310428-000 2001 - July PDF

F
Master Service Manual

RTX35/45
Electric Stand-Up Rider Truck
Effective Serial Number RTX3530317001 - UP
+1
01/2
+1
01/2
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

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

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
Drive Motor .................................................................................................. 165
Motor Disassembly .................................................................................. 166
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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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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11
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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12
F-code
Section
C-code
PS
Warning Symbols
Version no
T-code
001
Warning Symbols
Always follow the warnings given in this Instruction Manual
and on the truck to avoid accidents and incidents from
occurring.
1. Warning Levels
Warning texts are given in four levels and provide information
on the risks, describe the consequences, and instruct how to
avoid accidents.
DANGER
Warns that an accident will occur if the instructions are not
followed.
The consequences are serious personal injury or possibly
death, and/or extremely large material damage.
WARNING
Warns that an accident can occur if the instructions are not
followed.
The consequences are serious personal injury or possibly
death, and/or large material damage.
CAUTION
Warns that an accident can occur if the instructions are not
followed.
The consequences are personal injury and/or material
damage.
NOTE!
Marks the risk of an accident or breakdown if the
instructions are not followed.
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Service Manual
2001-03-15
13
F-code
Section
C-code
PS
Prohibitory Symbols
Version no
T-code
001
Prohibitory Symbols
NO SMOKING
If smoking occurs in situations where a restriction against
smoking is stated, a serious accident can occur.
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.
14
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Service Manual
2001-03-15
F-code
Section
C-code
PS
Safety
Version no
T-code
001
Safety
1. General Safety
Do NOT operate or work on this truck unless trained,
qualified, and authorized to do so and have read the
Operators Manual.
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
F-code
Section
C-code
PS
Safety
Version no
T-code
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
F-code
Section
C-code
PS
Safety
Version no
T-code
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
17
F-code
Section
C-code
PS
Safety
Version no
T-code
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.
18
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Service Manual
2001-03-15
F-code
Section
C-code
PS
Battery Safety
Version no
T-code
001
Battery Safety
WARNING As a battery is being charged, an
explosive gas mixture forms within and
around each cell. If the area is not properly
ventilated, this explosive gas can remain
in or around the battery for several hours
after charging. Be sure there are no open
flames or sparks in the charging area. An
open flame or spark can ignite this gas,
resulting in serious damage or injury.
WARNING Battery electrolyte is a solution of sulfuric
acid and water. Battery acid causes burns.
Should any electrolyte come in contact
with your clothing or skin, flush the area
immediately with cold water. Should the
solution get on your face or in your eyes,
flush the area with cold water and get
medical help immediately.
Read, understand, and follow procedures, recommendations
and specifications in the battery and battery charger
manufacturers manuals.
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
19
F-code
Section
C-code
PS
Battery Safety
Version no
T-code
001
Make sure a shower and eyewash station are nearby in case

there is an accident.
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.
20
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2001-03-15
F-code
Section
C-code
PS
Battery Safety
Version no
T-code
001
Do NOT lay tools or metal objects on top of the battery. 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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Service Manual
2001-03-15
21
F-code
Section
C-code
PS
Battery Safety
Version no
T-code
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.
22
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2001-03-15
F-code
Section
C-code
PS
Static Safety
Version no
T-code
001
Static Safety
Electronic circuit board and devices used on this truck can be
damaged by the discharge of static electricity, called
electrostatic discharge.
Static charges can accumulate from normal operation of the
truck as well as movement or contact between nonconductive materials such as, plastic bags, synthetic clothing,
synthetic soles on shoes, styrofoam coffee cups, etc.
Accumulated static can be discharged through human skin to
a circuit board or component by touching the parts. Static
discharge is also possible through the air when a charged
object is placed close to another surface at a different
electrical potential. Static discharge can occur without
your seeing or feeling it.
Whenever working on or near static-sensitive electronics,
always use static discharge precautions.
1. Place a static discharge wrist strap around your wrist.
Connect the ground lead to the wrist strap connector.
2. Connect the ground clamp to an unpainted, grounded
surface on the truck frame.
3. If removing or installing static-sensitive components,
place them on a properly grounded static mat.
4. To transport static-sensitive components, including failed
components being returned, place the components in an
antistatic bag or box.
The wrist strap and associated accessories should be tested
monthly. A wrist strap that is not working properly will not alert
that it is bad.
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Service Manual
2001-03-15
23
F-code
Section
C-code
PS
Welding Safety
Version no
T-code
001
Welding Safety
WARNING Flame cutting or welding on powder coat
painted surfaces may produce potentially
harmful fumes, smoke and vapors. Prior to
performing flame cutting or welding
operations, it is recommended that the
coating be removed in the vicinity where
the operation(s) will be performed.
WARNING Coating removal may be by mechanical
methods, chemical methods or a
combination of methods. Flame cutting
and/or welding operations should be
carried out only in well ventilated areas
using local exhaust if necessary.
Before working on this truck, make sure that:
Fire protection equipment is nearby.
Know where the nearest eyewash station is.
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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F-code
Section
C-code
PS
Welding Safety
Version no
T-code
001
Attach the ground cable as close to the weld area as

possible.
Disconnect all electrical cards before any type of electric

resistance welding is done.
Do not perform any welding operations near the electrical
components.
If welding must be done near the battery compartment,
remove the battery from the truck.
When finished welding, perform all ground tests and
electrical inspections before the truck is operated.
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Service Manual
2001-03-15
25
F-code
Section
C-code
PS
Welding Safety
Version no
T-code
001
26
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Service Manual
2001-03-15
F-code
Section
C-code
M
Introduction, Service Manual
Version no
001
T-code
RTX35/RTX45

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
Service Manual
2001-03-15
27
F-code
Section
C-code
M
Version no
T-code
001
RTX35/RTX45
28
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Service Manual
2001-03-15
F-code
Section
C-code
M
Contents, Section M
Version no
T-code
001
Contents, Section M
1. Machine Information
BT Prime-Mover Inc.
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M1.0
GENERAL PRODUCT INFORMATION
M2.0
TECHNICAL SERVICE DATA
M3.0
ORDERING SPARE PARTS
Service Manual
2001-03-15
29
F-code
Section
C-code
M
Contents, Section M
Version no
T-code
001
30
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Service Manual
2001-03-15
F-code
Section
C-code
M1.0
General Product Information
Version no
000
T-code
RTX35/RTX45

1. 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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Service Manual
2001-03-15
31
F-code
Section
C-code
M1.0
Version no
T-code
000
RTX35/RTX45
1.2. Open Back Compartment

The truck compartment has an open back design. The United
States Department of Labor Occupational Safety and Health
Administration (OSHA) has determined that when a stand up
narrow aisle lift truck tips over the operator should be trained
to step off the truck. The open back design allows the
operator to make the quickest exit from the truck should the
truck begin to tip over or fall from an elevated height such as
a loading dock or ramp. The ease of entering and exiting the
open back design also minimizes operator fatigue.
+1
1/2
0
Open
back
compartment
32
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2001-03-15
F-code
Section
C-code
M1.0
Version no
T-code
000
RTX35/RTX45
1.3. Intended Truck Application

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

The trucks are designed for handling goods indoors. It is not
permitted to use the trucks for other purposes including the
following:
-
As a towing tractor for trailers.
To tow other trucks.
To transport/lift passengers.
To drive on gravel or grass.
1.5. Truck Data

The following table provides information regarding some
technical data which is of value with daily use of the trucks.
The 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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Service Manual
2001-03-15
33
F-code
Section
C-code
M1.0
Version no
T-code
000
RTX35/RTX45
1.6. RTX35 Dimensions

The following diagram shows external dimensions for the
RTX35 truck in its standard design.
Dimensions shown in parentheses are metric, others are inches.
65
(16 .05
52)
5.5 (139)
16.0 (406) 32.0 (812)
to
to
30 (762), 36 (914), 42 (1066),
50.0 (1270)
29.5 (749)
1.75 (44) x 4.0 (101) Forks
40.5
31.0
(1028) (787)
48 (1219)
5.5 (139)
70.2 (1783)
B
5.7 (144)
A
43.5 (1104)
23.0 (584)
C
48.0 (1219)
95.0
(2413)
+4
11.75
(298)
Step
Height
3.0
(76)
OALH
-3
2.0
(50)
Battery
Roller 7.0 (177)
Height
14.4
(265)
9.1
(231)
55.45
(1408)
Free Lift
5.0 (127)
10% Empty and 6% Loaded Gradient Performance
34
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Service Manual
2001-03-15
F-code
Section
C-code
M1.0
Version no
000
T-code
RTX35/RTX45
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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Service Manual
2001-03-15
35
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Section
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M1.0
Version no
T-code
000
RTX35/RTX45
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.
Muscatine, IA 52761
310574-000
Legend
1
2
3
4
5
6
7
8
9
10
11
12
13
14
36
Return
Truck model number

Truck serial number
Weight less battery
Maximum battery weight
Minimum battery weight
Truck voltage DC
Battery type UL class
Battery maximum AMP hours
Hour rate
Truck type
Mast serial number
Attachment
Maximum degree rear tilt
Truck capacity
Service Manual
2001-03-15
F-code
Section
C-code
M1.0
Version no
000
T-code
RTX35/RTX45
2. Main Components
1
Hydraulic valve:
The valves are located to provide easy access.
Battery:
24/36V with different capacities and weights.
Battery connector:
The truck is connected to the battery through the battery connector.
When charging the battery, do not connect the battery charger to the
battery connector at the truck chassis.
Hydraulic unit:
Pump motor and pump are an integrated unit.
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):
16 Drive motor fuse (F1):
BT Prime-Mover Inc.
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Service Manual
2001-03-15
37
F-code
Section
C-code
M1.0
Version no
T-code
000
RTX35/RTX45
17 Pump motor fuse (F3):

RTX35 425A, 24V BT part number 305656-002
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):
22 Display power fuse (F54):
23 Relay1 fuse (F55):
24 Fuse (AF1):
25 Fuse (AF2):
26 Auxiliary power circuit fuse (AF3):
38
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Service Manual
2001-03-15
F-code
Section
C-code
M1.0
Version no
T-code
000
RTX35/RTX45
12
19
11
16
17
10
8
1+ 01/2
5
4
6
7
9
18
13
14
15
20
21
22
23
24
25
26
Main Components of Truck
BT Prime-Mover Inc.
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Service Manual
2001-03-15
39
F-code
Section
C-code
M1.0
Version no
T-code
000
RTX35/RTX45
3. Grease Point Location
1+ 01/2
40
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Service Manual
2001-03-15
F-code
Section
C-code
M1.0
Version no
000
T-code
RTX35/RTX45
4. Mast Adjustment Points
+1 1
0/2
BT Prime-Mover Inc.
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Service Manual
2001-03-15
41
F-code
Section
C-code
M1.0
Version no
T-code
000
RTX35/RTX45
42
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Service Manual
2001-03-15
F-code
Section
C-code
M1.1
Inch (SAE) and Metric Fasteners
Version no
T-code
001
10
10
1. Introduction
Threaded fasteners such as bolts, nuts, cap screws, and
studs are made to specifications that describe the mechanical
strength and hardness of the fastener. A fastener used in a
design application is selected in accordance with its
specifications. Fasteners that are similar cannot be used as
direct replacements.
Service persons must use replacement fasteners that have
the same specifications as the original. Fasteners made to
each specification have identification marks for that
specification. This specification is commonly called grade
for SAE standards and property for metric standards. This
section describes the identification of some common
fasteners.
The metric system used is described as SI (International
System of Units, also called SI in all languages). The SI
system of measurement is described in ISO Standard 1000,
1973.
BT Prime-Mover Inc.
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Service Manual
2001-03-15
43
F-code
Section
C-code
M1.1
Version no
T-code
001
2. Nomenclature, Threads
The thread design is specified by a series of numbers and
letters for inch and metric fasteners (see figure below). The
diameter of the shank of the fastener is shown first in the
series, e.g. M12=12 mm, M20=20 mm (1/2=1/2 inch, 3/4=3/4
inch).
The number of threads per inch is normally not shown for inch
nomenclature and only the UNC (Unified National Coarse) or
UNF (Unified National Fine) is shown. This number of threads
per inch is not shown because a UNC or UNF fastener has a
standard number of threads per inch for a specific diameter.
The length of a shank is often indicated as part of the
description of a fastener. This length is shown in inches for
inch fasteners and in millimeters for metric fasteners.
A cap screw will have the following description:
INCH
METRIC
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
44
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Service Manual
A = THREAD SIZE
B = PITCH
C = LENGTH
2001-03-15
F-code
Section
C-code
M1.1
Version no
T-code
001
3. Strength Identification
The most common property classes for metric fasteners are
8.8 and 10.9. The property class is marked with a number on
the head of the cap screw or on a nut. Property classes less
than 8.8 are often not marked. Grades for inch bolts go from 2
to 8. Grade 2 fasteners normally do not have marks. The
following tables show the marks that identify the grades and
property classes for different fasteners.
When fasteners must be replaced, new
CAUTION fasteners must be of same strength or
greater than original fasteners. The new
fasteners must also be the correct size.
NOTE! Identification marks are according to bolt
strength. The higher the number, or increase
in number of marks, indicates increased bolt
strength.
BT Prime-Mover Inc.
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Service Manual
2001-03-15
45
F-code
Section
C-code
M1.1
Version no
T-code
001
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
46
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Service Manual
2001-03-15
F-code
Section
C-code
M1.1
Version no
T-code
001
Table 2. Stud and Nut Designations
Types of
Fasteners
Metric Fasteners
Inch Fasteners
* 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
10
12
10
12
10
12
10
12
Service Manual
2001-03-15
47
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Section
C-code
M1.1
Version no
T-code
001
Table 3. Torque Nut Designations
Types of
Fasteners
Inch Fasteners
Metric Fasteners
10
10
or
All Metal Prevailing Torque
Nuts
G
9
10
or
All Metal Prevailing Torque
Flange Nuts
10
or
48
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Service Manual
2001-03-15
F-code
Section
C-code
M1.1
Version no
T-code
001
Table 4. Torque Nut with Nylon Insert Designations
Types of
Fasteners
Metric Fasteners
Inch Fasteners
10
10
or
Nylon Insert Prevailing Torque

Nuts
or
or
10
10
or
Nylon Insert Prevailing Torque

Flange Nuts
BT Prime-Mover Inc.
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Service Manual
2001-03-15
49
F-code
Section
C-code
M1.1
Version no
T-code
001
Table 5. Fastener Torque Values
Size and Pitch
Property, Class
8.8*
Property, Class
10.9**
Property, Class
12.9***
Nm
in-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

internally threaded fasteners made of property
class 10 material.
*** Property class 12.9, Protective Treatment CMHC
internally threaded fasteners of property class 12
material.
50
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Service Manual
2001-03-15
F-code
Section
C-code
M1.1
Version no
T-code
001
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)
BT Prime-Mover Inc.
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Torque Specification
Service Manual
2001-03-15
51
F-code
Section
C-code
M1.1
Version no
T-code
001
4. Conversion of Metric and English

Units
AREA
Multiply
By
To Get
Multiply
By
To Get
inches
6.451
centimeters (cm)
centimeters
0.155
inches (in)
feet
0.093
meters (m)
meters
10.764
feet (ft)
LINEAR
Multiply
By
To Get
Multiply
By
To Get
inches
25.4
millimeters(mm)
millimeter
0.039
inches (in.)
feet
0.305
meters (m)
meter
3.280
feet (ft)
yards
0.914
meters (m)
meter
1.094
yards (yd)
miles
1.609
kilometers (km)
kilometer
0.621
miles (mi)
MASS
Multiply
By
To Get
Multiply
By
To Get
ounces (oz)
28.49
grams (g)
grams
0.035
ounces (oz)
pounds (lb)
0.454
kilograms (kg)
kilograms
2.205
pounds (lb)
tons (2000 lb)
907.18
kilograms (kg)
kilograms
0.001
tons (2000 lb)
tons (2000 lb)
0.907
metric ton (t)
metric ton
1.102
tons (2000 lb)
POWER
Multiply
By
To Get
Multiply
By
To Get
horsepower
0.746
kilowatts (kW)
kilowatts
1.34
horsepower
(hp)
PRESSURE
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
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
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

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.
Return
Service Manual
2001-03-15
55
F-code
Section
C-code
PS
M2.0
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
Return
Service Manual
2001-03-15
F-code
Section
PS
C-code
M2.0
Version no
000
T-code
RTX35/RTX45
MODEL
RTX35
(192 inch mast)
RTX45
(210 inch mast)
11 cc upper/4 cc lower
N/A
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)
2000 lb (908 kg)
(2300 lb / 1044 kg)

2000 lb (908 kg)
(2300 lb / 1044 kg)
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
F-code
Section
C-code
PS
M2.0
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

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
C-code
PS
M3.0
Version no
T-code
000
60
Return
Service Manual
2001-03-15
F-code
PS
Version no
Section
C-code
P
Contents, Section P
T-code
001
Contents, Section P
1. Planned Maintenance
BT Prime-Mover Inc.
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
F-code
Section
C-code
PS
P
Contents, Section P
Version no
T-code
001
62
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Service Manual
2001-03-15
F-code
PS
Section
C-code
P1.0
Introduction, Maintenance
Version no
T-code
000
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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Service Manual
2001-03-15
63
F-code
Section
C-code
PS
P1.0
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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Service Manual
2001-03-15
F-code
PS
Section
C-code
P1.0
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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Service Manual
2001-03-15
65
F-code
Section
C-code
PS
P1.0
Version no
T-code
000
66
Return
Service Manual
2001-03-15
F-code
Section
PS
P2.0
Service Schedule
Version no
C-code
T-code
001
RTX35/RTX45
Service Schedule
1. Planned Maintenance Schedule
ITEM
0000
0000.1
0000.2
0000.3
0000.4
0000.5
0640
0640.1
0640.2
0640.3
1700
1700.1
1700.2
1700.3
1700.4
1700.5
1700.6
1700.7
2550
2550.1
3300
3300.1
WORK REQUIRED
Interval in Hours
Interval in Days/Weeks/Months
Chassis
Check that the truck identification
plate is legible
Check for damage and cracks
Retighten the truck body bolts
(to the chassis)
Check the cover screws
Replace any unreadable or
damaged decals.
Operator Controls
Check that the travel direction/
speed control is operational
Check that the horn button is
operational
Check that the lift pot and
auxiliary buttons are operational
Motors
Check for arcing due to poor
connections
All connections tight
Clean motor of dirt and dust
Check torque of motor bolts
Check for abnormal noise in
motor bearings
Blow carbon, copper, and plastic
particle accumulations from the
motor using compressed air.
Check electrical armature (See
Armature Electrical Check on
page 157.)
Drive Gear
Check for oil leakage
Brake
Clean dust and debris
BT Prime-Mover Inc.
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Service Manual
8
1d
30
1w
120
1m
240
2m
360
3m
720
6m
1440
12 m
4320
36 m
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
2001-03-15
67
F-code
Section
C-code
PS
P2.0
Service Schedule
Version no
T-code
001
RTX35/RTX45
ITEM
3300.2
3300.3
3300.4
3500
3500.1
3500.2
3500.3
3500.4
4100
4100.1
4100.2
5110
5110.1
5110.2
5110.3
5110.4
5200
5200.1
5300
5300.1
5300.2
5300.3
5300.4
5300.5
5400
5400.1
5400.2
68
Return
WORK REQUIRED
Interval in Hours
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
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.
Return
C-code
Service Manual
8
1d
30
1w
120
1m
240
2m
360
3m
720
6m
X
X
1440
12 m
4320
36 m
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
2001-03-15
69
F-code
Section
C-code
PS
P2.0
Service Schedule
Version no
T-code
001
RTX35/RTX45
ITEM
7200.4
7200.5
7200.6
7200.7
7310
7310.1
7310.2
7400.
7400.1
7400.2
7400.3
7400.4
7400.5
7400.6
7400.7
70
Return
WORK REQUIRED
Interval in Hours
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
proper reach stoke and timing.
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
F-code
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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Service Manual
2001-03-15
F-code
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.
BT Prime-Mover Inc.
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2001-03-15
73
F-code
Section
C-code
PS
P2.0
Service Schedule
Version no
T-code
001
RTX35/RTX45
2.2.4. Battery
Contact your battery dealer for specific instructions on care
and maintenance of the battery.
An average battery will have a specific gravity of 1.170 at the
80% discharged level. However, there are many different
batteries on the market. Only the battery manufacturer can
accurately determine the fully charged and 80% charged
levels. Contact the battery manufacturer for this information.
2.2.5. Electrical Connections
All electrical connections should be checked that they are
clean and tight. Plug-in connectors should be unplugged and
plugged back in to clean the terminals. If the truck is equipped
with any of the cold storage, freezer use, or corrosive
environment application packages, the di-electric compound
in the plug-in connectors should be renewed.
2.2.6. Contactor Tips (NOT Sealed)
Inspect contactor tips for arcing, pitting, or burning. Minor
pitting of the tips is not a problem. However, if the tips are
pitted through the tip to the copper bar, the tips should be
replaced. DO NOT file tips. Replace tips only in complete
sets. Some contactors have concealed tips or are fully sealed
so that tips cannot be replaced.
2.2.7. Motor Brushes
The drive motor is equipped with a brush wear sensor which
will indicate when the brushes need replacing. Minimum
brush lengths are given in the specifications section of this
manual. As a rule of thumb, the brushes should be replaced if
the brush spring is within 0.0625 inch (1.6 mm) of touching
the brush holder.
2.2.8. Drive Motor
Blow out the drive motor fan and vents. Check for any signs
of oil on the drive motor fan and air vents. Check for any
damage to the fan or air vents.
WARNING Compressed air used for cleaning MUST
be reduced to less than 30 psi (206 kPa),
and then only with effective chip-guarding
and personal protective equipment worn.
74
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Service Manual
2001-03-15
F-code
Section
PS
P2.0
Service Schedule
Version no
001
C-code
T-code
RTX35/RTX45
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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PS
P2.0
Service Schedule
Version no
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001
RTX35/RTX45
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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Section
PS
P2.0
Service Schedule
Version no
001
C-code
T-code
RTX35/RTX45
2.4.2. Transmission
The transmission fluid should be drained once a year. The
drain port is located on the lower portion of the side cover
opposite the drive tire. Remove the bolt to drain the
transmission fluid. Flush the transmission case. Pour clean
solution into the fill port accessed from battery compartment.
With drive tire off the floor, allow solution to run out of drain
port while transmission is running. Stop flushing when the
solution runs clean. Allow the solution to drain well before
replacing the drain plug bolt. Replace the drain plug bolt.
Refill the transmission with the proper clean oil before
operating the truck.
2.4.3. Battery
At approximately 1500 hours, contact an authorized battery
dealer to determine the overall condition of the battery.
Determine if the battery needs to be washed down. This can
only be done by properly equipped and trained personnel.
2.4.4. Hydraulic System
The hydraulic system should be drained, flushed and refilled,
and the pressure relief valve setting should be checked and
adjusted. This will maintain proper lubrication properties
within the system.
WARNING Before siphoning oil from reservoir, make
certain siphon is clean.
To drain the reservoir, remove the reservoir filter assembly.
Siphon oil from the reservoir and purge the oil out of hydraulic
system. Fill the reservoir with proper clean oil. Operate the
raise and lower function several times to purge air from
system. Check the oil level. Put a rated truck capacity load on
the forks and adjust pressure relief valve, if necessary, so
that truck will lift a rated load.
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PS
P2.0
Service Schedule
Version no
T-code
001
RTX35/RTX45
2.4.5. Brakes
Follow procedures for brake removal before inspecting.
Remove the brake assembly and inspect the friction disc for
wear. The friction disc should be replaced once thickness is
0.25 inch (6 mm) or less. The armature and magnetic coil
should be adjusted if machine will not meet stopping and
holding specifications. The air gap should not exceed 0.014
inch (0.36 mm) and should remain within 0.003 inch (0.076
mm) throughout the circumference.
2.4.6. Lift and Carriage Chains.
Lift and carriage chains should be checked every 720 hours.
A chain gauge should be used to check stretch of the links.
To adjust inner rails, loosen jam nut and tighten chains
equally until the top of the rails are level in the fully lowered
position. Retighten jam nut and torque. Carriage chains
should be adjusted in the fully lowered position with the forks
level. Adjust chains until the top of the forks are 2.0 inches
(50.8 mm) off of the floor.
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F-code
Section
PS
P3.0
Lubrication Chart
Version no
C-code
T-code
000
RTX35/RTX45
Lubrication Chart
Interval/Running Hours
Pos. No.
Service Point
1
2
3
4
5
6
360 h
Wheel bearings
Mast beam
Lifting chains
Hydraulic system
Steering bearings
Drive gear
720 h
1440 h
L
L
L
C
C
L= Lubrication
C = Check
O
L
O
Lubricant
(See Approved
Oils and Grease
on page 81.)
A
A
D
B
A
C
O = Oil change
2
3
+
1/21 0
5
1
1
Truck Lubrication Points
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P3.0
Lubrication Chart
Version no
T-code
000
RTX35/RTX45
80
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F-code
Section
C-code
PS
P4.0
Oil and Grease Specifications
Version no
T-code
000
RTX35/RTX45

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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P4.0
Version no
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RTX35/RTX45
B
+
1/21 0
C
A
A
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F-code
PS
Section
C-code
S
Contents, Section S
Version no
T-code
000
Contents, Section S
1. Service Instructions
NO
FUNCTION GROUP
C-CODE
TROUBLESHOOTING GUIDELINES
0
CHASSIS
0000
MOTORS
1000
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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PS
S
Contents, Section S
Version no
T-code
000
84
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F-code
Section
C-code
PS
S0.0
Troubleshooting Guidelines
Version no
000
T-code
RTX35/RTX45
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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S0.0
Version no
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RTX35/RTX45
The following information is required when placing a service

call:
Truck model and serial number
Service hour meter
Actual battery voltage at open circuit
Actual battery voltage at open circuit at hydraulic operation
under full load
Operating symptoms
Exact results of the testing performed
Perform the following steps before starting all troubleshooting
procedures:
1. 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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PS
S0.0
Version no
000
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RTX35/RTX45
2. Electrical
Many problems are caused by a faulty or dirty battery. Make
sure the battery is clean. Check the electrolyte level and state
of charge.
CAUTION Be sure to block the truck whenever a
troubleshooting procedure requires turning
key switch (S17) ON. This will avoid
accidents caused by unexpected truck
travel.
CAUTION Unless otherwise directed, disconnect the
battery connector when checking electrical
circuits or components with an ohmmeter.
Electrical current can damage the
ohmmeter.
For error code listings see pages 336 and 340. For
programming parameters see page 345. Visually inspect all
wiring and electrical components for the following:
Loose connections or connectors
Loose or broken terminals
Damaged terminals, blocks, or strips
Broken wiring and shorted conditions (especially those that
are close to metal edges or surfaces)
Proper connections from the main electronics card (A5) to
and from the battery
Use an ohmmeter to check for wiring continuity.
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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PS
S0.0
Version no
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000
RTX35/RTX45
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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PS
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Version no
000
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RTX35/RTX45
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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Version no
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RTX35/RTX45
- 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:
-
90
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Motors
Heat sinks
Power cables
Power circuit components
Control circuit components
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Version no
000
T-code
RTX35/RTX45
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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PS
S0.0
Version no
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000
RTX35/RTX45
3. Hydraulic
NOTE! Proper care and cleanliness should be
observed when servicing the truck to ensure
that the oil does not become contaminated
with dirt or other foreign material.
Contaminants drawn into the pump may
cause the pump to stick, score, or fail.
If the hydraulic pump assembly does not operate properly,
preliminary checks should be made of the following: For error
code listings see pages 336 and 340. For programming
parameters see page 345.
Proper oil level
All electrical connections tight
Battery fully charged
CAUTION After elevating or reaching the carriage for
troubleshooting, be sure to use blocks to
secure the carriage.
Use extreme care when blocking the mast
for any reason. Never remove a block when
it is supporting the mast.
Lower the carriage fully and retract the reach mechanism
fully.
If the truck is equipped with tilt, set the forks level, not tilted
either up or down.
If the truck is equipped with sideshift, center the forks
horizontally.
When checking voltage at solenoids, make sure hydraulic
lines and components are fully installed.
Whenever possible, keep the key switch OFF and the
battery connector disconnected.
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C-code
PS
S0.0
Version no
000
T-code
RTX35/RTX45
4. Definitions
Auxiliary Function. A hydraulic function other than lift/lower.
The truck includes: reach/retract; tilt; and sideshift. Some
auxiliary functions, or aux functions are optional features on
the truck.
Continuity. A continuous and uninterrupted path between
two or more locations in an electrical circuit, typically having a
resistance of less than 1 ohm.
Brake Pedal Switch. The switch in the truck that must be
closed to allow reach truck operation. It is activated by the
operator stepping on the foot pedal thus engaging the brake
pedal. Travel is prohibited when the brake is applied.
High Speed Travel Limit. A reduced speed initiated when
the truck is driven while the carriage is elevated above a
certain mast height. This is a safety feature that limits the
speed of travel with an elevated mast and helps prevent
unstable load conditions.
Mast Assembly. The elevating section of the truck, which
bolts to the chassis section adjacent to the battery. The mast
assembly consists of column sections, carriage assembly, lift
cylinders, lift chains, etc.
Mast Switch. A switch on the mast that is actuated when the
carriage is above a certain height on the mast. It is used to
activate the speed limit feature to limit travel speed when the
carriage is elevated.
Open Circuit. A lack of a continuous path between two or
more electrical connections. Generally, when such a circuit is
tested, it will have a resistance greater than ten megohms.
Overtemperature (Power Amplifier). Overtemperature
of
the motor power amplifier is from 185o F (85o C) and above.
At overtemperature the drive current limit is linearly
decreased from full set current down to zero. Plug current is
not reduced to provide full vehicle braking under all thermal
conditions.
Pulse Width Modulation. Pulse Width Modulation (PWM),
also called chopping, controls the speed of the motor by
switching the battery voltage to the motor on and off very
quickly.
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S0.0
Version no
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000
RTX35/RTX45
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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Section
PS
S0.1
Version no
001
C-code
0340
Chassis
T-code
RTX35/RTX45
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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Chassis
S0.1
0340
Version no
T-code
001
RTX35/RTX45
2. Top Console
The top console is a one piece unit. It covers the motor
compartment, the drive and pump transistor regulators, and
contactors. The operator display, key switch, emergency
disconnect switch, and optional push-button switches are
mounted in the top console.
2.1. Removal
1. Park truck on a level surface and block.
2. Turn keyswitch OFF and disconnect the battery
connector.
3. Remove hardware securing the top console to the
frame.
4. Lift the cover up enough to disconnect the wiring
harness connections to the key switch, emergency
disconnect switch, optional push-button switches,
and the operator display.
5. Lift the top console off the steering wheel and
control handle, removing it from the truck.
2.2. Installation
1. Place the top console over the steering wheel and
control handle.
2. Attach the harness connections to the operator
display, the key switch, the emergency disconnect
switch, and the optional push-button switches.
3. Align the bolt holes in the cover with the ones in the
frame.
4. Secure cover to the frame.
5. Reconnect battery connector.
6. Return truck to service.
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Chassis
T-code
RTX35/RTX45
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.
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Chassis
S0.1
0340
Version no
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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
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.
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C-code
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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.
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Chassis
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0340
Version no
T-code
001
RTX35/RTX45
5. Left Operator Compartment Panel

5.1. Removal
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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Service Manual
2001-03-15
F-code
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
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.
BT Prime-Mover Inc.
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Service Manual
2001-03-15
101
F-code
Section
C-code
PS
Chassis
S0.1
0340
Version no
T-code
001
RTX35/RTX45
7. Floor Board
7.1. Removal
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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Service Manual
2001-03-15
F-code
Section
PS
S0.1
Version no
001
C-code
0340
Chassis
T-code
RTX35/RTX45
8. Clipboard
The clipboard is located on the top console near the steering
wheel.
+
1 1/2
0
8.1. Removal
1. Loosen top console to gain access to the clip
mounting hardware.
2. Remove screw, small flat washer, compression
spring, and large flat washer from each clip shaft.
Clip
Large
Flat
Washer
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)
BT Prime-Mover Inc.
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Large Flat
Washer (2)
Service Manual
2001-03-15
103
F-code
Section
C-code
PS
Chassis
S0.1
0340
Version no
T-code
001
RTX35/RTX45
104
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Service Manual
2001-03-15
F-code
Section
C-code
PS
S0.2
0391
Battery Retainer Plates and Rollers
Version no
001
T-code
RTX35/RTX45
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.
BT Prime-Mover Inc.
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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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Service Manual
2001-03-15
F-code
Section
PS
S0.3
0451
Mounting Points
Version no
001
C-code
T-code
RTX35/RTX45
Mounting Points
1. Drive Motor
28
27
26
25
24
23
22
21
19
20
18
17
16
Item No.
BT Prime-Mover Inc.
Return
Description
Item No.
Description
16
Stop, steering
23
Sleeve
17
Screw, cap
24
O-ring
18
Screw, cap
25
Screw, cap
19
Ring, retainer
26
Drive motor assembly
20
Ring, retainer
27
Brake assembly
21
Bearing
28
Sensor assembly
22
Ring, seal
Service Manual
2001-03-15
107
F-code
Section
C-code
PS
S0.3
Mounting Points
0451
Version no
T-code
001
RTX35/RTX45
1.1. Removal
WARNING There is no brake on truck when drive motor
is removed from transmission assembly.
Block all wheels to prevent truck from
rolling.
1. Park the truck on a level surface and make sure all
wheels are blocked to prevent accidental
movement.
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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Service Manual
to
prevent
2001-03-15
F-code
Section
PS
S0.3
0451
Mounting Points
Version no
001
C-code
T-code
RTX35/RTX45
1.2. Installation
1. Remove cap from the top of transmission.
2. Lower drive motor straight down onto transmission.
The drive motor terminals and brush motor sensor
should be facing out.
3. Remove chain, S hooks, and eye bolts from brake
assembly.
4. Apply Loctite 242 to drive motor mounting bolts.
A magnet may be handy to help start the back bolt
or to retrieve a bolt if dropped behind the drive
motor.
5. Using an 9/16 inch (13 mm) socket tighten drive
motor mounting bolts (25).
6. Be sure to draw motor down evenly to allow the
gear on the motor shaft to properly mesh with the
transmission.
7. Attach brake electrical connection (R3).
8. Attach brush wear indicator connections.
9. Install drive motor power cables to terminal posts.
10. Add washers and nuts to terminal posts. Be sure
nuts are tight using an 11/16 inch (17 mm) wrench
for the armature and field connections.
11. Reconnect brush wear sensor, temperature
sensor, and two speed/directional sensor
connections.
BT Prime-Mover Inc.
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Service Manual
2001-03-15
109
F-code
Section
C-code
PS
S0.3
Mounting Points
0451
Version no
T-code
001
RTX35/RTX45
2. Pump Motor
1
2
3
4
5
6
Item
No.
Description
Item
No.
Description
Item
No.
Description
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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Service Manual
2001-03-15
F-code
Section
PS
S0.3
0451
Mounting Points
Version no
001
C-code
T-code
RTX35/RTX45
2.1. Removal
WARNING Block all wheels to prevent truck from
rolling.
Suction (Supply)
Hose To Pump

movement.
2. Lower carriage completely.
3. Drain hydraulic fluid. See System Draining on
page 400.
connector.
Motor
Bracket
Mounting
Bolts

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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2001-03-15
111
F-code
Section
C-code
PS
S0.3
Mounting Points
0451
Version no
T-code
001
RTX35/RTX45
Plug port and hose to prevent contamination of the

hydraulic system.
12. Disconnect brush wear indicator terminals at the
back of the motor.
13. Remove motor and pump assembly from truck. If a
hoist is available, attach a hoist to the bracket and
lift the assembly out. If a hoist is not available,
carefully lift the assembly out while standing in the
operator compartment. Use proper lifting practices
to avoid back injuries.
2.2. Installation
1. Place lift pump and motor assembly with bracket
onto truck frame. Make sure four rubber grommet
shock mounts (6) are in the bracket mounting
holes.
2. Align suction hose flange with reservoir hose. Slide
reservoir hose onto flange as the pump and motor
assembly is installed into the truck. Install hose
clamp at the flange. Be sure clamp is tightened to
prevent leakage. If a leak is found later, the drive
motor will have to be removed to access the
clamps.
Align
Hose
3. Install mounting bolts (4) to secure the motor/pump

into position. Apply Loctite to the four mounting
bolts. Insert bolts through the large washer (5),
then through the bracket mounting plate into truck
frame. Tighten bolts using an 9/16 inch (13 mm)
socket and extension if needed.
4. Install control valve on the bracket.
5. Install hydraulic line from the pump to the control
valve.
6. Install pump motor electrical power cables to the
motor, following the markings on the cables.
Tighten terminal nuts using a M10 wrench. Torque
motor cable securing nuts to 100-120 in-lbs (11.213.6 Nm). Use a second wrench on the stud
terminal securing nut to avoid twisting the stud.
112
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Service Manual
2001-03-15
F-code
Section
PS
S0.3
0451
Mounting Points
Version no
001
C-code
T-code
RTX35/RTX45
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.
10. Remove blocks from truck.
12. Bleed hydraulic system. See Bleeding Hydraulic
System on page 401.
13. Test hydraulic operation of truck.
BT Prime-Mover Inc.
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Service Manual
2001-03-15
113
F-code
Section
C-code
PS
S0.3
Mounting Points
0451
Version no
T-code
001
RTX35/RTX45
3. Transmission
18
17
16
15
14
13
12
10
11
Item
No.
114
Description
Item
No.
Description
Item
No.
Description
Plate, stop
11
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
Return
Service Manual
2001-03-15
F-code
Section
PS
S0.3
0451
Mounting Points
Version no
001
C-code
T-code
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.
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).
BT Prime-Mover Inc.
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Service Manual
2001-03-15
115
F-code
Section
C-code
PS
S0.3
Mounting Points
0451
Version no
T-code
001
RTX35/RTX45
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.
116
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Service Manual
2001-03-15
F-code
Section
PS
S0.4
0640
Driver Controls
Version no
C-code
T-code
001
RTX35/RTX45
Driver Controls
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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Service Manual
2001-03-15
21
117
F-code
Section
C-code
PS
S0.4
Driver Controls
0640
Version no
T-code
001
RTX35/RTX45
Item
No.
118
Return
Item
No.
Description
Description
Handle, control
17
Button, auxiliary
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
connector.
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.
5. Test the operation of truck. Return truck to service.
Handle
Interface
Module
BT Prime-Mover Inc.
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Service Manual
2001-03-15
119
F-code
Section
C-code
PS
S0.4
Driver Controls
0640
Version no
T-code
001
RTX35/RTX45
2. Control Handle
The control handle is the operators means of controlling
travel, lift/lower, and auxiliary functions. The control handle
assembly is located in the middle of the top console, to the
right of the steering wheel.
Lift/lower
Knob
Item
No.
Allen head
screw
Keep 14 of
cable off of the
control handle
straight
Description
Item
No.
Description
Handle, control
Screw
Pin, dowel
Plate, keeper
Support, travel
Module, interface
Screw, set
Screw
2.1. Removal
5
6
2
4

connector.
7
CAUTION Be sure to observe proper precautions
against electrostatic discharge (see Static
Safety on page 23).
3. Unplug control handle wiring harness from the
handle interface module (7).
4. Cut any tie-straps that secure the wiring harness.
5. Loosen Allen head screw (4) that secures the
control handle assembly to its support travel
bracket (3).
6. Slide the control handle assembly to the left, out of
its support bracket.
120
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Service Manual
2001-03-15
F-code
Section
PS
S0.4
0640
Driver Controls
Version no
001
C-code
T-code
RTX35/RTX45
2.2. Installation
1. Insert the shaft of the control handle assembly into
the support bracket (3).
2. Apply thread-locking compound to the threads of
the Allen head screw (4).
3. Hold the control handle in place.
4. Align the hole in the shaft with the set screw hole.
Torque the set screw to 30 ft-lb (42 Nm).
CAUTION To ensure long handle cable life, proper
wire routing is necessary. Make sure 14
inches (355 mm) of the cable off of the
control handle is kept straight.
5. Route the control handle wiring harness up and
plug it into the Handle Interface Module (7).
6. Secure the control handle wiring harness in place
with tie-straps. Ensure the cable extends out of the
handle as straight as possible to avoid kinking.
7. Reinstall top console.
8. Reconnect battery connector and turn key switch
ON.
2.3. Recalibration
Recalibration of the control handle is necessary whenever
error codes 30, 38 or 33 appear on the operator display.
To clear error code 30 (Control Handle Calibration Error
1): Key OFF the truck. Press and hold SW1 on the main
electronic card. Key ON truck until truck powers-up and the
display turns on. Release SW1 to prepare the main electronic
card for calibration of the control handle.
To clear error code 38 (Accelerator Pot Span Calibration
Error): With both foot pedals released, move the control
handle forward and backward the full range of travel until the
code 38 disappears. This calibrates the handle travel and
limit positions.
BT Prime-Mover Inc.
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2001-03-15
121
F-code
Section
C-code
PS
S0.4
Driver Controls
0640
Version no
T-code
001
RTX35/RTX45
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
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Service Manual
2001-03-15
F-code
Section
PS
C-code
S0.5
0642
Brake Pedal (RTX35)
Version no
T-code
000
RTX35/RTX45
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
Return
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
4. Remove the main electronics card panel (see
page 101).

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).
Return
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
Return
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
to make sure battery retainer plates are in place.
4. Remove the main electronics card panel (see
page 101).

foot brake pedal.
CAUTION Disconnect the wire connections to the right
foot pedal switch prior to removal of 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.
Return
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
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.
5. Test the operation of the light assembly, then
return truck to service.
130
Return
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.
Return
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.
Return
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
Return
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
rolling.
1. Park truck on a level surface. Block truck to
prevent accidental movement.
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.
Return
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.
138
Return
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.
Return
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
connector.
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.
5. Reconnect battery and return truck to service.
BT Prime-Mover Inc.
Return
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
Return
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
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
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
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
Severe load condition
Bad service condition
Wrong brush grade
See Copper in brush face

7-12
38-39-41-42
46-47
57-61-62
Copper in Brush Face

Wrong brush grade
2-3
43-46-47-48-49
59-61
Flashover at Brushes
Machine condition
Bad load condition
Lack of attention
14-35
38-39-41-53
5-11
Chattering or Noisy

Looseness in machine
Faulty machine adjust
High friction
Wrong brush grade
See specific surface in evidence

15-16-17
10-11
6-43-45-49-52-58-59
55-58-59
BT Prime-Mover Inc.
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Service Manual
2001-03-15
145
F-code
Section
C-code
PS
S1.2
1700
Version no
T-code
000
RTX35/RTX45

Indications
Immediate Causes
Primary Faults
Brush Chipping or Breakage

Looseness in machine
Vibration
Chattering

evidence
15-16-17
52
See Chattering or Noisy Brushes
14
Sluggish brush movement

Rough or Uneven Surface
1-2-3-4-17
Dull or Dirty Surface
5-44-60
Eccentric Surface
1-19-22-52
High Commutator Bar
Sparking
17
Low Commutator Bar

Streaking or Threading of
Surface
Sparking
Copper or foreign material in
brush face
Glowing
2-25
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
Wrong brush grade
See Copper in Brush Face

43-45-47-49
59-61
Rapid Commutator
Wear with Blackened Surface
Burning
Severe sparking
2-3-11-14
See Sparking
Rapid Commutator
Wear with Bright Surface
Copper Dragging
Foreign material in brush face

Wrong brush grade
Brush vibration
43-45-47-49
61
39-52-58-59
146
Return
Service Manual
See Glowing at Brush Face
2001-03-15
F-code
Section
C-code
PS
S1.2
1700
Version no
000
T-code
RTX35/RTX45

Indications
Immediate Causes
Primary Faults
Heating in Windings

Unbalanced magnetic field
Unbalanced armature currents
Poorly equalized parallel
operation
Lack of ventilation
38-41-42-53
18-19-20-21-27-28-29
8-19-22-25-27-28-29-37

Severe sparking
High friction
Poor commutator surface
Depreciation
High contact resistance
38-41-42
7-8-9-12-20-33-45-57
10-11-36-43-45-49-58-59
evidence
6-24
56

Severe sparking
Raw streaks on commutator
surface
Embedded 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.
Return
Service Manual
2001-03-15
7-13-23-24
147
F-code
Section
C-code
PS
S1.2
1700
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
Version no
000
T-code
RTX35/RTX45

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
Version no
T-code
000
RTX35/RTX45

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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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.
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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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Service Manual
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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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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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
Kit, field coil
14
Band, cover (optional)
Brush
15
Indicator kit, brush wear
Spring, brush
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2001-03-15
161
F-code
Section
PS
S1.4
Pump Motor (RTX 45)
Version no
T-code
000
RTX45
C-code
1750
1. Component Repair
1.1. Motor Disassembly
1. Remove pump motor from truck (see page 111).
2. Remove cover band (14) from the commutator end
of the motor.
the brush holders. Either position the brushes
outside the motor or remove the brush retaining
screws, and remove the brushes (7) from the
motor.
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.
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, drive
BT Prime-Mover Inc.
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2001-03-15
165
F-code
Section
C-code
PS
S1.5
Drive Motor
1760
Version no
T-code
000
RTX35/RTX45
1. Motor Disassembly
1. Remove drive motor from truck (see page 108).
2. For EE motors, remove the head band from the
commutator end of the motor.
the brush holders. Either position the brushes
outside the motor or remove the brush retaining
screws and remove the brushes from the motor.
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.
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)
BT Prime-Mover Inc.
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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
.
NOTE! Use care when pressing the new seal ring into
place so the seal is seated correctly in the
gear housing.
2. Press new seal ring (26) into transmission case
(38).
3. Press drive axle (17) into the transmission case.
Be sure the spacer (25) is aligned with the axle
(17) and that the splines on the drive axle (17) are
aligned with the splines in the bevel gear (33).
4. Place keeper washer (36) onto the drive axle end
and install new bolts (16). Use Loctite 242 on
bolts (16). Torque axle bolts (16) to 81 ft-lb (110
Nm).
5. Install a new O-ring (15) on the lower cover (37).
Install lower cover (37). Lubricate new bolts (34).
Secure lower cover (37) with new bolts (34).
Torque bolts (34) to 18 ft-lb (25 Nm). Make sure
O-ring (15) is not damaged during installation.
6. Install a new copper washer (18) on drain plug
(28). Install drain plug (28) in the transmission. Fill
transmission with oil (see Approved Oils and
Grease on page 81). Install fill level plug (35) in
the transmission case.
7. Install transmission on truck (see page 116).
172
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Service Manual
2001-03-15
F-code
Section
PS
S2.0
2550
Transmission.
Version no
000
C-code
T-code
RTX35/RTX45
2. Leakage
When there is leakage from the transmission top cover,
proceed as follows:
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).
(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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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.
(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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2001-03-15
F-code
Section
PS
S2.0
2550
Transmission.
Version no
000
C-code
T-code
RTX35/RTX45
3. Wheel Bolt
1. Drain transmission oil by removing drain plug (28).
2. Remove transmission from truck.
3. Remove drive axle from the transmission case.
4. Press or knock out the damaged bolt from the drive
axle rim.
NOTE! Always install a new drive axle seal during
assembly.
5. Smooth away any burring around the bolt hole.
Press or knock new bolt into place.
6. Install drive axle into the transmission case (see
page 172).
7. Install transmission on truck.
BT Prime-Mover Inc.
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2001-03-15
175
F-code
Section
C-code
PS
S2.0
Transmission.
2550
Version no
T-code
000
RTX35/RTX45
176
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Service Manual
2001-03-15
F-code
Section
PS
C-code
S3.0
3371
Electromagnetic Brake
Version no
T-code
001
RTX35/RTX45
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
rolling.
movement.

connector.
and left side panel to allow access to
electromagnetic brake.
BT Prime-Mover Inc.
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177
F-code
Section
C-code
PS
S3.0
3371
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
T-code
RTX35/RTX45
2. Installation
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
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
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
rolling.
movement.
connector.
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
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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Service Manual
2001-03-15
F-code
Section
PS
S3.1
Version no
C-code
3531
Drive Wheel
T-code
000
RTX35/RTX45
Drive Wheel
3
4
Item
No.
Description
Item
No.
Description
Tire
Nut
Wheel, drive
Washer, spherical
1. Removal
NOTE! Replace drive wheel when traction problems
develop.
1. Park truck on a level surface.
2. Turn key switch to OFF and disconnect battery at
the battery connector. Check to make sure battery
retainer plates are in place.
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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Service Manual
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
Return
Service Manual
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
Return
Service Manual
2001-03-15
F-code
Section
C-code
PS
S3.2
3541
Non-Braking Caster Assembly
Version no
001
T-code
RTX35

1
3
6
4
7
8
9
17
10
11
12
19
20
18
13
14
17
15
16
Return
Service Manual
2001-03-15
187
F-code
Section
C-code
PS
S3.2
3541
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
Version no
001
T-code
RTX35
1. Caster Pivot
1.1. Removal
connector. Check to make sure the battery retainer
plates are in place.
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.
Return
Service Manual
2001-03-15
189
F-code
Section
C-code
PS
S3.2
3541
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.
11. Test truck operation, then return to service.
190
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Service Manual
2001-03-15
F-code
Section
C-code
PS
S3.2
3541
Version no
001
T-code
RTX35
2. Thrust Bearing
2.1. Removal
3. Jack the rear of the truck.
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.
Return
Service Manual
2001-03-15
191
F-code
Section
C-code
PS
S3.2
3541
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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Service Manual
2001-03-15
F-code
Section
C-code
PS
S3.2
3541
Version no
001
T-code
RTX35
3. Caster Springs
3.1. Adjustment
5.375-5.50 inches
2. Turn key switch OFF, disconnect

connector, and securely block the truck.
battery

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)

3. Jack the rear of the truck.
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.
Return
Service Manual
8. The springs must be removed from the side.
2001-03-15
193
F-code
Section
C-code
PS
S3.2
3541
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)
21 inches (533 mm) / 2400 lb (1090 kg)
21 inches (533 mm) / 2600 lb (1180 kg)
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.

9. Test truck operation.
194
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Service Manual
2001-03-15
F-code
Section
C-code
PS
S3.2
3541
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.

10
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.
Return
Service Manual
2001-03-15
195
F-code
Section
C-code
PS
S3.2
3541
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

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.)
the battery connector. Check to make sure the
battery retainer plates are in place.
4. Remove wheel cap (8).
5. Bend lockwasher (5) tab down and remove locknut
(6).
BT Prime-Mover Inc.
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Service Manual
2001-03-15
197
F-code
Section
C-code
PS
S3.3
3542
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
Return
Service Manual
2001-03-15
F-code
PS
Version no
001
Section
C-code
S3.4
3543
Braking Caster Assembly
T-code
RTX45

1
2
3
5
4
25
26
23
24
23
7
9
17
21
22
10
11
12
20
19
13
18
14
16
BT Prime-Mover Inc.
Return
15
17
Service Manual
2001-03-15
199
F-code
Section
C-code
PS
S3.4
3543
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
Version no
001
T-code
RTX45
1. Removal
NOTE! For models with a brake on the caster wheels.
1.1. Caster Brake Adjustment

place.
4. Remove main
page 101).
electronic
card
panel
(see
CAUTION Pinch point. Keep fingers clear of the floor

foot brake pedal.
CAUTION Disconnect wire connections to the right
foot pedal switch prior to removal of 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
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
Return
Service Manual
2001-03-15
F-code
Section
C-code
PS
S3.5
3544
Braking Caster Wheel Assembly
Version no
T-code
000
RTX45

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
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.)
4. Remove wheel cap (8).
5. Bend down lockwasher (5) tab and remove locknut
(6).
6. Remove caster wheel assembly.
7. Inspect and replace the race and bearing (4) as
needed.
8. Remove E-ring (9) and cap screws (11) if brake
assembly is to be replaced, otherwise replace
brake shoes.
9. Remove nuts (12), washer (13), and slide brake
plunger (16) up to remove brake pivot (14) and
other washer (13).
10. Remove brake plunger (16) and spring (15).
204
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Service Manual
2001-03-15
F-code
Section
C-code
PS
S3.5
3544
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).
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
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.
Return
Description
Item
No.
Description
Axle
Washer, 16 gauge
Toe box
Bearing
Plate, rocker
Wheel, load
Ring, retainer
10
Nut
Fitting, grease
11
Bolt, shoulder
Washer, 10 gauge
Service Manual
2001-03-15
207
F-code
Section
PS
S3.6
Tandem Load Wheels
Version no
T-code
000
RTX35/RTX45
C-code
3551
1. Removal
NOTE! Replace load wheels when traction problems
develop.
2. Lower the carriage fully
3. Turn key switch to OFF. Disconnect the battery at
rolling.
4. Hoist truck so the load wheels are approximately 2
inches (50.8 mm) off the floor and securely block.
5. Remove retainer ring (4) from the axles.
6. Use a piece of rod or a punch to tap the axle (1)
back out through the wheels. Remove rocker plate
(3). Remove two washers (6 and 7) on each side of
the wheel (9). The axle is welded into the rocker
plate. Remove the load wheel (9) from the toe box
(2).
7. Inspect bearings (8).
208
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Service Manual
2001-03-15
F-code
PS
Section
C-code
S3.6
3551
Tandem Load Wheels
Version no
000
T-code
RTX35/RTX45
2. Installation
1. Pack bearings with grease.
2. Install bearings (8) in the load wheel (9).
WARNING Install bearing shield and 10 gauge
washer (6) properly.
3. Install load wheel assembly in the toe box (2).
NOTE! Place a block behind the axle (1) to hold it in
place while assembling the rocker plate and
snap rings.
4. Install axle (1), washers (6 and 7) and rocker plate
(3).
5. Install retainer rings (4) to axle (1).
7. Remove blocking and lower truck to the floor.
9. Test operate truck.
BT Prime-Mover Inc.
Return
Service Manual
2001-03-15
209
F-code
Section
PS
S3.6
Tandem Load Wheels
Version no
T-code
000
RTX35/RTX45
210
Return
C-code
3551
Service Manual
2001-03-15
F-code
PS
Section
C-code
S3.7
3555
Single Load Wheels
Version no
T-code
000
RTX35/RTX45
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.
2. Lower carriage fully. Turn key switch to OFF.
Disconnect the battery at battery connector. Check
place.
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).
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.
9. Test the operation of the load wheel and truck.
Return truck to service.
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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

rolling.
6
18
17
11
8
9
7
12
16
10
15
13
1. Park truck on a level surface and block wheels.

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.
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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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Service Manual
2001-03-15
F-code
Section
PS
S4.0
Version no
T-code
001
Spring
E-Clip
C-code
4110
Steer Tach
RTX35/RTX45
Steer Tach
The steer tach is attached to a bracket beneath the steering
wheel.
Item
No.
Set screw
Coupler
1
2
3
Description
Item
No.
Description
Cap, spinner
10
Bracket
Nut
11
Spring
Washer
12
Ring, retainer
Spinner
13
Coupler
Wheel, steering
14
Tachometer
Spacer, steering
15
Screw
Bushing, flat
16
Washer, flat
Bushing, flanged
17
Support, steering
Screw
18
Screw
1. Removal

rolling.
5
6
1. Park truck on a level surface and block wheels.
18
17
11

connector.
7
12

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.
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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.
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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.)
2. Turn key switch to OFF and disconnect the battery
at battery connector. Check to make sure the
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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Service Manual
2001-03-15
F-code
PS
Version no
001
Section
C-code
S5.0
5000
Electrical Functions
T-code
RTX35/RTX45
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
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

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
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.
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2001-03-15
223
F-code
Section
C-code
PS
S5.0
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
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.
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2001-03-15
225
F-code
Section
C-code
PS
S5.0
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
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.
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2001-03-15
227
F-code
Section
C-code
PS
S5.0
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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2001-03-15
F-code
PS
Version no
001
Section
C-code
S5.0
5000
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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229
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Section
PS
S5.0
Version no
T-code
001
RTX35/RTX45
C-code
5000
The main electronic card (A5) interprets the input from the
steer tachometer (depending upon the sensitivity setting
selected) and instructs the steer motor to rotate clockwise
(direction parameter 11 set to forward) by supplying Bvoltage through wire #60 from output 903 to the steer
motor with respect to wire #61, connector pin 904.
The drive wheel steers in a counter-clockwise direction
turning the forks of a moving, forks leading truck to the
right.
Turning the steering wheel counter-clockwise directs B+
current to the steer motor through a series of steps:
The steer tachometer determines the rate and direction of
steer wheel rotations.
Turning the steer tachometer counter-clockwise sends 0 to
-2.9 volts (depending upon the rate of rotation of the
steering wheel) to the main electronic card (A5) at input
502 with respect to connector pin 503.
The main electronic card (A5) interprets the input from the
steer tachometer (depending upon the sensitivity setting
selected) and instructs the steer motor to rotate
counterclockwise (direction parameter 11 set to forward)
by supplying B+ voltage through wire #60 from output 903
to the steer motor with respect to wire #61, connector pin
904.
The drive wheel steers in a clockwise direction turning the
forks of a moving, forks leading truck to the left.
230
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F-code
PS
Version no
001
Section
C-code
S5.0
5000
T-code
RTX35/RTX45
This page intentionally left blank
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231
F-code
Section
C-code
PS
S5.0
5000
Version no
T-code
001
RTX35/RTX45
A5
F53
67
810 12V +
31
811 -
32
58
S66
59
S67
22
57
S65
204
STEERING STOP A
203
STEERING STOP B
202
STEER WHEEL POSITION
40
40
902 (0V)
Wheel Direction Sensors
Legend
ELECTRIC POSITIVE
ELECTRIC NEGATIVE
LED OFF ( Not lit)
LED input (lit)
LED output (lit)
232
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F-code
PS
Version no
001
Section
C-code
S5.0
5000
T-code
RTX35/RTX45
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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233
F-code
Section
C-code
PS
S5.0
Version no
T-code
001
RTX35/RTX45
5000
Table 1: Sensor Sequence

S65
Steer Wheel
Position
A5 input 202
wire #57
S66
Steering
Stop A
A5 input 204
Wire #58
S67
Steering
Stop B
A5 input 203
Wire #59
Drive Wheel Steering Clockwise (viewed from top)

Sensor Status
Drive wheel is parallel to truck
ON
OFF
OFF
Drive wheel steers and approaches steering

stop
ON
ON
OFF
Drive wheel continues steering toward

steering stop
OFF
ON
OFF
At the Steering Stop
OFF
ON
ON
Drive Wheel Steering Counter-Clockwise (viewed from top)

Sensor Status
Drive wheel is parallel to truck
ON
OFF
OFF
Drive wheel steers and approaches steering

stop
ON
OFF
ON
Drive wheel continues steering toward

steering stop
OFF
OFF
ON
At Steering Stop
OFF
ON
ON
Drive Wheel Steering Direction

Sensor Status
234
Return
Failure Error
OFF
OFF
OFF
Failure Error
ON
ON
ON
Service Manual
2001-03-15
F-code
Section
PS
C-code
S5.0
5000
Version no
T-code
001
RTX35/RTX45
4. Brake Release
Brake release occurs when the brake pedal is fully
depressed. The emergency switch (S21) ON, key switch
(S17) ON and the brake pedal fully depressed (down) causes
the brake switch (S48) to open removing the input to the main
electronic card (A5) terminal 111 (wire #43). The brake
potentiometer (R3) output goes to a higher voltage than when
the brake pedal is released (up). The main electronic card
(A5) senses the increase in voltage at terminal 511 (wire
#65). The main electronic card (A5) responds by turning on
output 805 (wire #64) sending current to the magnetic brake
coil (Y1). The energizing of the brake coil (Y1) causes the
brake pressure plate to move from the brake friction plate,
releasing the brake and allowing the truck to travel.
Legend
ELECTRIC POSITIVE
ELECTRIC NEGATIVE
LED OFF ( Not lit)
LED input (lit)
LED output (lit)
K10
K10
A5
A1
44
F1
3
A2
M1
B+
ARMATURE
B-
S21
7
2
A1
K13
8
22
40
29 504 +7.35V
50 505 +3.65V
K13
M1
K11
902
FIELD
K11
101
34
30 510 0V
M
1
805
65
R3
64
Y01
51
K11
52
K13
511
803
F50
802
808
36V only
S48
43
21
S108
S21
24
S17
49
22
501
111
102
809
Brake Release
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235
F-code
Section
C-code
PS
S5.0
5000
Version no
T-code
001
RTX35/RTX45
K10
K10
A1
F1
A2
M1
A1
FIELD
M1
K11
B7
10
ARMATURE
2
K11
B+
44
K13
11
6
34
36
22
37
35
M
1
902
40
611
609 -
A71
HM104
HM105
29 504 +7.35V
50 505 +3.65V
HM110
30 510 0V
HM111
64
Y1
51
K11
52
K13
805
R1
Blue/white stripe
HM215
Orange/black stripe
F50
101
610
K13
8
A5
S21
R3
65 511
803
802
HM210
Red/white stripe
HM213
808
36V only
S48
43
21
S108
S21
24
S17
501
111
49
102
22 809
S60
39
104
Travel Request, Forks First
Legend
ELECTRIC POSITIVE
ELECTRIC NEGATIVE
LED OFF ( Not lit)
LED input (lit)
LED output (lit)
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T-code
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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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S5.0
Version no
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001
RTX35/RTX45
5000
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
4. The mast is extended above free lift height (S31). (See
5. Mast switches (S31 and S45) sequence error. (See
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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Section
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S5.0
5000
T-code
RTX35/RTX45
displayed and the control handle has been calibrated for truck
operation. If control handle calibration was not successful the
same or other codes may be displayed. Other codes could be
caused by incorrect calibrating procedure, a bad control
handle, a failed control handle interface card, a failed control
module (A5) or wiring.
The relationship between the drive transistor (A1) regulator
speed request voltage and travel potentiometer (R1) is an
approximate relationship and include the following:
The travel speed request voltage range is 0 to 5 volts. The
travel potentiometer (RI) voltage is approximately 0.6 to
2.2 volts with the center at approximately 1.4 volts.
Moving the control handle away from the operator causes
voltage to increase from 1.4 to 2.2 volts. For every 0.16
volt increase of the travel potentiometer (R1), the speed
request will increase approximately 1 volt.
The speed request voltage is from the main electronic card
(A5) terminal 610 through wire #36 to the drive transistor
(A1) regulator pin 10.
Wire #35, connecting the drive transistor (A1) regulator pin
6 and the main electronic card (A5) pin 609, is the common
reference for the speed request/current limit voltages.
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PS
S5.0
5000
Version no
T-code
001
RTX35/RTX45
K10
K10
A1
44
F1
3
A2
M1
B+
ARMATURE
2
A1
FIELD
K11
M1
K11
B10
K13
11
6
34
22
101
610
37
M
1
902
40
611
609 -
A71
HM104
35
HM105
29 504 +7.35V
50 505 +3.65V
HM110
30 510 0V
HM111
64
Y1
51
K11
52
K13
805
R1
Blue/white stripe
HM215
Orange/black stripe
F50
S21
36
K13
8
A5
R3
65
511
803
HM210
Red/white stripe
HM213
802
808
36V only
S48
43
21
S108
S21
24
501
111
49
102
22 809
S17
S60
104
39
Travel Request, Forks Trailing
Legend
ELECTRIC POSITIVE
ELECTRIC NEGATIVE
LED OFF ( Not lit)
LED input (lit)
LED output (lit)
240
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Section
C-code
S5.0
5000
T-code
RTX35/RTX45
6. Travel Request, Forks Trailing

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
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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Version no
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RTX35/RTX45
C-code
5000
(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
4. The mast is extended above free lift height (S31). (See
5. Mast switches (S31 and S45) sequence error. (See
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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T-code
RTX35/RTX45
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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Section
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PS
S5.0
5000
Version no
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001
RTX35/RTX45
K10
K10
A1
3
A2
M1
B+
K11
FIELD
M1
K13
11
37
M
1
609 611
A71
29
HM104
50
HM105
1
30
HM110
R1
22
40
610
35
6
8
902
103
36
10
K13
K11
101
34
38
2
A1
S21
B7
ARMATURE
A5
44
F1
504 +7.35V
505 +3.65V
510 0V
HM111
Blue/white stripe
Orange/black stripe
Red/white stripe
HM210
Y1
51
K11
52
K13
805
R3
HM215
64
511
65
803
802
HM213
F50
810 +
811 -
22
808
36V only
S48
21
S108
S21
24
S17
S
125
501
43
49
111
102
23
105
809
22
S
64
56
201
Plug Braking
Legend
ELECTRIC POSITIVE
ELECTRIC NEGATIVE
LED OFF ( Not lit)
LED input (lit)
LED output (lit)
244
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C-code
S5.0
5000
T-code
RTX35/RTX45
7. Plug Braking
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
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

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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T-code
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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
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
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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C-code
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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.
248
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Version no
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RTX35/RTX45
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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S5.0
5000
Version no
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001
RTX35/RTX45
CONTROL
HANDLE
S55 S56
S212 S211
S52 S51
S18
A5
A71
HM214 +7.35V
HM104
29
50
HM105
R11
HM208 +7.35V
HM106
HM211
HM110
82
30
504 +7.35V
505 +1.4V
506 +1.65V
510 0V
HM111
HM215 +7.35V
R1
R3
HM210
511
21
HM213
F50
1
Legend
7.35-Volt Power Supplies

ELECTRIC POSITIVE
ELECTRIC NEGATIVE
LED OFF ( Not lit)
LED input (lit)
LED output (lit)
250
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T-code
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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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5000
Version no
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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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Version no
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RTX35/RTX45
S45
A5
22 40
106
S31
207
107
79
22 40
88
40
Y10
A2
804
10
75
702
Speed Limit (S31) and Mast (S45) Switches
Legend
ELECTRIC POSITIVE
ELECTRIC NEGATIVE
LED OFF ( Not lit)
LED input (lit)
LED output (lit)
254
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Service Manual
2001-03-15
F-code
PS
Version no
001
Section
C-code
S5.0
5000
T-code
RTX35/RTX45
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.
BT Prime-Mover Inc.
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2001-03-15
255
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PS
S5.0
5000
Version no
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001
RTX35/RTX45
A8
A5
F52
22
3+
+5
4 0V
-2
125
126
40
S45
106
405 +
402 -
207
F53
810
31
U10
+
98
205
99
206
B
32
811
Legend
Height Indicator
ELECTRIC POSITIVE
ELECTRIC NEGATIVE
LED OFF ( Not lit)
LED input (lit)
LED output (lit)
256
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Service Manual
2001-03-15
F-code
PS
Version no
001
Section
C-code
S5.0
5000
T-code
RTX35/RTX45
11. Height Indicator

The height indicator is designed to display the fork height in
the main lifting zone. The components of the height indicator
system include: height counter (U10); fuse F52, height
display (A8); staging switch (S45); and main electronic card
(A5). The height counter is a two-counter pulse generator
(encoder). The height indicator provides a digital display of
fork height in English or metric units. The staging switch
(S45) signals the beginning and end of freelift. The main
electronic card (A5) processes the information from the
height counter (U10), mast switch (S45), and Fork Reference
Parameter 10. The result of the processed information is a
fork height value to be displayed by the height display.
Communication to the height display from the main electronic
card (A5) is by a two wire proprietary data communication
scheme.
With the battery connected, emergency switch ON and the
key OFF, the height display (A8) will display four vertical half
bars. This is the correct indication showing the height display
not communicating with the main electronic card (A5). When
the key is turned ON, the height display will go to four solid
decimal points. If the decimal points flash, lower the forks
below the reference height, into the freelift zone. Set the
Special Height Parameter 9 to the lift limit height or to the
maximum mast height. If the decimal points continue to flash,
check for a broken communication wire (wire #125 and #126),
a failed staging switch (S45), a failed height display (A8), or a
failed main electronic card (A5). When lifting, the height
display will show solid decimal points until the staging switch
(S45) turns OFF, removing voltage to the main electronic
card (A5) input 207 (wire #106). The main electronic card
(A5) responds by communicating the Fork Reference
Parameter 10 to the height display from outputs 405 (wire
#125) and 402 (wire #126). The height display shows the
Fork Reference Parameter value. When the intermediate
columns begin to lift, the mast cable turns the height counter.
The height counter is powered from the main electronic card
(A5) 12 volt supply, output 810 (wire #67), fuse F53 (wire
#31) and common, output 811 (wire #32). As the counter
turns, the two outputs (A and B) send pulses to the main
electronic card (A5), inputs 205 (wire #98) and input 206 (wire
# 99). The counter signals pulse between +12V and Gnd and
BT Prime-Mover Inc.
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Service Manual
2001-03-15
257
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Section
PS
S5.0
Version no
T-code
001
RTX35/RTX45
C-code
5000
can be monitored with a VOM while lifting slowly. The number

of pulses indicates the distance the mast has moved. The
phase relationship between the pulses indicates the direction
the mast is moving. As the main electronic card (A5)
processes the information from the height counter (U10), the
height display (A8) is continually updated with the new fork
height. As the mast approaches the value of the Special
Height Parameter 9 while lifting, the main electronic card (A5)
reduces and then stops the speed request to the pump
transistor (A2) regulator at the Special Height.
If the truck is equipped with an over-ride push button, the
operator can continue work above Special Height after
pushing the over-ride button. While lowering, the main
electronic card (A5) processes the information from the
height counter. The height display is continually updated with
the new fork height. When the staging switch (S45) enters the
inner column, the main electronic card (A5) stops counting
and resets to the Fork Reference height. The height display
(A8) shows four solid decimal points.
258
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Service Manual
2001-03-15
F-code
Section
PS
C-code
S5.0
5000
Version no
T-code
001
RTX35/RTX45
12. Drive Motor Brush Wear Indicator

Switches
Diagram covers the drive motor brush indicator switches
(SA1 and SA2). The drive motor on the reach truck contains a
pair of brush wear indicator switches. When the brushes need
replacing, an error code (C016) will display on the operator
display. This is accomplished by metal bars, connected by
wires to a connector in the motor frame, contacting the brush
spring as the brush wears down. This completes a circuit
allowing high side armature voltage to main electronic card
(A5) input 209 (wire #42) and/or low side armature voltage to
main electronic card (A5) input 208 (wire #41) depending on
whether the north or south pole brushes are worn. Brushes
should be inspected on a regular basis and replaced when
the error code displays.
K10
K10
A5
A1
F1
44
3
SA2
B+
B-
S21
101
34
M1
ARMATURE
2
SA1
902
40
FIELD
K11
K13
M1
K11
K13
8
M
41
803 51
K11
52
K13
208
Legend
802
ELECTRIC POSITIVE
42
209
ELECTRIC NEGATIVE
LED OFF ( Not lit)
LED input (lit)
LED output (lit)
BT Prime-Mover Inc.
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Drive Motor Brush Wear Indicator Switches

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2001-03-15
259
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Section
C-code
PS
S5.0
5000
Version no
T-code
001
RTX35/RTX45
13. Pump Motor Brush Wear Indicator

Switches
Diagram covers the pump motor brush wear indicator
switches (SA1 and SA2). The pump motor on the truck
contains a pair of brush wear indicator switches. When the
brushes need replacing, an error code (C017) will display on
the operator display. This is accomplished by metal bars,
connected by wires to a connector in the motor frame,
contacting the brush spring as the brush wears down. This
completes a circuit allowing high side armature voltage to
main electronic card (A5) input 211 (wire #78) and/or low side
armature voltage to main electronic card (A5) input 210 (wire
#77) depending on whether the north or south pole brushes
are worn. Brushes should be inspected on a regular basis
and replaced when the error code displays.
A2
14
F3
9
ARMATURE
M3
SA2
B+
B-
40
FIELD
M3
10
SA1
A5
77
210
Legend
ELECTRIC POSITIVE
78
ELECTRIC NEGATIVE
211
LED OFF ( Not lit)

LED input (lit)
LED output (lit)
260
Return
Pump Motor Brush Wear Indicator Switches

Service Manual
2001-03-15
F-code
Section
PS
C-code
S5.0
5000
Version no
T-code
001
RTX35/RTX45
14. Safety Check

Diagrams (Safety Check A and B) cover the safety checks on
the drive transistor regulator (A1). Once a year a safety check
of the system must be performed. The safety check is
performed by connecting the battery, turning the emergency
switch ON, turning the key switch ON, and placing a jumper
from the drive transistor regulator B-terminal to connector pin
2. The jumper will cause the line contactor (K10) to open and
the main electronic card (A5) to respond with an error code
E102. Successful completion of check confirms the circuit is
operating.
K10
K10
A1
3
A2
M1
B+
ARMATURE
2
K11
FIELD
B7
A1
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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PS
S5.0
5000
Version no
T-code
001
RTX35/RTX45
K10
K10
A1
3
A2
B+
ARMATURE
M1
2
K11
FIELD
B7
A1
A5
44
F1
S21
34
101
902
40
K13
M1
K11
K13
8
Legend
Safety Check B
ELECTRIC POSITIVE
ELECTRIC NEGATIVE
LED OFF ( Not lit)
LED input (lit)
LED output (lit)
262
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2001-03-15
F-code
PS
Section
C-code
S5.0
5000
Version no
T-code
001
RTX35/RTX45
15. Shunt Power Cable

The shunt power cable measures the total truck current
flowing to the negative side of the battery. This is a special
length and gauge of wire and must be replaced with the
correct parts for proper operation. Polarity of the two shunt
power cable lead wires (#606 + and #607 -) must be
observed when connecting to the main electronic card (A5).
The voltage measured by the main electronic card (A5)
across the shunt is used for battery discharge indication.
Shunt Wire
+
1
40
A5
606
607
608
Legend
ELECTRIC POSITIVE
606 -(+)
607 -(-)
608 +
Shunt Power Cable
ELECTRIC NEGATIVE
LED OFF ( Not lit)
LED input (lit)
LED output (lit)
BT Prime-Mover Inc.
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2001-03-15
263
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Section
C-code
PS
S5.0
Version no
T-code
001
RTX35/RTX45
5000
List of Symbols
264
Return
Symbol
Designation
Function
Remark
A1
Drive transistor regulator
Drive Motor
A2
Pump transistor regulator
Pump Motor
A5
Electronic card
Main Card
A6
Electronic card
Display
A7
Electronic card
Height Preset
A8
Electronic card
Height Indication
A71
Electronic card
Signal Conditioning Module
BT
Battery
E1
Light
Overhead Guard
E3
Light
Work
E4
Light
Work
E21
Heater
A1/A2
E22
Heater
Handle
E23
Heater
Handle
E24
Heater
Left Foot Switch
E25
Heater
Right Foot Switch
E26
Heater
A5
F1
Fuse
Drive Motor
250 Amp
F3
Fuse
Pump Motor
24V-425A
36V-355A (RTX35)
36V-500A (RTX45)
F50
Fuse
Control Circuit
10 Amp
F51
Fuse
Steering Motor
30 Amp
F52
Fuse
Lift Height Indicator
1/4 Amp
F53
Fuse
12 V. Sensor Feed
1/4 Amp
24/36 Volt
Service Manual
2001-03-15
F-code
PS
Section
C-code
S5.0
5000
Version no
001
T-code
RTX35/RTX45
List of Symbols
Symbol
BT Prime-Mover Inc.
Function
Remark
F54
Fuse
Display Power
1/4 Amp
F55
Fuse
Relay 1
10 Amp
F81
Fuse
Main Electronic Card and Control

Handle Heaters (Option)
10 Amp
F82
Fuse
Transistor Requlators and Pedal

Switch Heaters (Option)
10 Amp
F83
Fuse
Aux. Power Circuit
2 Amp
H1
Horn
Alarm
H2
Flashing light
Light
option
H3
Traction
Alarm
option
K10
Contactor
Main Contactor
K11
Contactor
Driving in Direction of Forks
Forks leading
K13
Contactor
Driving in Direction of Operator
Forks Trailing
K34
Contactor
Bypass Lift
RTX45 only
K101
Relay
Fan and Working Light
36 volt only
K102
Relay
Flashing Light
36 volt only
K103
Relay
A1/A2
36 volt only
K104
Relay
A5 Heater
36 volt only
K105
Relay
Solid State Horn
36 volt only
M1
Motor
Drive Motor
M3
Motor
Pump Motor
M6
Motor
Steering Motor
M12
Fan
Electronics
Potentiometer
Travel
R1
Return
Designation
Service Manual
2001-03-15
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PS
S5.0
Version no
T-code
001
RTX35/RTX45
5000
List of Symbols
Symbol
266
Return
Designation
Function
Remark
R3
Potentiometer
Brake
R11
Potentiometer
Lift/lower
R20
Resistor
Plug-in Module
Not used
R21
Resistor
Output Load
Not used
R22
Resistor
Output Load
S17
Switch
Key
S18
Switch
Horn
S21
Switch
Emergency stop
S31
Switch
Speed Limit
S33
Switch
Lift Limit Override
S45
Inductive sensor
Carriage Sensor
S48
Switch
Brake, 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
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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S5.0
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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F-code
Section
PS
C-code
S5.0
5000
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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R3
2001-03-15
269
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Section
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S5.0
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
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2001-03-15
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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
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)
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273
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T-code
001
RTX35/RTX45
C-code
5000
Legend
274
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Service Manual
2001-03-22
F-code
PS
Section
C-code
S5.2
5000
Version no
001
T-code
RTX35/RTX45
Legend
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2001-03-22
275
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Section
PS
S5.2
Version no
T-code
001
RTX35/RTX45
C-code
5000
Legend
276
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Service Manual
2001-03-22
F-code
PS
Section
C-code
S5.2
5000
Version no
001
T-code
RTX35/RTX45
Legend
BT Prime-Mover Inc.
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2001-03-22
277
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Section
PS
S5.2
Version no
T-code
001
RTX35/RTX45
C-code
5000
Legend
278
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Service Manual
2001-03-22
F-code
PS
Section
C-code
S5.2
5000
Version no
001
T-code
RTX35/RTX45
Legend
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2001-03-22
279
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Section
PS
S5.2
Version no
T-code
001
RTX35/RTX45
C-code
5000
Legend
280
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Service Manual
2001-03-22
F-code
PS
Section
C-code
S5.2
5000
Version no
001
T-code
RTX35/RTX45
Legend
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2001-03-22
281
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Section
PS
S5.2
Version no
T-code
001
RTX35/RTX45
C-code
5000
Legend
282
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2001-03-22
F-code
PS
Version no
001
Section
C-code
S5.2
5000
T-code
RTX35/RTX45
Legend
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2001-03-22
283
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Section
PS
S5.2
Version no
T-code
001
RTX35/RTX45
C-code
5000
Legend
284
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Service Manual
2001-03-22
F-code
Section
PS
S5.3
Version no
001
C-code
5110
Battery
T-code
RTX35/RTX45
Battery
Battery
Connector
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.
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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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2001-03-15
287
F-code
Section
C-code
PS
Battery
S5.3
5110
Version no
T-code
001
RTX35/RTX45
4. Storage
Before storing the battery, make sure the electrolyte is at the
proper level in all the cells, filler plugs are tight, and battery is
fully charged. Store battery in a clean, cool, dry location away
from radiators and other sources of heat. Check the
electrolyte level and specific gravity every 30 days during
storage. Whenever the specific gravity is less than 1.230,
charge the battery.
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
connector.
2. From the top of the overhead guard, remove four
screws securing the light/fan assembly.
3. Lower the light/fan assembly enough to disconnect
it from the harness.
4. Remove light/fan assembly from truck.
5. Repair or replacement of the light is achieved by
removing four screws in the sides of the light/fan
console assembly to detach the hanger bracket
from the top of console.
1.2. Installation
1. Reassemble the light/fan console assembly. Be
sure clip nuts are positioned over mounting holes
for attachment to the overhead guard.
2. Reconnect harness connections.
3. Install mounting screws through the top of
overhead guard to secure the assembly.
BT Prime-Mover Inc.
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Service Manual
2001-03-15
289
F-code
Section
C-code
PS
S5.4
Light Assemblies
5121
Version no
T-code
001
RTX35/RTX45
1
2
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
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.
4. Test the operation of warning lights, then return
truck to service.
290
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Service Manual
2001-03-15
F-code
Section
PS
S5.4
5121
Light Assemblies
Version no
001
C-code
T-code
RTX35/RTX45
3. Working Lights (Option)

The working lights option consists of two flood lights mounted
on the underside of the overhead guard.
3.1. Removal
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.
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
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).
4. Test the operation of the alarm, then return truck to
service.
292
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Service Manual
2001-03-15
F-code
Section
PS
S5.5
Version no
001
C-code
5160
Horn
T-code
RTX35/RTX45
Horn
NOTE! The horn can only be sounded with the key
switch in the ON position.
2
1. Removal
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.
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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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Service Manual
2001-03-15
F-code
PS
Version no
001
Section
C-code
S5.6
5192
Battery Connector
T-code
RTX35/RTX45
Battery Connector
2
1
4
Item No.
Battery
Connector
Description
Connector, SB-350
Cap screw
Cable, Negative
Cable, Positive
1. Location
The battery connector is located on the right side of the truck,
above the battery.
f
BT Prime-Mover Inc.
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Service Manual
2001-03-15
295
F-code
Section
PS
S5.6
Battery Connector
Version no
T-code
001
RTX35/RTX45
C-code
5192
2. Inspection
connector.
2. Check battery connector for damaged cables.
3. Check to see if battery cables are pulling out of the
connector.
4. Check cables at the battery terminals. Connections
should be tight, with no corrosion.
5. Look inside the connector. Check internal contacts
for damage, dirt, or corrosion. DO NOT use a
metal object to clean the connector.
3. Installation
The cables to either half of the connector have a lip on their
forward end. This lip snaps over a spring-loaded retainer
which is part of the connector. To remove a cable from the
connector, push retainer down while pulling the battery cable
towards the rear and out of the connector.
296
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Service Manual
2001-03-15
F-code
PS
Version no
001
Section
C-code
S5.7
5311
Start/Stop Switches
T-code
RTX35/RTX45
Start/Stop Switches
1. General
Refer to the electrical schematic to identify the electrical
circuit location of the switch (see Circuit Diagrams on
page 273 through page 284).
1.1. Test/Inspection
Examine the switch for signs of arcing, overheating,
discoloration, cracking, or other physical damage. Replace
switch if such damage is present.
To test a switch, isolate it from the electrical circuit. Remove
all the connections from the switch, making sure all wires are
labeled and identified for reconnection.
Use an ohmmeter set to a low resistance scale to measure
the resistance across the switch. In a closed position, the
switch should be less than 1 ohm. In an open position, the
switch should show a resistance greater than 10 megohms.
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
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2001-03-15
297
F-code
Section
PS
S5.7
Start/Stop Switches
Version no
T-code
001
RTX35/RTX45
C-code
5311
ON position, the ohmmeter should read less than 1 ohm. If

not, replace the switch.
2.2. Removal
connector.
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.
connector.
298
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Service Manual
2001-03-15
F-code
PS
Version no
001
Section
C-code
S5.7
5311
Start/Stop Switches
T-code
RTX35/RTX45
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
connector.
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
300
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Service Manual
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
+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
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Service Manual
2001-03-15
F-code
PS
Version no
001
Section
C-code
S5.8
5332
Mast Switch (S31)
T-code
RTX35/RTX45
3. Removal
1. Raise the empty carriage until the bottom of the tie
bar is even with the bottom of the mast switch.
2. Secure the carriage with blocks and a hoist to
prevent any movement.
connector.
4. Disconnect switch from the harness.
5. Loosen jam nut securing the mast switch to the
mast.
6. Remove mast switch from the mast.
BT Prime-Mover Inc.
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Service Manual
2001-03-15
303
F-code
Section
PS
S5.8
Mast Switch (S31)
Version no
T-code
001
RTX35/RTX45
C-code
5332
4. Installation
1. Install new mast switch.
2. Tighten jam nut to secure the switch.
3. Attach wiring harness.
5. Adjust switch following the procedure on page 302.
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

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.
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2001-03-15
305
F-code
Section
C-code
PS
S5.9
5391
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
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.
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2001-03-15
307
F-code
Section
C-code
PS
S5.9
5391
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.
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2001-03-15
309
F-code
Section
C-code
PS
S5.10
Contactors
5441
Version no
T-code
001
RTX35/RTX45
2. Directional Contactors
4
3
310
Return
Item
No.
Description
Item
No.
Contactor assembly
Base
Screw
Kit, service
Contactor
Service Manual
Description
2001-03-15
F-code
Section
PS
S5.10
Version no
001
C-code
5441
Contactors
T-code
RTX35/RTX45
2.1. Removal
connector.
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.
5. Turn key switch ON and test truck operation.
connector, and install the top console.
battery
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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
connector.
necessary.
5. Remove two screws (3) holding the contactor to
the mounting panel.
6. Remove contactor from contactor panel.
3.2. Installation
panel. Attach with screws (3).
securely.
connector, and install top console.
battery
BT Prime-Mover Inc.
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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
connector.
necessary.
5. Remove two screws (1) holding contactor to the
mounting panel.
6. Remove contactor from the contactor panel.
4.2. Installation
panel. Attach with screws (1).
securely.
connector, and install the top console.
battery
BT Prime-Mover Inc.
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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

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.
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Function
Service Manual
Minus connection to the motor's series field
2001-03-15
317
F-code
Section
C-code
PS
S5.11
5461
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
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
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.
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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

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
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
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
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
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.
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
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.
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

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
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.
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
Version no
T-code
001
RTX35/RTX45
5711
36 Volt Resistor
24 Volt Jumper
101
to
111
201
to
211
301
to
304
401
to
405
501
to
511
601
to
611
701
to
710
801
to
811
901
to
904
Terminal Locations
I=Input, green LED; O=Output, red LED
3. Connectivity to Truck
The main electronic card is connected to the trucks circuitry
by nine connectors. To remove connectors one through eight,
depress the connectors latch and unplug the connector. To
install the connectors, push the connectors together until the
latch snaps into position. To remove connector nine, grasp
the connector (do not grasp the wires) and, with a slight
rotational wiggling action, unplug the connector. To install,
push the connector onto the pins making sure all of the pins
are captured by the connector.
328
Return
Service Manual
2001-03-15
F-code
Section
PS
C-code
S5.13
5711
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
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
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
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 -
Service Manual
2001-03-15
F-code
PS
Section
Version no
T-code
001
Terminal
Number
Connection
901
902
903
904
I
I
O
O
LED
Color
POWER
STEER PWR
STEER OK
Green
Green
Green
C-code
S5.13
5711
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
Potentiometer
RV2
BT Prime-Mover Inc.
Return
Function
Adjustment of lowering speed
Service Manual
2001-03-15
333
F-code
Section
C-code
PS
S5.13
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
2001-03-15
F-code
PS
Version no
001
SW1
SW2
Section
C-code
S5.13
5711
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.
Service Manual
2001-03-15
335
F-code
Section
C-code
PS
S5.13
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
Service Manual
2001-03-15
F-code
PS
Section
C-code
S5.13
5711
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
F-code
Section
C-code
PS
S5.13
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
Service Manual
2001-03-15
F-code
PS
Version no
001
Section
C-code
S5.13
5711
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
F-code
Section
C-code
PS
S5.13
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
Steer chopper error
Steer chopper high temperature limit
Steer tacho error

Opened steer motor output - motor or connection failure
Security relay error 1
Steer chopper supply voltage under-voltage
Security relay error 2
Service Manual
2001-03-15
F-code
PS
Version no
001
Section
C-code
S5.13
5711
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
Service Manual
2001-03-15
341
F-code
Section
PS
S5.13
Version no
T-code
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).
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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PS
Version no
001
Section
C-code
S5.13
5711
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)
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.
transistor regulator (A1), pin #11, wire #37 with
respect to pin #6, wire #35. Voltage should be 0.75
BT Prime-Mover Inc.
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2001-03-15
343
F-code
Section
C-code
PS
S5.13
Version no
T-code
001
RTX35/RTX45
5711
When the accelerator is at full throttle, voltage

should be approximately 4.3 volts.
transistor regulator (A1), pin #8, wire #38, with
respect to battery negative. Voltage should be 0
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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2001-03-15
F-code
PS
Version no
001
Section
C-code
S5.13
5711
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.
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Spare parameter. Not used.

Maximum allowed lifting
height
2001-03-15
Special height
345
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Section
C-code
PS
S5.13
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
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Service Manual
RTX35
RTX45
0
CUSTOMER VALUE (IN.)
RANGE 0 - 531
MAST HEIGHT (INCH)
See Table 3
2001-03-15
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PS
Version no
001
Section
C-code
S5.13
5711
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:
BT Prime-Mover Inc.
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2001-03-15
347
F-code
Section
PS
S5.13
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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F-code
PS
Section
C-code
S5.13
5711
Version no
T-code
001
RTX35/RTX45
Parameter 13 Initial Value Table

Parameter
13 Value
Operating Light Duty

Battery Voltage/Cell
Operating Medium Duty

Operating Heavy Duty

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
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
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.
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
F-code
Section
PS
S5.13
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.
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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PS
Version no
001
Section
C-code
S5.13
5711
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.
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.
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2001-03-15
353
F-code
Section
PS
S5.13
Version no
T-code
001
RTX35/RTX45
C-code
5711
10. RV2 Adjustment Procedure
RV2 Trim Pot

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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PS
Version no
001
Section
C-code
S5.13
5711
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
F-code
Section
PS
S5.13
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

1. General
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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Screw, machine
Switch, right foot
Nut, twin
2001-03-15
357
F-code
Section
C-code
PS
S5.14
5751
Version no
T-code
001
RTX35/RTX45
2.1. Removal
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.
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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PS
Section
C-code
S5.14
5751
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.
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.
5. Adjust switch following the procedure on page 358.
BT Prime-Mover Inc.
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2001-03-15
359
F-code
Section
C-code
PS
S5.14
5751
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.
connector.
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.

9. Test operation of the sensor.
360
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2001-03-15
F-code
PS
Section
C-code
S5.14
5751
Version no
001
T-code
RTX35/RTX45
4.2. Removal
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.
BT Prime-Mover Inc.
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Service Manual
2001-03-15
361
F-code
Section
C-code
PS
S5.14
5751
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.
connector.
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.
9. Test operation of the sensor.
10. Install battery in truck.
TURN DRIVE
WHEEL
INWARD 90o
362
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Service Manual
2001-03-15
F-code
PS
Section
C-code
S5.14
5751
Version no
001
T-code
RTX35/RTX45
5.2. Removal
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.
4. Adjust sensors
page 362.
following
the
procedure
on
5. Test operation of truck.

BT Prime-Mover Inc.
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2001-03-15
363
F-code
Section
C-code
PS
S5.14
5751
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

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
2. Install cap screw (4).

5
3. Reconnect sensor to main harness assembly.

5. Test operation of truck before returning to service.
BT Prime-Mover Inc.
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Service Manual
2001-03-15
365
F-code
Section
C-code
PS
S5.14
5751
Version no
T-code
001
RTX35/RTX45
366
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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
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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Service Manual
2001-03-15
367
F-code
Section
C-code
PS
S6.0
Hydraulic System
6000
Version no
T-code
000
RTX35/RTX45
A71
HM214
A5
S55 EXTEND
HM201
83
507
HM107
S56 RETRACT
HM202
S211 TILT UP
HM203
HM109
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

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ELECTRIC NEGATIVE
368
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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
1.1. Control Handle Interface, Hydraulic

Control Operation
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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2001-03-15
369
F-code
Section
C-code
PS
S6.0
Hydraulic System
6000
Version no
T-code
000
RTX35/RTX45
Control
Handle
Function
Selected
Control
Handle
Interface
Card
Input Pin
Control Handle
Interface Card
Approximate Input
Voltage (measured
with respect to HM213)
Control Handle
Interface Card
Output Pin
(measured with
respect to HM110)
Control Handle
Interface Card
Nominal Output
Voltage
Wire #
Main Electronic
Card (A5) Input
Pin (measured
with respect to
510)
Main
Electronic
Card (A5)
Nominal Input
Voltage
No Reach
Function
Selected
HM201 and
HM202
0V (both inputs)
HM107
Min. 1.103V
Nom. 1.470V
Max 1.873V
83
507
Min. 1.103V
Nom. 1.470V
Max 1.873V
Reach
Low
Speed
HM201
7.35V
HM107
Min. 2.573V
Nom. 2.940V
Max. 3.307V
83
507
Min. 2.573V
Nom. 2.940V
Max. 3.307V
Reach
High
Speed
HM201 and
HM202
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
This page intentionally left blank
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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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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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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
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374
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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.
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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
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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.
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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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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.
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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

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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
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:
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.
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
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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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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
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
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
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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

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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:
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.
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
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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

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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
Enabling the sideshift solenoid (Y16) on the reach carriage
from output 709 (wire #95).
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
Return
Service Manual
2001-03-15
F-code
Section
PS
S6.0
6000
Hydraulic System
Version no
000
C-code
T-code
RTX35/RTX45
1.10. 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).
pedal depressed, pressing the sideshift left button (S51)
causes voltage to be sensed at HM205 on the control handle
Enabling the sideshift solenoid (Y16) on the reach carriage
from output 709 (wire #95).
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.
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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
Return
Service Manual
2001-03-15
F-code
Section
PS
S6.0
6000
Hydraulic System
Version no
000
C-code
T-code
RTX35/RTX45
1.11. 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.
pedal depressed, pressing the tilt up button (S211) causes
voltage to be sensed at HM203 on the control handle
Enabling the tilt solenoid (Y17) on the reach carriage from
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.
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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.
pedal depressed, pressing the tilt down button (S212) causes
voltage to be sensed at HM204 on the control handle
Enabling the tilt solenoid (Y17) on the reach carriage from
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.
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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
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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
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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.
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).
ON.
6. Operate lift until air in the system is heard.
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.
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.
connector.
BT Prime-Mover Inc.
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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.
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.
page 96.
3. Drain hydraulic system. See Hydraulic Fluid on
page 399.
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.
System on page 401.
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

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
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.
connector.
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.
4. Check hydraulic fluid level and refill as needed.
5. Replace top console.
7. Return to service.
406
Return
Service Manual
2001-03-15
F-code
Section
C-code
PS
S6.2
6131
Version no
001
T-code
RTX35/RTX45
2. Hydraulic Filter Adapter

2.1. Removal
connector.
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.
System on page 401.
connector.
BT Prime-Mover Inc.
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Service Manual
2001-03-15
407
F-code
Section
C-code
PS
S6.2
6131
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
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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
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).
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).
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
Return
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
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.
Return
Service Manual
2001-03-15
417
F-code
Section
C-code
PS
S6.4
Control Valve
6211
Version no
T-code
000
RTX35/RTX45
To
Mast
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

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
24
Piston
42
Body
25
Spring
43
Valve, check
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
DBV Kit
** 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

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
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.
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
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
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

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
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
Version no
000
T-code
RTX35/RTX45
6. Remove lifting gear from cylinder rod.

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
Version no
T-code
000
RTX35/RTX45
1.2. Disassembly
1. Remove bearing (12) from cylinder tube (3).
2. Remove and discard packing, back-up ring, O-ring,
rod wiper, and bearing retainer from bearing (12).
Use care NOT to damage inside of bearing (12).
1.3. Assembly
1. Install a new bearing, seals, and rod wiper in gland.
The lip of the wiper must face outward. It is not
necessary to replace wear ring (7), unless the rod
was removed for repair.
1.4. Installation
1. Install lifting gear, chains, hoses, and electric
cables.
2. Connect battery.
3. Test for proper operation.
432
Return
Service Manual
2001-03-15
F-code
PS
C-code
S6.7
6650
Reach Cylinder (RTX35)
Version no
001
Section
T-code
RTX35/RTX45
K
6
23
7
8
22
10
11
12
20
19
18 17
16
15
13
14
21
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
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
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
Version no
001
T-code
RTX35/RTX45
2. Disassembly
1. Before disassembly, clean the exterior of reach
cylinder 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 (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.
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Service Manual
2001-03-15
435
F-code
Section
C-code
PS
S6.7
6650
Version no
T-code
001
RTX35/RTX45
3. Inspection
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
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.
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Service Manual
2001-03-15
437
F-code
Section
C-code
PS
S6.7
6650
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
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
Version no
T-code
001
RTX35/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
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
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
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Service Manual
2001-03-15
F-code
PS
Section
C-code
S6.7
6650
Version no
001
T-code
RTX35/RTX45
2. Disassembly
1. Before disassembly, clean the exterior of reach
cylinder in a cleaning solution to remove all
contamination.
the cylinder. Stroking piston rod will help force fluid
out.
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.
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Service Manual
2001-03-15
441
F-code
Section
C-code
PS
S6.7
6650
Version no
T-code
001
RTX35/RTX45
3. Inspection
position them on a clean work surface.
2. Check rod assembly (17) for damage. Look for
stoning. Be extremely careful to not remove
replacement of piston rod assembly. Make sure
threads on rod are free of damage.
replacement.
442
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Service Manual
2001-03-15
F-code
PS
Version no
001
Section
C-code
S6.7
6650
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).
Coat the inside of cylinder tube and bearing
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.
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
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.
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
pressure.
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

13
14
11
7
5
12
10
1
2
3
4
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
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
T-code
RTX35/RTX45
2. Disassembly
1. Before disassembly, clean the exterior of tilt
cylinder (1) in a cleaning solution to remove all
contamination.
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.
Return
Service Manual
2001-03-15
447
F-code
Section
PS
S6.8
Version no
T-code
001
RTX35/RTX45
C-code
6660
3. Inspection
position parts on a clean work surface.
2. Check piston rod (10) for damage. Look for
stoning. Be extremely careful not to remove the
replacement of the piston rod assembly.
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
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.
Coat the inside of cylinder barrel and bearing
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
installation.
assembly moves fairly easy within barrel assembly
without binding.
10. Install cylinder bearing (7) and bearing retainer
(13).
Return
Service Manual
2001-03-15
449
F-code
Section
PS
S6.8
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.
6. Connect battery.
pressure.
7. Operate tilt to remove air from hydraulic hoses and
check operation of the whole hydraulic system.
the hydraulic tank with new clean oil.
450
Return
Service Manual
2001-03-15
F-code
Section
PS
C-code
S6.8
6660
Version no
T-code
001
RTX35/RTX45

14
15
13
12
9
8
6
11
10
5
4
2
3
Return
Item
No.
Description
Item
No.
Wiper
11
Rod, cylinder
Bushing
Seal
12
O-ring
Retainer, cylinder
Bearing, cylinder
13
Ring, back-up
Lockwasher
Ring, back-up
14
Retainer
Screw, cap
10
O-ring
15
Tube, cylinder
Service Manual
Description
2001-03-15
Item
No.
Description
451
F-code
Section
PS
S6.8
Version no
T-code
001
RTX35/RTX45
C-code
6660
1. Removal
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
T-code
RTX35/RTX45
2. Disassembly
1. Before disassembly, clean the exterior of tilt
cylinder (1) in a cleaning solution to remove all
contamination.
cylinder. Stroking piston rod will help force fluid out.
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.
Return
Service Manual
2001-03-15
453
F-code
Section
PS
S6.8
Version no
T-code
001
RTX35/RTX45
C-code
6660
3. Inspection
position them on a clean work surface.
2. Check piston rod (11) for damage. Look for
stoning. Be extremely careful to not remove the
replacement of piston rod assembly.
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
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.
Coat the inside of cylinder barrel and bearing
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
installation.
assembly moves fairly easy within the barrel
assembly without binding.
10. Install cylinder bearing (8) and bearing retainer
(14).
Return
Service Manual
2001-03-15
455
F-code
Section
PS
S6.8
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.
6. Connect battery.
pressure.
7. Operate tilt to remove air from hydraulic hoses and
check operation of the whole hydraulic system.
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

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
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
T-code
RTX35/RTX45
1. Shimming Carriage with Mast on

Truck
rolling. Park the truck on a level surface and
make sure all wheels are blocked to prevent
accidental movement.
connector. Remove battery from truck.
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
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
T-code
RTX35/RTX45
2. Three Stage Mast

2.1. Removal
Bolts

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.
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
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.
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
T-code
RTX35/RTX45
2.3. Assembly
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.
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.
8. Determine amount of shims required. Pry inner
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
Version no
T-code
000
RTX35/RTX45
C-code
7110

two bearings. Install shims under bearings.
10. Extend inner column through the intermediate
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
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
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
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
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
7110
Version no
T-code
000
RTX35/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
467
F-code
Section
PS
S7.0
Version no
T-code
000
RTX35/RTX45
C-code
7110
1. Shimming Carriage with Mast on

Truck
WARNING When blocking mast the columns to
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.
two bearings. Install shims under bearings.
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.
468
Return
Service Manual
2001-03-15
F-code
PS
Version no
000
Section
C-code
S7.0
7110
T-code
RTX35/RTX45
carriage in the fully lowered position. Pry carriage

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.
Return
Service Manual
2001-03-15
469
F-code
Section
C-code
PS
S7.0
Version no
T-code
000
RTX35/RTX45
7110
2. Three Stage Mast

2.1. Removal
Bolts

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.
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

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
Return
10. Remove two side mounting plates at the pivot

points on mast.
Service Manual
2001-03-15
F-code
PS
Version no
000
Section
C-code
S7.0
7110
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.
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.
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
Version no
T-code
000
RTX35/RTX45
C-code
7110
2.3. Assembly
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
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).
inch (0.76 mm).
7. Assemble inner column in the intermediate column.
8. Determine the amount of shims required. Pry inner
472
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2001-03-15
F-code
PS
Version no
000
Section
C-code
S7.0
7110
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
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).
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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2001-03-15
473
F-code
Section
PS
S7.0
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
3. Install two bolts in the middle of the battery box.
4. Install two bolts at base of overhead guard post.
5. Connect hydraulic hoses to lift cylinders.
6. Hydraulically lift up inner column enough to install
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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Version no
000
Section
C-code
S7.0
7110
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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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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F-code
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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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

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
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
1. Park truck on a level surface and apply brake. Turn
key switch OFF and disconnect battery connector.
Remove battery from truck.
on its side.
lowering.
3. Lower freelift cylinder so chains, hoses, and
electric cables are loose.
connector.
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.

8. Clean lifting gear.
486
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PS
S7.1
7170
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
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
Version no
T-code
000
RTX35/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
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
1. Park truck on a level surface and apply brake. Turn
key switch OFF and disconnect battery connector.
Remove battery from truck.
on its side.
lowering.
3. Lower freelift cylinder so chains, hoses, and
electric cables are loose.
connector.
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.
8. Clean lifting gear.
490
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Section
C-code
PS
S7.1
7170
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).
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.
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2001-03-15
491
F-code
Section
C-code
PS
S7.1
7170
Version no
T-code
000
RTX35/RTX45
4. Connect battery.
5. Remove blocking and test for proper operation.
492
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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
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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.
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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
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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.
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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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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.
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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.
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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
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Service Manual
2001-03-15
F-code
Section
PS
C-code
S7.3
7241
Reach, Single (RTX35)
Version no
T-code
001
RTX35/RTX45

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.
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2001-03-15
503
F-code
Section
C-code
PS
S7.3
7241
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
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Service Manual
2001-03-15
F-code
PS
Version no
001
Section
C-code
S7.3
7241
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.
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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505
F-code
Section
C-code
PS
S7.3
7241
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
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.
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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507
F-code
Section
C-code
PS
S7.3
7241
Version no
T-code
001
RTX35/RTX45

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
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
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2001-03-15
509
F-code
Section
C-code
PS
S7.3
7241
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
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.
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2001-03-15
511
F-code
Section
C-code
PS
S7.3
7241
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.
512
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Service Manual
2001-03-15
F-code
Section
PS
C-code
S7.3
7241
Version no
T-code
001
RTX35/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
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2001-03-15
513
F-code
Section
C-code
PS
S7.3
7241
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
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Service Manual
2001-03-15
F-code
PS
Section
C-code
S7.3
7241
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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515
F-code
Section
C-code
PS
S7.3
7241
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.
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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2001-03-15
F-code
PS
Section
C-code
S7.3
7241
Version no
001
T-code
RTX35/RTX45
2.1.5. Reach Cylinder Removal

WARNING Block reach to keep it from collapsing.
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.
4. Connect electrical cable.
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517
F-code
Section
C-code
PS
S7.3
7241
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
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2001-03-15
F-code
PS
Section
C-code
S7.3
7241
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.
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).
4. Remove blocking from the scissor mechanism.
BT Prime-Mover Inc.
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519
F-code
Section
C-code
PS
S7.3
7241
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
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2001-03-15
F-code
PS
Version no
001
Section
C-code
S7.3
7241
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.
BT Prime-Mover Inc.
Return
Service Manual
2001-03-15
521
F-code
Section
C-code
PS
S7.3
7241
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
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
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
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
Version no
T-code
000
RTX35/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
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
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.
and disconnect battery connector. Remove battery
from truck.
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.
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
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
Return

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F

Master Service Manual

WARNING Read and observe all warnings on this unit

WARNING DO NOT operate this equipment unless all

Part no: 310428-000

Date: July 30, 2001

Prime-Mover is a trademark of BT Prime-Mover Inc.,

BT Prime-Mover Standard Codes

BT Prime-Mover Standard Codes

Drive Gear / Transmission

Brake / Wheel System

Hydraulic / Pneumatic System

Operating Function-lifting Mast / Cylinders

Peripheral / Installation Equipment

BT Prime-Mover Standard Codes

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

Technical Service Data ................................................................................ 55

Driver Controls ............................................................................................ 117

Internal Fittings ........................................................................................... 129

Fan Motor ..................................................................................................... 141

Pump Motor (RTX35) ................................................................................... 151

Drive Wheel ..................................................................................................

Non-Braking Caster Assembly ..................................................................

Non-Braking Caster Wheels ....................................................................... 197

Electrical Symbols ...................................................................................... 271

Horn .............................................................................................................. 293

Start/Stop Switches ....................................................................................

Mast Switch (S31) ........................................................................................

Control Cable and Harness ........................................................................

Transistor Panel (Drive) .............................................................................. 317

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

OPEN FLAMES PROHIBITED

Know the trucks controls and what they do.

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

Operate this truck only from the operators position.

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

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

Follow the scheduled

Follow exactly the safety and repair instructions in this

Do NOT use an open flame near the truck.

Do NOT use gasoline or other flammable liquids for cleaning

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

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

Wear personal protective equipment to protect eyes, face,

Make sure a shower and eyewash station are nearby in case

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