
regulator (A1) output pin 8 (wire #38) signals the main
electronic card (A5) that the drive transistor regulator (A1)
and the drive motor are in plug brake mode. A current limit
signal proportional to the brake pedal request is also sent
from the main electronic card (A5) output 611 (wire #37) to
the drive transistor regulator (A1) input pin 11.
The current limit signal ranges from 0 volts to approximately
4.5 volts and controls the plugging force. Plug braking force is
regulated with the brake pedal. The greater the brake pedal is
raised the higher the current limit signal voltage and the
greater the plug braking force. Both speed request and
current limit signals are measured with respect to the main
electronic card (A5) output 609 (wire #35). The main
electronic card (A5) monitors the truck speed using the speed
sensor (S64). If the truck speed drops below approximately
0.25 mph (0.40 kph) before the brake pedal is pushed down,
the parking brake is applied and the truck is stopped.

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To return control to the direction/speed control handle pot


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

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8. 12-Volt Power Supply


A power supply on the main electronic card (A5) produces
12-Volts. It supplies power to the drive motor speed sensor
(S64), the drive motor direction sensor (S125), steering stop
A sensor (S66), steering stop B sensor (S67) and height
counter (U10). This supply has limited power capacity and is
not designed for user connection.

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)

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CONTROL
HANDLE
S55 S56
S212 S211
S52 S51
S18

A5

A71
HM214 +7.35V
HM104

29
50

HM105

R11

HM208 +7.35V
HM106
HM211
HM110

82
30

504 +7.35V
505 +1.4V
506 +1.65V
510 0V

HM111
HM215 +7.35V

R1

R3

HM210

511

21
HM213
F50
1

Legend

7.35-Volt Power Supplies


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

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9. 7.35-Volt Power Supplies


9.1. 7.35-Volt Power Supply Main
Electronic Card
A power supply on the main electronic card (A5) produces
7.35-Volts. It supplies power to the brake pedal potentiometer
(R3) and the control handle interface card. This is a precision
supply with limited power capability and not designed for user
connection.

9.2. 7.35-Volt Power Supply Control Handle


Interface Card
The 7.35-Volt power supply on the control handle interface
card increases the current capability of the 7.35-Volt power
supply from the main electronic card (A5). The control handle
interface card supplies power to the control handle travel (R1)
and lift/lower (R11) potentiometers. It also supplies power to
the reach extend (S55) and retract (S56) push buttons, the
sideshift right (S212), left (S211) switches, tilt up (S52) and
down (S51) switches, and horn (S18) push button. This is a
precision supply with limited power capability and not
designed for user connection.

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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

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10. Limit Switches


10.1. Truck Travel Speed Limiting
The speed limit proximity switch (S31) is located on the mast
tie bar at the bottom of the mast. It senses the presence or
absence of the lower mast tie bar on the inner column. When
the inner columns are elevated, and the load is above freelift,
the absence of the lower mast tie bar is detected. Speed limit
mast switch turns OFF removing voltage to the main
electronic card (A5) input 107 (wire #79). The main electronic
card (A5) limits the speed request to the drive transistor
regulator (A1) limiting truck travel speed proportional to the
value programmed by the Reduce Speed Parameter 4. When
the mast is lowered and the presence of the lower mast tie
bar is detected, the speed limit switch turns ON sending
voltage to the main electronic card (A5). The speed request
to the drive transistor (A1) regulator is no longer limited and
the truck is allowed to return to full travel speed.

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S45

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)

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10.2. Mast Staging Speed Limiting


Carriage lift speeds are limited during the transition from free
height to staging. The mast proximity switch (S45) is located
on the carriage. It senses the presences or absence of the
inner column. When the carriage is raised the mast switch
(S45) exists the top of the inner column at the end of free
height, and the absence of the inner column is detected. The
mast switch turns OFF removing voltage to the main
electronic card (A5) input 207 (wire #106). The main
electronic card limits the speed request to the lift transistor
regulator (A2) during the transition. The speed limit proximity
switch (S31) is also used to signal the main electronic card
(A5) for staging speed limiting. The speed limit proximity
switch (S31) is located on the mast tie bar at the bottom of the
mast. It senses the presence or absence of the lower mast tie
bar on the inner column. When the inner column begins to lift
the absence of the lower mast tie bar is detected. The speed
limit switch turns OFF removing voltage to the main electronic
card (A5) input 107 (wire #79). The speed request to the lift
transistor regulator (A2) is no longer limited. The lift is allowed
to return to full lift speed.
Carriage lowering speeds are limited during the transition
from staging to free height. As the inner column lowers the
presence of the lower mast tie bar is detected. The speed
limit switch (S31) turns on sending voltage to the main
electronic card (A5) input 107 (wire #79). The main electronic
card limits the signal to the proportional lowering valve (Y10),
limiting lowering speed during the transition. As the carriage
is lowered, the mast switch (S45) enters the top of the inner
column at the beginning of free height, and the presence of
the inner column is detected. The mast switch turns on
sending voltage to the main electronic card (A5) input 207
(wire #106). The signal to the proportional lowering valve
(Y10) is no longer limited. The lowering is allowed to return to
full lowering speed.

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A8

A5

F52

22

3+

+5

4 0V

-2

125
126

40

S45

106

405 +
402 -

207

F53
810

31
U10
+

98

205

99

206

B
32

811

Legend

Height Indicator

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

256

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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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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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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

ARMATURE
2

SA1

902

40

FIELD
K11

K13
M1

K11

K13
8
M

41

803 51

K11

52

K13

208

Legend

802

ELECTRIC POSITIVE

42
209

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

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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

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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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

A5

44

F1

S21
34

101
902

40

K13

M1
K11

K13
8

Legend

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

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K10

K10

A1
3

A2

B+

ARMATURE

M1

2
K11

FIELD

B7

A1

A5

44

F1

S21
34

101
902

40

K13

M1
K11

K13
8

Legend

Safety Check B

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

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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)

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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

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Electrical Functions

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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

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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, 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

F-code

PS
Version no

001

Section

C-code

S5.0
5000
Electrical Functions
T-code

RTX35/RTX45

List of Symbols
Symbol

BT Prime-Mover Inc.

Function

Remark

S113

Switch

A5 Thermostat

S125

Inductive sensor

Drive Direction

S211

Switch

Tilt Up

S212

Switch

Tilt Down

SA1

Switch

Carbon Brush Indicator, Drive/pump Motor (-)

SA2

Switch

Carbon Brush Indicator, Drive/pump Motor (+)

U1

Tachometer

Steering

U10

Pulse sensor

Height Counter

V101

Zener diode

Voltage Regulator

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, 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

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2001-03-15

267

F-code

Section

C-code

PS
S5.0
Electrical Functions
Version no

T-code

001

RTX35/RTX45

5000

Component Location (Figure 1 of 2)


S33, S96
S21
S97,
S17

S212, S211, S52, S51

U1

+
1 1/2
0

S18
R11
S55, S56
K11

A2

A1

K13

2
3

K10

K34

Y14

+1
01/2

Y15
Y17

Y16

268

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2001-03-15

F-code

Section

PS

C-code

S5.0
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.

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Service Manual

R3

2001-03-15

269

F-code

Section

PS
S5.0
Electrical Functions
Version no

T-code

001

RTX35/RTX45

270

Return

C-code

5000

Service Manual

2001-03-15

F-code

PS
Version no

000

Section

C-code

S5.1
5000
Electrical Symbols
T-code

RTX35/RTX45

Electrical Symbols
Electrical Symbols
Symbol

BT Prime-Mover Inc.

Return

Symbol

Description

Battery

Brake (coil)

Contactor

Diode

Emergency stop

Fuse

Horn

Inductive sensor
(normally closed)

Inductive sensor
(normally open)

Key switch

Magnet switch
(normally closed)

Magnet switch
(normally open)

Motor

Potentiometer

A1

Description

A2

Service Manual

2001-03-15

271

F-code

Section

C-code

PS
S5.1
Electrical Symbols

5000

Version no

T-code

000

RTX35/RTX45

Electrical Symbols
Symbol

Description
Push button switch
(normally closed)

Symbol

Description
Push button switch
(normally open)

Resistor

Switch

Switch
(normally closed)

Switch
(normally open)

Valve

272

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2001-03-15

F-code

PS

Section

C-code

S5.2
5000
Electrical Schematics

Version no

001

T-code

RTX35/RTX45

Electrical Schematics

Legend
Sh. = Sheet or page of Diagram
First number = Previous page wire was found.
Second number = Next page wire is found.

1. Circuit Diagram 1 (12)

BT Prime-Mover Inc.

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2001-03-22

273

F-code

Section

PS
S5.2
Electrical Schematics
Version no

T-code

001

RTX35/RTX45

C-code

5000

Legend
Sh. = Sheet or page of Diagram
First number = Previous page wire was found.
Second number = Next page wire is found.

2. Circuit Diagram 2 (12)

274

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2001-03-22

F-code

PS

Section

C-code

S5.2
5000
Electrical Schematics

Version no

001

T-code

RTX35/RTX45

Legend
Sh. = Sheet or page of Diagram
First number = Previous page wire was found.
Second number = Next page wire is found.

3. Circuit Diagram 3 (12)

BT Prime-Mover Inc.

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2001-03-22

275

F-code

Section

PS
S5.2
Electrical Schematics
Version no

T-code

001

RTX35/RTX45

C-code

5000

Legend
Sh. = Sheet or page of Diagram
First number = Previous page wire was found.
Second number = Next page wire is found.

4. Circuit Diagram 4 (12)

276

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2001-03-22

F-code

PS

Section

C-code

S5.2
5000
Electrical Schematics

Version no

001

T-code

RTX35/RTX45

Legend
Sh. = Sheet or page of Diagram
First number = Previous page wire was found.
Second number = Next page wire is found.

5. Circuit Diagram 5 (12)

BT Prime-Mover Inc.

Return

Service Manual

2001-03-22

277

F-code

Section

PS
S5.2
Electrical Schematics
Version no

T-code

001

RTX35/RTX45

C-code

5000

Legend
Sh. = Sheet or page of Diagram
First number = Previous page wire was found.
Second number = Next page wire is found.

6. Circuit Diagram 6 (12)

278

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2001-03-22

F-code

PS

Section

C-code

S5.2
5000
Electrical Schematics

Version no

001

T-code

RTX35/RTX45

Legend
Sh. = Sheet or page of Diagram
First number = Previous page wire was found.
Second number = Next page wire is found.

7. Circuit Diagram 7 (12)

BT Prime-Mover Inc.

Return

Service Manual

2001-03-22

279

F-code

Section

PS
S5.2
Electrical Schematics
Version no

T-code

001

RTX35/RTX45

C-code

5000

Legend
Sh. = Sheet or page of Diagram
First number = Previous page wire was found.
Second number = Next page wire is found.

8. Circuit Diagram 8 (12)

280

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2001-03-22

F-code

PS

Section

C-code

S5.2
5000
Electrical Schematics

Version no

001

T-code

RTX35/RTX45

Legend
Sh. = Sheet or page of Diagram
First number = Previous page wire was found.
Second number = Next page wire is found.

9. Circuit Diagram 9 (12)

BT Prime-Mover Inc.

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Service Manual

2001-03-22

281

F-code

Section

PS
S5.2
Electrical Schematics
Version no

T-code

001

RTX35/RTX45

C-code

5000

Legend
Sh. = Sheet or page of Diagram
First number = Previous page wire was found.
Second number = Next page wire is found.

10. Circuit Diagram 10 (12)

282

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2001-03-22

F-code

PS
Version no

001

Section

C-code

S5.2
5000
Electrical Schematics
T-code

RTX35/RTX45

Legend
Sh. = Sheet or page of Diagram
First number = Previous page wire was found.
Second number = Next page wire is found.

11. Circuit Diagram 11 (12)

BT Prime-Mover Inc.

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Service Manual

2001-03-22

283

F-code

Section

PS
S5.2
Electrical Schematics
Version no

T-code

001

RTX35/RTX45

C-code

5000

Legend
Sh. = Sheet or page of Diagram
First number = Previous page wire was found.
Second number = Next page wire is found.

12. Circuit Diagram 12 (12)

284

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2001-03-22

F-code

Section

PS

S5.3

Version no

001

C-code

5110
Battery

T-code

RTX35/RTX45

Battery

Battery
Connector

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.

1. Removal
1. After the truck is stopped and the brake pedal is
returned to the full up position, turn key switch to
the OFF position.

Battery
Roller

2. Disconnect battery connector located at the top of


the truck cover.

Battery
Retainer
Plate

3. Position battery replacement device in accordance


with the manufacturers recommendations.
4. Lift battery retainer plate upward, tilt the edge
toward the mast slightly forward to disengage the
tongue on the operator compartment end.
5. Remove battery with lifting device.

2. Installation
1. With a fully charged and tested battery on the lifting
device, position the lifting device at the truck
according to the manufacturers recommendations.
2. Position the battery in the compartment. Be sure
the battery has no more than 0.50 inch (13 mm) of
free play movement in the battery compartment.
3. Install battery retainer plate (see page 106).
4. Move lifting device from the area.
5. Reconnect battery connector, turn key switch ON,
and test the operation of truck.

BT Prime-Mover Inc.

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285

F-code

Section

C-code

PS
Battery

S5.3

5110

Version no

T-code

001

RTX35/RTX45

3. Battery Maintenance
The following information does not supercede or replace
information supplied by the battery and battery charger
manufacturer. Read, understand, and follow the procedures
in the manual supplied with the battery and battery charger.
Notify your supervisor if there are any concerns or questions
regarding battery safety or procedures.

3.1. Battery Inspection and Care


NOTE! Read, understand, and follow procedures,
recommendations, and specifications in the
battery and battery charger manufacturers
manuals.
Batteries in industrial reach trucks pick up various kinds of dirt
and dust depending on their surroundings and the types of
material handled. If cells are overfilled and electrolyte collects
on the covers, the following occurs:
1. The top of the battery becomes wet and stays wet,
since the acid in the electrolyte does not
evaporate.
2. This moist surface, in combination with certain
kinds of dirt, becomes electrically conductive and
permits stray currents to flow externally over the
top of the battery. This degrades battery
performance and truck operation.
3. The acid also causes corrosion of cell posts, nuts,
connectors and the steel battery case.
When inspecting batteries, check the following:
1. Wet covers can indicate overfilling, leaky seals at
posts, or excessive gassing during charge. If
covers are wet, determine the cause and correct
the problem.
2. Make sure batteries cannot move more than 0.5
inch (13 mm) in any horizontal direction. Shim or
block to restrain them.

286

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F-code

Section

PS

S5.3

Version no

001

C-code

5110
Battery

T-code

RTX35/RTX45

3.2. Battery Exterior Cleaning


Refer to the recommended battery manufacturers guidelines
for details.

3.3. Charging
OSHA regulations require that battery charging installations
be located in areas designated for that specific purpose. Such
areas must provide for flushing and neutralizing spilled
electrolyte, for fire protection, for protecting charging
equipment from damage by reach trucks and for adequate
ventilation of fumes from gassing batteries.
To charge a battery, direct current is passed through the
battery cells in the direction opposite that of discharge.
Charging time is 5% to 20% longer than discharge time.

Read, understand, and follow procedures, recommendations


and specifications in the battery and battery charger
manufacturers manuals.

CAUTION NEVER plug the battery charger into the


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

BT Prime-Mover Inc.

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287

F-code

Section

C-code

PS
Battery

S5.3

5110

Version no

T-code

001

RTX35/RTX45

4. Storage
Before storing the battery, make sure the electrolyte is at the
proper level in all the cells, filler plugs are tight, and battery is
fully charged. Store battery in a clean, cool, dry location away
from radiators and other sources of heat. Check the
electrolyte level and specific gravity every 30 days during
storage. Whenever the specific gravity is less than 1.230,
charge the battery.

5. Battery History Record


A battery record system is essential because battery failure
can cause production slowdowns and increased battery
operating costs. A properly supervised record system can
detect and call attention to such operating irregularities as:
Overcharging
Undercharging
Over-discharging
Excessive water consumption
Excessive dirt and corrosion
Worn-out batteries
Excessive current consumption of trucks
Records should be kept for each battery. Your battery
supplier should be able to provide maintenance record
sheets. Each report should contain:
Battery number, type, serial number, and service data
Specific gravity and voltage readings for each cell
Temperature of the air and electrolyte
Electrolyte
Amperes
Condition of connectors, covers, sealing compound and
tray
General cleanliness
Number of total cycles
Average specific gravity drop
Watering frequency
User comments and observations

288

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Service Manual

2001-03-15

F-code

Section

PS

S5.4
5121
Light Assemblies

Version no

001

C-code

T-code

RTX35/RTX45

Light Assemblies

1. Overhead Guard Lights (Option)

The overhead guard lights are mounted in a compartment on


the left side 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.
Item No.

Description

Light, dome

Bezel, light

Tie, wire

1.1. Removal
1. Turn key switch OFF and disconnect battery
connector.
2. From the top of the overhead guard, remove four
screws securing the light/fan assembly.
3. Lower the light/fan assembly enough to disconnect
it from the harness.
4. Remove light/fan assembly from truck.
5. Repair or replacement of the light is achieved by
removing four screws in the sides of the light/fan
console assembly to detach the hanger bracket
from the top of console.

1.2. Installation
1. Reassemble the light/fan console assembly. Be
sure clip nuts are positioned over mounting holes
for attachment to the overhead guard.
2. Reconnect harness connections.
3. Install mounting screws through the top of
overhead guard to secure the assembly.
BT Prime-Mover Inc.

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289

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Section

C-code

PS
S5.4
Light Assemblies

5121

Version no

T-code

001

RTX35/RTX45

4. Reconnect battery connector.

1
2

5. Test the operation of light assembly, then return


the truck to service.

2. Warning Lights (Option)

The warning lights are strobe lights. The color of the lights are
by customer request. Warning lights are mounted at the back
of the overhead guard, to the right of the back post.

Item
No.
3

Description

Item
No.

Description

Screw, slotted

Alarm, travel

Light

Screw

Bracket, mounting

2.1. Removal
1. Turn key switch OFF and disconnect battery
connector.
2. Disconnect electrical connection at the warning
light.
3. Remove two hex head screws (1) securing light
assembly (2) to the overhead guard bracket (3).
4. Replace light bulb or light assembly as required.

2.2. Installation
1. Secure light assembly to the overhead guard
bracket (3) with two hex head screws (1).
2. Reconnect wiring harness.
3. Reconnect battery connector.
4. Test the operation of warning lights, then return
truck to service.

290

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F-code

Section

PS

S5.4
5121
Light Assemblies

Version no

001

C-code

T-code

RTX35/RTX45

3. Working Lights (Option)


The working lights option consists of two flood lights mounted
on the underside of the overhead guard.

3.1. Removal
1. Turn key switch OFF and disconnect battery
connector.
2. Disconnect electrical connection at the working
light.
3. Remove screws securing light assembly to the
overhead guard.
4. Replace light bulb or light assembly as required.

3.2. Installation
1. Secure light assembly to the overhead guard.
2. Reconnect wiring harness.
3. Reconnect battery connector.
4. Test the operation of the working lights, then return
truck to service.

BT Prime-Mover Inc.

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Service Manual

2001-03-15

291

F-code

Section

C-code

PS
S5.4
Light Assemblies
Version no

T-code

001

RTX35/RTX45

5121

4. Travel/Back-up Alarm (Option)

1
2

The travel/back-up alarm option is installed to the bottom of


the overhead guard. This alarm may be configured to sound
any one of three ways: forks trailing travel only; forks first
travel only; or both forks first and forks trailing travel.

5
Item
No.
4

Description

Item
No.

Description

Screw, slotted

Alarm, travel

Light

Screw

Bracket, mounting

4.1. Removal
1. Turn key switch OFF and disconnect battery
connector.
2. Disconnect electrical connection at the travel/backup alarm.
3. Remove two hex head screws (5) securing the
travel/back-up alarm (4) to the overhead guard
bracket (3).
4. Replace alarm assembly as required.

4.2. Installation
1. Secure the travel/back-up alarm assembly to the
overhead guard bracket (3) with two hex head
screws (5).
2. Reconnect wiring harness.
3. Reconnect battery connector.
4. Test the operation of the alarm, then return truck to
service.

292

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F-code

Section

PS

S5.5

Version no

001

C-code

5160
Horn

T-code

RTX35/RTX45

Horn
NOTE! The horn can only be sounded with the key
switch in the ON position.
2

1. Removal
1. Turn key switch OFF and disconnect battery
connector.

2. Open motor compartment door to access the horn.


3. Disconnect three wires from the horn.
4. Remove horn mounting bolt (2) using a 1/2 inch
(13 mm) socket and ratchet.

2. Installation
1. Attach the horn to the truck frame and tighten
mounting bolt (2).
2. Attach the three wires.
3. Reconnect battery connector and test operation.
4. Close motor compartment door.

BT Prime-Mover Inc.

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Service Manual

2001-03-15

293

F-code

Section

C-code

PS
Horn

S5.5

5160

Version no

T-code

001

RTX35/RTX45

294

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2001-03-15

F-code

PS
Version no

001

Section

C-code

S5.6
5192
Battery Connector
T-code

RTX35/RTX45

Battery Connector
2

1
4

Item No.

Battery
Connector

Description

Connector, SB-350

Cap screw

Cable, Negative

Cable, Positive

1. Location
The battery connector is located on the right side of the truck,
above the battery.
f

BT Prime-Mover Inc.

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Service Manual

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295

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Section

PS
S5.6
Battery Connector
Version no

T-code

001

RTX35/RTX45

C-code

5192

2. Inspection
1. Turn key switch OFF and disconnect battery
connector.
2. Check battery connector for damaged cables.
3. Check to see if battery cables are pulling out of the
connector.
4. Check cables at the battery terminals. Connections
should be tight, with no corrosion.
5. Look inside the connector. Check internal contacts
for damage, dirt, or corrosion. DO NOT use a
metal object to clean the connector.

3. Installation
The cables to either half of the connector have a lip on their
forward end. This lip snaps over a spring-loaded retainer
which is part of the connector. To remove a cable from the
connector, push retainer down while pulling the battery cable
towards the rear and out of the connector.

296

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F-code

PS
Version no

001

Section

C-code

S5.7
5311
Start/Stop Switches
T-code

RTX35/RTX45

Start/Stop Switches
1. General
Refer to the electrical schematic to identify the electrical
circuit location of the switch (see Circuit Diagrams on
page 273 through page 284).

1.1. Test/Inspection
Examine the switch for signs of arcing, overheating,
discoloration, cracking, or other physical damage. Replace
switch if such damage is present.
To test a switch, isolate it from the electrical circuit. Remove
all the connections from the switch, making sure all wires are
labeled and identified for reconnection.
Use an ohmmeter set to a low resistance scale to measure
the resistance across the switch. In a closed position, the
switch should be less than 1 ohm. In an open position, the
switch should show a resistance greater than 10 megohms.

2. Key Switch (S17)

Key Switch

+
1

1/ 2

The reach truck is equipped with a two position (off/on) key


switch, which energizes all truck operations, including the
horn. The horn can be sounded only with the 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. The truck is equipped with cold storage freezer
package option. The heaters will operate with the Key Switch
in the Off position.

2.1. Inspection
With the battery plugged in and key switch in the ON position,
battery voltage B+ should be present on both terminals of the
switch. Test the key switch with an ohmmeter after removing
it from the electrical system. In the OFF position, the
ohmmeter should read greater than 10 megohms, and in the
BT Prime-Mover Inc.

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297

F-code

Section

PS
S5.7
Start/Stop Switches
Version no

T-code

001

RTX35/RTX45

C-code

5311

ON position, the ohmmeter should read less than 1 ohm. If


not, replace the switch.

2.2. Removal
1. Turn key switch OFF and disconnect battery
connector.
2. Remove top console (see page 96).
3. Disconnect wires from the bottom of the key
switch.
4. Remove mounting nut from the stem of the key
switch.
5. Remove key switch.

2.3. Installation
1. Install new key switch and tighten locking nut.
2. Connect wires to the terminals.
3. Reconnect battery connector and check operation.
4. Turn key switch OFF and disconnect battery
connector.
5. Install top console.
6. Reconnect battery connector.

298

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F-code

PS
Version no

001

Section

C-code

S5.7
5311
Start/Stop Switches
T-code

RTX35/RTX45

3. Emergency Disconnect Switch


(S21)

Emergency Stop
Switch

+
1

1/

The emergency disconnect or stop (S21) switch is located to


the left of the operator display on the top console. All reach
truck functions should be disabled when the emergency
disconnect switch is depressed.

3.1. Inspection
With the battery plugged in and the emergency disconnect
switch OUT, in the ON position, battery voltage B+ should be
present on both terminals of the switch. Test the emergency
disconnect switch with an ohmmeter after removing it from
the electrical system. In the OFF position, the ohmmeter
should read greater than 10 megohms, and in the ON
position, the ohmmeter should read less than 1 ohm. If not,
replace the switch.

3.2. Removal
1. Turn key switch OFF and disconnect battery
connector.
2. Remove top console (see page 96).
3. Disconnect electrical harness from the base of the
emergency disconnect switch.
4. Use a small phillips head screwdriver to loosen two
screws in the backside of the top console.
5. Press two halves of the emergency disconnect
switch together and turn counterclockwise to
disconnect the switch body from the top console.
6. Finish removing two screws.
7. Repair or replace as necessary.

BT Prime-Mover Inc.

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Service Manual

2001-03-15

299

F-code

Section

PS
S5.7
Start/Stop Switches
Version no

T-code

001

RTX35/RTX45

C-code

5311

3.3. Installation
1. Place switch operator down through the opening in
the top console.
2. Attach switch body to the operator from the
backside of the top console.
3. Turn the halves clockwise to engage the latches.
4. Secure the base of the emergency disconnect
switch to the back of the top console with two
screws.
5. Reconnect electrical harness to the base of the
emergency disconnect switch.
6. Install top console.
7. Reconnect battery connector.
8. Test truck operation, then return to service.

300

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2001-03-15

F-code

Section

PS

C-code

S5.8
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. Mast Switch (S31) serves two functions: truck
speed limiting and mast staging speed limiting. In the truck
speed limiting function, the mast switch (S31) is provided to
reduce travel speed to approximately 2.5 MPH after the first
stage of lift. The first stage of lift ends when the mast inner
columns begin to extend from the main mast frame. In the
mast staging speed limiting function, the mast switch signals
the main electronic card to limit lift speed during the staging
transition.

1. General
Refer to the electrical schematic to identify the electrical
circuit location of the switch (see Circuit Diagrams on
page 273 through page 284).

1.1. Test/Inspection
Examine the switch for signs of arcing, overheating,
discoloration, cracking, or other physical damage. Replace
switch if such damage is present.
+01/21

To test a switch, isolate it from the electrical circuit. Do this by


removing all the connections from the switch, making sure all
wires are labeled and identified for reconnection.
Item No.
1

High Speed
Travel Limit
Switch

BT Prime-Mover Inc.

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Service Manual

Description

Screw, bracket mounting

Bracket, switch

Sensor

2001-03-15

301

F-code

Section

PS
S5.8
Mast Switch (S31)
Version no

T-code

001

RTX35/RTX45

C-code

5332

2. Adjustment
1. Raise the empty carriage until the bottom of the tie
bar is even with the bottom of the mast switch.
2. Secure the carriage with blocks and a hoist to
prevent any movement.
3. Loosen jam nut securing the mast switch to the
mast.
4. Making sure the mast channel are pushed
completely to the rear, adjust the switch to 0.187
inch (4.76 mm). Allowable tolerance is +0.0625
inch (1.59 mm) and -0 mm.
5. Tighten jam nut.
6. Check the clearance with jam nut tightened.
7. Remove blocks and hoist.
8. Place a maximum capacity load on the forks. Verify
that the tie bar does not contact the switch under
normal working conditions.
9. Adjust the clearance as necessary to achieve
proper clearance when fully loaded.
10. Remove the load from forks.
11. Test the truck operation to verify normal travel
speed with the mast lowered.

302

Return

Service Manual

2001-03-15

F-code

PS
Version no

001

Section

C-code

S5.8
5332
Mast Switch (S31)
T-code

RTX35/RTX45

3. Removal
1. Raise the empty carriage until the bottom of the tie
bar is even with the bottom of the mast switch.
2. Secure the carriage with blocks and a hoist to
prevent any movement.
3. Turn key switch OFF and disconnect battery
connector.
4. Disconnect switch from the harness.
5. Loosen jam nut securing the mast switch to the
mast.
6. Remove mast switch from the mast.

BT Prime-Mover Inc.

Return

Service Manual

2001-03-15

303

F-code

Section

PS
S5.8
Mast Switch (S31)
Version no

T-code

001

RTX35/RTX45

C-code

5332

4. Installation
1. Install new mast switch.
2. Tighten jam nut to secure the switch.
3. Attach wiring harness.
4. Reconnect battery connector.
5. Adjust switch following the procedure on page 302.
6. Return truck to service.

304

Return

Service Manual

2001-03-15

F-code

PS

Section

Version no

T-code

001

Located on right side of


Operator Compartment

C-code

S5.9
5391
Control Cable and Harness
RTX35/RTX45

Control Cable and Harness


1. Fuses

F83

Examine the fuse for signs of overheating, discoloration,


cracking, or other physical damage. Replace the fuse if
damage is found.

F82

To test a fuse, remove it or isolate it from the electrical circuit.


Do this by removing the fuse from the truck or by removing all
the connections from one side of the fuse.

F81

Use an ohmmeter set to Rx1 scale and measure the


resistance across the fuse. The resistance should be less
than 1 ohm.

F55
F54
F53

Fuse
No.

Amp

F52

F1

250

Drive Motor Circuit

F3

425

Pump Circuit (24 volt, RTX35)

355

Pump Circuit (36 volt, 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

Auxiliary Power

F50

F51

Located under Top Console

Function

BB+

F1
F3

BT Prime-Mover Inc.

Return

Service Manual

2001-03-15

305

F-code

Section

C-code

PS
S5.9
5391
Control Cable and Harness
Version no

T-code

001

RTX35/RTX45

2. Wiring
2.1. Harness
Whenever working on the truck, use care around the wiring
harnesses.
Do not pull on wires.
Carefully mate and unmate all connectors.
Do not pry apart connectors with unspecified tools.
Examine and maintain any added materials used to dress
or protect the wire. This includes spiral wrap, brackets,
cable ties, fasteners, flexible conduit, etc.
Check harness wires for abrasions, scrapes, nicks in the
wire, damage from overheating or burns, or other general
insulation damage.
Replace terminations with exposed wire visible at the
connectors. Damaged terminations, exposed wires, or
damaged connectors can cause operational failure of the
truck.
During troubleshooting and repairs, it is sometimes
necessary to unmate a connector, move a harness, cut a
cable tie, or remove the wire from a bracket. Note carefully
the location of the wire and all protective or securing
attachments before moving the harness.
After repair, return or replace all protective and/or securing
hardware to its original condition. Protective materials are
necessary to provide reliable performance of the interconnect
system.
NOTE! It is normal to find unused connectors for
uninstalled options that have had heat shrink
applied over them and have been strapped to
the harness.
There should be a wire marker at each termination. If the
marker is missing or unreadable, remark the wire to allow
easier identification.

306

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Service Manual

2001-03-15

F-code

PS

Section

C-code

S5.9
5391
Control Cable and Harness

Version no

001

T-code

RTX35/RTX45

2.2. 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. Power cables are marked on the terminal lug with
the location where they belong. If the marking is missing or is
not readable, remark the cable with the correct information.
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.

BT Prime-Mover Inc.

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

308

Return

Description

Fitting, wire

Lockwasher

Screw

Terminal

Service Manual

2001-03-15

F-code

Section

PS

S5.10

Version no

001

C-code

5441
Contactors

T-code

RTX35/RTX45

Contactors
1. General
1.1. Testing Resistance
Visually inspect the contactor for any signs of burning or
physical damage.
1. Turn trucks key switch OFF and disconnect
battery connector.
2. Disconnect two wires from the base of the
contactor.
3. Connect one lead of the ohmmeter to the one wire
from the contactor. Connect the other lead to the
other wire from the contactor.
4. The reading should be between 20 and 40 ohms. If
it is not, replace the contactor.

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

4
3

310

Return

Item
No.

Description

Item
No.

Contactor assembly

Base

Screw

Kit, service

Contactor

Service Manual

Description

2001-03-15

F-code

Section

PS

S5.10

Version no

001

C-code

5441
Contactors

T-code

RTX35/RTX45

2.1. Removal
1. Turn key switch OFF and disconnect battery
connector.
2. Remove top console (see page 96).
3. Disconnect cables by removing hex nuts. Identify
cables and their location. Label, if necessary, for
proper installation.
4. Remove contactor coil wires by pulling the wire
connector. Note their locations and label if
necessary.
5. Remove two screws (2) holding the contactor to
the mounting panel.
6. Remove contactor from the contactor panel.

2.2. Installation
1. Position contactor over the holes in the mounting
panel. Attach with screws.
2. Attach coil wires by sliding the connector onto the
appropriate spade terminal.
3. Attach cables to the appropriate lugs and tighten
securely.
4. Reconnect battery connector.
5. Turn key switch ON and test truck operation.
6. Turn key switch OFF, disconnect
connector, and install the top console.

battery

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

Item No.

312

Return

Description

Contactor

Kit, service

Screw

Service Manual

2001-03-15

F-code

Section

PS

S5.10

Version no

001

C-code

5441
Contactors

T-code

RTX35/RTX45

3.1. Removal
1. Turn key switch OFF and disconnect battery
connector.
2. Remove top console (see page 96).
3. Disconnect cables by removing hex nuts. Identify
cables and their location. Label, if necessary, for
proper installation.
4. Remove contactor coil wires by pulling the wire
connector. Note their locations and label if
necessary.
5. Remove two screws (3) holding the contactor to
the mounting panel.
6. Remove contactor from contactor panel.

3.2. Installation
1. Position contactor over the holes in the mounting
panel. Attach with screws (3).
2. Attach coil wires by sliding the connector onto the
appropriate spade terminal.
3. Attach cables to the appropriate lugs and tighten
securely.
4. Reconnect battery connector.
5. Turn key switch ON and test truck operation.
6. Turn key switch OFF, disconnect
connector, and install top console.

battery

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

2
3

Item No.

314

Return

Description

Screw

Contactor

Cover, bridge

Kit, service

Service Manual

2001-03-15

F-code

Section

PS

S5.10

Version no

001

C-code

5441
Contactors

T-code

RTX35/RTX45

4.1. Removal
1. Turn key switch OFF and disconnect battery
connector.
2. Remove top console (see page 96).
3. Disconnect cables by removing hex nuts. Identify
cables and their location. Label, if necessary, for
proper installation.
4. Remove contactor coil wires by pulling the wire
connector. Note their locations and label if
necessary.
5. Remove two screws (1) holding contactor to the
mounting panel.
6. Remove contactor from the contactor panel.

4.2. Installation
1. Position contactor over the holes in the mounting
panel. Attach with screws (1).
2. Attach coil wires by sliding the connector onto the
appropriate spade terminal.
3. Attach cables to the appropriate lugs and tighten
securely.
4. Reconnect battery connector.
5. Turn key switch ON and test truck operation.
6. Turn key switch OFF, disconnect
connector, and install the top console.

battery

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

3
4

Item
No.

Description

Item
No.

Transistor controller, drive

Nut

Screw

Screw

Lockwasher

Screw

Description

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

Brake diode to the motor's series field and armature

B-

Battery minus

B+

Battery plus

BT Prime-Mover Inc.

Return

Function

Service Manual

Minus connection to the motor's series field

2001-03-15

317

F-code

Section

C-code

PS
S5.11
5461
Transistor Panel (Drive)
Version no

T-code

001

RTX35/RTX45

1.1. Connections for controls


LED No.

Color

Green

Supply voltage

Yellow

Upper/lower temperature

Red

Fault in power circuits

Red

Fault in reference value circuit

Terminal
Number

Connection

Start/stop and internal supply

Safety test

7 1

318

Return

Function

Function

7
8
9

1
3
4

10
11

Not connected

Logic OV

Logic OV

Common differential

Safety circuit

Braking indication

Voltage output

10

Speed command

11

Current limit command

Service Manual

2001-03-15

F-code

PS
Version no

001

Section

C-code

S5.11
5461
Transistor Panel (Drive)
T-code

RTX35/RTX45

2. Circuit Check.
This check applies to reach trucks equipped with a transistor
regulator type.
1. Jack up the rear of the truck (see Safe Jacking
Procedure on page 64).
2. Remove console cover (see page 96).
3. Turn key switch so that the main electronic card is
ON.

Battery
negative

4. 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. The main contactor,
K10, should now open to indicate that the drive
transistor regulators safety system is functioning. If
K10 does not open, replace the entire drive
transistor regulator.

71
7
8
9
10
11

1
2
3
4
5
6

5. Reset the safety circuits by turning the ignition key


to the OFF position.
Control
current
connector

BT Prime-Mover Inc.

Return

6. Return truck to its original condition after the check.

Service Manual

2001-03-15

319

F-code

Section

C-code

PS
S5.11
5461
Transistor Panel (Pump)
Version no

T-code

001

RTX35/RTX45

Transistor Panel (Pump)


2

3
4
Item
No.

Description

Item
No.

Transistor controller, lift

Nut

Screw

Screw

Lockwasher

Screw

Description

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

B-

Battery minus

B+

Battery plus

320

Return

Function

Minus connection to the motor's series field

Service Manual

2001-03-15

F-code

PS

Section

C-code

S5.11
5461
Transistor Panel (Pump)

Version no

T-code

001

RTX35/RTX45

1.1. Connections for controls


LED No.

Color

Green

Supply voltage

Yellow

Upper/lower temperature

Red

Fault in power circuits

Red

Fault in reference value circuit

Terminal
Number

Connection

Function

Function

7 1
7
8
9
10
11

1
2

3
4

Current value

Voltage value

5
6

Not connected

5
6

Logic OV
I

BT Prime-Mover Inc.

Return

Start/stop and internal supply

Common differential
Not connected

Temperature value

Voltage output

10

Speed command

11

Current limit command

Service Manual

2001-03-15

321

F-code

Section

C-code

PS
S5.11
5461
Transistor Panel (Pump)
Version no

T-code

001

RTX35/RTX45

322

Return

Service Manual

2001-03-15

F-code

Section

PS

S5.12
5511
Micro Switches

Version no

001

C-code

T-code

RTX35/RTX45

Micro Switches
1. General
Refer to the electrical schematic to identify the electrical
circuit location of the switch (see Circuit Diagrams on
page 273 through page 284). Examine the switch for signs of
arcing, overheating, discoloration, cracking, or other physical
damage. Replace switch if such damage is present.
To test a switch, isolate it from the electrical circuit. Remove
all the connections from the switch, making sure all wires are
labeled and identified for reconnection. Use an ohmmeter set
to a low resistance scale to measure the resistance across
the switch. In a closed position, the switch should be less
than 1 ohm. In an open position, the switch should show a
resistance greater than 10 megohms.

BT Prime-Mover Inc.

Return

Service Manual

2001-03-15

323

F-code

Section

PS
S5.12
Micro Switches
Version no

T-code

001

RTX35/RTX45

C-code

5511

2. 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. The lift
limit cutout height is a programmable parameter setting on
the main electronic card. If the lift limit with override option is
available, pressing the switch on the top console will allow lift
to function above the cutout height. As long as the carriage
remains above the preset cutout height, the operator can lift
and lower without pressing the override switch again. If the
carriage drops below the cutout height, or the hydraulic
system is inactive for a set time, the override switch must be
pressed again to reactivate lift.

2.1. Removal
1. Turn key switch OFF and disconnect battery
connector.
2. Loosen top console to allow access to the wiring
harness connection at the switch cluster.
3. Pull two wires off the tabs on the back of the
switch.
4. Unscrew nut securing the switch in the switch
cluster.
5. Lift switch from the switch cluster.

2.2. Installation
1. Place new switch in the switch cluster.
2. Secure switch with nut.
3. Attach two wires to the tabs on the back of the
switch.
4. Secure top console to the truck.
5. Reconnect battery connector.
6. Check the operation of the truck, then return truck
to service.

324

Return

Service Manual

2001-03-15

F-code

Section

PS

S5.12
5511
Micro Switches

Version no

001

Working
Light
Switch

C-code

T-code

RTX35/RTX45

3. Optional Light and Fan Switches


(S96, S97 and S99)
The optional light and fan switches are located in a switch
cluster to the left of the key switch on the top console. A blank
cap indicates the option is unavailable.
The operator fan switch (S96) is in the upper left corner of the
cluster. The overhead light switch (S99) is located in the
lower left corner. The switch for working lights (S97) is in the
upper right corner of the cluster.

Operator
Fan
Switch

Overhead
Light
Switch

3.1. Removal
1. Turn key switch OFF and disconnect battery
connector.
2. Loosen the top console to allow access to wiring
harness connection at the switch cluster.
3. Pull two wires off the tabs on the back of the
switch.
4. Unscrew nut securing the switch in the switch
cluster.
5. Lift switch from the switch cluster.

3.2. Installation
1. Place new switch in the switch cluster.
2. Secure switch with the nut.
3. Attach two wires to the tabs on the back of the
switch.
4. Secure top console to truck.
5. Reconnect battery connector.
6. Check operation of truck, then return truck to
service.

BT Prime-Mover Inc.

Return

Service Manual

2001-03-15

325

F-code

Section

PS
S5.12
Micro Switches
Version no

T-code

001

RTX35/RTX45

326

Return

C-code

5511

Service Manual

2001-03-15

F-code

PS

Section

C-code

S5.13
5711
Main Electronic Card

Version no

001

T-code

RTX35/RTX45

Main Electronic Card


The main electronic card is located in the right side electrical
compartment and enclosed in a protective casing.
Replacement of main electronic card should be as an entire
unit (card and enclosure).

1. Removal
1. Turn key switch OFF and disconnect battery
connector.
2. Remove main
page 101).

electronic

card

panel

(see

3. Disconnect all electrical cables from main


electronic card. Be sure to note connection points
for installation.
4. Remove four Allen head mounting screws.
5. Remove main electronic card unit from truck.

2. Installation
1. Place main electronic card unit against the outside
wall of the chassis. Align mounting holes.
2. Secure main electronic card to truck frame with
four Allen head screws.
3. Reconnect all electrical cables to main electronic
card.
4. Install main electronic card panel.
5. Reconnect battery connector.
6. Perform RV2
page 354).

adjustment

procedure

(see

7. Test operation of truck, then return to service.

BT Prime-Mover Inc.

Return

Service Manual

2001-03-15

327

F-code

Section

C-code

PS
S5.13
Main Electronic Card
Version no

T-code

001

RTX35/RTX45

5711

36 Volt Resistor
24 Volt Jumper

101
to
111

201
to
211

301
to
304

401
to
405

501
to
511

601
to
611

701
to
710

801
to
811

901
to
904

Terminal Locations
I=Input, green LED; O=Output, red LED

3. Connectivity to Truck
The main electronic card is connected to the trucks circuitry
by nine connectors. To remove connectors one through eight,
depress the connectors latch and unplug the connector. To
install the connectors, push the connectors together until the
latch snaps into position. To remove connector nine, grasp
the connector (do not grasp the wires) and, with a slight
rotational wiggling action, unplug the connector. To install,
push the connector onto the pins making sure all of the pins
are captured by the connector.

328

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Service Manual

2001-03-15

F-code

Section

PS

C-code

S5.13
5711
Main Electronic Card

Version no

T-code

001

RTX35/RTX45

The nine connectors are grouped functionally from the top


down: digital inputs (2); communications (2); analog inputs
(1); analog outputs (1); digital outputs (2); and power output
(1). The main electronic cards top eight connectors and light
emitting diodes (LED) are clearly identified by numbers.
When the main electronic card is connected correctly to the
trucks battery, the digital input LEDs light green indicating
that the input is on and battery voltage is present at the input
pin. The digital output LEDs light red when the output is on
and battery voltage is present at output pin. The
communications and analog voltage inputs and outputs do
not have LEDs. The ninth connector is power for the steer
motor. Six green LEDs near connector 9 indicate the main
electrical card status. For the truck to be operational, all six
LEDs must be ON.

BT Prime-Mover Inc.

Return

Terminal
Number

LED
No.

Connection

101
102
103
104
105
106
107
111

101
102
103
104
105
106
107
111

I
I
I
I
I
I
I
I

LED No.

Color

Function

TX

Green

Height indication -TX, transmits data

Service Manual

Function
Traction power amplifier - OK
Right foot switch
Plug braking
Drive, temperature sense
Drive direction
Lift limit override
Speed reduction
Brake switch

2001-03-15

329

F-code

Section

C-code

PS
S5.13
Main Electronic Card

5711

Version no

T-code

001

RTX35/RTX45

Terminal
Number

LED
No.

Connection

201
202
203
204
205
206
207
208
209
210
211

201
202
203
204
205
206
207
208
209
210
211

I
I
I
I
I
I
I
I
I
I
I

Terminal
Number

330

Drive wheel directional reference


Steering stop B
Steering stop A
Height counter A
Height counter B
Height reference
Brush wear indicator - (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

S5.13
5711
Main Electronic Card
RTX35/RTX45

Function
24/36 volt select
Steering/tach +
Steering/tach Positive 7.35 volts
Speed request value
Lift/lower
Reach/retract
Tilt
Sideshift
Zero voltage

Terminal
Number

Connection

601
602
603
604
606
607
608
609
610
611

I
I
I
I
I
I
I
O
O
O

Service Manual

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

F-code

Section

C-code

PS
S5.13
Main Electronic Card
Version no

T-code

001

RTX35/RTX45

5711

Terminal
Number
701
702
703
704
705
706
707
708
709
710
711

332

Return

LED
No.

704
705
706
707
708
709
710
711

Connection
O
O
O
O
O
O
O
O
O
O
O

Function
Negative for 702-703
Lift regulator speed request value +
Lift regulator current limit +
Fork lift
Direction A
Direction B
Reach out
Reach in (Retract)
Sideshift
Tilt
Pedal sense

Terminal
Number

LED
No.

Connection

801
802
803
804
805
806
807
808
809
810
811

801
802
803
804
805

O
O
O
O
O

Traction alarm control

I
O

+24/36 volt

Function

Drive, operator direction (forks trailing)


Drive, fork direction (forks first)
Fork lower
Brake coil

+24/36 volt supply outputs


Sensor feed + (12 volt)
Sensor feed -

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PS

Section

Version no

T-code

001

Terminal
Number

Connection

901
902
903
904

I
I
O
O

LED

Color

POWER
STEER PWR
STEER OK

Green
Green
Green

C-code

S5.13
5711
Main Electronic Card
RTX35/RTX45

Function
+24/36 volt steer motor
Zero voltage
+ steer motor
- steer motor

Function
Indication, all voltage is fed to the electronic card
Voltage feed to control electronics
Steering OK

Switch
SW 1
SW 2
SW 3

Function
Switch to program parameters and error codes
Switch to program parameters and error codes
Switch to program parameters and error codes

Potentiometer
RV2

BT Prime-Mover Inc.

Return

Function
Adjustment of lowering speed

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S5.13
Main Electronic Card
Version no

T-code

001

RTX35/RTX45

SW1

SW2

5711

4. Display

SW3

ANTY

It is possible to look at the trucks specific register and


program the clock. The truck cannot be driven with any
functions when it is in the programming mode.

SW3

SW2

SW1

To look at the trucks specific register:

111

107

109

105

101

103

1. Remove main electronic card panel in the


operators compartment.

205

204

202

2. Turn key switch so the main electronic card is ON.


211

207

209

3. Press button SW3, on the main electronic card,


three times to view the specific registers.

303

301

RV1

403

RV2

401

305

304

404

405

501
505

503

Press SW1 to see the date the error code


registered.
Press SW1 again to see the time the error code
registered.
Press SW2 to see the next registered error
code.
Turn key switch OFF or wait approximately 20
seconds to return to run mode.

4. Press SW3 once again to view the parameters


setting.

If only the colon (A) displays when the key switch is turned to
the ON position, the truck must be serviced.

+
1
1/2

H G F E D

334

Return

Press SW2 to scroll through the parameters.


SW1 has no function at this time.

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.

Service Manual

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Version no

001

SW1

SW2

Section

C-code

S5.13
5711
Main Electronic Card
T-code

RTX35/RTX45

4.1. Time

SW3

ANTY

It is possible to program the clock. The hour character


window (A) will flash after pressing SW3. Press SW3 again
and the minutes will flash.

SW3

SW2

SW1

105

101

103

1. Change the time by stepping up using SW2 or


down using SW1.
111

107

109

2. Save the values and display the function by


pressing SW3.

205

204

202

3. Exiting this function can be done in three ways;


211

207

209

301

303

RV1

305

304

RV2

403

401

Press SW3 three more times.


Wait approximately 20 seconds.
Turn the key switch OFF.

405

404

Function

501

Value

505

503

Hours
Minutes

09=9h
35=35 min.

+
1
1/2

When error codes are displayed in the character window (B),


the character box (F) will light. When the parameters are
displayed in the character window (B), the character box (E)
will light. However, it is not possible to reprogram the
parameters in this mode. To change to the programming
mode, see Programming Parameters.

H G F E D

BT Prime-Mover Inc.

Return

Complete the programming process by turning the key switch


OFF and ON once. Programming mode will quit if a key is not
pressed within 10 seconds.

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Main Electronic Card
Version no

T-code

001

RTX35/RTX45

5711

5. Warning/Caution codes
Character

Error
Warning/
Caution

When an error occurs a buzzer will sound. A code is


displayed for 10 seconds on the right-hand side of the
character window (B). If the error remains after 1 minute, the
warning and buzzer will be reactivated for an additional 2
second period. This process continues until the fault is
corrected. However, the truck can be driven with all functions
as set out in the warning table.

1
1/2

The error is also indicated in the indicator window (F).

H G F E D

Error
No.

336

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

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PS

Section

C-code

S5.13
5711
Main Electronic Card

Version no

001

T-code

RTX35/RTX45

Error
No.

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 - No operation
Lift potentiometer zero memory value or span memory
value error. Control handle calibration required (see
page 121). No lift/lower operation.
Lift potentiometer not centered within calibration limits.
Center, recalibrate, or replace control handle. No lift/
lower operation.
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.
Control handle calibration required. Allowed operation
may be limited.
Accelerator potentiometer zero memory value or span
memory value error. Control handle calibration required.
No travel operation.
Accelerator potentiometer not centered within calibration
limits. Center, recalibrate, or replace control handle.
Complete accelerator potentiometer calibration by
moving the control handle to both ends of travel. Left foot
pedal (brake) must be released during calibration.
Function of drive motor speed and direction sensors.
Significant travel speed requested with minimum
movement detected. Travel speed limited.
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.

Return

Service Manual

2001-03-15

337

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Section

C-code

PS
S5.13
Main Electronic Card
Version no

T-code

001

RTX35/RTX45

Error
No.

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). One or more of
the drive wheel steering limit control sensors are not
correctly signalling the control module. A minimum of
one sensor and control module input LED should be on
during the allowed steering rotational distance of the
drive wheel. If all three sensors are on or if all three
sensors are off, error code 80 will be displayed.
Lift potentiometer end value(s) exceeded the maximum
limits
Shorted or opened lift potentiometer input
Shorted or opened tilt request input
Shorted or opened reach request input
Shorted or opened sideshift request input

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PS
Version no

001

Section

C-code

S5.13
5711
Main Electronic Card
T-code

RTX35/RTX45

6. Error codes
Character

Error
Error

When an error occurs a buzzer will sound. An error code is


displayed on the right-hand side of the character window (B).
The buzzer will sound until the key switch is turned OFF. 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).
A

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.

1/2

H G F E D

BT Prime-Mover Inc.

Return

Service Manual

2001-03-15

339

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Section

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PS
S5.13
Main Electronic Card
Version no

T-code

001

RTX35/RTX45

Error
No.

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. Control handle calibration required
(see page 121). Lift/lower may also be in error and
disabled.
Shorted or opened accelerator potentiometer input.
Accelerator potentiometer end point value(s) exceeded
the maximum limit.
Potentiometer/pushbutton supply voltage failure
Pedal/parking brake potentiometer adjustment or failure
Pedal/parking brake switch adjustment or failure
Shorted or open parking brake output
Speed and direction sensor failure
Drive motor speed sensor failure
Drive motor direction sensor failure
Drive chopper reversing signal failure
Control module internal error
Steer chopper error
Steer chopper high temperature limit

Steer tacho error


Opened steer motor output - 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

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Version no

001

Section

C-code

S5.13
5711
Main Electronic Card
T-code

RTX35/RTX45

6.1. E102 Troubleshooting Procedures


The top console cover should be removed to expose the drive
transistor regulator (A1). The drive transistor regulator (A1)
has 4 LED indicators to assist in determining faults. The
LEDs are as follows:
LED1
LED2

Green
Yellow

LED3

Red

LED4

Red

Drive chopper detects no faults.


Drive chopper upper/lower temperature.
(Will not display an error code)
Fault in the power circuits
(See Power Circuit Checks, paragraph
6.1.1)
Fault in the reference value circuit
(See Reference Value Circuit Checks,
page 343)

If the machine is cold storage, verify that all the thermostats


and heaters are working. Moisture contamination at the drive
transistor regulator (A1), pump transistor regulator (A2) or
main electronic card (A5) may cause this error. Verify that
wire #16 and #17, control power wires for cold storage, are
wired to the battery positive side of the main contactor (K10).
If the #16 and #17 wires have been placed on the normally
open (N.O.) side of the main contactor (K10), the drive
transistor regulator (A1) internal capacitors will not be allowed
to charge correctly and will cause this error code.
6.1.1. POWER CIRCUIT CHECKS (LED #3)
NOTE! Do not manually close the main contactor
(K10) with the battery connected.
If the main contactor (K10) does not close when the truck is
powered up, the following checks should be performed:
1. Check the 250 amp drive fuse. A blown fuse will
cause this error when the truck is powered up. A
partially severed fuse will not cause this error until
the operator attempts to accelerate. Both
symptoms are typically caused from the operator
pushing loads.
2. Check for welded main contactor (K10) tips.

BT Prime-Mover Inc.

Return

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2001-03-15

341

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Section

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S5.13
Main Electronic Card
Version no

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001

RTX35/RTX45

C-code

5711

3. Check for a loose or open connection at the main


contactor (K10) coil, wire #44 or wire #40.
4. Check for loose or open connections at the
emergency disconnect switch (S21).
5. Check the voltage at the control plug on the drive
transistor regulator (A1) at pin #1, wire #22 with
respect to battery negative. This input should be
battery voltage when machine is powered up. If 0
volts (there will be no LED indicator lit at the drive
transistor regulator), check for an open wire from
the key switch to the drive transistor regulator (A1).
6. Check the voltage at the control plug on the drive
transistor regulator (A1) at pin #7, wire #34 with
respect to battery negative. This output should be
battery voltage when the drive transistor regulator
(A1) detects no faults.
7. Check the voltage at pin #101, wire #34, at the
main electronic card (A5) with respect to battery
negative. This input voltage from the drive
transistor regulator (A1), should be battery voltage
when the drive transistor regulator (A1) detects no
faults. If 0 volts, check for an open line on wire #34
between the drive transistor regulator (A1) and the
main electronic card (A5).
8. Check the voltage at wire #34 at the emergency
disconnect switch (S21) with respect to battery
negative. This should be battery voltage when the
drive transistor regulator (A1) detects no faults. If 0
volts, check for an open line on wire #34 between
the drive transistor regulator (A1) and the
emergency disconnect switch (S21).
9. Check the voltage on wire #44 at the emergency
disconnect switch (S21). This should be battery
voltage when the truck is powered up. If 0 volts,
check for a loose or missing connection on wire
#44 at the emergency disconnect switch (S21).
Check for an open line on wire #44 between the
emergency disconnect switch (S21) and the
connections at the main contactor (K10). Check for
a faulty emergency disconnect switch (S21).

342

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Version no

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S5.13
5711
Main Electronic Card
T-code

RTX35/RTX45

If the main contactor (K10) closes when the truck is powered


up, the following checks should be performed:
1. Check for battery voltage through the main
contactor (K10), with respect to battery negative,
when the contactor is closed.
2. Check for pitted or burned contactor tips.
3. Check for dirt or dust contamination at the
contactor tips.
4. Check the 250 amp drive fuse. A partially severed
fuse will not cause this error until the operator
attempts to accelerate. A blown fuse will cause this
error when machine is powered up. Both
symptoms are typically caused from the operator
pushing loads.
NOTE! Care must taken to keep power cables that
are removed from shorting. All cable ends
should be wrapped with electrical tape.
5. Check for loose or shorted power cable
connections at the 250 amp drive power fuse, main
contactor (K10), drive transistor regulator (A1) and
pump transistor regulator (A2). A defective or
shorted pump transistor regulator (A2) may cause
this error. If a pump transistor regulator (A2) or
related power cable is suspected to be shorted or
defective, it may be disconnected from the system
to verify that it is causing the error.
6.1.2. REFERENCE CIRCUIT VALUE CHECKS (LED #4)
1. Check the voltage at the control plug on the drive
transistor regulator (A1), pin #10, wire #36 with
respect to pin #6, wire #35. Voltage should be 0.15
volts when the accelerator is in the static position.
When the accelerator is at full throttle, voltage
should be approximately 4.93 volts.
2. Check the voltage at the control plug on the drive
transistor regulator (A1), pin #11, wire #37 with
respect to pin #6, wire #35. Voltage should be 0.75
volts when the accelerator is in the static position.
BT Prime-Mover Inc.

Return

Service Manual

2001-03-15

343

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Section

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S5.13
Main Electronic Card
Version no

T-code

001

RTX35/RTX45

5711

When the accelerator is at full throttle, voltage


should be approximately 4.3 volts.
3. Check the voltage at the control plug on the drive
transistor regulator (A1), pin #8, wire #38, with
respect to battery negative. Voltage should be 0
volts when the accelerator is in the static position.
If these checks are performed and the error still exist, 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.

7. Parameters

SW3

ANTY

The significance of the different parameters is shown in the


Programming Parameters table on the next page. To see
the different parameters, press SW2 or SW3.

SW3

SW2

SW1

111

107

109

105

101

103

8. Running time

205

204

202

When the running time reading is shown, the character box


(b) is illuminated. 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

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PS
Version no

001

Section

C-code

S5.13
5711
Main Electronic Card
T-code

RTX35/RTX45

9. Programming Parameters

1. Press SW3 on the electronic card at the same time


as the key switch is turned ON.
2. Scroll through the parameter options using SW2
(up) and SW1 (down) to reach the parameter to be
changed.

+
1
1/2

3. Press SW3 (the character window flashes).


H G F E D

4. Change the value using SW1 or SW2.

5. Press SW3 to accept the value (the character


window stops flashing).
CAUTION Modifying specific truck parameters will
change the driving characteristics of the
truck. Do not change any parameters
without the necessary knowledge.
If more parameters are to be changed, scroll using SW1 or
SW2 to reach the parameter to be change and repeat from
Step 3.
Programming Parameters
No.

Parameter
Name

Value
Range

Default

Inc

Values

Comment

Steer Prog Par

1-6

(1)

1-Least sensitivity
5-Most sensitivity
6-Test curve

Speed curve selection. Speed


curve selection has a greater
affect at high speed.

Steer Wheel Par

0-3

(0)

0-Least sensitivity
2-Most sensitivity

Steer tachometer sensitivity.

Top Speed Par

10-100%

100

% of maximum speed

Drive speed reduction.

Red Speed Par

10-50%

(40)

% of maximum speed

Limited speed reduction.

Accel Par

10-100%

(50)

% of maximum acceleration

Acceleration reduction.

Reach Scale Par

10-100%

(80)

% of maximum reach speed

Reach movement speed


reduction.

Decel Par

50-100%

(70)

% of maximum deceleration

Deceleration reduction
parameter.

Not Used

(0)

Spec Height Par

0-531 in.

(0)

10

Fork Ref Par

60-177 in.

(90)

Mast free height

Mast reference height

11

Steer Dir Par

0-1

(1)

0-Backward (Eur.)
1-Forward (US)

Steer direction

BT Prime-Mover Inc.

Return

Service Manual

Spare parameter. Not used.


Maximum allowed lifting
height

2001-03-15

Special height

345

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PS
S5.13
Main Electronic Card

5711

Version no

T-code

001

RTX35/RTX45

Programming Parameters
No.

Parameter
Name

Value
Range

Default

Inc

Values

Comment

12

Timer Sel Par

1-4

(2)

1-Key time (total time)


2-Drive, pump, and lowering
time (active time)
3-Drive time
4-Pump time

Displayed timer

13

Battery Par

1-30

(15)

1-Shallow discharge
29-Deep discharge (not a
permanent parameter)
30-Force BDI to full charge
battery indication (not a
permanent parameter
value.)

Battery discharge curve

14

Pump Type Par

0-3

(0)

0-36V Std. (RTX35)


1-24V Std. (RTX35)
2-Reserved
3-36V HD. (RTX45)

Hydraulic pump type

15

Alarm Options
Par

0-2

(0)

0-None
1-Travel Alarm
2-Backup Alarm

Value determines alarm options


enabled

16

Hyd Options Par

0-3

(0)

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.

17

Clock Year

0-99

(0)

18

Clock Day

0-31

(0)

Clock Day

19

Clock Month

0-12

(0)

Clock Month

20

Clock Hour

0-24

(0)

Clock Hour (set in normal


operating mode)

21

Clock Minute

0-59

(0)

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.)
RANGE 0 - 531
MAST HEIGHT (INCH)
See Table 3

2001-03-15

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Version no

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S5.13
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

9.1. Parameter 13 Battery Type


Adjustment
Parameter 13 is the battery type parameter. This parameter
will allow the programmer a variety of options relating to the
BDI display reading.
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 1.75 volts per cell
under load. The Parameter 13 has a value setting between 1
and 30. A setting of 1 will result in the most shallow
discharge. A setting of 29 will result in the deepest discharge.
A setting of 30 will force the BDI to reset to full charge, this is
not a permanent setting.
Parameter 13 should be adjusted so the 10 bar BDI display
will reflect the battery discharge as the BDI display
decrements down from the fully charged level, to the 80%
discharged level (see charts on page 350 or page 352). A full
charge level on the BDI display should have an open battery
voltage of approximately 2.1 volts per cell. The 80%
discharged level on the BDI display should reflect the
preferred battery discharge level.
Fully charged battery BDI full scale reset voltage:
- 24 volt truck is 25 volts
- 36 volt truck is 37.5 volts
Fully discharged battery voltage:
- 24 volt truck is 21.0 volts
- 36 volt truck is 31.5 volts

BT Prime-Mover Inc.

Return

Service Manual

2001-03-15

347

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S5.13
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. Fully discharged battery BDI response
time is approximately 2 operating hours from full battery
indication with Parameter 13 set to value 20 at minimum
shunt current. Response time decreases with smaller
Parameter 13 values and larger shunt currents. Response
time will increase with larger Parameter 13 values.
Parameter 13 values listed on the following page represent a
starting guide only. The final value depends on the
application, battery condition, battery capacity, etc. Final
values are valid only for different batteries of equal
performance characteristics and equal applications. Typical
RTX35 applications are Light Duty. Typical RTX45
applications are Medium Duty.
To initially set Parameter 13, select the operating duty of the
machine. Select the desired discharged battery voltage
under load. Program Parameter 13 with the value from the
table.

348

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2001-03-15

F-code

PS

Section

C-code

S5.13
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

2.09

1.94

1.87

2.03

1.88

1.81

1.96

1.81

1.74

1.89

1.73

1.66

1.81

1.66

1.57

BT Prime-Mover Inc.

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Battery Exceeds
Full Discharge

1.59

1.74

1.52
NOT
VALID

1.67
Force Reset

1.53
Force Reset

Service Manual

2001-03-15

Force Reset

349

F-code

Section

PS
S5.13
Main Electronic Card
Version no

T-code

001

RTX35/RTX45

C-code

5711

The previous chart represents the discharge voltage


measured under load. The charts on the following pages
allow BDI bar levels to be checked and adjusted, based on
battery state-of-charge, using open voltage measurements.
9.1.1. 24 Volt Unit Adjustment
Battery Discharge Indicator Bar Level Chart (24Volt)
Bar Level

Color

10 min.
Green
9 max.
Green
9 min.
Green
8 max.
Green
8 min.
Green
7 max.
Green
7 min.
Green
6 max.
Green
6 min.
Green
5 max.
Green
5 min.
Green
4 max.
Yellow
4 min.
Yellow
3 max.
Yellow
3 min.
Yellow
2 max.
Red
2 min.
Red
1 max.
Red
1 min.
Red
Open Circuit Voltage
Discharge Level

350

Return

Open Cell Open Cell Open Cell Open Cell


Voltage
Voltage
Voltage
Voltage
25.00
24.79
24.58
24.36
24.15
23.94
23.73
23.51
23.30
23.09
22.88
22.66
22.45
22.24
22.03
21.81
21.60
21.39
21.18
1.8 volts

25.00
24.83
24.65
24.48
24.30
24.13
23.95
23.78
23.60
23.43
23.25
23.08
22.90
22.73
22.55
22.38
22.20
22.03
21.85
1.85 volts

Service Manual

25.00
24.86
24.73
24.59
24.45
24.31
24.18
24.04
23.90
23.76
23.63
23.49
23.35
23.21
23.08
22.94
22.80
22.66
22.53
1.9 volts

25.00
24.90
24.80
24.70
24.60
24.50
24.40
24.30
24.20
24.10
24.00
23.90
23.80
23.70
23.60
23.50
23.40
23.30
23.20
1.95 volts

Open Cell
Voltage
25.00
24.94
24.88
24.81
24.75
24.69
24.63
24.56
24.50
24.44
24.38
24.31
24.25
24.19
24.13
24.06
24.00
23.94
23.88
2.0 volts

2001-03-15

F-code

PS
Version no

001

Section

C-code

S5.13
5711
Main Electronic Card
T-code

RTX35/RTX45

Due to the variety of different batteries available, Parameter


13 should be set to the specific battery that will be used to
insure an accurate BDI reading. To verify the BDI display
reflects the preferred open battery voltage discharge, the
following procedures should be followed.
1. Install a fully charged battery into the truck.
2. Take an open voltage reading across the battery
terminals. A fully charged 24 volt battery should
have an approximate open voltage of 25.2 volts.
3. Power-up the truck and verify the 10 bar indicator
is lit to the top bar (green). This indicates a fully
charged battery.
NOTE! Do not charge the battery at anytime during
the shift until adjustment of Parameter 13 is
complete.
4. Put the truck into service for an 8 hour shift.
5. Take an open voltage reading across the battery
terminals. Find the column containing the preferred
discharge level from the chart above.
6. Check voltage reading to see if it matches the
corresponding bar level and respond accordingly.
Yes) Battery Parameter 13 needs no further
adjustment.
No) Go to step 7.
7. 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. If the open voltage of the battery is
higher than the corresponding BDI bar level from
the chart, the Battery Parameter 13 should be
increased.
8. Repeat steps 1 through 7.

BT Prime-Mover Inc.

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2001-03-15

351

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Section

PS
S5.13
Main Electronic Card
Version no

T-code

001

RTX35/RTX45

C-code

5711

9.1.2. 36 Volt Unit Adjustment


Battery Discharge Indicator Bar Level Chart (36Volt)
Bar Level

Color

10 min.
Green
9 max.
Green
9 min.
Green
8 max.
Green
8 min.
Green
7 max.
Green
7 min.
Green
6 max.
Green
6 min.
Green
5 max.
Green
5 min.
Green
4 max.
Yellow
4 min.
Yellow
3 max.
Yellow
3 min.
Yellow
2 max.
Red
2 min.
Red
1 max.
Red
1 min.
Red
Open Circuit Voltage
Discharge Level

Open Cell Open Cell Open Cell Open Cell Open Cell
Voltage
Voltage
Voltage
Voltage
Voltage
37.5
37.18
36.86
36.54
36.23
35.91
35.59
35.27
34.95
34.63
34.31
33.99
33.68
33.36
33.04
32.72
32.4
32.08
31.76
1.8 Volts

37.5
37.24
36.98
36.71
36.45
36.19
35.93
35.68
35.4
35.14
34.88
34.61
34.35
34.09
33.83
33.56
33.3
33.04
32.77
1.85 Volts

37.5
37.29
37.09
36.88
36.68
36.47
36.26
36.06
35.85
35.64
35.44
35.23
35.03
34.82
34.61
34.41
34.2
33.99
33.79
1.9 Volts

37.5
37.35
37.2
37.05
36.9
36.75
36.6
36.45
36.3
36.15
36
35.85
35.7
35.55
35.4
35.25
35.1
34.95
34.8
1.95 Volts

37.5
37.41
37.31
37.22
37.13
37.03
36.94
36.84
36.75
36.68
36.56
36.47
36.38
36.28
36.19
36.09
36
35.91
35.81
2.0 Volts

Due to the variety of different batteries available, Parameter


13 should be set to the specific battery that will be used to
insure an accurate BDI reading. To verify the BDI display
reflects the preferred battery discharge, the following
procedures should be followed.
1. Install a fully charged battery into the truck.
2. Take an open voltage reading across the battery
terminals. A fully charged 36 volt battery should
have an approximate open voltage of 37.8 volts.
3. Power-up the truck and verify the 10 bar indicator
is lit to the top bar (green). This indicates a fully
charged battery.

352

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F-code

PS
Version no

001

Section

C-code

S5.13
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.
4. Put truck into service for an 8 hour shift.
5. Take an open voltage reading across the battery
terminals. Find the column containing the preferred
discharge level from the chart above.
6. Check voltage reading to see if it matches the
corresponding bar level and respond accordingly.
Yes) Battery Parameter 13 needs no further
adjustment.
No) Go to step 7.
7. 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. If the open voltage of the battery is
higher than the corresponding BDI bar level from
the chart, the Battery Parameter 13 should be
increased.
8. Repeat steps 1 through 7.

BT Prime-Mover Inc.

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2001-03-15

353

F-code

Section

PS
S5.13
Main Electronic Card
Version no

T-code

001

RTX35/RTX45

C-code

5711

10. RV2 Adjustment Procedure

RV2 Trim Pot


1. Remove main electronic card panel.
2. Raise fork carriage so that it is visible from the
operator compartment.
3. Locate RV2 trim pot on main electronic card. The
RV2 trim pot will be just above the right corner of
the #4 electrical connector.
NOTE! The RV2 Trim Pot is a 270 degree turn Pot.
Over turning the Pot can cause damage to the
Pot.
4. Turn RV2 Trim Pot fully clockwise.
NOTE! This adjustment must be performed each time
the main electronic card is replaced.

354

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F-code

PS
Version no

001

Section

C-code

S5.13
5711
Main Electronic Card
T-code

RTX35/RTX45

5. While standing on the platform switch, rotate the


lift/lower knob 0.0625 inch (1.6 mm). Adjust the
RV2 trim pot so the fork carriage will just begin to
lower.

11. Adjustment Procedures for


Setting Brake Switch and Brake
Transducer
1. Remove main electronic card access panel (see
page 101).
2. Remove floor plate (see page 102).
3. Verify pedal up and down bumpers are in good
condition.
4. Go
into
programming
mode.
Programming Parameters.
-

Refer

to

Set parameter 12 at 4
Set parameter 17 at 50

5. After changing these parameters, switch OFF and


turn back ON.
6. The display should read 10 with the pedal way up.
7. Press brake pedal all the way down. The display
should read 247.
8. With the pedal all the way up, loosen bolts on
brake transducer and adjust until 10 appears on
the display.
9. With the pedal all the way down, verify that 247
appears on the display.
10. The brake switch should be adjusted so it actuates
between 45 and 52 on the display when
depressing the pedal.
11. After making adjustments,
programming mode.
BT Prime-Mover Inc.

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go

back

into

Set parameter 12 at 2.
Set parameter 17 to the current year.
2001-03-15

355

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Section

PS
S5.13
Main Electronic Card
Version no

T-code

001

RTX35/RTX45

C-code

5711

12. Reinstall the floor plate and the main electrical card
access panel.

356

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2001-03-15

F-code

PS

Section

C-code

S5.14
5751
Switches and Sensors

Version no

T-code

001

RTX35/RTX45

Switches and Sensors


1. General
Refer to the electrical schematic to identify the electrical
circuit location of the switch (see Circuit Diagrams on
page 273 through page 284).

1.1. Test/Inspection
Examine the switch for signs of arcing, overheating,
discoloration, cracking, or other physical damage. Replace
switch if such damage is present.
To test a switch, isolate it from the electrical circuit. Do this by
removing all the connections from the switch, making sure all
wires are labeled and identified for reconnection.

2. Platform (Right Foot) Switch (S23)


The platform (right foot) switch (S23) is located under the
floor board of the operator compartment. Activation of the
platform switch allows lift and auxiliary functions to operate
without depression of the brake pedal.
While selecting a hydraulic function, 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. The
indicator also lights if the truck is driven without both the
brake pedal and the platform (right foot) switches engaged.
-

+
1

Item No.

1/2

Description

BT Prime-Mover Inc.

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Service Manual

Screw, machine

Switch, right foot

Nut, twin

2001-03-15

357

F-code

Section

C-code

PS
S5.14
5751
Switches and Sensors
Version no

T-code

001

RTX35/RTX45

2.1. Removal
1. Turn key switch OFF and disconnect battery
connector.
2. Remove floor board (see page 102).
3. Remove two screws (1) securing switch (2) to twin
nut (3) at switch bracket.

2.2. Installation
f

1. Install two screws (1) through switch (2) into twin


nut (3) on the opposite side of the switch bracket.
2. Install floor board.
3. Reconnect battery connector.
1

4. Test operation of platform switch before returning


the truck to service.

3. Staging Switch (S45)


The staging switch (S45) is a proximity sensor located on the
outside of the carriage. Its function is to let the main electronic
card know when the carriage has almost completed the first
stage of lift (freelift). When the sensor extends beyond the
limits of the inner columns, the main electronic card receives
a signal. This triggers a slowing of lift and allows a smoother
transition as the columns begin to move, preventing the load
on the forks from being jarred.

3.1. Adjustment
1. Raise the empty carriage until the top of the
staging switch is even with the top of the staging
column.
2. Secure carriage with blocks and a hoist to prevent
any movement.
3. Loosen switch mounting bracket screws.

358

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S5.14
5751
Switches and Sensors

Version no

001

T-code

RTX35/RTX45

4. Adjust switch to 0.187 inch (4.76 mm). Allowable


tolerance is +0.0625 inch (1.59 mm) and -0 mm.
5. Tighten switch mounting bracket screws.
6. Check clearance with the screws tight.
7. Remove blocks and hoist.
8. Test mast operation to verify proper operation of
staging switch.

3.2. Removal
1. Raise empty carriage until the top of the staging
switch is above the top of the staging column.
2. Secure carriage with blocks and a hoist to prevent
any movement.
3. Turn key switch OFF and disconnect battery
connector.
4. Disconnect switch from wiring harness.
5. Remove switch mounting bracket screws.

3.3. Installation
1. Install switch on the mounting bracket.
2. Tighten switch mounting bracket screws.
3. Connect switch to wiring harness.
4. Reconnect battery connector.
5. Adjust switch following the procedure on page 358.
6. Return truck to service.

BT Prime-Mover Inc.

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359

F-code

Section

C-code

PS
S5.14
5751
Switches and Sensors
Version no

T-code

001

RTX35/RTX45

4. Wheel Direction Sensor


S65

The wheel direction sensor (S65) detects directional


information from the top of the drive unit. This sensor works in
conjunction with the steer stop proximity sensors (S66 and
S67) located directly across the drive unit. S65 is 90 degrees
left of center, S66 and S67 are approximately 90 degrees
right of center allowing a total of 180 degrees steering.

4.1. Adjustment
CAUTION Adjustment of sensor with wheel nuts
facing inward will result in shearing of
sensor when the drive wheel is rotated.
1. Position drive wheel with wheel nuts facing
outward.
2. Turn key switch OFF and disconnect battery
connector.
3. Remove top console, motor compartment door,
and left side panel to allow access to drive unit.
4. Loosen jam nut securing the sensor to the frame.
5. Turn wheel direction sensor by hand in a clockwise
direction until it contacts the drive unit housing.
6. Back sensor out by turning
counterclockwise 1-1/4 turns.

the

sensor

7. Tighten jam nut securing the sensor to the frame.


8. Reconnect battery connector.
9. Test operation of the sensor.

360

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2001-03-15

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PS

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S5.14
5751
Switches and Sensors

Version no

001

T-code

RTX35/RTX45

4.2. Removal
1. Turn key switch OFF and disconnect battery
connector.
2. Disconnect sensor at the main wiring harness.
3. Loosen jam nut securing the sensor to the frame.
4. Turn sensor counterclockwise to remove it from the
frame.

4.3. Installation
1. Install sensor in the frame.
2. Tighten by hand in a clockwise direction until it just
contacts the drive unit housing.
3. Set the proper sensor distance by turning the
sensor counterclockwise 1-1/4 turns.
4. Tighten jam nut securing the sensor to the frame.
5. Reconnect sensor electrical connection to the main
wiring harness.
6. Reconnect battery connector.
7. Return truck to service.

BT Prime-Mover Inc.

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PS
S5.14
5751
Switches and Sensors
Version no

T-code

001

RTX35/RTX45

S66

5. 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. S66 connector is grey in
color and located in the front. S67 connector is blue in color
and located in the back. 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.

5.1. Adjustment
CAUTION Adjustment of sensors with wheel nuts
facing outward will result in shearing of
sensors when the drive wheel is rotated.
1. Position drive wheel with wheel nuts facing inward.
2. Turn key switch OFF and disconnect battery
connector.
3. Remove top console, motor compartment door,
and left side panel to allow access to drive unit.
STEER
STOP
SENSORS

4. Loosen jam nuts securing the sensors to the frame.


5. Turn steer stop sensors by hand until they contact
the drive unit housing.
6. Back sensors out by turning the sensors 1-1/4
turns.
7. Tighten jam nuts securing the sensors to the
frame.
8. Reconnect battery connector.
9. Test operation of the sensor.
10. Install battery in truck.
11. Return truck to service.

TURN DRIVE
WHEEL
INWARD 90o
362

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Section

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S5.14
5751
Switches and Sensors

Version no

001

T-code

RTX35/RTX45

5.2. Removal
1. Turn key switch OFF and disconnect battery
connector.
2. Disconnect sensors from wiring harness.
3. Remove jam nuts securing the sensors to the
frame.
4. Remove sensors from truck.

5.3. Installation
1. Place new sensors in the frame.
NOTE! Do not overtighten jam nuts. Overtightening
can cause damage to the sensors.
2. Secure sensors to frame with jam nuts.
3. Reconnect wiring harness.
4. Adjust sensors
page 362.

following

the

procedure

on

5. Test operation of truck.


6. Return truck to service.

BT Prime-Mover Inc.

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363

F-code

Section

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PS
S5.14
5751
Switches and Sensors
Version no

T-code

001

RTX35/RTX45

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.
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.
Item
No.

Description

Item
No.

Description

Screw

Sensor, speed
(male plug) S64

Nut, sensor

Housing, sensor

Spacer, brake
sensor

Sensor, direction
(female plug) S125

Screw, cap

6.1. Removal
1

1. Turn key switch OFF and disconnect battery


connector.

2
4

3. Remove cap screw (4) securing sensor (7 or 5) to


spacer (6).

7
6

364

Return

2. Disconnect drive motor speed and/or directional


sensor from main wiring harness.

4. Remove sensor (7 or 5) from spacer (6). Note the


style of the wire ends (male or female) and location
for reassembly.

Service Manual

2001-03-15

F-code

PS

Section

Version no

001

T-code

RTX35/RTX45

6.2. Installation

1. Install sensor (7 or 5) in spacer (6). Be sure the


style of the wire ends and location match the ones
noted during removal. Sensors that are improperly
installed will result in an error code appearing when
the truck is returned to service.

3
7
6

C-code

S5.14
5751
Switches and Sensors

2. Install cap screw (4).


5

3. Reconnect sensor to main harness assembly.


4. Reconnect battery connector.
5. Test operation of truck before returning to service.

BT Prime-Mover Inc.

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2001-03-15

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F-code

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C-code

PS
S5.14
5751
Switches and Sensors
Version no

T-code

001

RTX35/RTX45

366

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2001-03-15

F-code

Section

PS

S6.0
6000
Hydraulic System

Version no

000

C-code

T-code

RTX35/RTX45

Hydraulic System
WARNING DO NOT use your hands to check for
hydraulic leakage. Use a piece of
cardboard or paper to search for leaks.
Escaping fluid under pressure can
penetrate the skin causing serious injury.
Relieve pressure before disconnecting
hydraulic or other lines. Tighten all
connections before applying pressure.
Keep hands and body away from pinholes
and nozzles which eject fluids under high
pressure.

1. Operation
See RTX35 Hydraulic Schematic on page 396 or RTX45
Hydraulic Schematic on page 397. For a listing of error
codes see pages page 336 and 340. For a listing of
parameters see page 345. For information on the fuses and
their location see page 305.

BT Prime-Mover Inc.

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367

F-code

Section

C-code

PS
S6.0
Hydraulic System

6000

Version no

T-code

000

RTX35/RTX45

A71
HM214
A5
S55 EXTEND
HM201

83
507

HM107

S56 RETRACT
HM202
S211 TILT UP
HM203

HM109

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

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2001-03-15

F-code

Section

PS

S6.0
6000
Hydraulic System

Version no

000

C-code

T-code

RTX35/RTX45

1.1. 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. Analog signals (travel and lift/lower) from
the control handle are relayed unchanged to the main
electronic card. Digital signals from the control handle include
reach, tilt, and sideshift. The digital signals are decoded by
converting the possible combinations of push-buttons to
different analog voltage levels. The following table shows the
relationship of the selected control handle function to the
output of the control handle interface card.

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C-code

PS
S6.0
Hydraulic System

6000

Version no

T-code

000

RTX35/RTX45

Control
Handle
Function
Selected

Control
Handle
Interface
Card
Input Pin

Control Handle
Interface Card
Approximate Input
Voltage (measured
with respect to HM213)

Control Handle
Interface Card
Output Pin
(measured with
respect to HM110)

Control Handle
Interface Card
Nominal Output
Voltage

Wire #

Main Electronic
Card (A5) Input
Pin (measured
with respect to
510)

Main
Electronic
Card (A5)
Nominal Input
Voltage

No Reach
Function
Selected

HM201 and
HM202

0V (both inputs)

HM107

Min. 1.103V
Nom. 1.470V
Max 1.873V

83

507

Min. 1.103V
Nom. 1.470V
Max 1.873V

Reach
Low
Speed

HM201

7.35V

HM107

Min. 2.573V
Nom. 2.940V
Max. 3.307V

83

507

Min. 2.573V
Nom. 2.940V
Max. 3.307V

Reach
High
Speed

HM201 and
HM202

7.35V (both inputs)

HM107

Min. 5.513V
Nom. 5.880V
Max. 6.247V

83

507

Min. 5.513V
Nom. 5.880V
Max. 6.247V

Retract
Low
Speed

HM202

7.35V

HM107

Min. 4.043V
Nom. 4.410V
Max. 4.777V

83

507

Min. 4.043V
Nom. 4.410V
Max. 4.777V

Retract
High
Speed

HM202 and
HM201

7.35V (both inputs)

HM107

Min. 5.513V
Nom. 5.880V
Max. 6.247V

83

507

Min. 5.513V
Nom. 5.880V
Max. 6.247V

No Tilt
Function
Selected

HM203 and
HM204

0V (both inputs)

HM109

Min. 1.103V
Nom. 1.470V
Max 1.873V

84

508

Min. 1.103V
Nom. 1.470V
Max 1.873V

Tilt Up

HM203

7.35V

HM109

Min. 2.573V
Nom. 2.940V
Max. 3.307V

84

508

Min. 2.573V
Nom. 2.940V
Max. 3.307V

Tilt Down

HM204

7.35V

HM109

Min. 4.043V
Nom. 4.410V
Max. 4.777V

84

508

Min. 4.043V
Nom. 4.410V
Max. 4.777V

No Sideshift
Function
Selected

HM205 and
HM206

0V (both inputs)

HM108

Min. 1.103V
Nom. 1.470V
Max 1.873V

85

509

Min. 1.103V
Nom. 1.470V
Max 1.873V

Sideshift
Left

HM205

7.35V

HM108

Min. 2.573V
Nom. 2.940V
Max. 3.307V

85

509

Min. 2.573V
Nom. 2.940V
Max. 3.307V

Sideshift
Right

HM206

7.35V

HM108

Min. 4.043V
Nom. 4.410V
Max. 4.777V

85

509

Min. 4.043V
Nom. 4.410V
Max. 4.777V

Travel

HM210

Min. 0.6V Rev


Nom. 1.4V
Max. 2.2V Fwd

HM105

Min. 0.6V Rev


Nom. 1.4V
Max. 2.2V Fwd

50

505

Min. 0.6V Rev


Nom. 1.4V
Max. 2.2V Fwd

Lift/Lower

HM211

Min. 0.6V Lift


Nom. 1.65V
Max. 2.7V Lwr

HM106

Min. 0.6V Lift


Nom. 1.65V
Max. 2.7V Lwr

82

506

Min. 0.6V Lift


Nom. 1.65V
Max. 2.7V Lwr

Notes:

370

Return

1.

Voltages at the main electronic card (A5) inputs greater than 6.615 volts and less than 0.735 volts indicate
shorted or open signal wires for reach, tilt, and sideshift.

2.

Voltages at the main electronic card inputs other than the stated voltages will select no function for reach, tilt,
and sideshift.

3.

Voltages at the main electronic card inputs greater than 6.75 volts and less than 0.6 volts indicate shorted or
open signal wires for travel and lift/lower.

4.

The center and travel limits of the travel and lift/lower potentiometers are learned. Therefore, the voltages listed
are a rough approximation.

Service Manual

2001-03-15

F-code

Section

PS

S6.0
6000
Hydraulic System

Version no

000

C-code

T-code

RTX35/RTX45

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2001-03-15

371

F-code

Section

C-code

PS
S6.0
Hydraulic System

6000

Version no

T-code

000

RTX35/RTX45

CONTROL
HANDLE
S55

R11
S56

S212
S52

S211

S51
S18
A71

A5

HANDLE
INTERFACE
MODULE

701

74
6

(-)

40

B-

702

703

75
76
10
11

A2

To
Y 10/2

B+

From
Y10/3

M
Relief
Valve

M3
(+)

10

P1

Pressure Auxiliary
Return Auxiliary

P2
Y11 Dump Valve
Filter

Tank

Supply Schematic
LEGEND
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372

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Service Manual

2001-03-15

F-code

Section

PS

S6.0
6000
Hydraulic System

Version no

000

C-code

T-code

RTX35/RTX45

1.2. Supply
A voltage from lift (R11), reach (S55/S56), sideshift (S51/
S52), or tilt (S211/S212) on the control handle to the control
handle interface card to the main electronic card (A5) initiates
a pump request to the pump transistor regulator (A2). The
electronic card (A5) turns on speed request output 702 (wire
#75) to a level proportional to the control handle request. This
signal is sent to the pump transistor regulator (A2) input pin
10. A current limit signal is also sent from the main electronic
card (A5) output 703 (wire #76) to the pump transistor
regulator (A2) input pin 11 limiting the current from the pump
transistor regulator (A2) to the motor. Both speed request and
current limit signals range from 0 volts to approximately 4.5
volts and are measured with respect to main electronic card
(A5) output 701 (wire #74). The pump transistor regulator
sends the amplified signal to the pump motor (M3)
commanding pumping.
Hydraulic functions can be performed by using the brake
pedal, the right foot pedal, or both. By depressing the right
foot pedal and releasing the brake pedal setting the parking
brake, hydraulic functions can be performed with the truck
parked in position.
Oil is pumped by a two-section pump from the hydraulic tank
into the hydraulic system. The small section of the pump is
used for the auxiliary functions. Appropriate solenoids are
activated opening valves and the auxiliary functions are
performed. The combination of the oil from both sections
through the Y11 dump valve is used for lifting. If the pressure
in the system increases to the preset value of the relief valve,
it will open directing oil back to the hydraulic tank. The
lowering function is powered by gravity and proportionally
controlled. Returned oil is filtered at the hydraulic tank.

BT Prime-Mover Inc.

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Service Manual

2001-03-15

373

F-code

Section

C-code

PS
S6.0
Hydraulic System

6000

Version no

T-code

000

RTX35/RTX45

3
11

11
R11
1

A71

HM211
HANDLE
INTERFACE
MODULE
HM106

82

A5
804

88

704

89

506
Y10/2

711

Y10/3
(-)

40

R
Y11

P2

P1
Lifting Schematic

LEGEND
PRESSURE OIL
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Service Manual

2001-03-15

F-code

Section

PS

S6.0
6000
Hydraulic System

Version no

000

C-code

T-code

RTX35/RTX45

1.3. Lifting
With the key switch ON and brake pedal and/or right foot
switch depressed, rotating the lift/lower control lever upward
on the control handle causes R11 to output a voltage less
than when in the neutral position. The control handle interface
card senses this decrease in voltage at terminal HM211 and
notifies the main electronic card (A5) input 506 (wire #82).
The main electronic card (A5) responds by enabling voltage
to the dump valve coil (Y11) and the lift valve coil (Y10/2).
The lift speed can be infinitely varied to the maximum lift
speed.
Oil is fed from the pump to the lift valve (Y10) and from the
valve to the free lift and main lift cylinders. The free lift
cylinder, having less weight on it, will lift first. After the free lift
cylinder has reached full extension, the main lift cylinders will
begin to lift. If the pressure in the system increases to the
relief valves preset value, oil flows back to the hydraulic tank.

BT Prime-Mover Inc.

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Service Manual

2001-03-15

375

F-code

Section

C-code

PS
S6.0
Hydraulic System

6000

Version no

T-code

000

RTX35/RTX45

11

11

R11

A71

HM211
HANDLE
INTERFACE
MODULE

A5
804

HM106

88

506
704

89
Y10/2
Y10/3

(-)

40

R
Lowering Schematic

LEGEND
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376

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Service Manual

2001-03-15

F-code

Section

PS

S6.0
6000
Hydraulic System

Version no

000

C-code

T-code

RTX35/RTX45

1.4. Lowering
With the key switch ON and brake pedal and/or right foot
switch depressed, rotating the lift/lower control lever
downward on the control handle causes R11 to output a
voltage greater than when in the neutral position. The control
handle interface card senses this increase in voltage at
terminal HM211 and notifies the main electronic (A5) card
input 506 (wire #82). The main electronic (A5) card enables
voltage to the proportional lower solenoid coil (Y10/3). The
lowering speed is regulated by the proportional lowering
valve (Y10/3) in direct proportion to the voltage from (R11).
Proportional lower solenoid coil (Y10/3) is normally closed.
Oil flows from the cylinders through the valve, returning to the
hydraulic tank. A reach, tilt, or sideshift function can be
performed while lowering.

BT Prime-Mover Inc.

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Service Manual

2001-03-15

377

F-code

Section

C-code

PS
S6.0
Hydraulic System

6000

Version no

T-code

000

RTX35/RTX45

S55

EXTEND
BUTTON

Y14

A71

Y15

HM201
HM214

A5

HANDLE
INTERFACE
MODULE

707

HM107

83

507

708
706
705

(-)

92
93
91
90

40

Y12

Y13

Low Speed Extend Schematic


LEGEND
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RETURN OIL
ELECTRIC POSITIVE
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378

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Service Manual

2001-03-15

F-code

Section

PS

S6.0
6000
Hydraulic System

Version no

000

C-code

T-code

RTX35/RTX45

1.5. Low Speed Extend


Reach extends the forks away from the mast assembly when
the reach button on the control handle is depressed. With the
key switch ON and the brake pedal and/or right foot pedal
depressed, pressing the reach button causes voltage to be
sensed at HM201 on the control handle interface card. The
control handle interface card encodes the digital signal
sensed at HM201 to an analog voltage level of approximately
2.94 volts at HM107 and sends to the main electronic (A5)
card input 507 (wire #83). The main electronic (A5) card
responds by:
Enabling voltage to the direction A solenoid coil (Y12) from
output 705 (wire #90).
Enabling the reach solenoid(s) (Y14 and Y15) on the reach
carriage from outputs 707 (wire #92) and 708 (wire #93).
Reach solenoids Y14 and Y15 are combined into one
solenoid on some reach models.
Sending a speed request to the pump transistor regulator.
Speed request is dependent on truck voltage and reach
model. The truck voltage and reach model is configured by
Pump Type Parameter 14.
The speed request signal to the pump transistor regulator
provides the PWM frequency rate to pulse the pump motor.
Oil is fed through direction A (Y12) valve, through Reach1
(Y14) valve to the rear ports on the reach cylinders, and
drives the pistons outwards. The oil flows from the front ports
of the cylinders, through Reach2 (Y15) valve to direction A
(Y12) valve, and back to the hydraulic tank.

BT Prime-Mover Inc.

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Service Manual

2001-03-15

379

F-code

Section

C-code

PS
S6.0
Hydraulic System

6000

Version no

T-code

000

RTX35/RTX45

S55
EXTEND
BUTTON
S56
RETRACT
BUTTON

Y14

A71

HM201

Y15

HM202
HM214

A5

HANDLE
INTERFACE
MODULE

707

HM107

83

507

708
706
705

(-)

92
93
91
90

40

Y12

Y13

High Speed Extend Schematic


LEGEND
PRESSURE OIL
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ELECTRIC POSITIVE
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380

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Service Manual

2001-03-15

F-code

Section

PS

S6.0
6000
Hydraulic System

Version no

000

C-code

T-code

RTX35/RTX45

1.6. High Speed Extend


Reach extends the forks away from the mast assembly when
the reach button on the control handle is depressed. When
the reach button is held and the retract button is depressed,
high speed reach occurs. With the key switch ON and the
brake pedal and/or right foot pedal depressed, pressing the
reach and then retract button causes voltage to be sensed at
HM201 and HM202 on the control handle interface card. The
control handle interface card encodes the digital signal
sensed at HM201 and HM202 to an analog voltage level of
approximately 5.88 volts at HM107 and sends to the main
electronic (A5) card input 507 (wire #83). The main electronic
(A5) card responds by:
Enabling voltage to the direction A solenoid coil (Y12) from
output 705 (wire #90).
Enabling the reach solenoid(s) (Y14 and Y15) on the reach
carriage from outputs 707 (wire #92) and 708 (wire #93).
Reach solenoids Y14 and Y15 are combined into one
solenoid on some reach models.
Sending a larger value speed request to the pump
transistor regulator. Speed request is dependent on truck
voltage and reach model. The truck voltage and reach
model is configured by Pump Type Parameter 14.
The speed request signal to the pump transistor regulator
provides the PWM frequency rate to pulse the pump motor.
Oil is fed through direction A (Y12) valve, through Reach1
(Y14) valve to the rear ports on the reach cylinders, and
drives the pistons outwards. The oil flows from the front ports
of the cylinders, through Reach2 (Y15) valve to direction A
(Y12) valve, and back to the hydraulic tank.

BT Prime-Mover Inc.

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Service Manual

2001-03-15

381

F-code

Section

C-code

PS
S6.0
Hydraulic System

6000

Version no

T-code

000

RTX35/RTX45

S56
RETRACT
BUTTON

Y14

A71

Y15

HM202
HM214

A5

HANDLE
INTERFACE
MODULE

707

HM107

83

507

708
706
705

(-)

92
93
91
90

40

Y12

Y13

Low Speed Retract Schematic


LEGEND
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ELECTRIC POSITIVE
ELECTRIC NEGATIVE

382

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Service Manual

2001-03-15

F-code

Section

PS

S6.0
6000
Hydraulic System

Version no

000

C-code

T-code

RTX35/RTX45

1.7. Low Speed Retract


Retract withdraws the forks toward the mast assembly when
the retract button on the control handle is depressed. With the
key switch ON and the brake pedal and/or the right foot pedal
depressed, pressing the retract button causes voltage to be
sensed at HM202 on the control handle interface card. The
control handle interface card encodes the digital signal
sensed at HM202 to an analog voltage level of approximately
4.41 volts at HM107 and to A5 input 507 (wire #83). The main
electronic (A5) card responds by:
Enabling voltage to the direction B solenoid coil (Y13) from
output 706 (wire #91).
Enabling the reach solenoid(s) (Y14 and Y15) on the reach
carriage from outputs 707 (wire #92) and 708 (wire #93).
Reach solenoids Y14 and Y15 are combined into one
solenoid on some reach models.
Sending a speed request to the pump transistor regulator.
Speed request is dependent on truck voltage and reach
model. The truck voltage and reach model is configured by
Pump Type Parameter 14.
The speed request signal to the pump transistor regulator
provides the PWM frequency rate to pulse the pump motor.
Oil is fed through direction B (Y13) valve, through Reach2
(Y15) valve to the front ports on the reach cylinders, and
drives the pistons inwards. The oil flows from the rear ports of
the cylinders, through Reach1 (Y14) valve to direction B
(Y13) valve, and back to the hydraulic tank.

BT Prime-Mover Inc.

Return

Service Manual

2001-03-15

383

F-code

Section

C-code

PS
S6.0
Hydraulic System

6000

Version no

T-code

000

RTX35/RTX45

S55
EXTEND
BUTTON
S56
RETRACT
BUTTON

A71

Y14

Y15

HM202 HM201
HM214

A5

HANDLE
INTERFACE
MODULE

707

HM107

83

507

708
706
705

92
93
91
90

40

Y12

Y13

High Speed Retract Schematic


LEGEND
PRESSURE OIL
RETURN OIL
ELECTRIC POSITIVE
ELECTRIC NEGATIVE

384

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Service Manual

2001-03-15

F-code

Section

PS

S6.0
6000
Hydraulic System

Version no

000

C-code

T-code

RTX35/RTX45

1.8. High Speed Retract


Retract withdraws the forks toward the mast assembly when
the retract button (S56) on the control handle is depressed.
When the retract button (S56) is held and the reach button
(S55) is pushed high speed retract occurs. With the key
switch ON and the brake pedal and/or right foot pedal
depressed, pressing the retract and then reach button causes
voltage to be sensed at HM202 and HM201 on the control
handle interface card. The control handle interface card
encodes the digital signal sensed at HM202 and HM201 to an
analog voltage level of approximately 5.88 volts at HM107
and to A5 input 507 (wire #83). The main electronic (A5) card
responds by:
Enabling voltage to the direction B solenoid coil (Y13) from
output 706 (wire #91).
Enabling the reach solenoid(s) (Y14 and Y15) on the reach
carriage from outputs 707 (wire #92) and 708 (wire #93).
Reach solenoids Y14 and Y15 are combined into one
solenoid on some reach models.
Sending a larger value speed request to the pump
transistor regulator. Speed request is dependent on truck
voltage and reach model. The truck voltage and reach
model is configured by Pump Type Parameter 14.
The speed request signal to the pump transistor regulator
provides the PWM frequency rate to pulse the pump motor.
Oil is fed through direction B (Y13) valve, through Reach2
(Y15) valve to the front ports on the reach cylinders, and
drives the pistons inwards. The oil flows from the rear ports of
the cylinders, through Reach1 (Y14) valve to direction B
(Y13) valve, and back to the hydraulic tank.

BT Prime-Mover Inc.

Return

Service Manual

2001-03-15

385

F-code

Section

C-code

PS
S6.0
Hydraulic System

6000

Version no

T-code

000

RTX35/RTX45

S52
SIDESHIFT
RIGHT
BUTTON

Y16
A71

HM206
HM214
HANDLE
INTERFACE
MODULE

A5

HM108

85

509

709

706

95

91
90

705

(-)

40

Y12

Y13

Right Sideshift Schematic


LEGEND
PRESSURE OIL
RETURN OIL
ELECTRIC POSITIVE
ELECTRIC NEGATIVE

386

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Service Manual

2001-03-15

F-code

Section

PS

S6.0
6000
Hydraulic System

Version no

000

C-code

T-code

RTX35/RTX45

1.9. Right Sideshift


Sideshift allows the operator to move the fork carriage to the
right or left in relation to the mast. The amount of sideshift is 2
or 4 inches (50 or 100 mm) depending on the baseleg
opening (BLO).
With the key switch ON and the brake pedal and/or right foot
pedal depressed, pressing the sideshift right button (S52)
causes voltage to be sensed at HM206 on the control handle
interface card. The control handle interface card encodes the
digital signal sensed at HM206 to an analog voltage level of
approximately 4.41 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 B solenoid coil (Y13) from
output 706 (wire #91).
Enabling the sideshift solenoid (Y16) on the reach carriage
from output 709 (wire #95).
Sending a speed request to the pump transistor regulator.
Speed request is dependent on truck voltage and reach
model. The truck voltage and reach model is configured by
Pump Type Parameter 14.
The speed request signal to the pump transistor regulator
provides the PWM frequency rate to pulse the pump motor.
Oil is fed through direction B (Y13) valve to the sideshift (Y16)
valve, to the rear port of the sideshift cylinder driving the
piston outward. The oil flows from the front port of the
cylinder, to the sideshift (Y16) valve, to the direction B (Y13)
valve, and returns to the hydraulic tank.

BT Prime-Mover Inc.

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Service Manual

2001-03-15

387

F-code

Section

C-code

PS
S6.0
Hydraulic System

6000

Version no

T-code

000

RTX35/RTX45

S51
SIDESHIFT
LEFT
BUTTON

Y16
A71

HM205
HM214
HANDLE
INTERFACE
MODULE

A5
85

HM108

709

706
705

(-)

95

509

40

91
90

Y12

Y13

Left Sideshift Schematic


LEGEND
PRESSURE OIL
RETURN OIL
ELECTRIC POSITIVE
ELECTRIC NEGATIVE

388

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Service Manual

2001-03-15

F-code

Section

PS

S6.0
6000
Hydraulic System

Version no

000

C-code

T-code

RTX35/RTX45

1.10. Left Sideshift


Sideshift allows the operator to move the fork carriage to the
right or left in relation to the mast. The amount of sideshift is 2
or 4 inches (50 or 100 mm) depending on the baseleg
opening (BLO).
With the key switch ON and the brake pedal and/or right foot
pedal depressed, pressing the sideshift left button (S51)
causes voltage to be sensed at HM205 on the control handle
interface card. The control handle interface card encodes the
digital signal sensed at HM205 to an analog voltage level of
approximately 2.94 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).
Enabling the sideshift solenoid (Y16) on the reach carriage
from output 709 (wire #95).
Sending a speed request to the pump transistor regulator.
Speed request is dependent on truck voltage and reach
model. The truck voltage and reach model is configured by
Pump Type Parameter 14.
The speed request signal to the pump transistor regulator
provides the PWM frequency rate to pulse the pump motor.
Oil is fed through direction A (Y12) valve, to the sideshift
(Y16) valve, to the front port of the sideshift cylinder, driving
the piston inward. The oil flows from the rear port of the
cylinder, to the sideshift (Y16) valve, to the direction A (Y12)
valve, and returns to the hydraulic tank.

BT Prime-Mover Inc.

Return

Service Manual

2001-03-15

389

F-code

Section

C-code

PS
S6.0
Hydraulic System

6000

Version no

T-code

000

RTX35/RTX45

S211
TILT UP
BUTTON

Y17
A71

HM203
HM214
HANDLE
INTERFACE
MODULE

A5
94
84

HM109

710
508

91
706
90
705

(-)

40

Y12

Y13

Fork Tilt Up Schematic


LEGEND
PRESSURE OIL
RETURN OIL
ELECTRIC POSITIVE
ELECTRIC NEGATIVE

390

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Service Manual

2001-03-15

F-code

Section

PS

S6.0
6000
Hydraulic System

Version no

000

C-code

T-code

RTX35/RTX45

1.11. Fork Tilt Up


Fork tilt allows the operator to raise or lower the tips of the
forks. Standard fork tilt is 4o up and 3o down.
With the key switch ON and the brake pedal and/or right foot
pedal depressed, pressing the tilt up button (S211) causes
voltage to be sensed at HM203 on the control handle
interface card. The control handle interface card encodes the
digital signal sensed at HM203 to an analog voltage level of
approximately 2.94 volts at HM109 and sends to main
electronic (A5) card input 508 (wire #84). The main electronic
(A5) card responds by:
Enabling voltage to the direction B solenoid coil (Y13) from
output 706 (wire #91).
Enabling the tilt solenoid (Y17) on the reach carriage from
output 710 (wire #94).
Sending a speed request to the pump transistor regulator.
Speed request is dependent on truck voltage and reach
model. The truck voltage and reach model is configured by
Pump Type Parameter 14.
The speed request signal to the pump transistor regulator
provides the PWM frequency rate to pulse the pump motor.
Oil is fed through direction B (Y13) valve, to the tilt (Y17)
valve, to the rear port of the tilt cylinder, driving the piston
outward. The oil flows from the front port of the cylinder, to
the direction B (Y13) valve, returning to the hydraulic tank.

BT Prime-Mover Inc.

Return

Service Manual

2001-03-15

391

F-code

Section

C-code

PS
S6.0
Hydraulic System

6000

Version no

T-code

000

RTX35/RTX45

S212
TILT DOWN
BUTTON

Y17
A71

HM204
HM214
HANDLE
INTERFACE
MODULE

A5
94
84

HM109

710
508
706

705

(-)

40

91

90

Y13

Y12

Fork Tilt Down Schematic


LEGEND
PRESSURE OIL
RETURN OIL
ELECTRIC POSITIVE
ELECTRIC NEGATIVE

392

Return

Service Manual

2001-03-15

F-code

Section

PS

S6.0
6000
Hydraulic System

Version no

000

C-code

T-code

RTX35/RTX45

1.12. Fork Tilt Down


Fork tilt allows the operator to raise or lower the tips of the
forks. Standard fork tilt is 4o up and 3o down.
With the key switch ON and the brake pedal and/or right foot
pedal depressed, pressing the tilt down button (S212) causes
voltage to be sensed at HM204 on the control handle
interface card. The control handle interface card encodes the
digital signal sensed at HM204 to an analog voltage level of
approximately 4.41 volts at HM109 and sends to main
electronic (A5) card input 508 (wire #84). The main electronic
(A5) card responds by:
Enabling voltage to the direction A solenoid coil (Y12) from
output 705 (wire #90).
Enabling the tilt solenoid (Y17) on the reach carriage from
output 710 (wire #94).
Sending a speed request to the pump transistor regulator.
Speed request is dependent on truck voltage and reach
model. The truck voltage and reach model is configured by
Pump Type Parameter 14.
The speed request signal to the pump transistor regulator
provides the PWM frequency rate to pulse the pump motor.
Oil is fed through direction A (Y12) valve, to the front port of
the tilt cylinder, driving the piston inward. The oil flows from
the rear port of the cylinder, to the tilt (Y17) valve, to the
direction A (Y12) valve, returning to the hydraulic tank.

BT Prime-Mover Inc.

Return

Service Manual

2001-03-15

393

F-code

Section

C-code

PS
S6.0
Hydraulic System

6000

Version no

T-code

000

RTX35/RTX45

List of Symbols
Symbol

Designation

Function

1-2

Cylinder

Staging

Cylinder

Free lift

Cylinder

Reach/retract

Cylinder

Tilt

Cylinder

Sideshift

11

Valve

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

Filter

Main filter

M3

Motor

Pump motor

Pump

Hydraulic pump

R1

Potentiometer

Travel

R11

Potentiometer

Lift/lower

S51

Switch

Sideshift Left

S52

Switch

Sideshift Right

S55

Switch

Reach Extend

394

Return

Service Manual

Remarks

2001-03-15

F-code

Section

PS

S6.0
6000
Hydraulic System

Version no

000

C-code

T-code

RTX35/RTX45

List of Symbols
Symbol

Designation

Function

S56

Switch

Reach Retract

S211

Switch

Tilt Up

S212

Switch

Tilt Down

Y10/2

Valve

Lift of Forks

Y10/3

Valve

Proportional Valve, 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.

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Service Manual

2001-03-15

Remarks

395

F-code

Section

C-code

PS
S6.0
Hydraulic System

6000

Version no

T-code

000

RTX35/RTX45

2. 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

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

Y13
Y12

P
R
Y11
F

C2

C1

C3

C1

C2

C4

Y15

Y17

S1

Y16

CV
300 PSI

REACH CYLINDERS

BT Prime-Mover Inc.

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Service Manual

2001-03-15

TILT CYLINDER

SIDESHIFT CYLINDER

397

F-code

Section

PS
S6.0
Hydraulic System
Version no

T-code

000

RTX35/RTX45

398

Return

C-code

6000

Service Manual

2001-03-15

F-code

Section

PS

S6.1
6112
Hydraulic Fluid

Version no

000

C-code

T-code

RTX35/RTX45

Hydraulic Fluid
1. Hydraulic Fluid Selection
Before adding or changing hydraulic fluid, determine the
environment and usage of the truck. To make the proper oil/
lubricant selection see Oil and Grease Specifications on
page 81.

2. Changing Hydraulic System Fluid


1. Be sure the truck is in a clean area, away from any
possible contaminating elements that could enter
the hydraulic system during the changing process.
Check that the carriage is fully lowered, reach
retracted, and tilt is fully down.
2. Drain hydraulic reservoir completely. Also, drain as
much oil as possible from the hydraulic lines and
cylinders.
3. Fill hydraulic reservoir with proper fluid.
4. With lift system running, operate the lift/lower and
auxiliary functions for approximately 2 minutes to
purge the system.
5. Check for possible hydraulic leaks.
6. Bleed entire hydraulic system before placing truck
into service. See Bleeding Hydraulic System on
page 401.
7. Check reservoir oil level.
The remainder of the original hydraulic fluid left in the system,
(approximately 5%), should not be harmful to the operation of
the truck.

BT Prime-Mover Inc.

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Service Manual

2001-03-15

399

F-code

Section

C-code

PS
S6.1
Hydraulic Fluid

6112

Version no

T-code

000

RTX35/RTX45

3. System Draining
1. Lower the carriage fully, tilt forks down completely
and retract reach mechanism fully.
2. Turn key switch OFF and disconnect battery
connector.
3. Remove top console and open motor compartment
door.
4. Use female half of the diagnostic fitting (24 inch
hose) and direct the hydraulic fluid into a waste
container with a capacity greater than 5 gallons (19
liters).
5. Reconnect battery connector and turn key switch
ON.
6. Operate lift until air in the system is heard.
7. Turn key switch OFF and disconnect battery
connector.
8. Remove drainage tube and replace diagnostic
fitting.
9.

Remove female half of diagnostic fitting and hose.

10. If it is necessary to flush the reservoir, remove


reservoir.
11. Dispose of old hydraulic fluid according to local
regulations for hazardous materials.

400

Return

Service Manual

2001-03-15

F-code

Section

PS

S6.1
6112
Hydraulic Fluid

Version no

000

C-code

T-code

RTX35/RTX45

4. System Refilling
1. If reservoir was removed for flushing, install
reservoir.
2. Install hydraulic filter.
3. Fill hydraulic reservoir through breather cap/fill
hole. Be sure to use the proper grade of fluid. The
reservoir holds 5 gallons (19 liters) of fluid.
4. Reconnect battery connector and turn key switch
ON.
5. Bleed hydraulic system. See paragraph 5 below.
6. Install top console and secure motor compartment
door.

5. 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. Elevate forks 2 to 3 inches (50 to 75 mm) off the
floor.
2. Turn key switch OFF and disconnect battery
connector.

BT Prime-Mover Inc.

Return

Service Manual

2001-03-15

401

F-code

Section

C-code

PS
S6.1
Hydraulic Fluid

6112

Version no

T-code

000

RTX35/RTX45

CAUTION Use caution. The mast may drop when


bleeding the cylinder.
3. Use an Allen wrench to loosen (but do NOT
remove) the bleed screw at the top of the freelift
cylinder. Hold a rag close to and beneath the bleed
screw to keep hydraulic fluid from spraying out.
4. Repeat step 3 for each of the two staging cylinders.
5. Reconnect battery connector and turn key switch
ON.
6. Lower forks all the way down to the floor.
7. Fully extend and retract the reach mechanism
several times.
8. When hydraulic fluid starts flowing from the bleed
screw hole, securely tighten the bleed screw.
9. If truck is equipped with tilt, tilt the carriage all the
way forward and backward several times.
10. If truck is equipped with sideshift, shift the carriage
all the way to the left and right several times.
11. Thoroughly clean up any spilled hydraulic fluid.
12. Check hydraulic reservoir level and refill as
necessary.

402

Return

Service Manual

2001-03-15

F-code

Section

PS

S6.1
6112
Hydraulic Tank

Version no

C-code

T-code

000

RTX35/RTX45

Hydraulic Tank
1

Item
No.

Description

Tank, hydraulic (RTX35)

Tank, hydraulic (RTX45)

1. Removal
1. Lower carriage fully and retract reach mechanism
fully.
2. Remove top console. See Top Console on
page 96.
3. Drain hydraulic system. See Hydraulic Fluid on
page 399.
4. Turn key switch OFF and disconnect battery
connector.
5. Remove drive motor and brake assembly.
6. Remove lift pump and motor.
BT Prime-Mover Inc.

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Service Manual

2001-03-15

403

F-code

Section

C-code

PS
S6.1
Hydraulic Tank

6112

Version no

T-code

000

RTX35/RTX45

7. Disconnect hydraulic hose to the mast. Plug ends


to prevent contamination.
8. Disconnect hydraulic hose to the control valve.
Plug the end to prevent contamination.
9. To remove reservoir, tilt chassis end of reservoir
up. Pull reservoir back, away from the mast. Once
the front of the reservoir has cleared the front
chassis frame, lift the reservoir out.
10. Remove hydraulic filter adapter
Align
Hose

2. Installation
1. Install hydraulic filter adapter.
2. Install hydraulic filter.
3. Angle mast end of reservoir down and push
forward to the frame. Let the chassis end of the
reservoir drop straight down at this point.
4. Install lift pump and motor assembly.
5. Connect hoses to reservoir.
6. Fill hydraulic reservoir.
7. Install drive motor and brake assembly.
8. Reconnect battery connector.
9. Bleed hydraulic system. See Bleeding Hydraulic
System on page 401.
10. Test operate truck.
11. Turn key switch OFF and disconnect battery
connector. Install top console. Reconnect battery
connector.

404

Return

Service Manual

2001-03-15

F-code

Section

C-code

PS
S6.2
6131
Hydraulic Filter and Adapter
Version no

T-code

001

RTX35/RTX45

Hydraulic Filter and Adapter


7

13
11
8

1, 2

3, 4

5, 6
12
10

Item
No.

BT Prime-Mover Inc.

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Description

Item
No.

Description

Screw

O-ring

Washer

Ring

Screw

10

Element, filter

Washer

11

U-gasket

Plate

12

Gasket, tank

Gasket

13

Cap, filter

Filter assembly

Service Manual

2001-03-15

405

F-code

Section

C-code

PS
S6.2
6131
Hydraulic Filter and Adapter
Version no

T-code

001

RTX35/RTX45

1. Hydraulic Filter
1.1. Removal
NOTE! It is recommended that the hydraulic fluid be
drained from the hydraulic tank prior to
replacing the filter.
1. Lower carriage fully to ensure all hydraulic
pressure is relieved.
2. Turn key switch OFF and disconnect battery
connector.
3. Remove top console (see page 96).
4. Remove blue cover (13) on the filter adapter collar.
5. Remove filter attached to the bottom of the blue
cover by pulling straight down to snap it out of the
latch.

1.2. Installation
1. Snap filter onto blue cover (13).
2. Install cap and filter assembly in hydraulic tank.
3. Test operate truck.
4. Check hydraulic fluid level and refill as needed.
5. Replace top console.
6. Reconnect battery connector.
7. Return to service.

406

Return

Service Manual

2001-03-15

F-code

Section

C-code

PS
S6.2
6131
Hydraulic Filter and Adapter
Version no

001

T-code

RTX35/RTX45

2. Hydraulic Filter Adapter


2.1. Removal
1. Turn key switch OFF and disconnect battery
connector.
2. Remove top console. See Top Console on
page 96.
3. Remove blue cap and filter.
4. Remove four mounting screws attaching collar
assembly to the plastic hydraulic tank.

2.2. Installation
1. Clean all parts thoroughly. Clean the mating
surface of hydraulic tank.
2. Align collar mounting holes with the hydraulic tank
holes. Torque four mounting screws to 44.4 inch lb
(50 Nm).
3. Install cap and filter.
4. Check fill level fluid in the hydraulic tank.
5. Reconnect battery connector.
6. Bleed hydraulic system. See Bleeding Hydraulic
System on page 401.
7. Test operate truck.
8. Turn key switch OFF and disconnect battery
connector.
9. Install top console.
10. Reconnect battery connector.

BT Prime-Mover Inc.

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Service Manual

2001-03-15

407

F-code

Section

C-code

PS
S6.2
6131
Hydraulic Filter and Adapter
Version no

T-code

001

RTX35/RTX45

408

Return

Service Manual

2001-03-15

F-code

Section

PS

S6.3
6141
Hydraulic Pump

Version no

C-code

T-code

000

RTX35/RTX45

Hydraulic Pump
3

4
5
3
6
7
8
9
5

10
8
7
6

19

5
6

18

12

11

7
8

17

13

14
8
7
6

16
5

15

2
1

BT Prime-Mover Inc.

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Service Manual

2001-03-15

409

F-code

Section

C-code

PS
S6.3
Hydraulic Pump

6141

Version no

T-code

000

RTX35/RTX45

Item No.

Description

Item No.

Description

Screw

11

Gear, driven

Pump Assembly

12

Flange, mounting

O-ring

13

Seal, shaft

Spacer

14

Gear, drive

Pin, dowel

15

Gear, driven

Seal, back-up

16

Body

Seal, plate

17

End, cap

Bearing

18

Washer

Body

19

Screw

10

Gear, drive

1. Removal
Remove hydraulic pump from pump motor. (See Removal
on page 111.)

2. Pump Disassembly
CAUTION Overhaul pump only in a clean, dust-free
location, using clean tools and equipment.
Dirt or grit will damage the highly machined
surfaces and will result in leakage or
premature failure of the pump.
1. Scribe match mark on the bodies (9, 16), covers
(12, 17), and spacer (4) to insure that the dual
pump will be reassembled in the same manner. If
the bodies or covers are replaced during overhaul,
scribe a match mark on the replaced part.
2. Thoroughly clean outside of dual pump and air dry.
3. Secure unit in vise (use light clamping pressure on
the ears of the front cover) with shaft end down.
Remove capscrews (19) and washers (18).

410

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Service Manual

2001-03-15

F-code

Section

PS

S6.3
6141
Hydraulic Pump

Version no

000

C-code

T-code

RTX35/RTX45

4. Separate rear cover (17) from body (16). The back


static seal (3) may remain either with the body or
the cover. Remove and discard back static seal (3).
Bearing
Block

Outlet
Side
(Discharge
Pressure)

Inlet
Side
(Suction)

NOTE! During disassembly, take special note of the


wear patterns on the bearing blocks (8) and
body (16). Relate these patterns to the inlet
and outlet side of the pump. The large port
whether in the body (16) or the rear cover (17)
corresponds to the inlet side of the pump. The
inlet side of the body can be identified by the
gear contact pattern in the gear bore. The
bearing block will have somewhat heavier
wear patterns on the inlet side.
5. Lift out the rear bearing block (8), drive gear (14),
and driven gear (15).
6. Separate body (16) from spacer (4). Dowel pins (5)
and the front static seal (3) may remain with either
the body (16) or back cover (17). Remove and
discard front static seal (3).
7. Invert body (16) and lift out front bearing block (8).
8. Remove spacer (4). Dowel pins (5) may remain
with spacer (4).
9. Separate body (9) from front cover (12). The back
static seal (3) may remain either with the body or
the cover. Remove and discard back static seal (3).
NOTE! During disassembly, take special note of the
wear patterns on the bearing blocks (8) and
body (9). Relate these patterns to the inlet
and outlet side of the pump. The large port
whether in the body (9) or the front cover (12)
corresponds to the inlet side of the pump. The
inlet side of the body can be identified by the
gear contact pattern in the gear bore. The
bearing block will have somewhat heavier
wear patterns on the inlet side.
10. Lift out the rear bearing block (8), drive gear (10),
and driven gear (11).

BT Prime-Mover Inc.

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Service Manual

2001-03-15

411

F-code

Section

C-code

PS
S6.3
Hydraulic Pump

6141

Version no

T-code

000

RTX35/RTX45

11. Dowel pins (5) and the front static seal (3) may
remain with either the body (9) or front cover (13).
Remove and discard front static seal (3).
12. Invert body (9) and lift out front bearing block (8).
CAUTION Care should be taken not to damage
(gouge) the shaft seal bore because this
will result in shaft seal leakage.
13. Invert front cover (12) with shaft seal up. Remove
shaft seal (4) by prying it out with a large
screwdriver.

412

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Service Manual

2001-03-15

F-code

Section

PS

S6.3
6141
Hydraulic Pump

Version no

C-code

T-code

000

RTX35/RTX45

3. Parts Inspection
1. Wash all parts and dry thoroughly.
NOTE! A somewhat heavier wear pattern is normal
on the low pressure (inlet) side of the bearing
blocks (8). There should be no heavy scoring
on this area.
2. Inspect front and rear bearing blocks (8). Replace if
scoring or uneven wear is observed.
3. Remove anti extrusion seal (6) and pressure
loading seal (7) from each bearing block and
discard.
4. Inspect bushings in each bearing block (8).
Replace bearing block if bushings are heavily
scored or burned.
5. Inspect gear journals and faces. If faces or journals
are scored or worn, replace pump.
6. Inspect bodies for wear and scoring. If gear contact
wear on low pressure side (inlet) exceeds 0.005
(0.127 mm) depth, replace pump. If the body is
usable, lightly wipe and remove burrs with suitable
de-burring tool.
8
7
6

BT Prime-Mover Inc.

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Service Manual

2001-03-15

413

F-code

Section

C-code

PS
S6.3
Hydraulic Pump

6141

Version no

T-code

000

RTX35/RTX45

4. Pump Reassembly
1. Place the front cover (12) on a flat plate with the
shaft seal bore up. Install new shaft seal (13).
Press seal until it is 0.157 inch (4.0 mm) below
front surface. Pack the area between the double lip
of the seal with Lubriplate or equivalent grease.

Face
of Pilot
Diameter

Arbor
press

0.15
(4.0 mm)

Seal
Pressing
Tool
Front
Cover
(12)

Shaft
Seal (13)

NOTE! The installation of new parts contained in the


seal kit is recommended at each overhaul of
the pump. Seal kit parts consists of items 3, 6,
7, and 14.

Shaft Seal

2. Clamp front cover into vise so the seal ring groove


is up. Apply a small amount of grease to the seal
groove and install a new seal ring (3) into the
groove.

Drive Shaft
Installation
Tool (Bullet)

3. Apply Lubriplate or equivalent to outer surface of


drive shaft installation tool. Insert tool (Bullet) into
shaft seal from seal ring groove side of front cover

Lubricate
414

Return

Service Manual

2001-03-15

F-code

Section

PS

S6.3
6141
Hydraulic Pump

Version no

000

C-code

T-code

RTX35/RTX45

NOTE! Drive shaft installation tool wall thickness


should be approximately 0.010 inch (0.25
mm). If tool is not available, grease assemble
being very careful not to cut seal (13).

Shaded area represents


the W seal

4. Place a small amount of grease in the seal groove


on the front bearing block (8). Install a new load
seal (7) and anti-extrusion seal (6) in the groove.
Insert the bearing block in the body, making sure
that the load seal (7) and anti-extrusion seal (6) are
positioned properly. Ensure the outside of the W
seal is exposed to the discharge pressure.
5. Apply a small amount of grease to the dowel pins
(5) and install into the body (9).

Outlet
Side
(Discharge
Pressure)

Inlet
Side
(Suction)

6. Set the body (9) on the front cover (12), matching


the scribe marks on the body and front cover.
Insert dowel pins (5) into the mating holes on the
front cover (12).
7. Install drive gear (10) and driven gear (11).
8. Place a small amount of grease in the seal groove
on the back bearing block (8). Install a new load
seal (7) and anti-extrusion seal (6) in the groove.
Insert the bearing block in the body, making sure
that the load seal (7) and anti-extrusion seal (6) are
positioned properly. Ensure the outside of the W
seal is exposed to the discharge pressure.
9. Clamp spacer (4) into vise so the seal ring groove
is up. Apply a small amount of grease to the seal
groove and install a new seal ring (3) into the
groove. Remove spacer from vise and turn it
around and place in vise. Apply a small amount of
grease to the seal groove and install a new seal
ring (3) into the groove.
10. Install spacer (4) matching the scribe marks. Apply
a small amount of grease to the dowel pins (5) and
install into the spacer (4).
11. Place a small amount of grease in the seal groove
on the rear bearing block (8). Install a new load
seal (7) and anti-extrusion seal (6) in the groove,
making sure that they are positioned properly.

BT Prime-Mover Inc.

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Service Manual

2001-03-15

415

F-code

Section

C-code

PS
S6.3
Hydraulic Pump

6141

Version no

T-code

000

RTX35/RTX45

Insure outside of W seal is exposed to the


discharge pressure.
12. Apply a small amount of grease to the seal groove
in the rear cover (17). Install a new seal ring (3)
into the groove. Set the rear cover (17) onto the
body (16), matching the scribe marks on the body
(16) and rear cover (17).
13. Insert washers (18) and capscrew (19). Torque to
42-46 ft-lbs (57-62 Nm).
14. Check that drive shaft turns with adjustable wrench
without evidence of mechanical bind.

5. Testing
1. Mount pump on truck and operate for two minutes
at minimum pressure and one-quarter engine
speed.
2. Increase discharge pressure to relief setting with
control valve. Hold for five seconds and release.
Continue cycle for two minutes.
3. Repeat step 2 for three minutes at one-half pump
speed.
4. Repeat step 2 for three minutes at full pump speed.
5. With truck at idle speed, check pump and hydraulic
system for leaks. No shaft seal leakage sufficient to
form a drop is permissible. No external leakage is
permissible.

416

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Service Manual

2001-03-15

F-code

Section

PS

S6.4
6211
Control Valve

Version no

000

To
Mast

Y10 Lift and


Prop. Lower

Y12 DIRA
Y13 DIRB

C-code

T-code

RTX35/RTX45

Control Valve
1. Removal
1. Turn key switch OFF and disconnect battery
connector.
2. Remove top console.
3. Remove motor compartment rear door.

To
Reservoir

WARNING Take precautions to prevent fluid from


getting into the drive motor and/or brake
assembly when removing fittings from
control valve.

To Aux.
Functions
To
Pump

Y11 Dump Valve

4. Loosen fittings on two large hoses, toward the lift


motor, with a 1-1/8 inch (28.58 mm) wrench.
5. Disconnect the electrical wires from Y10, Y11,
Y12, and Y13.
6. Use a 13/16 inch (20.64 mm) wrench to loosen
fittings on two smaller hoses.
7. Loosen hose clamp to remove return hose from
reservoir.
8. Using a 1/2 inch (13 mm) socket, remove 3 bolts
securing the control valve to bracket.
Mounting Bolt
(one shown)

2. Installation
1. Apply thread locking compound to three mounting
bolts.
2. Tighten using a 1/2 inch (13 mm) socket.
3. Attach hoses to control valve in the following order:
- Control valve to reservoir
- Return hose to mast 1-1/8 inch (28.58 mm)
- Control valve to lift pump 1-1/8 inch (28.58
mm)

BT Prime-Mover Inc.

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Service Manual

2001-03-15

417

F-code

Section

C-code

PS
S6.4
Control Valve

6211

Version no

T-code

000

RTX35/RTX45

To
Mast

Y10 Lift and


Prop. Lower

Y12 DIRA
Y13 DIRB

- Two small hoses 13/16 inch (20.64 mm) on


the front of control valve. Hose with 90 degree
fitting goes on the bottom, tighten before
installing the top hose. Install 90 degree fitting
in the top port of control valve, then install
remaining small hose.
4. For large hoses, finger tighten fittings until both
ends are attached. Torque nut to 480 + 25 in. lbs.
(54 Nm).
5. Connect the electrical wires from Y10, Y11, Y12,
and Y13.

To
Reservoir
To Aux.
Functions
To
Pump

6. Install top console.


7. Install motor compartment rear door.

Y11 Dump Valve

NOTE! To service either the drive motor or pump


motor, control valve may be removed from the
bracket (leaving all hoses attached) and laid
up over the reservoir.
If the reservoir needs to be replaced, leave
the control valve on the bracket. Remove
return hose at reservoir. Lay hose over
control valve and let the loose end drop into
the operator compartment.

418

Return

Service Manual

2001-03-15

F-code

Section

PS

S6.4
6211
Control Valve

Version no

000

C-code

T-code

RTX35/RTX45

Control Valve
Solenoid Mounting Screws
17
2
18
3
4

20

4a

21

4b

13

19

22
14

15

38

23
16

29a

29

Valve Block

36

24
25
26
27
28

20

37

39
40
34

41

46
31

30

45

42

43

33
33

47
20

47

44

49
32

39
20
48

35
BT Prime-Mover Inc.

Return

Service Manual

2001-03-15

419

F-code

Section

C-code

PS
S6.4
Control Valve

6211

Version no

T-code

000

RTX35/RTX45

Item
No.

Description

Item
No.

Description

Description

Valve assembly,
control

Plug

O-ring

O-ring

13

Screw **

4a

O-ring

Insert

15

Spring **

4b

Seal

4a

O-ring

16

Insert, dampener **

14

USIT-ring

4b

Seal

29

Plug **

18

Nut

29a

Plug **

20

Seal

30

Screw **

31

Seal

17

Screw

35

Screw, adjusting

32

Nut

18

Nut

36

Screw, valve mounting

33

Seal

19

Screw

37

Washer, flat

34

O-ring

20

Ring, seal

38

Valve assembly,
manifold

21

Disc

39

Coil

22

Spring

40

Valve, check

Kit, seal (for item # 40)

23

Guide spring

41

Valve, 4 way 3 position

Kit, seal (for item # 41)

24

Piston

42

Body

Kit, seal (for item # 43)

25

Spring

43

Valve, check

Kit, seal (for item # 44)

26

Spring

44

Valve, poppet, N.O.

27

Sleeve

45

Spring **

28

Ball

46

Ball, check **

47

Plug **

48

Plug **

49

Plug **

420

Return

Seal Kit
(Contains items below)

Item
No.

Individual Valve Seal Kits

Proportional Pre-Pressure
Relief Valve Kit
(Contains items below)

DBV Kit
(Contains items below)

** Items 13, 15, 16, 29, 29a, 30, 45, 46, 47, 48, and 49 are
shown for reference only. They are not serviceable individually.

Service Manual

2001-03-15

F-code

Section

PS

S6.4
6211
Control Valve

Version no

000

C-code

T-code

RTX35/RTX45

3. Repair
WARNING When disassembling, replacing piece
parts, and resealing, it is advisable that the
valve assembly be removed from the
truck. The mast carriage must be fully
lowered. Hot oil under pressure may be
present. Some spillage of hydraulic oil will
occur. Perform any procedures in a clean
environment. Make sure all parts are
cleaned before disassembly and kept
clean during assembly.

3.1. Proportional Pre-Pressure Reducing


Valve, (Items 3, 4, 4a, 4b):
1. Remove three screws and lift off twin solenoid
block (2) from valve block.
2. Remove O-ring seal (3). Screw valve insert (4) out
of block.
3. Check piston in valve insert for smooth operation.
4. Inspect insert (4) and seals (4a and 4b). Replace if
necessary.
5. Screw insert with seals into valve block. Make sure
piston in valve insert operates smoothly when
assembled.
6. Install outer seal (20). Mount solenoid to valve
block with three screws.

3.2. Valve Assembly SWR14 (Item 38)


1. Remove two screws (36) and washers (37). The
SWR14 valve will separate from lift control valve
assembly (1).
2. Inspect O-rings and replace if necessary.
3. Reverse procedure to assemble. Torque two
screws to 15 ft-lb (20 Nm).

BT Prime-Mover Inc.

Return

Service Manual

2001-03-15

421

F-code

Section

C-code

PS
S6.4
Control Valve

6211

Version no

T-code

000

RTX35/RTX45

3.3. Pressure Limiting Valve Assembly


(Items 17 to 28)
1. Remove screw (19). Items 17 and 18 can remain
intact. Inspect seal (20) for damage and replace if
necessary.
Relief
Valve
Adjusting
Screw

2. Pull out inner parts (21 to 28). Do not damage


surface of dampening piston (24) or bore of valve
seat.
3. Reverse procedure to assemble. During assembly
make sure that the dampening piston operates
smoothly. Use a light grease when assembling
items 24 through 28.
4. Check pressure setting with a pressure gauge.

3.4. Setting Lift/Auxiliary Pressure Relief


with a Rated Load
Relief Pressure
Test Port
(beneath
reservoir hose)

NOTE! To set the system pressure, a calibrated


pressure gauge capable of measuring 300 psi
(2068 kPa) at mid-range is needed.
The lift/auxiliary pressure relief adjusting screw is located on
top of the main control valve, near solenoid Y10. The relief
pressure test port is on the side of the control valve, to the
right of hydraulic lines to reservoir and pump.
1. Lift a rated load (maximum capacity listed on the
specification plate plus 10%).
2. Loosen locknut (18) so adjuster screw (17) can be
turned. Turn adjuster screw counter-clockwise to
reduce pressure and clockwise to increase
pressure.
3. The pressure at rated load should be the truck
capacity weight +10%. Turn adjuster screw until
the load can be lifted.
4. Be sure locknut is secure when adjustment is
complete.

422

Return

Service Manual

2001-03-15

F-code

Section

PS

S6.4
6211
Control Valve

Version no

000

C-code

T-code

RTX35/RTX45

3.5. Hydraulic Lowering Rate Adjustment


1. Loosen sealed locknut (32) so
adjusting screw (35) can be turned.
2. Adjust screw counter-clockwise
lowering rate of speed.

that

to

the

increase

NOTE! If the lowering speed is to fast, it will cause


the safety valves on the lift cylinder to close
and/or cause the columns to miss stage.
3. Adjust screw clockwise to decrease lowering rate
of speed.
4. The maximum lowering rate for the RTX35 with a
rated load is 80 fpm and 95 fpm for the RTX45.
5. After adjustment is complete, tighten sealed
locknut (32).

3.6. Recondition Seal Kit for Lift/ Lower


Valve (Items 3, 4a, 4b, 14, 18, 20, 31, 32, 33,
and 34)
1. Refer to paragraph 3.1 for items 3, 4a, and 4b.
2. Remove screw (13). The spring (15) is inserted
inside screw.
3. Check damping
contamination.

insert

(16) for damage

or

4. Install seal (14) and assemble. Take care that the


spring (15) stays inside screw (13). Torque screw
to 6 ft-lb (8 Nm).
5. Loosen locknut (18) and remove adjuster screw
(17). Replace locknut.
6. Remove screw (19) and replace seal (20).
7. Remove screw (30) and pull out spring (45) with
check ball (46). Inspect for contamination or
damage.

BT Prime-Mover Inc.

Return

Service Manual

2001-03-15

423

F-code

Section

C-code

PS
S6.4
Control Valve

6211

Version no

T-code

000

RTX35/RTX45

8. Replace seal (31). Ensure during assembly that


spring (45) and ball (46) are installed as shown in
the illustration on page 419. The maximum torque
value of screw (30) is 6 ft-lb (8 Nm).
9.

Loosen locknut (32) and remove adjustment screw


(35). Replace locknut.

10. Remove plug (29) and replace seal (20). Screw


plug in two turns.
11. Remove opposite screw (49) and replace seal (20).
Install screw and tighten items 29 and 49.
12. Remove plug (29a) and replace seal (20). Screw
plug in two turns.
13. Remove plug (48) and replace seal (20). Install
plug and tighten items 29a and 48.
14. Remove plug (47) and replace seal (33). Install
plug.
15. To replace O-rings (34), refer to Valve Assembly
SWR 14.

424

Return

Service Manual

2001-03-15

F-code

PS

Section

C-code

S6.5
6610
Staging Cylinder, 3 Stage

Version no

T-code

000

RTX35/RTX45

Staging Cylinder, 3 Stage


7

3
1

2
4

9
10
11
12
13
16

15

14

Item No.

BT Prime-Mover Inc.

Return

Description

Item No.

Description

Screw

Ring, wear

Washer, seal

10

Piston

Cylinder tube, 1 Port

11

Ring, retainer

Cylinder tube, 2 Port

12

Rod, cylinder

Plugger assembly

13

O-ring

Spring

14

Bearing

Plug

15

Seal, rod

O-ring

16

Wiper

Service Manual

2001-03-15

425

F-code

Section

C-code

PS
S6.5
6610
Staging Cylinder, 3 Stage
Version no

T-code

000

RTX35/RTX45

1. Staging Cylinder Repair


1.1. Removal
1. Park truck on a level surface and apply the brake.
2. Fully extend cylinders to inspect cylinder rod (12)
for gouges or pits. If gouges or pits are detected,
then the cylinder must be removed for repair.
WARNING When blocking the mast columns to
prevent lowering, always block both sides
of the column. If both sides are not
blocked, truck could tip on its side.
3. Lift mast so inner column is raised approximately
12 inches (305 mm). Securely block the mast,
using 4 x 4 inch (102 x 102 mm) blocks under each
side of inner columns.
4. Remove bolts from the top end of the staging
cylinder rods. Lower cylinder rods hydraulically.
5. Clean exterior of lift cylinder.
WARNING Compressed air used for cleaning MUST
be reduced to less than 30 psi (206 kPa),
and then only with effective chip-guarding
and personal protective equipment.

1.2. Disassembly
1. Remove cylinder rod (12) from cylinder tube.
2. Remove and discard all seals, rod wiper (16), rod
seal (15), and wear ring (9) from bearing (14). Use
care NOT to damage the inside of the bearing.

426

Return

Service Manual

2001-03-15

F-code

PS

Section

C-code

S6.5
6610
Staging Cylinder, 3 Stage

Version no

000

T-code

RTX35/RTX45

1.3. Assembly
1. Install new wear ring (9), seals, and rod wiper (16)
in gland (14). The lip of the wiper must face
outward. It is not necessary to replace wear ring
(9), unless cylinder was removed for rod repair.

1.4. Installation
1. Install lifting gear, chains, hoses, and electric
cables.
2. Test for proper operation.

BT Prime-Mover Inc.

Return

Service Manual

2001-03-15

427

F-code

Section

C-code

PS
S6.5
6610
Staging Cylinder, 3 Stage
Version no

T-code

000

RTX35/RTX45

428

Return

Service Manual

2001-03-15

F-code

PS

Section

C-code

S6.6
6620
Freelift Cylinder, 3 Stage

Version no

T-code

000

RTX35/RTX45

Freelift Cylinder, 3 Stage


K
2

3
15
8

14
13
7
12
6

11

5
10

4
Seal Kit Contains Items Marked with K

Item
No.

Screw

10K

O-ring

Tube cylinder

11K

Back-up ring

Ring, retainer

12

Plunger assembly

13K

Ring, guide

Spring

14K

Seal

Ring, guide

15K

Wiper

Service Manual

Piston

2001-03-15

Description

Washer, seal

BT Prime-Mover Inc.

Item
No.

7K

Return

Description

Rod cylinder

Bearing

Kit, seal

429

F-code

Section

C-code

PS
S6.6
6620
Freelift Cylinder, 3 Stage
Version no

T-code

000

RTX35/RTX45

The lift cylinders are positive displacement type, meaning


there are NO seals on the lower end of cylinder rod. The lift
cylinder can be resealed without removal from truck.
NOTE! Perform procedures in a clean environment.
Make sure all parts are cleaned before
disassembly and kept clean during assembly.

1. Freelift Cylinder Repair


1.1. Removal
1. Park truck on a level surface and apply brake.
2. Fully extend cylinder to inspect cylinder rod (9) for
gouges or pits. If gouges or pits are detected, then
cylinder must be removed for repair.
WARNING When blocking mast columns to prevent
lowering, always block both sides of the
column. Otherwise, the truck could tip over
on its side.
3. Lift carriage/reach approximately 6 inches (152
mm). Securely block carriage/reach to prevent
lowering.
4. Lower cylinder so chains, hoses, and electric
cables are loose. Disconnect battery.
5. Remove chains, hoses, and electric cables from
lifting gear.

430

Return

Service Manual

2001-03-15

F-code

PS

Section

C-code

S6.6
6620
Freelift Cylinder, 3 Stage

Version no

000

T-code

RTX35/RTX45

6. Remove lifting gear from cylinder rod.


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.
7. Clean exterior of lift cylinder.

BT Prime-Mover Inc.

Return

Service Manual

2001-03-15

431

F-code

Section

C-code

PS
S6.6
6620
Freelift Cylinder, 3 Stage
Version no

T-code

000

RTX35/RTX45

1.2. Disassembly
1. Remove bearing (12) from cylinder tube (3).
2. Remove and discard packing, back-up ring, O-ring,
rod wiper, and bearing retainer from bearing (12).
Use care NOT to damage inside of bearing (12).

1.3. Assembly
1. Install a new bearing, seals, and rod wiper in gland.
The lip of the wiper must face outward. It is not
necessary to replace wear ring (7), unless the rod
was removed for repair.

1.4. Installation
1. Install lifting gear, chains, hoses, and electric
cables.
2. Connect battery.
3. Test for proper operation.

432

Return

Service Manual

2001-03-15

F-code

PS

C-code

S6.7
6650
Reach Cylinder (RTX35)

Version no

001

Section

T-code

RTX35/RTX45

Reach Cylinder (RTX35)

K
6

23

7
8

22

10

11
12

20
19

18 17

16

15
13
14

21

Seal Kit Contains Items Marked with K


1

5
1
4
3

Forks Direction
BT Prime-Mover Inc.

Return

Service Manual

2001-03-15

433

F-code

Section

C-code

PS
S6.7
6650
Reach Cylinder (RTX35)
Version no

T-code

001

RTX35/RTX45

Item
No.

Item
No.

Description

Description

Pin, roll

9K

Ring, guide

Pin, clevis

10K

Pin, clevis

Item
No.

Description

17

Bearing

Ring, sealing

18K

Seal rod

11K

O-Ring

19K

Ring, guide

Right reach cylinder assembly

12

Rod assembly

20K

Ring, back-up

Left reach cylinder assembly

13

Nut

21K

Seal, rod

Right tube cylinder

14

Screw, set

22

O-Ring

Left tube cylinder

15

Yoke, cylinder

23

Grease Fitting

Wiper

Kit, seal

8K

Retainer

16K

1. Removal
1. Park truck on a level surface and apply brake.
2. Extend reach about 1/2 to 3/4 of total reach.
3. Block and chain reach mechanism to prevent
movement of reach mechanism.
4. Relieve pressure on reach cylinders.
5. Remove hoses from reach cylinder.
6. Remove front cylinder mounting pins (3).
7. Raise reach assembly above full freelift. Remove
rear cylinder mounting pins (2).
8. Remove reach cylinder from truck.

434

Return

Service Manual

2001-03-15

F-code

PS

Section

C-code

S6.7
6650
Reach Cylinder (RTX35)

Version no

001

T-code

RTX35/RTX45

2. Disassembly
NOTE! Perform procedures in a clean environment.
Make sure all parts are cleaned before
disassembly and kept clean during assembly.
1. Before disassembly, clean the exterior of reach
cylinder in a cleaning solution to remove all
contamination.
WARNING Compressed air used for cleaning MUST
be reduced to less than 30 psi (206 kPa),
and then only with effective chip-guarding
and personal protective equipment.
2. Be sure all hydraulic fluid has been removed from
cylinder. Stroking piston rod will help force fluid out.
3. Put base end of cylinder in a vise equipped with
soft jaws.
4. Remove bearing retainer (8) and bearing (22) by
rotating bearing from cylinder tube (6 or 7) with a
spanner wrench.
5. Remove rod assembly (12).
6. Remove and discard all seals and rod wiper (16).
7. Inspect mounting bearings (22) located at the base
end of cylinders. It will not be necessary to remove
bearings unless they are found to be unfit for
further service.

BT Prime-Mover Inc.

Return

Service Manual

2001-03-15

435

F-code

Section

C-code

PS
S6.7
6650
Reach Cylinder (RTX35)
Version no

T-code

001

RTX35/RTX45

3. Inspection
WARNING Compressed air used for cleaning MUST
be reduced to less than 30 psi (206 kPa),
and then only with effective chip-guarding
and personal protective equipment.
1. Carefully clean all parts in a cleaning solution and
position parts on a clean work surface.
2. Check rod assembly (12) for damage. Look for
gouges, scratches, corrosion, or evidence of
unusual wear. Minor surface damage can be
repaired by the use of fine abrasion cloth or
stoning. Be extremely careful not to remove
chrome plating. Deeper damage will require
replacement of piston rod assembly (12). Make
sure threads on rod are free of damage.
3. Check cylinder bore for any damage. Parts with
deep gouges or pitted surfaces will require
replacement.

436

Return

Service Manual

2001-03-15

F-code

PS
Version no

001

Section

C-code

S6.7
6650
Reach Cylinder (RTX35)
T-code

RTX35/RTX45

4. Assembly
1. Install new O-rings and rod wiper (16) in bearing
assembly (17). The lip of the wiper must face
outward.
2. Install new bearing seals (18 & 19), back-up ring
(20), and O-rings (21) on bearing (17).
3. If necessary, replace rod assembly (12) with new.
Install rod assembly (12).
4. Apply clean hydraulic fluid to piston rod assembly.
Coat the inside of cylinder tube and bearing
assembly with clean fluid.
5. Carefully slide bearing assembly (17) onto cylinder
rod assembly (12). Be sure rod end does not cut or
nick wiper or packing upon installation.
6. Install bearing assembly into cylinder tube. Use
care so the seals are not nicked or cut upon
installation.
7. Check installation by making sure piston rod
assembly moves smoothly within tube assembly
without binding.
8. Install retainer (8).

BT Prime-Mover Inc.

Return

Service Manual

2001-03-15

437

F-code

Section

C-code

PS
S6.7
6650
Reach Cylinder (RTX35)
Version no

T-code

001

RTX35/RTX45

5. Installation
1. Raise reach assembly to full freelift height. Install
reach cylinder rear mounting pins (2). Secure
mounting pins with roll pins.
2. Lower reach assembly. Install reach cylinder front
mounting pins (3). Secure mounting pins with roll
pins.
3. Connect correct hydraulic hoses to reach cylinders.
4. Remove blocking and chains.
5. Fill hydraulic tank with new clean oil.
6. Connect battery.
7. Operate reach to remove air from hydraulic hoses.
Check operation of the whole hydraulic system.
CAUTION DO NOT use your hands to check for
hydraulic leakage. Use a piece of
cardboard or paper to search for leaks.
Escaping fluid under pressure can
penetrate the skin causing serious injury.
Relieve pressure before disconnecting
hydraulic or other lines. Tighten all
connections before applying pressure.
Keep hands and body away from pinholes
and nozzles which eject fluids under high
pressure.
8. After running the hydraulic system, check and fill
the hydraulic tank with new clean oil.

438

Return

Service Manual

2001-03-15

F-code

PS

Section

C-code

S6.7
6650
Reach Cylinder (RTX45)

Version no

T-code

001

RTX35/RTX45

Reach Cylinder (RTX45)

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

6
7
10

3
2

5
4

8
7
6

Forks Direction
BT Prime-Mover Inc.

Return

Service Manual

2001-03-15

439

F-code

Section

C-code

PS
S6.7
6650
Reach Cylinder (RTX45)
Version no

T-code

001

RTX35/RTX45

Item
No.

Item
No.

Description

Description

Item
No.

Description

Spacer

11

Right tube cylinder

21K Wiper

Right reach cylinder assembly

12

Left tube cylinder

Left reach cylinder assembly

13K Retainer

23K Seal, rod

Screw

14K Ring, guide

24K Ring, guide

Lockwasher

15K Ring, sealing

25K Ring, back-up

Washer, flat

16K O-ring

26K O-Ring

Pin, cotter

17

Rod assembly

27

Bearing

Pin

18

Nut

28

Fitting, grease

Spacer

19

Screw, set

Kit, Seal

10

Pin

20

Yoke, cylinder

22

Bearing

1. Removal
1. Park truck on a level surface and apply brake.
2. Extend reach about 1/2 to 3/4 of total reach.
3. Block and chain reach mechanism to prevent
movement of reach mechanism.
4. Relieve pressure on reach cylinders.
5. Remove hoses from reach cylinder.
6. Remove screws (4), washers (5 and 6) and cotter
pins (7) securing front cylinder mounting pins in
position. Remove front cylinder mounting pins (8).
7. Raise reach assembly above full freelift. Remove
screws (4), washers (5 and 6) and cotter pins (7)
securing rear cylinder mounting pins in position.
Remove rear cylinder mounting pins (10).
8. Remove reach cylinder from truck.

440

Return

Service Manual

2001-03-15

F-code

PS

Section

C-code

S6.7
6650
Reach Cylinder (RTX45)

Version no

001

T-code

RTX35/RTX45

2. Disassembly
NOTE! Perform procedures in a clean environment.
Make sure all parts are cleaned before
disassembly and kept clean during assembly.
1. Before disassembly, clean the exterior of reach
cylinder in a cleaning solution to remove all
contamination.
WARNING Compressed air used for cleaning MUST
be reduced to less than 30 psi (206 kPa),
and then only with effective chip-guarding
and personal protective equipment.
2. Be sure all hydraulic fluid has been removed from
the cylinder. Stroking piston rod will help force fluid
out.
3. Put base end of cylinder in a vise equipped with
soft jaws.
4. Remove bearing retainer (13) and bearing (22) by
rotating bearing from cylinder tube (11 or 12) with a
spanner wrench.
5. Remove rod assembly (17).
6. Remove and discard all seals and rod wiper (21).
7. Inspect mounting bearings (27) located at the base
end of cylinders. It will not be necessary to remove
bearings unless they are found to be unfit for
further service.

BT Prime-Mover Inc.

Return

Service Manual

2001-03-15

441

F-code

Section

C-code

PS
S6.7
6650
Reach Cylinder (RTX45)
Version no

T-code

001

RTX35/RTX45

3. Inspection
WARNING Compressed air used for cleaning MUST
be reduced to less than 30 psi (206 kPa),
and then only with effective chip-guarding
and personal protective equipment.
1. Carefully clean all parts in a cleaning solution and
position them on a clean work surface.
2. Check rod assembly (17) for damage. Look for
gouges, scratches, corrosion, or evidence of
unusual wear. Minor surface damage can be
repaired by the use of fine abrasion cloth or
stoning. Be extremely careful to not remove
chrome plating. Deeper damage will require
replacement of piston rod assembly. Make sure
threads on rod are free of damage.
3. Check cylinder bore for any damage. Parts with
deep gouges or pitted surfaces will require
replacement.

442

Return

Service Manual

2001-03-15

F-code

PS
Version no

001

Section

C-code

S6.7
6650
Reach Cylinder (RTX45)
T-code

RTX35/RTX45

4. Assembly
1. Install new rod wiper (21) in bearing assembly. The
lip of the wiper must face outward.
2. Install new bearing seals (23 & 24), back-up ring
(25), and O-rings (26) on bearing assembly.
3. If necessary, replace rod assembly (17) with new.
Install rod assembly (17).
4. Apply clean hydraulic fluid to piston rod assembly.
Coat the inside of cylinder tube and bearing
assembly with clean fluid.
5. Carefully slide bearing assembly (22) onto cylinder
rod assembly (17). Be sure rod end does not cut or
nick wiper or packing upon installation.
6. Install piston and cylinder rod assembly into
cylinder tube (11 or 12). Be careful that piston
seals are not nicked or cut on the edge of cylinder
tube or when sliding them over the groove within
the tube.
7. Install bearing assembly into cylinder tube. Use
care so seals are not nicked or cut upon
installation.
8. Check installation by making sure piston rod
assembly moves smoothly within tube assembly
without binding.
9.

BT Prime-Mover Inc.

Return

Service Manual

Install retainer (13).

2001-03-15

443

F-code

Section

C-code

PS
S6.7
6650
Reach Cylinder (RTX45)
Version no

T-code

001

RTX35/RTX45

5. Installation
1. Raise reach assembly to full freelift height. Install
reach cylinder rear mounting pins (10). Secure
mounting pins in position with cotter pins (7),
washers (5 and 6) and screws (4).
2. Lower reach assembly. Install reach cylinder front
mounting pins (8). Secure mounting pins in
position with cotter pins (7), washers (5 and 6) and
screws (4).
3. Connect correct hydraulic hoses to reach cylinders.
4. Remove blocking and chains.
5. Fill hydraulic tank with new clean oil.
6. Connect battery.
7. Operate reach to remove air from hydraulic hoses.
Check operation of the whole hydraulic system.
CAUTION DO NOT use your hands to check for
hydraulic leakage. Use a piece of
cardboard or paper to search for leaks.
Escaping fluid under pressure can
penetrate the skin causing serious injury.
Relieve pressure before disconnecting
hydraulic or other lines. Tighten all
connections before applying pressure.
Keep hands and body away from pinholes
and nozzles which eject fluids under high
pressure.
8. After running the hydraulic system, check and fill
hydraulic tank with new clean oil.

444

Return

Service Manual

2001-03-15

F-code

Section

PS

C-code

S6.8
6660
Tilt Cylinder (RTX35)

Version no

T-code

001

RTX35/RTX45

Tilt Cylinder (RTX35)


13
14
11

7
5

12

10

1
2
3
4

BT Prime-Mover, Inc.

Return

Item
No.

Description

Item
No.

Tilt cylinder assembly

Seal

11

O-ring

Bushing

Bearing, cylinder

12

Ring, back-up

Retainer, cylinder

Ring, back-up

13

Retainer

Screw, cap

O-ring

14

Tube, cylinder

Wiper

10

Rod, cylinder

Service Manual

Description

2001-03-15

Item
No.

Description

445

F-code

Section

PS
S6.8
Tilt Cylinder (RTX35)
Version no

T-code

001

RTX35/RTX45

C-code

6660

1. Removal
1. Park truck on a level surface and apply the brake.
2. Raise reach approximately 12 inches (305 mm)
and block so reach will not lower.
3. Relieve pressure on tilt cylinder (1).
4. Pivot carriage/reach upward and block to prevent
the fork frame from lowering.
5. Remove strap (3) and cap screws (4) that secure
the cylinder to the fork frame.
6. Remove hydraulic hoses from tilt cylinder (1).
7. Remove tilt cylinder (1) from truck.

446

Return

Service Manual

2001-03-15

F-code

PS
Version no

001

Section

C-code

S6.8
6660
Tilt Cylinder (RTX35)
T-code

RTX35/RTX45

2. Disassembly
WARNING Compressed air used for cleaning MUST
be reduced to less than 30 psi (206 kPa),
and then only with effective chip-guarding
and personal protective equipment.
NOTE! Perform procedures in a clean environment.
Make sure all parts are cleaned before
disassembly and kept clean during assembly.
1. Before disassembly, clean the exterior of tilt
cylinder (1) in a cleaning solution to remove all
contamination.
2. Be sure all hydraulic fluid has been removed from
the cylinder. Stroking the piston rod will help force
the fluid out.
3. Put the base end of the cylinder in a vise equipped
with soft jaws.
4. Remove bearing retainer (13) and cylinder bearing
(7) from the cylinder tube.
5. Remove bearing assembly, seals, rings, rod (10),
and piston seals.
6. Remove and discard all seals and rod wiper (5, 6,
8, 9, 11, and 12).
7. Inspect mounting bushings (2) located at both ends
of the cylinder. It will not be necessary to remove
bushings unless they are found to be unfit for
further service.

BT Prime-Mover, Inc.

Return

Service Manual

2001-03-15

447

F-code

Section

PS
S6.8
Tilt Cylinder (RTX35)
Version no

T-code

001

RTX35/RTX45

C-code

6660

3. Inspection
WARNING Compressed air used for cleaning MUST
be reduced to less than 30 psi (206 kPa),
and then only with effective chip-guarding
and personal protective equipment.
1. Carefully clean all parts in a cleaning solution and
position parts on a clean work surface.
2. Check piston rod (10) for damage. Look for
gouges, scratches, corrosion, or evidence of
unusual wear. Minor surface damage can be
repaired by the use of fine abrasion cloth or
stoning. Be extremely careful not to remove the
chrome plating. Deeper damage will require
replacement of the piston rod assembly.
3. Check cylinder bore for any damage. Parts with
deep gouges or pitted surfaces will require
replacement.
4. Check threaded section of the cylinder tube to be
sure the threads have not been damaged.

448

Return

Service Manual

2001-03-15

F-code

PS
Version no

001

Section

C-code

S6.8
6660
Tilt Cylinder (RTX35)
T-code

RTX35/RTX45

4. Assembly
1. Install new packing and rod wipers in the bearing
assembly. The lip of the wiper must face outward.
2. Install new bearing seals, back-up ring, and
retainer (13) on the bearing assembly.
3. Install new piston seals on the piston.
4. Install piston on the rod.
5. Apply clean hydraulic fluid to piston rod assembly.
Coat the inside of cylinder barrel and bearing
assembly with clean fluid.
6. Carefully slide bearing assembly on piston rod. Be
sure rod end does not cut or nick wiper or packing
upon installation.
7. Install piston and rod into cylinder barrel. Be careful
that piston seals are not nicked or cut on the edge
of the cylinder barrel or when sliding them over the
groove within the barrel.
8. Install bearing assembly into cylinder barrel. Use
care so seals are not nicked or cut upon
installation.
9. Check installation by making sure piston rod
assembly moves fairly easy within barrel assembly
without binding.
10. Install cylinder bearing (7) and bearing retainer
(13).

BT Prime-Mover, Inc.

Return

Service Manual

2001-03-15

449

F-code

Section

PS
S6.8
Tilt Cylinder (RTX35)
Version no

T-code

001

RTX35/RTX45

C-code

6660

5. Installation
1. Install cylinder on reach front frame.
2. Install mounting straps (3). Secure with four cap
screws (4).
3. Properly connect correct hydraulic hoses to the
front and rear of tilt cylinder.
4. Remove blocking and chains.
5. Fill hydraulic tank with new clean oil.
6. Connect battery.
WARNING DO NOT use your hands to check for
hydraulic leakage. Use a piece of
cardboard or paper to search for leaks.
Escaping fluid under pressure can
penetrate the skin causing serious injury.
Relieve pressure before disconnecting
hydraulic or other lines. Tighten all
connections before applying pressure.
Keep hands and body away from pinholes
and nozzles which eject fluids under high
pressure.
7. Operate tilt to remove air from hydraulic hoses and
check operation of the whole hydraulic system.
8. After running the hydraulic system, check and fill
the hydraulic tank with new clean oil.

450

Return

Service Manual

2001-03-15

F-code

Section

PS

C-code

S6.8
6660
Tilt Cylinder (RTX45)

Version no

T-code

001

RTX35/RTX45

Tilt Cylinder (RTX45)


14

15

13
12
9

8
6

11

10

5
4

2
3

BT Prime-Mover, Inc.

Return

Item
No.

Description

Item
No.

Tilt cylinder assembly

Wiper

11

Rod, cylinder

Bushing

Seal

12

O-ring

Retainer, cylinder

Bearing, cylinder

13

Ring, back-up

Lockwasher

Ring, back-up

14

Retainer

Screw, cap

10

O-ring

15

Tube, cylinder

Service Manual

Description

2001-03-15

Item
No.

Description

451

F-code

Section

PS
S6.8
Tilt Cylinder (RTX45)
Version no

T-code

001

RTX35/RTX45

C-code

6660

1. Removal
1. Park truck on a level surface and apply brake.
2. Raise reach approximately 12 inches (305 mm)
and block so reach will not lower.
3. Relieve pressure on tilt cylinder (1).
4. Pivot carriage/reach upward and block to prevent
carriage/reach from lowering.
5. Remove cylinder retainers (3), lockwashers (4),
and cap screws (5) that secure cylinder to carriage/
reach.
6. Remove hydraulic hoses from tilt cylinder (1).
7. Remove tilt cylinder (1) from truck.

452

Return

Service Manual

2001-03-15

F-code

PS
Version no

001

Section

C-code

S6.8
6660
Tilt Cylinder (RTX45)
T-code

RTX35/RTX45

2. Disassembly
WARNING Compressed air used for cleaning MUST
be reduced to less than 30 psi (206 kPa),
and then only with effective chip-guarding
and personal protective equipment.
NOTE! Perform procedures in a clean environment.
Make sure all parts are cleaned before
disassembly and kept clean during assembly.
1. Before disassembly, clean the exterior of tilt
cylinder (1) in a cleaning solution to remove all
contamination.
2. Be sure all hydraulic fluid has been removed from
cylinder. Stroking piston rod will help force fluid out.
3. Put base end of cylinder in a vise equipped with
soft jaws.
4. Remove bearing retainer (14) and cylinder bearing
(8) from cylinder tube.
5. Remove bearing assembly, seals, rings, rod (11),
and piston seals.
6. Remove and discard all seals and rod wiper (6, 7,
9, 10, 12, and 13).
7. Inspect mounting bushings (2) located at both ends
of cylinder. It will not be necessary to remove them
unless they are found to be unfit for further service.

BT Prime-Mover, Inc.

Return

Service Manual

2001-03-15

453

F-code

Section

PS
S6.8
Tilt Cylinder (RTX45)
Version no

T-code

001

RTX35/RTX45

C-code

6660

3. Inspection
WARNING Compressed air used for cleaning MUST
be reduced to less than 30 psi (206 kPa),
and then only with effective chip-guarding
and personal protective equipment.
1. Carefully clean all parts in a cleaning solution and
position them on a clean work surface.
2. Check piston rod (11) for damage. Look for
gouges, scratches, corrosion, or evidence of
unusual wear. Minor surface damage can be
repaired by the use of fine abrasion cloth or
stoning. Be extremely careful to not remove the
chrome plating. Deeper damage will require
replacement of piston rod assembly.
3. Check cylinder bore for any damage. Parts with
deep gouges or pitted surfaces will require
replacement.
4. Check threaded section of cylinder tube to be sure
threads have not been damaged.

454

Return

Service Manual

2001-03-15

F-code

PS
Version no

001

Section

C-code

S6.8
6660
Tilt Cylinder (RTX45)
T-code

RTX35/RTX45

4. Assembly
1. Install new packing and rod wipers in bearing
assembly. The lip of the wiper must face outward.
2. Install new bearing seals and back-up ring on
bearing assembly.
3. Install new piston seals on piston.
4. Install piston on rod.
5. Apply clean hydraulic fluid to piston rod assembly.
Coat the inside of cylinder barrel and bearing
assembly with clean fluid.
6. Carefully slide bearing assembly on piston rod. Be
sure rod end does not cut or nick wiper or packing
upon installation.
7. Install piston and rod into cylinder barrel. Be careful
that piston seals are not nicked or cut on the edge
of cylinder barrel or when sliding them over the
groove within the barrel.
8. Install bearing assembly into cylinder barrel. Use
care so seals are not nicked or cut upon
installation.
9. Check installation by making sure piston rod
assembly moves fairly easy within the barrel
assembly without binding.
10. Install cylinder bearing (8) and bearing retainer
(14).

BT Prime-Mover, Inc.

Return

Service Manual

2001-03-15

455

F-code

Section

PS
S6.8
Tilt Cylinder (RTX45)
Version no

T-code

001

RTX35/RTX45

C-code

6660

5. Installation
1. Install cylinder on reach front frame.
2. Install cylinder retainers (3). Secure with four
lockwashers (4) and cap screws (5).
3. Properly connect correct hydraulic hoses to the
front and rear of tilt cylinder.
4. Remove blocking and chains.
5. Fill hydraulic tank with new clean oil.
6. Connect battery.
WARNING DO NOT use your hands to check for
hydraulic leakage. Use a piece of
cardboard or paper to search for leaks.
Escaping fluid under pressure can
penetrate the skin causing serious injury.
Relieve pressure before disconnecting
hydraulic or other lines. Tighten all
connections before applying pressure.
Keep hands and body away from pinholes
and nozzles which eject fluids under high
pressure.
7. Operate tilt to remove air from hydraulic hoses and
check operation of the whole hydraulic system.
8. After running the hydraulic system, check and fill
hydraulic tank with new clean oil.

456

Return

Service Manual

2001-03-15

F-code

PS

Section

C-code

S7.0
7110
Mast, 3 Stage (RTX35)

Version no

T-code

000

RTX35/RTX45

Mast, 3 Stage (RTX35)


33
27

32
34
5

34
35

28

29
30
31

28

3
4

10

3
1
7
4
11

22
14

12
13

15
3
26

14
21

20

15

23

18
5

38

36

16

37 36

17
40

25

24
BT Prime-Mover Inc.

Return

17 19

Service Manual

2001-03-15

39
457

F-code

Section

PS
S7.0
Mast, 3 Stage (RTX35)
Version no

T-code

000

RTX35/RTX45

Item
No.

458

C-code

7110

Description

Item
No.

Description

Item
No.

Description

Anchor, chain

15

Nut, jam

29

Sheave, chain

Chain, Staging lift

16

Line, hydraulic

30

Bearing, roller

Pin, cotter

17

Screw, cap

31

Race, inner

Pin, chain

18

Column, Intermediate

32

Lockwasher

Shim

19

Bracket

33

Screw, cap

Bearing

20

Screw, cap

34

Fitting, grease

Staging cylinder
assembly

21

Lockwasher

35

Shaft

Screw, button head

22

Sheave

36

Spacer

Column, inner

23

Screw, cap

37

Sheave, hose

10

Chain, Free lift

24

Washer, flat

38

Screw, cap

11

Freelift cylinder
assembly

25

Screw, cap

39

Shaft, sheave

12

Pin, anchor

26

Column, outer

40

Sheave, hydraulic,
and electrical

13

Pin, cotter

27

Shaft

14

Nut

28

Washer, shim

Return

Service Manual

2001-03-15

F-code

PS
Version no

000

Section

C-code

S7.0
7110
Mast, 3 Stage (RTX35)
T-code

RTX35/RTX45

1. Shimming Carriage with Mast on


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

Return

Service Manual

2001-03-15

459

F-code

Section

PS
S7.0
Mast, 3 Stage (RTX35)
Version no

T-code

000

RTX35/RTX45

C-code

7110

carriage in the fully lowered position. Pry the


carriage to one side and check with a 0.030 inch
(0.76 mm) shim. Maximum clearance must not
exceed 0.030 inch (0.76 mm). Check for excessive
bearing clearance with the carriage in fully raised
position. Pry carriage to one side and check with a
0.030 inch (0.76 mm) shim. Maximum clearance
must not exceed 0.030 inch (0.76 mm).
9. Lower carriage to install hydraulic hoses, lift chain
anchor pins, and electrical cable. When installing
lift chains, chains are to be free of twists and
adjusted for equal tension with adjusting nuts
(wheel nuts) and locknuts (jam nuts) torqued to
200 ft-lb (271 Nm). Chains are to be centered on
the sheave within 0.03125 inch (0.8 mm)
10. Remove hoist from carriage and test operation of
unit. Check operation first with no load, then with a
capacity rated load.

460

Return

Service Manual

2001-03-15

F-code

PS
Version no

000

Section

C-code

S7.0
7110
Mast, 3 Stage (RTX35)
T-code

RTX35/RTX45

2. Three Stage Mast


2.1. Removal
WARNING Block all wheels to prevent truck from
rolling. Park the truck on a level surface and
make sure all wheels are blocked to prevent
accidental movement.
1. Turn key switch OFF and disconnect battery
connector. Remove battery from truck.
Bolts

WARNING When blocking the mast columns to


prevent lowering, always block both sides
of the column. If the truck is not blocked, it
could tip on its side.
2. Attach a hoist to the top of carriage assembly.
Hoist to loosen lift chains. Jack truck up (see Safe
Jacking Procedure on page 64). This will allow
removal of lift chain anchor pins, electrical cable,
and hydraulic hoses.
3. Hydraulically lift up inner column enough to remove
reach carriage assembly.
4. Disconnect hydraulic supply line which is located in
the lower left corner of the battery box and cap.

1+ 01/2

5. Disconnect two hydraulic supply lines located by


the emergency disconnect and cap.
6. Disconnect electric wiring harness located by the
emergency disconnect.

Plate

7. If truck is equipped with a light and/or fan package,


disconnect harness located at the base of
overhead guard post.
8. Connect a hoist to the top tie bars of mast. Tighten
enough to remove all slack in chains.
9. Remove two mast bolts located in the middle of the
battery box.
10. Remove two side mounting plates at the pivot
points on mast.

BT Prime-Mover Inc.

Return

Service Manual

2001-03-15

461

F-code

Section

PS
S7.0
Mast, 3 Stage (RTX35)
Version no

T-code

000

RTX35/RTX45

C-code

7110

11. Remove two bolts at the base of overhead guard


post.
12. Lift mast enough to clear chassis and lay mast on
the floor.

2.2. Disassembly
1. Lower mast assembly to a horizontal position
before work can begin.
2. Remove lift chain anchors, lift chain, attachment
hydraulic hoses, and electrical cable from the
mast.
3. Remove freelift chain anchor, two cotter pins, and
two cylinder anchor pins from inner column. Pull
straight up to remove freelift cylinder assembly.
NOTE! Lift cylinder can be repaired at this time, if
needed.
4. Remove chain sheaves and cable sheaves from all
columns.
5. Pull inner column straight forward until it stops (hits
bearings) and then 90 degrees straight up from
intermediate column.
6. Remove cap screws from the top of intermediate
column. Remove staging cylinder assemblies by
pushing intermediate column forward.
NOTE! Lift cylinder can be repaired at this time, if
needed.
7. Pull intermediate column straight forward until it
stops (hits bearings) and then pull 90 degrees
straight up from the outer column.
8. Remove mast bearings and shim washers from all
columns.
9. Thoroughly clean all parts.

462

Return

Service Manual

2001-03-15

F-code

PS
Version no

000

Section

C-code

S7.0
7110
Mast, 3 Stage (RTX35)
T-code

RTX35/RTX45

2.3. Assembly
WARNING Compressed air used for cleaning MUST
be reduced to less than 30 psi (206 kPa),
and then only with effective chip-guarding
and personal protective equipment.
1. Thoroughly clean all parts and air dry.
2. Install mast roller bearing on both intermediate and
outer columns.
3. Assemble intermediate column in outer column.
Slide columns together.
4. Determine amount of shims required. Pry inner
column to one side and slip shims between bearing
and web on mast. Add shims by hand until no more
can be added.
5. Divide shims as equally as possible between the
two bearings. Install shims under the bearings.
6. Extend intermediate column through the outer
column as far as it will go under normal operation.
Check bearing shimming as column is extended.
Remove shims as required if tight spots are
encountered where an assembler cannot roll the
mast by hand.
Check for excessive clearance with columns in
fully closed position. Pry column to one side and
check with a 0.030 inch (0.76 mm) shim. Maximum
clearance must not exceed 0.030 inch (0.76 mm).
Check for excessive bearing clearance with
columns in the fully extended position. Pry column
to one side and check with a 0.030 inch (0.76 mm)
shim. Maximum clearance must not exceed 0.030
inch (0.76 mm).
7. Assemble inner column in intermediate column.
Slide columns together.
8. Determine amount of shims required. Pry inner
column to one side and slip shims between bearing
and web on the mast. Add shims by hand until no
more can be added.
BT Prime-Mover Inc.

Return

Service Manual

2001-03-15

463

F-code

Section

PS
S7.0
Mast, 3 Stage (RTX35)
Version no

T-code

000

RTX35/RTX45

C-code

7110

9. Divide shims as equally as possible between the


two bearings. Install shims under bearings.
10. Extend inner column through the intermediate
column as far as it will go under normal operation.
Check bearing shimming as the column is
extended. Remove shims as required if tight spots
are encountered where an assembler cannot roll
the mast by hand.
Check for excessive clearance with columns in the
fully closed position. Pry column to one side and
check with a 0.060 inch (1.5 mm) shim. Maximum
clearance must not exceed 0.060 inch (1.5 mm).
Check for excessive bearing clearance with
columns in the fully extended position. Pry column
to one side and check with a 0.030 inch (0.76 mm)
shim. Maximum clearance must not exceed 0.030
inch (0.76 mm).
11. Install staging lift cylinder assembly in outer
column lower end.
12. Press roller bearings in lift chain sheaves. Grease
roller bearings, then slide inner races in roller
bearings.
13. Install shim washers on either side of lift chain
sheaves and install in intermediate column. Slide
pins through sheaves and secure pins with two (2)
cap screws and lockwashers. Complete this for
both chain sheave pins.
14. Install a bearing in the electrical sheave. Grease
bearing and install spacers on either side of
bearing.
15. Install electrical sheave in the proper location on
intermediate column. Secure sheave with one cap
screw and lockwasher.
16. Push intermediate and outer columns together.
Install a cap screw in intermediate column to
secure staging lift cylinder.
17. Install lift chain anchors through outer column.
Thread a wheel nut on each anchor and secure
with a jam nut.
464

Return

Service Manual

2001-03-15

F-code

PS

Section

C-code

S7.0
7110
Mast, 3 Stage (RTX35)

Version no

000

T-code

RTX35/RTX45

18. Install lift chain on chain anchors and secure with


chain pins. After chain pins have been installed,
run lift chain over chain sheaves. Make sure chain
and sheaves are properly aligned.
19. Install freelift cylinder assembly on inner column.
Secure with four cap screws and nuts.
20. Connect hydraulic lines to lift cylinder.
21. Lubricate grease fittings using a standard lube gun
(see Oil and Grease Specifications on page 81).

2.4. Installation
1. Install mast using a hoist.
2. Install side mounting plates. Torque mounting plate
bolts to 85 ft-lb (115 Nm).
3. Install two bolts in middle of the battery box.
Torque to 400 ft-lb (543 Nm).
4. Install two bolts at the base of overhead guard
post. Torque to 25 ft-lb (34 Nm).
5. Connect hydraulic hoses to lift cylinders.
6. Hydraulically lift up inner column enough to install
reach carriage assembly.
7. Connect all electrical connectors.
8. Adjust lift chains.
Loosen jam nut and tighten staging chains equally
until the top of the rails are level in the fully lowered
position. Retighten jam nut and torque.
Freelift chains should be adjusted in the fully
lowered position. Adjust chains until the top of forks
are 2.0 inches (50 mm) off the floor.
9. Grease all chain sheaves.
10. Bleed any air from cylinders.
11. Install and connect battery. Test operations of mast
and unit.

BT Prime-Mover Inc.

Return

Service Manual

2001-03-15

465

F-code

Section

C-code

PS
S7.0
Mast, 3 Stage (RTX45)

7110

Version no

T-code

000

RTX35/RTX45

Mast, 3 Stage (RTX45)


28

29

24
25

30
8

26
27

31

24

9
4

10
6

3
1

4
11
18
12
13

14

37

15

19

14
15

22

38
17

4
16

23

5
6

6
20

32

33

32

21
35

34

466

Return

36

Service Manual

2001-03-15

F-code

PS
Version no

000

Item
No.

Description

Item
No.

Description

Item
No.

Section

T-code

RTX35/RTX45

Description

Anchor, chain

14

Nut

27

Race, inner

Chain, Staging lift

15

Nut, jam

28

Lockwasher

Pin, cotter

16

Line, hydraulic

29

Screw, cap

Pin, chain

17

Screw, cap

30

Fitting, grease

Shim

18

Column, Intermediate

31

Shaft

Bearing

19

Bracket

32

Spacer

Staging cylinder
assembly

20

Screw, cap

33

Sheave, hose

Screw, button head

21

Shaft, sheave

34

Screw, cap

Column, inner

22

Column, outer

35

Washer, shim

10

Chain, Free lift

23

Screw, cap

36

Sheave, hydraulic,
and electrical

11

Freelift cylinder
assembly

24

Washer, shim

37

Manifold

12

Pin, anchor

25

Sheave, chain

38

Screw

13

Pin, cotter

26

Bearing, roller

BT Prime-Mover Inc.

Return

Service Manual

2001-03-15

C-code

S7.0
7110
Mast, 3 Stage (RTX45)

467

F-code

Section

PS
S7.0
Mast, 3 Stage (RTX45)
Version no

T-code

000

RTX35/RTX45

C-code

7110

1. Shimming Carriage with Mast on


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

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PS
Version no

000

Section

C-code

S7.0
7110
Mast, 3 Stage (RTX45)
T-code

RTX35/RTX45

carriage in the fully lowered position. Pry carriage


to one side and check with a 0.030 inch (0.76 mm)
shim. Maximum clearance must not exceed 0.030
inch (0.76 mm). Check for excessive bearing
clearance with carriage in the fully raised position.
Pry carriage to one side and check with a 0.030
inch (0.76 mm) shim. Maximum clearance must not
exceed 0.030 inch (0.76 mm).
9. Lower carriage to install hydraulic hoses, lift chain
anchor pins, and electrical cable. When installing
lift chains, chains are to be free of twists and
adjusted for equal tension. Adjusting nuts (wheel
nuts) and locknuts (jam nuts) should be torqued to
200 ft-lb (271 Nm). Chains are to be centered on
the sheave within 0.03125 inch (0.8 mm).
10. Remove hoist from the carriage. Test operation of
unit. Check operation first with no load, then with a
capacity rated load.

BT Prime-Mover Inc.

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Service Manual

2001-03-15

469

F-code

Section

C-code

PS
S7.0
Mast, 3 Stage (RTX45)
Version no

T-code

000

RTX35/RTX45

7110

2. Three Stage Mast


2.1. Removal
WARNING Block all wheels to prevent truck from
rolling. Park the truck on a level surface and
make sure all wheels are blocked to prevent
accidental movement.
1. Turn key switch OFF and disconnect battery
connector. Remove battery from truck.
Bolts

WARNING When blocking the mast columns to


prevent lowering, always block both sides
of the column. If the truck is not blocked, it
could tip on its side.
2. Attach a hoist to the top of carriage assembly.
Hoist to loosen lift chains. Read and follow correct
operating procedures for your jack or hoist. This
will allow removal of lift chain anchor pins,
electrical cable, and hydraulic hoses.
3. Hydraulically lift up inner column enough to remove
reach carriage assembly.
4. Disconnect hydraulic supply line located in lower
left corner of battery box and cap.
5. Disconnect two hydraulic supply lines located near
the emergency disconnect switch and cap.

+
01/21 -

6. Disconnect electric wiring harness located near the


emergency disconnect switch.

Plate

7. If truck is equipped with a light and/or fan package,


disconnect harness located at the base of
overhead guard post.
8. Connect a hoist to the top tie bars of mast and
tighten enough to remove all slack in the chains.
9. Remove two mast bolts located in the middle of the
battery box.

Bolts
470

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10. Remove two side mounting plates at the pivot


points on mast.
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PS
Version no

000

Section

C-code

S7.0
7110
Mast, 3 Stage (RTX45)
T-code

RTX35/RTX45

11. Remove two bolts at base of overhead guard post.


12. Lift mast enough to clear chassis. Lay mast flat on
floor.

2.2. Disassembly
1. Lower mast assembly to a horizontal position
before work can begin.
2. Remove lift chain anchors, lift chain, attachment
hydraulic hoses, and electrical cable from mast.
3. Remove freelift chain anchor, two cotter pins, and
two cylinder anchor pins from inner column.
Remove freelift cylinder assembly by pulling
straight up.
NOTE! Lift cylinder can be repaired at this time, if
needed.
4. Remove chain sheaves and cable sheaves from all
columns.
5. Pull inner column straight forward until it stops (hits
bearings) and then 90 degrees straight up from
intermediate column.
6. Remove cap screws from the top of intermediate
column. Remove staging cylinder assemblies by
pushing the intermediate column forward.
NOTE! Lift cylinder can be repaired at this time, if
needed.
7. Pull intermediate column straight forward until it
stops (hits bearings) and then pull 90 degrees
straight up from the outer column.
8. Remove mast bearings and shim washers from all
columns.
9.

BT Prime-Mover Inc.

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Service Manual

Thoroughly clean all parts.

2001-03-15

471

F-code

Section

PS
S7.0
Mast, 3 Stage (RTX45)
Version no

T-code

000

RTX35/RTX45

C-code

7110

2.3. Assembly
WARNING Compressed air used for cleaning MUST
be reduced to less than 30 psi (206 kPa),
and then only with effective chip-guarding
and personal protective equipment.
1. Thoroughly clean all parts and air dry.
2. Install mast roller bearing on both the intermediate
and outer columns.
3. Assemble intermediate column
column. Slide columns together.

in the outer

4. Determine the amount of shims required. Pry the


inner column to one side and slip shims between
the bearing and web on the mast. Add shims by
hand until no more can be added.
5. Divide shims as equally as possible between two
bearings. Install shims under bearings.
6. Extend intermediate column through the outer
column as far as it will go under normal operation.
Check bearing shimming as column is extended.
Remove shims as required if tight spots are
encountered where an assembler cannot roll the
mast by hand.
Check for excessive clearance with the columns in
the fully closed position. Pry column to one side
and check with a 0.030 inch (0.76 mm) shim.
Maximum clearance must not exceed 0.030 inch
(0.76 mm).
Check for excessive bearing clearance with the
columns in the fully extended position. Pry column
to one side and check with a 0.030 inch (0.76 mm)
shim. Maximum clearance must not exceed 0.030
inch (0.76 mm).
7. Assemble inner column in the intermediate column.
Slide columns together.
8. Determine the amount of shims required. Pry inner
column to one side and slip shims between bearing

472

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F-code

PS
Version no

000

Section

C-code

S7.0
7110
Mast, 3 Stage (RTX45)
T-code

RTX35/RTX45

and web on the mast. Add shims by hand until no


more can be added.
9. Divide shims as equally as possible between two
bearings. Install shims under the bearings.
10. Extend inner column through the intermediate
column as far as it will go under normal operation.
Check bearing shimming as the column is
extended. Remove shims as required if tight spots
are encountered where an assembler cannot roll
the mast by hand.
Check for excessive clearance with the columns in
the fully closed position. Pry the column to one side
and check with a 0.060 inch (1.5 mm) shim.
Maximum clearance must not exceed 0.060 inch
(1.5 mm).
Check for excessive bearing clearance with the
columns in the fully extended position. Pry column
to one side and check with a 0.030 inch (0.76 mm)
shim. Maximum clearance must not exceed 0.030
inch (0.76 mm).
11. Install staging lift cylinder assembly in the
intermediate column lower end.
12. Press roller bearings in the lift chain sheaves.
Grease roller bearings, then slide the inner races
into the roller bearings.
13. Install shim washers on either side of the lift chain
sheaves. Install in the intermediate column. Slide
pins through the sheaves and secure pins with two
(2) cap screws and lockwashers. Complete this to
both chain sheave pins.
14. Install a bearing in the electrical sheave. Grease
bearing and install spacers on either side of
bearing.
15. Install electrical sheave in the proper location on
the intermediate column. Secure with one cap
screw and lockwasher.
16. Push intermediate and outer columns together.
Install a cap screw in the intermediate column to
secure the staging lift cylinder.
BT Prime-Mover Inc.

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Service Manual

2001-03-15

473

F-code

Section

PS
S7.0
Mast, 3 Stage (RTX45)
Version no

T-code

000

RTX35/RTX45

C-code

7110

17. Install lift chain anchors through the outer column.


Thread a wheel nut on each anchor and secure
with a jam nut.
18. Install lift chain on the chain anchors. Secure with
chain pins. After chain pins have been installed,
run the lift chain over the chain sheaves. Make
sure chain and sheaves are properly aligned.
19. Install freelift cylinder assembly on the inner
column. Secure with four cap screws and nuts.
20. Connect hydraulic lines to the lift cylinder.
21. Lubricate grease fittings using a standard lube gun
(see Oil and Grease Specifications on page 81).

2.4. Installation
1. Install mast using a hoist.
2. Install side mounting plates. Torque mounting plate
bolts to 85 ft-lb (115 Nm).
3. Install two bolts in the middle of the battery box.
Torque to 400 ft-lb (543 Nm).
4. Install two bolts at base of overhead guard post.
Torque to 25 ft-lb (34 Nm).
5. Connect hydraulic hoses to lift cylinders.
6. Hydraulically lift up inner column enough to install
reach carriage assembly.
7. Connect all electrical connectors.
8. Adjust lift chains.
Loosen jam nut and tighten chains equally until top
of rails are level in the fully lowered position.
Retighten jam nut and torque.
Carriage chains should be adjusted in the fully
lowered position. Adjust chains until the top of forks
are 2.0 inch (50 mm) off the floor.
9. Grease all chain sheaves.
10. Bleed any air from the cylinders.

474

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2001-03-15

F-code

PS
Version no

000

Section

C-code

S7.0
7110
Mast, 3 Stage (RTX45)
T-code

RTX35/RTX45

11. Install and connect battery. Test operations of mast


and truck.

BT Prime-Mover Inc.

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Service Manual

2001-03-15

475

F-code

Section

C-code

PS
Lift Chain

S7.0

7110

Version no

T-code

000

RTX35/RTX45

Lift Chain
Lift chains are very important components of the truck. The
chain system on the mast was designed for efficient, reliable
transmission of lifting force from the hydraulic cylinder to the
forks. Safe, uninterrupted use of the truck depends on proper
care and maintenance of lift chains.
After 100 hours of truck operation, lift chains should be
inspected and lubricated. When operating in unfamiliar
corrosive environment, inspect chains every 50 hours.

1. Lift Chain Adjustment


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

2. Lift Chain Maintenance


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

3. Lift Chain Inspection


After every 100 hours of truck operation, lift chains should be
inspected and lubricated. Inspect chains every 50 hours
when operating in unfamiliar corrosive environment. When
performing inspection, observe the following chain conditions:
chain wear; rust and corrosion; cracked plates; protruding or
turned pins; and chain side wear.

476

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F-code

Section

PS

S7.0

Version no

000

C-code

7110
Lift Chain

T-code

RTX35/RTX45

3.1. Wear
As the chain flexes on and off the sheaves, the joints
gradually wear. The stretch a chain develops in service is
due to material being worn off the pin on the outside diameter
and the pitch hole inside diameter on the inside plates.

Chain
Wear
Scale

Chain wear can be measured by using a wear scale or a steel


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

New Chain

Stretched
Chain

3.2. Rust and Corrosion


Lift chains are highly stressed precision components. It is
very important that maintenance is performed throughout the
chain service life. Corrosion will cause a major reduction in
the load-carrying capacity of the lift chain or roller chain
because corrosion causes sideplate cracking. It is extremely
important to protect the lift chain from corrosion, whether in
service or in storage.
NOTE! Do not steam clean or degrease new lift
chains.
Lift chain lubricant serves both as a joint lubricant and
corrosion inhibitor. During inspection, carefully examine the
external lift chain surfaces for the presence of an oily film.
Under normal operating conditions, oil lift chains every 100
hours and more frequent under adverse conditions.

Stress-corrosion Cracking

NOTE! In all cases, the external surface of the lift


chains must be protected with a film of oil.
Outside plates are susceptible to stress-corrosion cracking. If
lift chains are heavily rusted or corroded, remove them from
the mast to thoroughly inspect for cracked plates. Replace all

BT Prime-Mover Inc.

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Service Manual

2001-03-15

477

F-code

Section

C-code

PS
Lift Chain

S7.0

7110

Version no

T-code

000

RTX35/RTX45

lift chains on the truck if the plates are cracked. Lubricate the
chains when reinstalled on the truck.

3.3. Cracked Plates


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

Ultimate Strength Failure


This type of failure is caused by overload in excess of the
truck design load.

Broken Plate Caused by Overload


All joints in roller chain or lift chain should flex freely. Tight
joints resist flexure, increase internal friction, increasing chain
tension required to lift a given load. Increased tension
accelerates wear and fatigue problems.

478

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Section

PS

S7.0

Version no

000

C-code

7110
Lift Chain

T-code

RTX35/RTX45

In roller chain, tight joints are usually caused by rust or inside


plates moving outward on bushings. Replace chains if rusty.

Tight joints prevent proper flexing of roller chain

Bent or peened plates on lift chains can


cause tight joints and prevent flexing.
Tap bushing plates inward to remedy a plate walking
problem. If plate walking persists, replace lift chain. This
type of link plate displacement is accelerated by poor
lubrication. The majority of roller chains with tight joints have
been run with little or no lube.
Tight joints in lift chains can be caused by the following:

BT Prime-Mover Inc.

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Bent pins or plates

Rusty joints

Peened plate edges

Oily rusty chains with bent or peened components

2001-03-15

479

F-code

Section

C-code

PS
Lift Chain

S7.0

7110

Version no

T-code

000

RTX35/RTX45

Peening of plates edges may be caused by worn sheaves,


unusually heavy loads or chain sliding past a guide in the
mast.

3.4. Protruding or Turned Pins


Heavily loaded chains operating with little lube cause wear
between the pin and plates (pin and bushing in roller chain).
In some extreme cases, the torque in the joint can turn pins in
the press-fit outside plate.
If the chain is allowed to operate in this condition, the pins
slowly work out of the chain, causing chain failure. Turned
pins can be quickly spotted because the flats on the V head
are no longer in line.
NOTE! Pins have turned 90o. Chains with turned or
protruding pins should be replaced. Do not
attempt to repair the chain by driving the pins
back into the chain.

480

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Section

PS

S7.0

Version no

000

C-code

7110
Lift Chain

T-code

RTX35/RTX45

Protruding Pins

MA0633.ill
MA0000.ill

Turned Pins

Out-of-line flats on V heads indicate that pins have turned in


place.

3.5. Chain Side Wear


A wear pattern on pin heads and outside plates indicates
misalignment. This condition damages chain and sheaves as
well as increasing internal wear in the chain system.

3.6. Chain Anchors and Sheaves


An inspection of the chain system includes a close look at the
chain anchors and sheaves. Check chain anchors for wear,
breakage, and misalignment. Anchors with worn or broken
fingers should be replaced. Anchors should be adjusted to
eliminate twisting or other misalignment in the chain. When
chain is misaligned, load is not spread uniformly between the
plates. Prolonged operation will result in premature failure.
BT Prime-Mover Inc.

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2001-03-15

481

F-code

Section

C-code

PS
Lift Chain

S7.0

7110

Version no

T-code

000

RTX35/RTX45

Sheaves with badly worn flanges and outside diameter


should be replaced. Heavy flange wear indicates chain
misalignment.

4. Lift Chain Lubrication


Lubrication of the lift chain in field maintenance is a very
important duty. Hard working, heavily loaded chains cannot
be expected to give satisfactory wear life without scheduled
periodic relubrication. Like all bearing surfaces, a film of oil
between mating parts is required to prevent rapid wear.
Maintaining an oil film on all chain surface will cause the
following:

Minimize joint wear (chain stretch)

Prevent corrosion

Reduce possibility of pin turning

Minimize tight joints in roller chain

Promote smooth, quiet chain action

Lower chain tension by reducing internal wear in


the chain system

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


drained from truck engines is adequate for lubricating
exposed lift chains). Brush chains with heavy motor oil (#40
weight oil) to lubricate lift chain rather than #10 weight oil or
automatic transmission fluid. Lubricate the entire length of all
strands every 100 hours (50 hours in corrosive environment).
Do not use dry film lubes on lift chain.
The oil must penetrate chain joint to prevent wear. Applying
oil to the external surface will prevent rust, but oil must flow
into the live bearing surface for maximum wear life.

482

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Section

PS

S7.0

Version no

000

C-code

7110
Lift Chain

T-code

RTX35/RTX45

Lubricate

Lubricate

Apply oil to chains with a narrow paint brush. A plastic liquid


detergent bottle makes a handy lube applicator. Flood the
chain with oil over its entire length.
The best estimate of lube period is 100 hours (or 4 weeks)
actual truck operating time. Trucks in severe service (or
parked outside) may require more frequent relube to maintain
an oil film on all chain surfaces.

BT Prime-Mover Inc.

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Service Manual

2001-03-15

483

F-code

Section

C-code

PS
Lift Chain

S7.0

7110

Version no

T-code

000

RTX35/RTX45

5. Lift Chain Replacement


1. All chains should be replaced if any strand has
wear elongation of 3% or if any of the conditions
listed in Lift Chain Inspection on page 476 are
evident during inspection.
2. Replace all chains as a set.
3. Do not degrease or paint new chains.
4. Replace anchors and anchor pins when installing
new chains.

484

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2001-03-15

F-code

Section

C-code

PS
S7.1
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.

BT Prime-Mover Inc.

Return

Description

Item
No.

Description

Fitting, grease

Sheave, chain

Ring, retainer

Head, sheave

Shim

Sheave, hydraulic and electrical

Race

Shaft

Bearing, roller

10

Screw, set

Service Manual

2001-03-15

485

F-code

Section

C-code

PS
S7.1
7170
Lifting Gear (Crosshead) (RTX35)
Version no

T-code

000

RTX35/RTX45

The lifting gear is located on the top of the freelift cylinder.

1. Lifting Gear Repair


1.1. Removal
WARNING Block all wheels to prevent truck from
rolling. Park the truck on a level surface and
make sure all wheels are blocked to prevent
accidental movement.
1. Park truck on a level surface and apply brake. Turn
key switch OFF and disconnect battery connector.
Remove battery from truck.
WARNING When blocking mast columns to prevent
lowering, always block both sides of the
column. Otherwise, the truck could tip over
on its side.
2. Lift carriage/reach approximately 6 inches (152
mm). Securely block carriage/reach to prevent
lowering.
3. Lower freelift cylinder so chains, hoses, and
electric cables are loose.
4. Turn key switch OFF and disconnect battery
connector.
5. Remove chains, hoses, and electric cables from
lifting gear sheaves (6 and 8).
6. Loosen set screw (10) at the base of sheave head
(7).
7. Lift lifting gear assembly off the freelift cylinder rod.

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.
8. Clean lifting gear.

486

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F-code

Section

C-code

PS
S7.1
7170
Lifting Gear (Crosshead) (RTX35)
Version no

000

T-code

RTX35/RTX45

1.2. Disassembly
1. Remove retaining ring (2) from one end of the
lifting gear assembly.
2. Slide shim (3), bearing roller and race (5 and 4),
chain sheave (6) and the second shim (3) off the
shaft (9).
3. Repeat steps 1 and 2 for the opposite side.
4. Loosen set screw (10) in the side of the sheave
head (7).
5. Remove shaft (9) from sheave head (7) releasing
the hydraulic/electric sheave (8).

1.3. Assembly
1. Place hydraulic/electric sheave (8) into the sheave
head.
2. Lube sheave head. Insert shaft (9) into sheave
head (7), through the hydraulic/electric sheave (8).
3. Secure shaft in position with a set screw (10).
4. Install one shim (3), one chain sheave with bearing
assembly (6, 5, 4), a second shim (3), and a
retaining ring (2) on shaft (9).
5. Repeat step 4 for the opposite side.
6. Install a grease fitting (1) in each end of the shaft
(9).

BT Prime-Mover Inc.

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2001-03-15

487

F-code

Section

C-code

PS
S7.1
7170
Lifting Gear (Crosshead) (RTX35)
Version no

T-code

000

RTX35/RTX45

1.4. Installation
1. Place lifting gear assembly on top of freelift
cylinder.
2. Tighten set screw (10) in the base of sheave head
(7) to secure the lifting gear to the cylinder.
3. Grease chain sheaves. Install chains, hoses, and
electric cables.
4. Connect battery.
5. Remove blocking and test for proper operation.

488

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2001-03-15

F-code

Section

C-code

PS
S7.1
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.

BT Prime-Mover Inc.

Return

Description

Item
No.

Description

Fitting, grease

Sheave, chain

Ring, retainer

Head, sheave

Shim

Sheave, hydraulic and electrical

Race

Shaft

Bearing, roller

10

Screw, set

Service Manual

2001-03-15

489

F-code

Section

C-code

PS
S7.1
7170
Lifting Gear (Crosshead) (RTX45)
Version no

T-code

000

RTX35/RTX45

The lifting gear, is located on the top of the freelift cylinder.

1. Lifting Gear Repair


1.1. Removal
WARNING Block all wheels to prevent truck from
rolling. Park the truck on a level surface and
make sure all wheels are blocked to prevent
accidental movement.
1. Park truck on a level surface and apply brake. Turn
key switch OFF and disconnect battery connector.
Remove battery from truck.
WARNING When blocking mast columns to prevent
lowering, always block both sides of the
column. Otherwise, the truck could tip over
on its side.
2. Lift carriage/reach approximately 6 inches (152
mm). Securely block carriage/reach to prevent
lowering.
3. Lower freelift cylinder so chains, hoses, and
electric cables are loose.
4. Turn key switch OFF and disconnect battery
connector.
5. Remove chains, hoses, and electric cables from
lifting gear sheaves (6 and 8).
6. Loosen set screw (10) at the base of sheave head
(7).
7. Lift the lifting gear assembly off freelift cylinder rod.
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.
8. Clean lifting gear.

490

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2001-03-15

F-code

Section

C-code

PS
S7.1
7170
Lifting Gear (Crosshead) (RTX45)
Version no

000

T-code

RTX35/RTX45

1.2. Disassembly
1. Remove retaining ring (2) from one end of the
lifting gear assembly.
2. Slide shim (3), bearing roller and race (5 and 4),
chain sheave (6) and the second shim (3) off shaft
(9).
3. Repeat steps 1 and 2 for the opposite side.
4. Loosen set screw (10) in the side of sheave head
(7).
5. Remove shaft (9) from sheave head (7) releasing
the hydraulic/electric sheave (8).

1.3. Assembly
1. Place hydraulic/electric sheave (8) into the sheave
head.
2. Lube sheave head. Insert shaft (9) into the sheave
head (7), through the hydraulic/electric sheave (8).
3. Secure shaft in position with a set screw (10).
4. Install one shim (3), one chain sheave with bearing
assembly (6, 5, 4), a second shim (3), and a
retaining ring (2) on the shaft (9).
5. Repeat step 4 for the opposite side.
6. Install a grease fitting (1) in each end of the shaft
(9).

1.4. Installation
1. Place lifting gear assembly on the top of the freelift
cylinder.
2. Tighten set screw (10) in the base of the sheave
head (7) to secure the lifting gear to the cylinder.
3. Grease chain sheaves. Install chains, hoses, and
electric cables.

BT Prime-Mover Inc.

Return

Service Manual

2001-03-15

491

F-code

Section

C-code

PS
S7.1
7170
Lifting Gear (Crosshead) (RTX45)
Version no

T-code

000

RTX35/RTX45

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

492

Return

Service Manual

2001-03-15

F-code

Section

PS

S7.2

Version no

C-code

7211
Sideshifter

T-code

000

RTX35/RTX45

Sideshifter
1
2
25

24

21

23

22 20

19

18 17

16

26

15
14

29

3
X

7
28

10

27
13
11

12

BT Prime-Mover Inc.

Return

Service Manual

2001-03-15

493

F-code

Section

C-code

PS
S7.2
Sideshifter

7211

Version no

T-code

000

RTX35/RTX45

Item
No.

494

Return

Description

Item
No.

Description

Item
No.

Description

Screw

11

Hook, lower

21

Ring, cylinder cap

Bracket

12

Pad, lower

22

Cap, left cylinder

Support

13

Plate, lower hook

23

Seal

Pad, upper

14

Cap, right

24

Seal

Frame

15

Body, cylinder

25

Rod

Bolt, lower hook

16

Seal

26

Cylinder

Bolt, stop

17

Piston

27

Washer

Set screw, lower hook

18

O-ring

28

Screw

Washer, stop bolt

19

Ring

29

Restrictor, flow

10

Washer, lower hook

20

Bushing

Service Manual

2001-03-15

F-code

Section

PS

S7.2

Version no

000

C-code

7211
Sideshifter

T-code

RTX35/RTX45

1. Mounting Instructions
1.1. Installation
NOTE! Clean the fork carriage and inspect to be sure
it is free of damage or grooves before
installing the sideshift carriage. Apply grease
to the fork carriage frame where the lower
pads slide.
1. Remove lower pads (12) from sideshift assembly.
Grease lower pads and return to the sideshift unit.
2. Lift sideshift unit onto the trucks carriage using a
lifting device with a minimum capacity of 1000 lbs
(454 kg).
3. Make sure centering lug (X) on cylinder support (3)
fits completely in the center notch of the truck
carriage.
4. Remove cylinder retaining caps (21).
5. Loosen two lower hook securing bolts (6). Lift lower
hook (11), bringing the plastic pad (12) in contact
with the underside of the truck carriage. Torque
securing bolts (6) to 65 ft-lb (90 Nm).
6. Remove safety screw (28) located between the
lower hook mounting bolts (6).
7. Tighten set screw (8) to 21 ft-lb (30 Nm) torque.
8. Install safety screw (28) into the hole with the set
screw (8). Torque safety screw to 70 ft-lb (100
Nm).
9. Connect hydraulic fittings to the sideshift cylinder.
Tighten fittings to 56 ft-lb (80 Nm).
10. Mount forks in the notches on the upper bar of the
sideshift carriage.
11. Install fork stop bolt (7) with washer (9, 10) into the
lower bar of the sideshift carriage.

BT Prime-Mover Inc.

Return

Service Manual

2001-03-15

495

F-code

Section

C-code

PS
S7.2
Sideshifter

7211

Version no

T-code

000

RTX35/RTX45

12. Sideshift the unit several times to insure there are


no leaks. Check sideshift unit for smooth operation
with no interference.
NOTE! Following assembly, check the operation of
the sideshift unit by sideshifting first without a
load, then with a load.

2. Operation
Always operate the truck controls in a smooth manner.
Sudden movements of the sideshift at high lifts can
compromise the stability of the truck, as well as cause
damage to the overall system.

3. Maintenance
Maintenance on the sideshift unit should be performed on a
regular basis to receive the best performance from the unit.
Refer to the scheduled maintenance chart on page 67 for
service tasks and intervals.
NOTE! In a dirty environment or rough operations, it
is necessary to inspect the sideshift unit more
frequently.

496

Return

Service Manual

2001-03-15

F-code

Section

PS

S7.2

Version no

000

C-code

7211
Sideshifter

T-code

RTX35/RTX45

3.1. Carriage Removal


1. Remove fork stop bolt (7) from sideshift carriage.
2. Remove forks.
NOTE! Be sure the pressure is relieved from the
hydraulic system before detaching the hoses
from the sideshift cylinder.
3. Detach hoses from sideshift cylinder. Cap the ends
of the hoses to prevent contamination of the
hydraulic system.
4. Remove safety screws (28). Loosen lower hook
mounting bolts (6) and set screws (8) until lower
hooks (11) are completely lowered.
5. Lift sideshift unit from the trucks carriage using a
lifting device with a minimum capacity of 1000 lbs
(454 kg).

3.2. Upper Pad Replacement


Always replace all of the upper pads at the same time to
ensure even wear and proper movement. The upper pad (4)
should be replaced if the pad is worn to 0.0625 inch (1.5 mm)
or less at any point on the round surface.
1. Remove sideshift carriage from the truck. See
paragraph 3.1 above.
2. Lift the upper pads (4) from the cylinder support
bracket (3).
3. Install new pads on the cylinder support bracket.
Be sure the centering pins on each pad are seated
in the notches in the support bracket.
4. Lubricate the upper pads with grease.
5. Install sideshift carriage on the truck. See
Mounting Instructions on page 495.

BT Prime-Mover Inc.

Return

Service Manual

2001-03-15

497

F-code

Section

C-code

PS
S7.2
Sideshifter

7211

Version no

T-code

000

RTX35/RTX45

3.3. Lower Pad Replacement


Replace the lower pads (12) if the pad is worn to 0.20 inch (5
mm) or less at any point. The sideshift carriage does not need
to be removed to replace the lower pads. 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.
2. Remove forks.
NOTE! Be sure the pressure is relieved from the
hydraulic system before detaching the hoses
from the sideshift cylinder.
3. Detach hoses from sideshift cylinder. Cap the ends
of the hoses to prevent contamination of the
hydraulic system.
4. Remove safety screws (28).
5. Loosen lower hook mounting bolts (6) and set
screws (8) until lower hooks are completely
lowered.
6. Lift lower part of sideshift carriage away from fork
carriage (leave the top of the sideshift attached to
fork carriage).
7. Securely block sideshift carriage away from the
fork carriage with a 3 inch (70 mm) spacer.
8. Remove lower pads (12) using a screwdriver.
9. Lubricate lower pads with grease, then place new
pads into lower hook (11). Be sure they are seated.
10. Remove blocking spacer and lower sideshift
carriage to fork carriage.
11. Lift lower hook (11), bringing plastic pad (12) in
contact with underside of truck carriage. Torque
securing bolts (6) to 65 ft-lb (90 Nm).
12. Tighten set screw (8) to 21 ft-lb (30 Nm) torque.

498

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Service Manual

2001-03-15

F-code

Section

PS

S7.2

Version no

000

C-code

7211
Sideshifter

T-code

RTX35/RTX45

13. Install safety screw (28) into the hole with the set
screw (8). Torque safety screw to 70 ft-lb (100
Nm).
14. Connect hydraulic fittings to the sideshift cylinder.
Tighten fittings to 56 ft-lb (80 Nm).
15. Mount forks in the notches on the upper bar of
sideshift carriage.
16. Install fork stop bolt (7) with washer (9, 10) into
lower bar of the sideshift carriage.
17. Sideshift the unit several times to insure there are
no leaks. Check the sideshift unit for smooth
operation with no interference.
NOTE! Following assembly, check operation of
sideshift unit by sideshifting first without a
load, then with a load.

BT Prime-Mover Inc.

Return

Service Manual

2001-03-15

499

F-code

Section

C-code

PS
S7.2
Sideshifter

7211

Version no

T-code

000

RTX35/RTX45

3.4. Cylinder
1. Remove sideshift carriage from
Carriage Removal on page 497.

truck.

See

2. Remove cylinder from cylinder support. Loosen


locking screws (1). Remove brackets (2). Lift
cylinder assembly (26) from the support.
3. Secure body of the cylinder in a vice equipped with
soft jaws. The bracket slots should be facing
upwards.
NOTE! When replacing the seals, follow the correct
mounting sequence.
4. Use a wrench to turn the cap (22) until the ring (21)
comes out. Turn the ring, slowly removing the cap.
Check that the seal passes through the recess
(press the seals through the recess with a
screwdriver).
5. Reassemble cylinder.
NOTE! If the cylinder rod (25) becomes scored, a
minimal amount of scoring may be removed
by polishing with a fine emery cloth. Deep
scoring requires that the cylinder (26) be
replaced.
6. Secure cylinder in cylinder support (3) using
brackets (2) and screws (1).
7. Install sideshift carriage on truck. See Mounting
Instructions on page 495.

500

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Service Manual

2001-03-15

F-code

Section

PS

S7.2

Version no

000

C-code

7211
Sideshifter

T-code

RTX35/RTX45

4. Troubleshooting
Below are three symptoms and the corrective actions to be
taken for each.

4.1. No Sideshifting
1. Check that input pressure is not greater than 3200
psi (22060 kPa). Average working pressure should
be 1000 psi (6894 kPa). Recommended oil flow is
2 gallons per minute (7.5 liters per minute) and
should be a minimum of 1 gallon per minute (4
liters per minute).
2. Check carriage frame for damage.
3. Check relationship of lower hook (11) to truck
carriage.
4. Check for leaks in the hydraulic circuit or cylinder.

4.2. Very Slow Sideshifting


1. Check that input pressure is not greater than 3200
psi (22060 kPa). Average working pressure should
be 1000 psi (6894 kPa). Recommended oil flow is
2 gallons per minute (7.5 liters per minute) and
should be a minimum of 1 gallon per minute (4
liters per minute).
2. Check carriage frame for damage.
3. Check that lower hook pads (12) are not too tight
against truck fork carriage.
4. Check hydraulic lines and cylinder for leaks.
5. Remove flow restrictor (29). If necessary, enlarge
the hole in flow restrictor disk.
6. Check oil level in hydraulic tank.
7. Check upper and lower pads (4, 12) for wear.
Replace as necessary.

BT Prime-Mover Inc.

Return

Service Manual

2001-03-15

501

F-code

Section

C-code

PS
S7.2
Sideshifter

7211

Version no

T-code

000

RTX35/RTX45

4.3. Irregular Sideshifting


1. Check hydraulic system to be sure there is no air.
Bleed hydraulic system if necessary.
2. Check upper and lower pads (4, 12) for wear.
Replace as necessary.

502

Return

Service Manual

2001-03-15

F-code

Section

PS

C-code

S7.3
7241
Reach, Single (RTX35)

Version no

T-code

001

RTX35/RTX45

Reach, Single (RTX35)


1. Maintenance
The only maintenance required on the reach mechanism is
the normal Planned Maintenance per the schedule (see
page 67).

19

18

20
7
6
5
8

12
7
10

13

14 15
21

22
16
11

9
45 46

3
2
43 1

24
44

42

48

47

23

7
6

26
36
40

38

25
34

36

23

35

41

39

17

33
27

35

28
29

32

37

31

32

30

BT Prime-Mover Inc.

Return

Service Manual

2001-03-15

503

F-code

Section

C-code

PS
S7.3
7241
Reach, Single (RTX35)
Version no

T-code

001

RTX35/RTX45

Item
No.

504

Description

Item
No.

Description

Item
No.

Description

Screw, cap

17

Frame, forward

33

Bushing

Pin

18

Pin, roll

34

Screw, socket head

Frame, rear

19

Pin

35

Bumper

Screw, flat head

20

Bushing

36

Shim

Arm, left

21

Bar, fork

37

Shim

Bushing

22

Screw, cap

38

Screw, cap

Fitting, grease

23

Washer

39

Manifold

Bushing

24

Washer

40

Screw

Arm, inner

25

Pin

41

Clamp

10

Control valve

26

Arm, right

42

Washer, flat

11

Screw, lock

27

Washer, flat

43

Bracket

12

Cover, valve

28

Nut, jam

44

Nut

13

Clamp, poly

29

Set, bearing

45

Cap, bearing

14

Cover

30

Screw, 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

F-code

PS
Version no

001

Section

C-code

S7.3
7241
Reach, Single (RTX35)
T-code

RTX35/RTX45

2. Reach Repair
2.1. Removal
NOTE! The reach can be repaired without removal
from the mast.
1. Remove forks.
2. Remove load
page 532.

backrest.

See

Removal

on

3. Jack truck up (see Safe Jacking Procedure on


page 64).
4. Extend reach approximately half way. Securely
block reach so it will not retract.
WARNING Block all wheels to prevent truck from
rolling. Park the truck on a level surface and
make sure all wheels are blocked to prevent
accidental movement.
5. Park truck on a level surface. Turn key switch OFF
and disconnect battery connector. Remove battery
from truck.

2.1. Disassembly
2.1.1. Front Frame Removal
1. Disconnect hydraulic hoses from tilt and sideshift
cylinders from the input side of junction block. Cap
hoses with plugs to prevent contamination.
2. Secure front frame with a hoist to prevent
movement before removing cap screw (1) and pins
(25).
3. Remove cap screw (1) at the front frame (17).
4. Drive pins (25) to the outside by hitting with a soft
hammer.
5. Remove front frame (17) from inner arm (9) rollers
(46).

BT Prime-Mover Inc.

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Service Manual

2001-03-15

505

F-code

Section

C-code

PS
S7.3
7241
Reach, Single (RTX35)
Version no

T-code

001

RTX35/RTX45

2.1.2. Outer Arm Removal


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

506

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Service Manual

2001-03-15

F-code

PS
Version no

001

Section

C-code

S7.3
7241
Reach, Single (RTX35)
T-code

RTX35/RTX45

8. Remove rollers (32). Keep track of shims (37) to


each roller and roller to pin location.
9. Clean and inspect all bearing, pins, rollers,
washers, and wear strips for damage or wear.
2.1.5. Reach Cylinder Removal
WARNING Block reach to keep it from collapsing.
1. Disconnect hydraulic hoses. Plug to prevent
contamination.
2. Remove lock pins from rear frame.
3. Remove cylinder tube mounting pins.
4. Repair reach cylinders as needed.

2.2. Assembly
Install new bearing, rollers, and pins as needed.
2.2.1. Reach Cylinder Installation
1. Install rear frame pins.
2. Install locking pins.
3. Connect hydraulic hoses.
2.2.2. Rear Frame Installation
NOTE! Install same number of shims as removed for
initial adjustment.
1. Install shims (37) and rollers (32).
NOTE! Adjust frame rollers so there is 0.000 to 0.030
inch (0 to 0.76 mm) side movement of the
rear frame at tightest part of the inner mast
channel.
2. Lower inner mast channel onto rear frame rollers
(32).
BT Prime-Mover Inc.

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Service Manual

2001-03-15

507

F-code

Section

C-code

PS
S7.3
7241
Reach, Single (RTX35)
Version no

T-code

001

RTX35/RTX45

3. Connect hydraulic hoses.


4. Connect electrical cable.
5. Install lift chain anchors.
2.2.3. Inner Arm Installation
1. Install upper end of inner arms (9) into rear frame
(3).
2. Install a new bearing (8) in each side arm.
3. Install pins (2) in the rear frame and inner arms (9).
4. Install cap screw (1) and tighten. Torque to 85 ft-lb
(115 Nm). Arms should pivot freely with some
drag.
5. Install washers (24), rollers (46), and cap (45).
6. Connect hydraulic hoses to the reach cylinder.
7. Install pins in the rod end of the reach cylinder.
8. Install roll pins into the cylinder rod pins.
2.2.4. Outer Arm Installation
1. Install rollers (32), caps (31) and screws (30) on
outer arms (5 and 26).
2. Install bearing (29) in outer arms (5 and 26).
3. Install outer arms (5 and 26) on the center stud of
inner arm (9).
4. Install washer (27) and nut (28) and tighten.
Torque nut to 295 ft-lb (405 Nm).
5. Check for side clearance. Arms should pivot freely
with some drag.
6. Install front frame (17).
Installation on page 509.

See

Front

Frame

7. Connect tilt cylinder hoses.


8. Grease all fittings on reach.
9. Test for proper operation of reach. Install forks and
load backrest.

508

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Service Manual

2001-03-15

F-code

PS

Section

C-code

S7.3
7241
Reach, Single (RTX35)

Version no

001

T-code

RTX35/RTX45

2.2.5. Front Frame Installation


1. Install front frame (17) onto inner arm (9) rollers
(46).
2. Install washer (23) and pivot shaft (25) in bushing
in outer arm.
3. Install cap screw (1).
4. Reconnect hydraulic hoses to the tilt and sideshift
cylinders at junction box.

3. Carriage Bumpers
The carriage/reach retract bumpers assure that the carriage
remains square with the truck in its nested position. The
RTX35 reach uses rectangular bumpers (35) attached to
each side and at the bottom of the carriage/reach rear frame.
These bumpers are attached with socket head screws (34).
Verify that the (3) reach retract bumpers (35) are in good
condition. There should be no splitting, cracking, or
deformation on the bumpers. The reach retract bumpers are
critical to the proper operation of the reach assembly and
must be inspected at every Planned Maintenance visit.
Bumpers that show signs of wear, cracking, splitting, or
deformation must be replaced.

3.1. Reach Adjustment


1. Install a 0.125 inch (3 mm) shim (36) behind each
reach retract bumper (35).

CAUTION The cylinder rod should never be adjusted


where the rod end touches the inner arm
assembly.
2. Fully extend the reach assembly. Loosen reach rod
jam nuts. Adjust reach cylinder rods so the reach
assembly extends in time.
3. Fully retract reach assembly.
4. The reach assembly must retract evenly to all three
retract bumpers (35). If the reach assembly does

BT Prime-Mover Inc.

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Service Manual

2001-03-15

509

F-code

Section

C-code

PS
S7.3
7241
Reach, Single (RTX35)
Version no

T-code

001

RTX35/RTX45

not retract to all bumpers evenly, use a 0.0625 inch


(1.5 mm) or 0.125 inch (3 mm) shim (36)
accordingly to achieve proper retraction to all three
reach bumpers.
5. Repeat steps 2 through 4 until proper retraction is
achieved.
6. With the reach fully retracted, measure from the
face of the inner column to the backside of fork
hanger carriage (21). Note this measurement.
7. Subtract the retracted measurement from the
extended measurement. This is your overall reach
stroke. (Example: Extended measurement of 25.75
inches (654 mm) minus retracted measurement of
2.75 inches (70 mm) equals an overall reach stroke
of 23 inches (584 mm)).
8. BT Prime-Mover specifications allow a maximum
overall reach stroke between 22.75 and 23 inches
(578 and 584 mm).

CAUTION The cylinder rod should never be adjusted


where the rod end touches the inner arm
assembly. The pins and bushings for the
inner arms should be inspected if the
amount of threads are excessively less or
greater than the three threads.
9. Adjust cylinder rods so that the overall reach stroke
is between 22.75 and 23 inches (578 and 584
mm). When measurement is correct, there should
be approximately three full threads showing above
the jam nuts at the clevis end of reach cylinders.

CAUTION The piston threads must be cleaned and


have Loctite applied whenever the reach
assembly is readjusted. The jam nuts must
be inspected for tightness at every Planned
Maintenance visit to insure proper
operation of the reach assembly.

510

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Service Manual

2001-03-15

F-code

PS
Version no

001

Section

C-code

S7.3
7241
Reach, Single (RTX35)
T-code

RTX35/RTX45

10. When proper adjustment is achieved, clean rod


threads and apply Loctite 242 thread locking
compound. Lock down jam nuts.

4. Fork Carriage Pivot Pins


RTX35 reach trucks use a pin (18) and roll pin (19)
combination for the fork carriage pivot pin.

5. Carriage Roller Bearings


Two roller bearings (32) are located within the mast assembly
on either side. The carriage must be removed to access
these bearings.
The lower bearings are shimmed at the factory so that no play
exists between the carriage and inner columns. If carriage
becomes loose within inner columns, lower roller bearings
may require additional shims. If possible, maintain an equal
amount of shim thickness on each side.
If carriage hangs up in the column during lowering, one or
more of the roller bearings may be damaged or worn and
requires replacement.

5.1. Removal
1. Remove carriage/reach.
2. The carriage bearing should slide off the shaft with
hand pressure. If necessary, a suitable bearing
puller may be required for removal.
3. Repeat step 2 for the other three bearings.

BT Prime-Mover Inc.

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Service Manual

2001-03-15

511

F-code

Section

C-code

PS
S7.3
7241
Reach, Single (RTX35)
Version no

T-code

001

RTX35/RTX45

5.2. Installation
1. Install new bearing on shaft.
2. Repeat step 1 for the other three bearings.
3. Reinstall carriage/reach. See Shimming Carriage
with Mast on Truck on page 459.
4. Test lift/lower functions of the carriage.
5. Return truck to service.

512

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Service Manual

2001-03-15

F-code

Section

PS

C-code

S7.3
7241
Reach, Single (RTX45)

Version no

T-code

001

RTX35/RTX45

Reach, Single (RTX45)


1. 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

12
13
14

4
1

10
38

37 36
35

34

20
33 21 22 6
27
25
26

11 3

5
32 22

39

28

36
40

30

29

24
23
22
19
20
21
17
16

18

35
31

6
8
7

15
5

2
3
BT Prime-Mover Inc.

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Service Manual

2001-03-15

513

F-code

Section

C-code

PS
S7.3
7241
Reach, Single (RTX45)
Version no

T-code

001

RTX35/RTX45

Item
No.

514

Description

Item
No.

Description

Item
No.

Description

Screw

21

Lockwasher

41

Solenoid valve

Cap, bearing

22

Flat Washer

42

Frame, carriage

Bearing

23

Pin, cotter

43

Screw

Arm, left

24

Pin

44

Bearing

Fitting, grease

25

Bearing

45

Spacer

Bearing

26

Reach cylinder

46

Screw

Bearing

27

Pin

47

Ring, retainer

Bearing, thrust

28

Spacer

48

Shaft

Shim

29

Screw

49

Frame, fork

10

Arm, inner

30

Solenoid valve

50

Nut

11

Plug, wear

31

Frame, back

51

Screw

12

Screw

32

Screw

52

Lockwasher

13

Shaft-half

33

Lockwasher

53

Spacer

14

Shaft-half

34

Pin, pivot

54

Bumper

15

Arm, right

35

Shim

55

Screw

16

Nut

36

Bearing, mast guide

56

Screw

17

Lockwasher

37

Cap, bearing

57

Plate, wear

18

Bearing, thrust

38

Screw

58

Cylinder, tilt

19

Spacer

39

Guide, hose

59

Bearing

20

Screw

40

Screw

60

Bracket, cylinder

Return

Service Manual

2001-03-15

F-code

PS

Section

C-code

S7.3
7241
Reach, Single (RTX45)

Version no

001

T-code

RTX35/RTX45

2. Reach Repair
NOTE! The reach can be repaired without removal
from the mast.
1. Remove forks.
2. Remove load
page 532.

backrest.

See

Removal

on

3. Jack truck up (see Safe Jacking Procedure on


page 64).
4. Extend the reach approximately half way. Securely
block reach so it will not retract.
5. Disconnect battery.

2.1. Disassembly
2.1.1. Front Frame Removal
1. Disconnect hydraulic hoses from the tilt and
sideshift cylinders from the input side of the
solenoid valve. Cap hoses with plugs to prevent
contamination.
2. Remove screw (12) and half shafts (13 and 14)
from the front frame (42).
3. Remove front frame (42) from inner arm (10) rollers
(3).
2.1.2. Outer Arm Removal
1. Remove nut (16) and lockwasher (17).
2. Remove thrust bearing (18).
3. Remove right outer arm (15).
4. Repeat steps 1 thru 3 to remove left outer arm (4).
5. Remove shims (9), thrust bearing (8), and bearing
(7) from the center stud of outer arms (4 and 15).
6. Remove screws (1), bearing caps (2), and bearing
(3) from outer arms (4 and 15).

BT Prime-Mover Inc.

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Service Manual

2001-03-15

515

F-code

Section

C-code

PS
S7.3
7241
Reach, Single (RTX45)
Version no

T-code

001

RTX35/RTX45

2.1.3. Inner Arm Removal


1. Remove screws (20) and washer (22).
2. Drive cotter pins (23) out of the reach cylinder rod
end pins.
3. Disconnect hydraulic lines from manifold block
(30). Plug to prevent contamination.
4. Remove reach cylinder rod end pins (24) from the
inner frame (10).
5. Remove cap screw (32) and washer (33) at the
rear frame (31).
6. Drive pins (34) out by hitting with a soft hammer.
7. Remove inner arms (10).
2.1.4. Rear Frame Removal
1. Lift rear frame (31) until all tension is removed from
the lift chains.
2. Disconnect lift chain from the chain anchors on the
rear frame.
3. Disconnect hydraulic hoses. Plug to prevent
contamination.
4. Disconnect electrical cable.
5. Lower rear frame.
NOTE! Connect a hoist to rear frame to prevent it
from dropping when the channel is raised.
6. Raise inner mast channel.
7. Remove rear frame out the bottom of the mast.
8. Remove rollers (36). Keep track of shims (35) to
each roller and roller to pin location.
9. Clean and inspect all bearing, pins, rollers,
washers, and wear strips for damage or wear.

516

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Service Manual

2001-03-15

F-code

PS

Section

C-code

S7.3
7241
Reach, Single (RTX45)

Version no

001

T-code

RTX35/RTX45

2.1.5. Reach Cylinder Removal


WARNING Block reach to keep it from collapsing.
1. Disconnect hydraulic hoses. Plug to prevent
contamination.
2. Remove screws (20) and cotter pins from rear
frame.
3. Remove cylinder tube mounting pins (27).
4. Repair reach cylinders as needed.

2.2. Assembly
Install new bearing, rollers, and pins as needed.
2.2.1. Reach Cylinder Installation
1. Install rear frame pins (27).
2. Install cotter pins (23), washers (21 and 22), and
screws (20).
3. Connect hydraulic hoses to reach cylinder.
2.2.2. Rear Frame Installation
NOTE! Install same number of shims as removed for
initial adjustment.
1. Install shims (35) and rollers (36).
2. Lower inner mast channel onto rear frame rollers
(36).
NOTE! Adjust frame rollers so there is 0.000 to 0.030
inch (0 to 0.76 mm) side movement of the
rear frame at the tightest part of the inner
mast channel.
3. Connect hydraulic hoses.
4. Connect electrical cable.

BT Prime-Mover Inc.

Return

Service Manual

2001-03-15

517

F-code

Section

C-code

PS
S7.3
7241
Reach, Single (RTX45)
Version no

T-code

001

RTX35/RTX45

5. Install lift chain anchors.


2.2.3. Inner Arm Installation
1. Install bearing (6) in inner arm (10).
2. Install upper end of inner arms (10) into rear frame
(31).
3. Install pins (34) in rear frame (31) and inner arms
(10).
4. Install washer (33) and cap screw (32) and tighten.
Torque to 85 ft-lb (115 Nm). Arms should pivot
freely with some drag.
5. Install rollers (3) and cap screw (11).
6. Connect hydraulic hoses to reach cylinder (26).
2.2.4. Outer Arm Installation
1. Install bearing (3), bearing cap (2) and screw (1) on
the arms (4 and 15).
2. Install bearing (7), thrust bearing (8), and shims (9)
on the center stud of outer arms (4 and 15).
3. Install outer arms (4 and 15) through the center
hole of inner arm (10).
4. Install bearing (18), washer (17), and nut (16).
Torque nut to 295 ft-lb (405 Nm).
5. Check for side clearance. Arms should pivot freely
with some drag.
6. Install front frame (42). See paragraph 2.2.5 below.
7. Connect tilt cylinder hoses.
8. Grease all fittings on reach.
9. Test for proper operation of reach. Install forks and
load backrest.
2.2.5. Front Frame Installation
1. Install front frame (42) onto inner arm (10) rollers
(3).
2. Install half shafts (13 and 14) and screw (12)
attaching front frame to outer arm.

518

Return

Service Manual

2001-03-15

F-code

PS

Section

C-code

S7.3
7241
Reach, Single (RTX45)

Version no

001

T-code

RTX35/RTX45

3. Reconnect hydraulic hoses to tilt and sideshift


cylinders from the input side of solenoid valve.

3. Reach Carriage Wear Strip


A wear strip (57) is used on the RTX45 reach truck. The wear
strip is located on the back of the reach carriage front frame
(42). This is the surface the inner scissor arm roller travels
against.

3.1. Removal
1. Partially extend the carriage so that the end of the
inner scissor arm (10) is midway down the track,
exposing the top and the bottom of the reach wear
strip (57).
2. Place a block on each side of the carriage between
the scissors lower back bearings and the
carriages bottom support plate.
3. Turn key switch OFF and disconnect battery
connector.
4. Unbolt two flat head screws (56) at the top and
bottom of reach wear strip (57).

3.2. Installation
1. Grease and wedge the new reach wear strip (57)
between bearing (3) and track.
2. Install top and bottom flat head screws (56).
3. Reconnect battery connector.
4. Remove blocking from the scissor mechanism.

BT Prime-Mover Inc.

Return

Service Manual

2001-03-15

519

F-code

Section

C-code

PS
S7.3
7241
Reach, Single (RTX45)
Version no

T-code

001

RTX35/RTX45

4. Fork Carriage Pivot Pins


RTX45 reach trucks use a shaft (48) with a retainer ring (47).
The shaft is attached to the reach carriage front frame with a
screw (46) and nut (50).

5. Carriage Bumpers
The carriage bumpers assure that the carriage remains
square with the truck in its nested position. The RTX45 reach
uses rectangular bumpers (54) attached to the chassis side
(back side) of the front frame (42).

6. Carriage Roller Bearings


The upper carriage roller bearing is accessible when the
carriage is elevated. Two other roller bearings are located
within the mast assembly on either side. The carriage must
be removed to access these bearings.
The lower bearings are shimmed at the factory so that no play
exists between the carriage and the inner columns. If the
carriage becomes loose within the inner columns, the lower
roller bearings may require additional shims. If possible,
maintain an equal amount of shim thickness on each side.
If the carriage hangs up in the columns during lowering, one
or more of the roller bearings may be damaged or worn and
requires replacement.

6.1. Removal
1. Remove carriage/reach.
2. Remove socket head cap screw (38) and washer
(37) on the end of bearing (36).
3. The carriage bearing should slide off the shaft with
hand pressure. If necessary, a suitable bearing
puller may be required for removal.

520

Return

Service Manual

2001-03-15

F-code

PS
Version no

001

Section

C-code

S7.3
7241
Reach, Single (RTX45)
T-code

RTX35/RTX45

6.2. Installation
1. Install new bearing on shaft. Apply thread locking
compound to socket head cap screw (38). Fasten
cap screw (38) and washer (37) in place.
2. Reinstall carriage/reach. See Shimming Carriage
with Mast on Truck on page 459.
3. Test lift/lower functions of the carriage.
4. Return truck to service.

BT Prime-Mover Inc.

Return

Service Manual

2001-03-15

521

F-code

Section

C-code

PS
S7.3
7241
Reach, Single (RTX45)
Version no

T-code

001

RTX35/RTX45

522

Return

Service Manual

2001-03-15

F-code

Section

PS

S9.0
9311
Height Indication

Version no

000

C-code

T-code

RTX35/RTX45

Height Indication

+1/21
0

Item
No.
1

BT Prime-Mover Inc.

Return

Service Manual

2001-03-15

Description
Indicator, lift height

523

F-code

Section

PS
S9.0
Height Indication
Version no

T-code

000

RTX35/RTX45

C-code

9311

1. General
A height indicator is fitted to trucks with high lifting heights.
The height indicator shows the current position of the forks
within the staging zone. The character window (1) shows the
fork height, based on information from the sensing device
(pulse sensor) mounted on the mast.

2. Operation
The measurement in the staging zone starts when the
reference switch (S45) is activated and sends a signal to the
main electronic card. The pulse sensor sends pulses to the
main electronic card. The pulse sensor has two channels, A
and B, which give signals at 90 degrees to each other. This
gives information to the main electronic card on whether the
forks are moved up or down.

3. Error Code 13
To clear error code 13 (Height counter error): See Height
Indicator Error on page 336. Error code 13 only appears if
current is not flowing to the height indicator. Before checking
wires, turn key switch OFF and disconnect battery connector.
Check continuity for disconnected or broken electrical wire,
broken cable wire, or faulty terminal connection and repair as
necessary. Reconnect battery connector and turn key switch
ON. Error code 13 should disappear. If error code 13 fails to
disappear continue to check for faulty wires.

524

Return

Service Manual

2001-03-15

F-code

PS

Section

C-code

S9.0
9311
Height Indicator (RTX35)

Version no

T-code

000

RTX35/RTX45

Height Indicator (RTX35)

13

17

18
1

14
10

16

11
12 15

7
6
8

19

Wiring
Harness

Item
No.

BT Prime-Mover Inc.

Return

Description

Item
No.

Description

Item
No.

Description

Support

Ring, locking

15

Device, sensing

Cover

Bearing

16

Screw

Anchor, bottom

10

Washer

17

Nut

Spring

11

Screw

18

Screw

Roller

12

Arm

19

Cable

Bearing

13

Screw

Ring, snap

14

Setscrew

Service Manual

2001-03-15

525

F-code

Section

C-code

PS
S9.0
9311
Height Indicator (RTX35)
Version no

T-code

000

RTX35/RTX45

1. Pulse sensor
1.1. Repair
1. Unplug wiring harness at the sensing unit.
2. Remove screws (16) and cover (2).
3. To replace the pulse sensor (15), loosen setscrew
(14) and remove pulse sensor.
4. Remove screws (13) and arm (12). Reverse the
procedure to reinstall pulse sensor.

1.2. Cable
NOTE! Keep cable in good condition. Worn or cables
with deteriorated cable coatings will result in
less accurate lift height readings.
1.2.1. Removal
1. To replace cable (19), remove bolt from the bottom
anchor (3) relieving spring tension.
2. Remove spring (4) and anchor (3) from cable (19).
3. Remove cable (19) from the top anchor. Remove
cable from the pulley.
1.2.2. Installation
1. Install a new cable (19) on the top anchor. Wrap
cable once around the pulley wheel.
2. Attach spring (14) and bottom anchor (3) to the
cable (19).
3. Stretch the cable (19) tight and reinstall the bottom
anchor bolt.

526

Return

Service Manual

2001-03-15

F-code

PS

Section

C-code

S9.0
9311
Height Indicator (RTX35)

Version no

000

T-code

RTX35/RTX45

1.3. Pulley
1.3.1. Removal
1. To replace roller (5), remove cover (2), pulse
sensor, and cable (19).
2. Remove screw (11) and roller.
3. Remove bearing (9), retaining rings (7 and 8), and
bearing (6).
4. Reverse procedure to reinstall.

BT Prime-Mover Inc.

Return

Service Manual

2001-03-15

527

F-code

Section

C-code

PS
S9.0
9311
Height Indicator (RTX45)
Version no

T-code

000

RTX35/RTX45

Height Indicator (RTX45)


17
18

16

10 11
1

13
14
15

19

12

Wiring
Connector

20

Item
No.

528

Return

Description

Item
No.

Description

Item
No.

Description

Support

Ring, locking

15

Device, sensing

Cover

Mount, bearing

16

Screw

Anchor, bottom

10

Washer

17

Nut

Spring

11

Screw

18

Screw

Roller

12

Arm

19

Cable

Bearing

13

Screw

20

Screw

Ring, retainer

14

Screw, set

Service Manual

2001-03-15

F-code

PS
Version no

000

Section

C-code

S9.0
9311
Height Indicator (RTX45)
T-code

RTX35/RTX45

1. Pulse sensor
1.1. Repair
1. Unplug wiring harness at the sensing unit.
2. Remove screws (16) and cover (2).
3. Loosen setscrew (14) and remove pulse sensor
(15).
4. Remove screws (13) and arm (12). Reverse
procedure to reinstall pulse sensor.

1.2. Cable
NOTE! Keep cable in good condition. Worn or cables
with deteriorated cable coatings will result in
less accurate lift height readings.
1.2.1. Removal
1. To replace cable (19), remove bolt from the bottom
anchor (3) relieving spring tension.
2. Remove spring (4) and anchor (3) from cable (19).
3. Remove cable (19) from the top anchor. Remove
cable from pulley.
1.2.2. Installation
1. Install a new cable (19) on the top anchor. Wrap
the cable once around the pulley wheel.
2. Attach spring (14) and bottom anchor (3) to cable
(19).
3. Stretch cable (19) tight and reinstall the bottom
anchor bolt.

BT Prime-Mover Inc.

Return

Service Manual

2001-03-15

529

F-code

Section

C-code

PS
S9.0
9311
Height Indicator (RTX45)
Version no

T-code

000

RTX35/RTX45

1.3. Pulley
1.3.1. Removal
1. To replace roller (5), remove cover (2), pulse
sensor, and cable (19).
2. Remove screw (11) and roller.
3. Remove bearing (9), retaining rings (7 and 8), and
bearing (6).
4. Reverse procedure to reinstall.

530

Return

Service Manual

2001-03-15

F-code

Section

PS

S9.1
9501
Load Backrest

Version no

C-code

T-code

001

RTX35/RTX45

Load Backrest

3
2

Item No.

BT Prime-Mover Inc.

Return

Service Manual

Description

Backrest

Screw, cap

Washer, flat

2001-03-15

531

F-code

Section

C-code

PS
S9.1
Load Backrest

9501

Version no

T-code

001

RTX35/RTX45

1. Removal
WARNING The load backrest extension also serves as
a fork stop. All BT Prime-Mover trucks are
shipped with the extension installed.
Removal of extension could result in injury
or product damage.
WARNING Block all wheels to prevent truck from
rolling. Park the truck on a level surface and
make sure all wheels are blocked to prevent
accidental movement.
1. Park truck on a level surface. Turn key switch OFF
and disconnect battery connector. Remove battery
from truck.
2. Turn key switch OFF and disconnect battery
connector.
3. Use a 3/4 inch (19 mm) socket to remove four
screws (2) (two on each side).
4. Lift backrest off the front fork frame.
5. If truck has sideshift, be sure to retrieve two shims
that go between the backrest and front fork frame.

2. Installation
1. Place load backrest on front fork frame.
2. For units with sideshift, slide shims between frame
and backrest, aligning mounting holes.
3. Insert mounting screws (2) and tighten.
4. Repeat steps 2 and 3 for the opposite side.
5. Reconnect battery connector.
6. Return truck to service.

532

Return

Service Manual

2001-03-15

Index

Carriage/Reach . . . . . . . . . . . . . 509

Adjustment Points . . . . . . . . . . . . . . . . 41
Alarm
Back-up . . . . . . . . . . . . . . . . . . . . 292
Travel . . . . . . . . . . . . . . . . . . . . . 292
Applications, Intended . . . . . . . . . . . . 33
Applications, Prohibited . . . . . . . . . . . 33
Aux. Power Hook-Up . . . . . . . . . . . . 308

B
Backrest, Load . . . . . . . . . . . . . . . . . 531
Back-up Alarm . . . . . . . . . . . . . . . . . 292
Battery . . . . . . . . . . . . . . . . . . . . . . . 285
Charging . . . . . . . . . . . . . . . . . . . 287
Cleaning Exterior . . . . . . . . . . . . . 287
Connector . . . . . . . . . . . . . . . . . . 295
History Record . . . . . . . . . . . . . . 288
Inspection and Care . . . . . . . . . . 286
Installation . . . . . . . . . . . . . . . . . . 285
Maintenance . . . . . . . . . . . . . . . . 286
Removal . . . . . . . . . . . . . . . . . . . 285
Retainer Plates . . . . . . . . . . . . . . 106
Rollers . . . . . . . . . . . . . . . . . . . . . 106
Storage . . . . . . . . . . . . . . . . . . . . 288
Bleeding Hydraulic System . . . . . . . . 401
Brake
Adjustment, Caster . . . . . . . . . . . 201
Caster . . . . . . . . . . . . . . . . . . . . . 199
Removal . . . . . . . . . . . . . . . . . 201
Electromagnetic . . . . . . . . . . . . . 177
Adjustment . . . . . . . . . . . . . . . 180
Armature & Coil . . . . . . . . . . . 181
Friction Plate . . . . . . . . . . . . . 182
Installation . . . . . . . . . . . . . . . 179
Removal . . . . . . . . . . . . . . . . . 177
Brake Pedal . . . . . . . . . . . . . . . . . . . 123
Adjustment . . . . . . . . . . . . . . . . . 128
Bearing Replacement . . . . . . . . . 125
Removal . . . . . . . . . . . . . . . 124, 127
Braking Caster Assembly . . . . . . . . . 199
Bumpers
Carriage . . . . . . . . . . . . . . . . . . . 520
Bumpers, Retract

C
Cable, Height Indicator
RTX35 . . . . . . . . . . . . . . . . . . . . 526
RTX45 . . . . . . . . . . . . . . . . . . . . 529
Card
Main Electronic . . . . . . . . . . . . . . 327
Carriage
Bumpers . . . . . . . . . . . . . . . . . . . 520
Reach, Wear Strip . . . . . . . . . . . 519
Roller Bearings
Installation . . . . . . . . . . . .512, 521
Removal . . . . . . . . . . . . .511, 520
Sideshifter . . . . . . . . . . . . . . . . . . 493
Pad Replacementl . . . . . . . . . .497
Removal . . . . . . . . . . . . . . . . .497
Troubleshooting . . . . . . . . . . .501
Carriage, Reach, RTX35 . . . . . . . . . 503
Adjustment . . . . . . . . . . . . . . . . . 509
Assembly . . . . . . . . . . . . . . . . . . 507
Disassembly . . . . . . . . . . . . . . . . 505
Maintenance . . . . . . . . . . . . . . . . 503
Repair . . . . . . . . . . . . . . . . . . . . . 505
Carriage, Reach, RTX45 . . . . . . . . . 513
Assembly . . . . . . . . . . . . . . . . . . 517
Disassembly . . . . . . . . . . . . . . . . 515
Maintenance . . . . . . . . . . . . . . . . 513
Repair . . . . . . . . . . . . . . . . . . . . . 515
Carriage/Reach
Bumpers, Retract . . . . . . . . . . . . 509
Caster Brake Adjustment . . . . . . . . . 201
Clipboard . . . . . . . . . . . . . . . . . . . . . 103
Codes
Error . . . . . . . . . . . . . . . . . . . . . . 339
Warning/Caution . . . . . . . . . . . . . 336
Codes, Standard . . . . . . . . . . . . . . . . . 1
Components
Control Handle . . . . . . . . . . . . . . . 37
Drive . . . . . . . . . . . . . . . . . . . . . . . 37
Hydraulic . . . . . . . . . . . . . . . . . . . . 37
Mast . . . . . . . . . . . . . . . . . . . . . . . 37
Steering . . . . . . . . . . . . . . . . . . . . 37
Components, Location . . . . . . . . . . . . 37

BT Prime-Mover Inc.

Return

533

Index
Contactor
Battery Cut-out
Installation . . . . . . . . . . . . . . . 315
Removal . . . . . . . . . . . . . . . . . 315
Lift Bypass
Installation . . . . . . . . . . . . . . . 313
Removal . . . . . . . . . . . . . . . . . 313
Testing Resistance . . . . . . . . . . . 309
Tip Inspection . . . . . . . . . . . . . . . 309
Control Handle . . . . . . . . . . . . . . . . . 120
Installation . . . . . . . . . . . . . . . . . . 121
Removal . . . . . . . . . . . . . . . . . . . 120
Control Valve . . . . . . . . . . . . . . . . . . 417
Repair . . . . . . . . . . . . . . . . . . . . . 421
Conversion Formulas . . . . . . . . . . . . . 52
Cover
Main Electronic Card Panel . . . . . 101
Motor Compartment Door . . . . . . . 97
Operator Compartment Panel, Left 100
Side Panel, Left . . . . . . . . . . . . . . . 98
Top Console . . . . . . . . . . . . . . . . . 96
Cylinder
Freelift . . . . . . . . . . . . . . . . . . . . . 429
Assembly . . . . . . . . . . . . . . . . 432
Disassembly . . . . . . . . . . . . . 432
Installation . . . . . . . . . . . . . . . 432
Removal . . . . . . . . . . . . . . . . . 430
Reach, RTX35 . . . . . . . . . . . . . . . 433
Assembly . . . . . . . . . . . . . . . . 437
Disassembly . . . . . . . . . . . . . 435
Inspection . . . . . . . . . . . . . . . 436
Installation . . . . . . . . . . . . . . . 438
Removal . . . . . . . . . . . . . . . . . 434
Reach, RTX45 . . . . . . . . . . . . . . . 439
Assembly . . . . . . . . . . . . . . . . 443
Disassembly . . . . . . . . . . . . . 441
Inspection . . . . . . . . . . . . . . . 442
Installation . . . . . . . . . . . . . . . 444
Removal . . . . . . . . . . . . . . . . . 440
Sideshifter . . . . . . . . . . . . . . . . . . 500
Staging . . . . . . . . . . . . . . . . . . . . 425
Assembly . . . . . . . . . . . . . . . . 427
Disassembly . . . . . . . . . . . . . 426
Installation . . . . . . . . . . . . . . . 427
Removal . . . . . . . . . . . . . . . . . 426

Tilt, RTX35 . . . . . . . . . . . . . . . . . 445


Assembly . . . . . . . . . . . . . . . . .449
Disassembly . . . . . . . . . . . . . .447
Inspection . . . . . . . . . . . . . . . .448
Installation . . . . . . . . . . . . . . . .450
Removal . . . . . . . . . . . . . . . . .446
Tilt, RTX45 . . . . . . . . . . . . . . . . . 451
Assembly . . . . . . . . . . . . . . . . .455
Disassembly . . . . . . . . . . . . . .453
Inspection . . . . . . . . . . . . . . . .454
Installation . . . . . . . . . . . . . . . .456
Removal . . . . . . . . . . . . . . . . .452

D
Data Plate . . . . . . . . . . . . . . . . . . . . . 36
Decals . . . . . . . . . . . . . . . . . . . . . . . 133
Definition
Caution . . . . . . . . . . . . . . . . . . . . . 13
Codes . . . . . . . . . . . . . . . . . . . . . . . 1
Danger . . . . . . . . . . . . . . . . . . . . . 13
Note . . . . . . . . . . . . . . . . . . . . . . . 13
Warning . . . . . . . . . . . . . . . . . . . . 13
Definitions . . . . . . . . . . . . . . . . . . . . . 93
Dimensional Data
RTX35 . . . . . . . . . . . . . . . . . . . . . 34
RTX45 . . . . . . . . . . . . . . . . . . . . . 35
Door, Motor Compartment . . . . . . . . . 97
Drive
Motor . . . . . . . . . . . . . . . . . 107, 165
Motor Direction Sensor . . . . . . . . 364
Motor Speed Sensor . . . . . . . . . . 364

E
Electrical Compartment Fan . . . . . . 141
Electrical Components, Location . . . 268
Electrical Functions . . . . . . . . . . . . . 221
Electrical Schematics . . . . . . . . . . . . 273
Electrical Symbols . . . . . . . . . . . . . . 271
Electrical Troubleshooting . . . . . . . . . 87
Emergency Disconnect Switch . . . . 299
Inspection . . . . . . . . . . . . . . . . . . 299
Installation . . . . . . . . . . . . . . . . . 300
Removal . . . . . . . . . . . . . . . . . . . 299

BT Prime-Mover Inc.

Return

534

Index

Error Codes . . . . . . . . . . . . . . . 339344

F
Fan
Electrical Compartment . . . . . . . . 141
Operator . . . . . . . . . . . . . . . . . . . 129
Fasteners . . . . . . . . . . . . . . . . . . . . . . 43
Designations . . . . . . . . . . . . . . . . . 46
Strength Identification . . . . . . . . . . 45
Torque Values . . . . . . . . . . . . . . . . 50
Truck Torque Specifications . . . . . 51
Filter, Hydraulic . . . . . . . . . . . . . . . . . 405
Floor Board . . . . . . . . . . . . . . . . . . . . 102
Fuses . . . . . . . . . . . . . . . . . . . . . . . . 305

G
Gear
Steering Motor . . . . . . . . . . . . . . . 139
General Troubleshooting . . . . . . . . . . 85
Glossary . . . . . . . . . . . . . . . . . . . . . . . 93
Guard
Overhead . . . . . . . . . . . . . . . . . . 131

H
Handle Interface Module . . . . . . . . . 119
Handle, Control . . . . . . . . . . . . . . . . . 120
Height Indicator
RTX35 . . . . . . . . . . . . . . . . . . . . . 525
RTX45 . . . . . . . . . . . . . . . . . . . . . 528
Horn . . . . . . . . . . . . . . . . . . . . . . . . . 293
Hydraulic Filter . . . . . . . . . . . . . . . . . 405
Hydraulic Pump . . . . . . . . . . . . . . . . 409
Hydraulic System
List of Symbols . . . . . . . . . . . . . . 394
Hydraulic System, Bleeding . . . . . . . 401
Hydraulic Troubleshooting . . . . . . . . . 92

I
Inspection and Care, Battery . . . . . . 286
Introduction . . . . . . . . . . . . . . . . . . . . . 27

Key Switch . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . .

L
Left Operator Compartment Panel . . 100
Left Side Panel . . . . . . . . . . . . . . . . . . 98
Lift Chain, 3 Stage Mast . . . . . . . . . . 476
Lift Limit Override Switch . . . . . . . . . 324
Installation . . . . . . . . . . . . . . . . . 324
Removal . . . . . . . . . . . . . . . . . . . 324
Lifting Gear, RTX35 . . . . . . . . . . . . . 485
Assembly . . . . . . . . . . . . . . . . . . 487
Disassembly . . . . . . . . . . . . . . . . 487
Installation . . . . . . . . . . . . . . . . . 488
Removal . . . . . . . . . . . . . . . 486, 505
Lifting Gear, RTX45 . . . . . . . . . . . . . 489
Assembly . . . . . . . . . . . . . . . . . . 491
Disassembly . . . . . . . . . . . . . . . . 491
Installation . . . . . . . . . . . . . . . . . 491
Removal . . . . . . . . . . . . . . . . . . . 490
Lights
Overhead Guard . . . . . . . . . . . . . 289
Warning . . . . . . . . . . . . . . . . . . . 290
Working . . . . . . . . . . . . . . . . . . . 291
Load Backrest . . . . . . . . . . . . . . . . . 531
Installation . . . . . . . . . . . . . . . . . 532
Removal . . . . . . . . . . . . . . . . . . . 532
Lubricants
Cold Storage . . . . . . . . . . . . . . . . . 65
Lubrication Chart . . . . . . . . . . . . . . . . 79
Lubrication Points . . . . . . . . . . . . . . . 40

M
Main Electronic Card . . . . . . . . . . . . 327
Maintenance . . . . . . . . . . . . . . . . . . . 72
Sideshifter . . . . . . . . . . . . . . . . . . 496
Maintenance Procedures, Planned . . 72
Maintenance Schedule . . . . . . . . . . . 67
Maintenance, Battery . . . . . . . . . . . . 286

BT Prime-Mover Inc.

Return

535

297
297
298
297

Index
Maintenance, Introduction . . . . . . . . . 63
Mast Switch . . . . . . . . . . . . . . . . . . . 301
Adjustment . . . . . . . . . . . . . . . . . 302
Installation . . . . . . . . . . . . . . . . . . 304
Removal . . . . . . . . . . . . . . . . . . . 303
Mast, 3 Stage
Lift Chain . . . . . . . . . . . . . . . . . . . 476
Module, Handle Interface . . . . . . . . . 119
Motor
Brush Performance . . . . . . . . . . . 145
Direction Sensor . . . . . . . . . . . . . 364
Drive . . . . . . . . . . . . . . . . . . 107, 165
General . . . . . . . . . . . . . . . . . 143
Operating Environment . . . . . 143
Troubleshooting . . . . . . . . . . . 144
Primary Sources . . . . . . . . . . . . . 148
Pump . . . . . . . . . . . . . . . . . . . . . . 110
Speed Sensor . . . . . . . . . . . . . . . 364
Steering . . . . . . . . . . . . . . . . . . . . 137
Motor Compartment Door . . . . . . . . . . 97

O
Operator Compartment Floor . . . . . .
Operator Fan . . . . . . . . . . . . . . . . . .
Operator Fan Switch . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . .
Overhead Guard . . . . . . . . . . . . . . . .
Overhead Guard Lights . . . . . . . . . .
Overhead Light Switch . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . .

102
129
325
325
325
131
289
325
325
325

Programming Parameters . . . . . . . .
Proximity Sensor
Steer Stop . . . . . . . . . . . . . . . . . .
Pulley, Height Indicator
RTX35 . . . . . . . . . . . . . . . . . . . .
RTX45 . . . . . . . . . . . . . . . . . . . .
Pulse Sensor, Height Indicator
RTX35 . . . . . . . . . . . . . . . . . . . .
RTX45 . . . . . . . . . . . . . . . . . . . .
Pump Motor . . . . . . . . . . . . . . . . . . .
Pump, Hydraulic . . . . . . . . . . . . . . . .

345
362
527
530
526
529
110
409

R
Reach Carriage, RTX35 . . . . . . . . . . 503
Adjustment . . . . . . . . . . . . . . . . . 509
Assembly . . . . . . . . . . . . . . . . . . 507
Disassembly . . . . . . . . . . . . . . . . 505
Maintenance . . . . . . . . . . . . . . . . 503
Repair . . . . . . . . . . . . . . . . . . . . . 505
Reach Carriage, RTX45 . . . . . . . . . . 513
Assembly . . . . . . . . . . . . . . . . . . 517
Disassembly . . . . . . . . . . . . . . . . 515
Maintenance . . . . . . . . . . . . . . . . 513
Repair . . . . . . . . . . . . . . . . . . . . . 515
Reach Wear Strip . . . . . . . . . . . . . . . 519
Roller Bearings
Carriage
Installation . . . . . . . . . . . .512, 521
Removal . . . . . . . . . . . . .511, 520
Rollers, Battery . . . . . . . . . . . . . . . . 106
RV2 Adjustment Procedure . . . . . . . 354

S
P
Panel, Left Operator Compartment . 100
Panel, Left Side . . . . . . . . . . . . . . . . . 98
Panel, Main Electronic Card . . . . . . . 101
Pivot Pins, Fork Carriage . . . . . 511, 520
Plate, Data . . . . . . . . . . . . . . . . . . . . . 36
Plates, Battery Retainer . . . . . . . . . . 106
Platform Switch . . . . . . . . . . . . . . . . . 357
Installation . . . . . . . . . . . . . . . . . . 358
Removal . . . . . . . . . . . . . . . . . . . 358

Safety
Battery . . . . . . . . . . . . . . . . . . . . . 19
Electrostatic Discharge . . . . . . . . . 23
General . . . . . . . . . . . . . . . . . . . . . 15
Jacking Procedure . . . . . . . . . . . . 64
Welding . . . . . . . . . . . . . . . . . . . . . 24
Sensor
Drive Motor Direction . . . . . . . . . 364
Installation . . . . . . . . . . . . . . . .365
Removal . . . . . . . . . . . . . . . . .364

BT Prime-Mover Inc.

Return

536

Index
Drive Motor Speed . . . . . . . . . . . 364
Installation . . . . . . . . . . . . . . . 365
Removal . . . . . . . . . . . . . . . . . 364
Steer Stop Proximity . . . . . . . . . . 362
Wheel Direction . . . . . . . . . . . . . . 360
Sensor, Pulse
RTX35 . . . . . . . . . . . . . . . . . . . . . 526
RTX45 . . . . . . . . . . . . . . . . . . . . . 529
Sideshifter
Carriage . . . . . . . . . . . . . . . . . . . 493
Pad Replacement . . . . . . . . . 497
Removal . . . . . . . . . . . . . . . . . 497
Cylinder . . . . . . . . . . . . . . . . . . . . 500
Installation . . . . . . . . . . . . . . . . . . 495
Maintenance . . . . . . . . . . . . . . . . 496
Operation . . . . . . . . . . . . . . . . . . 496
Spare Parts, Ordering . . . . . . . . . . . . . 59
Specification Plate . . . . . . . . . . . . . . . 36
Specifications, Oil and Grease . . . . . . 81
Staging Switch . . . . . . . . . . . . . . . . . 358
Installation . . . . . . . . . . . . . . . . . . 359
Removal . . . . . . . . . . . . . . . . . . . 359
Steer
Tachometer . . . . . . . . . . . . . . . . . 217
Wheel . . . . . . . . . . . . . . . . . . . . . 215
Steer Stop Proximity Sensor . . . . . . 362
Adjustment . . . . . . . . . . . . . . . . . 362
Installation . . . . . . . . . . . . . . . . . . 363
Removal . . . . . . . . . . . . . . . . . . . 363
Steering
Bearing . . . . . . . . . . . . . . . . . . . . 219
Motor . . . . . . . . . . . . . . . . . . . . . . 137
Storage, Battery . . . . . . . . . . . . . . . . 288
Switches
Emergency Disconnect . . . . . . . . 299
Key Switch . . . . . . . . . . . . . . . . . 297
Lift Limit Override . . . . . . . . . . . . 324
Mast Switch . . . . . . . . . . . . . . . . . 301
Operator Fan . . . . . . . . . . . . . . . . 325
Overhead Light . . . . . . . . . . . . . . 325
Platform Switch . . . . . . . . . . . . . . 357
Staging . . . . . . . . . . . . . . . . . . . . 358
Test/Inspection . . 297, 301, 323, 357
Work Light . . . . . . . . . . . . . . . . . . 325
Symbols

Caution . . . . . . . . . . . . . . . . . . . . .
Danger . . . . . . . . . . . . . . . . . . . . .
Ordinance . . . . . . . . . . . . . . . . . . .
Prohibitory . . . . . . . . . . . . . . . . . .
Warning . . . . . . . . . . . . . . . . . . . .

T
Tachometer, Steer . . . . . . . . . . . . . . 217
Technical Service Data . . . . . . . . . . . 55
Theory of Operation
Fork Tilt, Down . . . . . . . . . . . . . . 393
High Speed Extend . . . . . . . . . . . 381
Hydraulic Control Handle Interface 369
Hydraulic Supply . . . . . . . . . . . . . 373
Lifting . . . . . . . . . . . . . . . . . . . . . 375
Low Speed Extend . . . . . . . . . . . 379
Lowering . . . . . . . . . . . . . . . . . . . 377
Retract, High Speed . . . . . . . . . . 385
Retract, Low Speed . . . . . . . . . . 383
Sideshift, Left . . . . . . . . . . . . . . . 389
Sideshift, Right . . . . . . . . . . . . . . 387
Top Console . . . . . . . . . . . . . . . . . . . . 96
Transmission . . . . . . . . . . . . . . . . . . 169
Fluid Changing . . . . . . . . . . . . . . 115
Repair
Leakage, Lower Cover . . . . . .174
Leakage, Top Cover . . . . . . . .173
Wheel Bolts . . . . . . . . . . . . . . .175
Travel Alarm . . . . . . . . . . . . . . . . . . . 292
Troubleshooting
General Instructions . . . . . . . . . . . 85
Sideshifter . . . . . . . . . . . . . . . . . . 501
Troubleshooting Guidelines
Electrical . . . . . . . . . . . . . . . . . . . . 87
Hydraulic . . . . . . . . . . . . . . . . . . . . 92
Truck Installation
Cold Storage Conditioning . . . . . . 65
Truck Lubrication Points . . . . . . . . . . 79
Truck Specifications . . . . . . . . . . . . . . 33
Truck Torque Specifications . . . . . . . 51

V
Valve

BT Prime-Mover Inc.

Return

537

13
13
14
14
13

Index
Control . . . . . . . . . . . . . . . . . . . . .
Lowering Rate Adjustment . . . . .
Pressure Limiting, Repair . . . . . .
Pressure Reducing, Repair . . . . .
Pressure Setting . . . . . . . . . . . . .
Seal Kit . . . . . . . . . . . . . . . . . . . .
SWR14, Repair . . . . . . . . . . . . . .

417
423
422
421
422
423
421

W
Warning Lights . . . . . . . . . . . . . . . . . 290
Warning/Caution Codes . . . . . . . 336??
Wear Strip, Reach Carriage . . . . . . . 519
Wheel
Steering . . . . . . . . . . . . . . . . . . . . 215

Wheel Direction Sensor . . . . . . . . . . 360


Adjustment . . . . . . . . . . . . . . . . . 360
Installation . . . . . . . . . . . . . . . . . 361
Removal . . . . . . . . . . . . . . . . . . . 361
Wheels
Caster . . . . . . . . . . . . . . . . . . . . . 197
Caster, with brake . . . . . . . . . . . . 203
Load
Single . . . . . . . . . . . . . . . . . . .211
Tandem . . . . . . . . . . . . . . . . . .207
Work Light Switch . . . . . . . . . . . . . . 325
Installation . . . . . . . . . . . . . . . . . 325
Removal . . . . . . . . . . . . . . . . . . . 325
Working Lights . . . . . . . . . . . . . . . . . 291

BT Prime-Mover Inc.

Return

538

Return

Back Cover

BT Prime-Mover, Inc., 3305 N. Highway 38, Muscatine, Iowa 52761-8800 U.S.A.


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

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