BT PRIME MOVER RTX35/45 MASTER SERVICE MANUAL 310428-000 – PDF DOWNLOAD

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BT PRIME MOVER RTX35/45 MASTER SERVICE MANUAL 310428-000 July 2001 – PDF DOWNLOAD

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BT PRIME MOVER RTX35/45 MASTER SERVICE MANUAL 310428-000 July 2001 – PDF DOWNLOAD

Language : English
Pages : 542
Downloadable : Yes
File Type : PDF

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BT PRIME MOVER RTX35/45 MASTER SERVICE MANUAL 310428-000 July 2001 – PDF DOWNLOAD

BT Prime-Mover Standard Codes...........................................................................................  3
	Worksheet standard..................................................................................................  3
	C-Code List.........................................................................................................  3
Warning Symbols......................................................................................................... 15
	1. Warning Levels................................................................................................... 15
		DANGER.......................................................................................................... 15
		WARNING......................................................................................................... 15
		CAUTION......................................................................................................... 15
		NOTE!........................................................................................................... 15
Prohibitory Symbols..................................................................................................... 16
	NO SMOKING.......................................................................................................... 16
	OPEN FLAMES PROHIBITED.............................................................................................. 16
	GENERAL PROHIBITION................................................................................................. 16
	1. Ordinance Symbols................................................................................................ 16
		SAFETY SHOES.................................................................................................... 16
		PROTECTIVE GLASSES.............................................................................................. 16
Safety.................................................................................................................. 17
	1. General Safety................................................................................................... 17
Battery Safety.......................................................................................................... 21
Static Safety........................................................................................................... 25
	1. Place a static discharge wrist strap around your wrist. Connect the ground lead to the wrist s................... 25
	2. Connect the ground clamp to an unpainted, grounded surface on the truck frame.................................... 25
	3. If removing or installing static-sensitive components, place them on a properly grounded stati................... 25
	4. To transport static-sensitive components, including failed components being returned, place th................... 25
Welding Safety.......................................................................................................... 26
Introduction, Service Manual............................................................................................ 29
Contents, Section M..................................................................................................... 31
	1. Machine Information.............................................................................................. 31
General Product Information............................................................................................. 33
	1. Truck Presentation............................................................................................... 33
		1.1. Truck Side Views........................................................................................... 33
		1.2. Open Back Compartment...................................................................................... 34
		1.3. Intended Truck Application................................................................................. 35
		1.4. Prohibited Truck Application............................................................................... 35
		1.5. Truck Data................................................................................................. 35
		1.6. RTX35 Dimensions........................................................................................... 36
		1.7. RTX45 Dimensions........................................................................................... 37
		1.8. Data Plate................................................................................................. 38
			Legend...................................................................................................... 38
				1 Truck model number.................................................................................... 38
				2 Truck serial number................................................................................... 38
				3 Weight less battery................................................................................... 38
				4 Maximum battery weight................................................................................ 38
				5 Minimum battery weight................................................................................ 38
				6 Truck voltage DC...................................................................................... 38
				7 Battery type UL class................................................................................. 38
				8 Battery maximum AMP hours............................................................................. 38
				9 Hour rate............................................................................................. 38
				10 Truck type........................................................................................... 38
				11 Mast serial number................................................................................... 38
				12 Attachment........................................................................................... 38
				13 Maximum degree rear tilt............................................................................. 38
				14 Truck capacity....................................................................................... 38
	2. Main Components.................................................................................................. 39
		1 Hydraulic valve:.............................................................................................. 39
		2 Battery:...................................................................................................... 39
		3 Battery connector:............................................................................................ 39
		4 Hydraulic unit:............................................................................................... 39
		5 Drive unit with brake:........................................................................................ 39
		6 Electrical steering:.......................................................................................... 39
		7 Data plate:................................................................................................... 39
		8 Cover:........................................................................................................ 39
		9 Pedal:........................................................................................................ 39
		10 Control console:............................................................................................. 39
		11 Instrument panel (Operator Display):......................................................................... 39
		12 Mast:........................................................................................................ 39
		13 Electronics:................................................................................................. 39
		14 Control circuit fuse (F50):.................................................................................. 39
		15 Steering circuit fuse (F51):................................................................................. 39
		16 Drive motor fuse (F1):....................................................................................... 39
		17 Pump motor fuse (F3):........................................................................................ 40
		18 Right foot pedal............................................................................................. 40
		19 Emergency stop............................................................................................... 40
		20 Lift height indicator fuse (F52):............................................................................ 40
		21 12 volt sensor feed fuse (F53):.............................................................................. 40
		22 Display power fuse (F54):.................................................................................... 40
		23 Relay1 fuse (F55):........................................................................................... 40
		24 Fuse (AF1):.................................................................................................. 40
		25 Fuse (AF2):.................................................................................................. 40
		26 Auxiliary power circuit fuse (AF3):.......................................................................... 40
		Main Components of Truck........................................................................................ 41
	3. Grease Point Location............................................................................................ 42
	4. Mast Adjustment Points........................................................................................... 43
Inch (SAE) and Metric Fasteners......................................................................................... 45
	1. Introduction..................................................................................................... 45
	2. Nomenclature, Threads............................................................................................ 46
	3. Strength Identification.......................................................................................... 47
	4. Conversion of Metric and English Units........................................................................... 54
Technical Service Data.................................................................................................. 57
	MODEL............................................................................................................... 57
		RTX35 (192 inch mast)........................................................................................... 57
		RTX45 (210 inch mast)........................................................................................... 57
	Series - DC......................................................................................................... 57
	Series - DC......................................................................................................... 57
	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 l................... 57
	1 hour continuous................................................................................................... 57
	1 hour continuous................................................................................................... 57
	0.8 inch (20 mm).................................................................................................... 57
	0.8 inch (20 mm).................................................................................................... 57
	2.90 inches (74 mm)................................................................................................. 57
	2.90 inches (74 mm)................................................................................................. 57
	6.4 oz. (180 grams)................................................................................................. 57
	6.4 oz. (180 grams)................................................................................................. 57
	Vertical motor spiral-bevel output.................................................................................. 57
	Vertical motor spiral-bevel output.................................................................................. 57
	17.57............................................................................................................... 57
	17.57............................................................................................................... 57
	1 gallons (3.79 liters)............................................................................................. 57
	1 gallons (3.79 liters)............................................................................................. 57
	SAE 80W90........................................................................................................... 57
	SAE 80W/90.......................................................................................................... 57
	ATF................................................................................................................. 57
	SAE 80W90........................................................................................................... 57
	SAE 80W/90.......................................................................................................... 57
	ATF................................................................................................................. 57
	13.5 x 5.5 x 10.0 inches (343 x 140 x 254 mm)....................................................................... 58
	13.5 x 5.5 x 10.0 inches (343 x 140 x 254 mm)....................................................................... 58
	1600 lb battery 14.5” BC - 6735 (3054) 2000 lb battery 16.5” BC - 4315 (1959)....................................... 58
	2000 lb battery 16.5” BC - 4750 (2156) 2400 lb battery 21” BC - 4910 (2229)......................................... 58
	1600 lb battery 14.5” BC - 3240 (1471) 2000 lb battery 16.5” BC - 3430 (1557)....................................... 58
	2000 lb battery 16.5” BC - 3780 (1716) 2400 lb battery 21” BC - 4025 (1827)......................................... 58
	95 ft-lb (130 N•m).................................................................................................. 58
	95 ft-lb (130 N•m).................................................................................................. 58
	5.0 x 3.6 inches (127 x 91 mm)...................................................................................... 58
	5.0 x 3.6 inches (127 x 91 mm)...................................................................................... 58
	1600 lb battery 14.5” BC - 6860 (3114 2000 lb battery 16.5” BC - 7145 (3244)........................................ 58
	2000 lb battery 16.5” BC - 8595 (3902) 2400 lb battery 21” BC - 8690 (3945)......................................... 58
	300 Amp 400 Amp..................................................................................................... 58
	Not Applicable (N/A) 425 Amp........................................................................................ 58
	24V -1400 empty-750 loaded 36V - 2100 empty-1500 loaded............................................................. 58
	36V - 2250 empty-1450 loaded........................................................................................ 58
	36 volt 11.6 HP with 20% duty cycle................................................................................. 58
	20% on 5 minute cycles.............................................................................................. 58
	0.8 inch (20 mm).................................................................................................... 58
	0.62 inch (16 mm)................................................................................................... 58
	2.90 inches (74 mm)................................................................................................. 58
	2.80 inches (72 mm)................................................................................................. 58
	6.4 oz (180 grams).................................................................................................. 58
	40 oz (1120 grams).................................................................................................. 58
	2450 psi (16890 kPa)................................................................................................ 58
	2450 psi (16890 kPa)................................................................................................ 58
	11 cc upper/4 cc lower.............................................................................................. 59
	16 cc upper/4 cc lower 8 cc upper/4 cc lower........................................................................ 59
	N/A................................................................................................................. 59
	23 cc upper/4 cc lower 11 cc upper/4 cc lower....................................................................... 59
	5 gallons (19 liters)............................................................................................... 59
	5 gallons (19 liters)............................................................................................... 59
	Sunoco TH........................................................................................................... 59
	ATF................................................................................................................. 59
	Texaco 15........................................................................................................... 59
	Sunoco TH........................................................................................................... 59
	ATF................................................................................................................. 59
	Texaco 15........................................................................................................... 59
	250 Amp............................................................................................................. 59
	250 Amp............................................................................................................. 59
	425 Amp............................................................................................................. 59
	355 Amp............................................................................................................. 59
	N/A................................................................................................................. 59
	500 Amp............................................................................................................. 59
	10 Amp.............................................................................................................. 59
	10 Amp.............................................................................................................. 59
	14.4 x 38.8 x 32.0 inches........................................................................................... 59
	(366 x 986 x 813 mm)................................................................................................ 59
	16.4 x 38.8 x 32.0 inches........................................................................................... 59
	(417 x 986 x 813 mm)................................................................................................ 59
	16.4 x 38.8 x 32.0 inches........................................................................................... 59
	(417 x 986 x 813 mm)................................................................................................ 59
	20.9 x 38.8 x 32.0 inches........................................................................................... 59
	(531 x 986 x 813 mm)................................................................................................ 59
	1020 Amp hours...................................................................................................... 59
	1000 Amp hours 875 Amp hours........................................................................................ 59
	N/A................................................................................................................. 59
	1000 Amp hours 875 Amp hours........................................................................................ 59
	14.5 inches (368 mm) 1600 lb (726 kg)............................................................................... 59
	(2300 lb / 1044 kg)................................................................................................. 59
	16.5 inches (419 mm) 2000 lb (908 kg)............................................................................... 59
	(2300 lb / 1044 kg)................................................................................................. 59
	16.5 inches (419 mm) 2000 lb (908 kg)............................................................................... 59
	(2300 lb / 1044 kg)................................................................................................. 59
	21.0 inches (533 mm) 2400 lb (1089 kg).............................................................................. 59
	(2900 lb (1317 kg).................................................................................................. 59
	6.0 mph (9.65 kph).................................................................................................. 60
	6.5 mph (10.46 kph)................................................................................................. 60
	N/A................................................................................................................. 60
	6.5 mph (10.46 kph)................................................................................................. 60
	5.5 mph (8.85 kph).................................................................................................. 60
	6.0 mph (9.65 kph).................................................................................................. 60
	N/A................................................................................................................. 60
	6.0 mph (9.65 kph).................................................................................................. 60
	57 fpm (17.37 m/min.)............................................................................................... 60
	80 fpm (24.4 m/min.)................................................................................................ 60
	N/A................................................................................................................. 60
	95 fpm (29 m/min.).................................................................................................. 60
	34 fpm (10.4 m/min.)................................................................................................ 60
	60 fpm (18.3 m/min.)................................................................................................ 60
	N/A................................................................................................................. 60
	60 fpm (18.3 m/min.)................................................................................................ 60
	80 fpm (24.4 m/min.)................................................................................................ 60
	90 fpm (27.5 m/min.)................................................................................................ 60
	80 fpm (24.4 m/min.)................................................................................................ 60
	95 fpm (29 m/min.).................................................................................................. 60
	95 Amps............................................................................................................. 60
	80 Amps............................................................................................................. 60
	N/A 90 Amps......................................................................................................... 60
	115 Amps............................................................................................................ 60
	95 Amps............................................................................................................. 60
	N/A................................................................................................................. 60
	105 Amps............................................................................................................ 60
	170 Amps............................................................................................................ 60
	215 Amps............................................................................................................ 60
	145 Amps............................................................................................................ 60
	200 Amps............................................................................................................ 60
	235 Amps............................................................................................................ 60
	170 Amps............................................................................................................ 60
	N/A................................................................................................................. 60
	310 Amps............................................................................................................ 60
	225 Amps............................................................................................................ 60
	N/A................................................................................................................. 60
	330 Amps............................................................................................................ 60
	240 Amps............................................................................................................ 60
	325 Amps............................................................................................................ 60
	395 Amps............................................................................................................ 60
	270 Amps............................................................................................................ 60
	355 Amps............................................................................................................ 60
	430 Amps............................................................................................................ 60
	300 Amps............................................................................................................ 60
	N/A................................................................................................................. 60
	530 Amps............................................................................................................ 60
	390 Amps............................................................................................................ 60
	N/A................................................................................................................. 60
	550 Amps............................................................................................................ 60
	395 Amps............................................................................................................ 60
Ordering Spare Parts.................................................................................................... 61
	1. Locate the fault on the truck.................................................................................... 61
	2. Identify truck model, serial number, and battery voltage......................................................... 61
	3. Locate the page with the exploded diagram and find the item number for the part required......................... 61
	4. Locate the item number in the table. Select the column for the actual truck model and serial n................... 61
	5. Note the part number............................................................................................. 61
	6. Call your local BT Prime-Mover Dealer and indicate the part number............................................... 61
	7. If the model, serial number, or the article number cannot be found on the truck, call your loc................... 61
Contents, Section P..................................................................................................... 63
	1. Planned Maintenance.............................................................................................. 63
Introduction, Maintenance............................................................................................... 65
	1. Safe Jacking Procedure........................................................................................... 66
		1. Lower the forks completely. Remove any load.................................................................. 66
		1.1. Elevate Rear of Truck...................................................................................... 66
			1. Place the jack in the designated jacking position........................................................ 66
		1.1. Elevate Either Side of Truck............................................................................... 66
			1. Place the jack in the designated jacking position........................................................ 66
	2. Lubricants....................................................................................................... 67
		2.1. Cold Storage Conditioning.................................................................................. 67
		2.2. Electrical Component Cold Storage Conditioning............................................................. 67
Service Schedule........................................................................................................ 69
	1. Planned Maintenance Schedule..................................................................................... 69
		ITEM............................................................................................................ 69
		WORK REQUIRED................................................................................................... 69
			Interval in Hours........................................................................................... 69
			8........................................................................................................... 69
			30.......................................................................................................... 69
			120......................................................................................................... 69
			240......................................................................................................... 69
			360......................................................................................................... 69
			720......................................................................................................... 69
			1440........................................................................................................ 69
			4320........................................................................................................ 69
			Interval in Days/Weeks/Months............................................................................... 69
			1 d......................................................................................................... 69
			1w.......................................................................................................... 69
			1 m......................................................................................................... 69
			2 m......................................................................................................... 69
			3 m......................................................................................................... 69
			6 m......................................................................................................... 69
			12 m........................................................................................................ 69
			36 m........................................................................................................ 69
	2. Planned Maintenance Procedures................................................................................... 74
		2.1. Services Performed Daily or Every 8 Operating Hours........................................................ 74
			2.1.1. Battery Discharge Indicator with slow down........................................................... 74
			2.1.2. Hydraulic System..................................................................................... 74
			2.1.3. Frame/Sheet Metal.................................................................................... 75
			2.1.4. Wheels/Tires......................................................................................... 75
			2.1.5. Functions/Operations................................................................................. 75
		2.2. Services Performed Monthly or Every 120 Operating Hours.................................................... 75
			2.2.1. Inspection........................................................................................... 75
			2.2.2. Transmission......................................................................................... 75
			2.2.3. Brake................................................................................................ 75
			2.2.4. Battery.............................................................................................. 76
			2.2.5. Electrical Connections............................................................................... 76
			2.2.6. Contactor Tips (NOT Sealed).......................................................................... 76
			2.2.7. Motor Brushes........................................................................................ 76
			2.2.8. Drive Motor.......................................................................................... 76
			2.2.9. Hydraulic Reservoir.................................................................................. 77
			2.2.10. Frame Lube (“Lubrication Chart” on page79)......................................................... 77
			2.2.11. Pivot Points........................................................................................ 77
		2.3. Services Performed Every 480 or 960 Operating Hours........................................................ 78
			2.3.1. Drive Motor.......................................................................................... 78
				1. Dusty or sandy locations; that is cement plant, lumber or flour mills, coal dust or stone-crus....... 78
		2.4. Services Performed Annually or Every 1440 Operating Hours.................................................. 78
			2.4.1. Inspection........................................................................................... 78
			2.4.2. Transmission......................................................................................... 79
			2.4.3. Battery.............................................................................................. 79
			2.4.4. Hydraulic System..................................................................................... 79
			2.4.5. Brakes............................................................................................... 80
			2.4.6. Lift and Carriage Chains............................................................................. 80
Lubrication Chart....................................................................................................... 81
	Interval/Running Hours.............................................................................................. 81
	Lubricant........................................................................................................... 81
		720 h........................................................................................................... 81
			Truck Lubrication Points.................................................................................... 81
Oil and Grease Specifications........................................................................................... 83
	1. Approved Oils and Grease......................................................................................... 83
		Specification................................................................................................... 83
		Lubricant....................................................................................................... 83
		Standard and Corrosion.......................................................................................... 83
		Cold Storage.................................................................................................... 83
		Freezer......................................................................................................... 83
		Application area................................................................................................ 83
		Continuous Operation Above 23 F (-5 C)........................................................................ 83
		Continuous Operation To 5 F (-15 C) Intermittent Operation To -13 F (-25 C)................................. 83
		Continuous Operation To 31 F (-35 C).......................................................................... 83
Contents, Section S..................................................................................................... 85
	1. Service Instructions............................................................................................. 85
Troubleshooting Guidelines.............................................................................................. 87
	1. General.......................................................................................................... 87
		1. Inspect truck for physical damage or mechanical malfunction. Contactors must be free to move a............... 88
		2. Check for ground faults from the electrical system to the frame with an ohmmeter. A minimum of............... 88
		3. Check that the battery is fully charged and connected........................................................ 88
		4. Operate the truck in all modes to determine the exact symptoms. DO NOT forget that these syste............... 88
	2. Electrical....................................................................................................... 89
		2.1. Shorts to Frame Test....................................................................................... 89
			1. Turn the key switch OFF and disconnect the battery connector............................................. 90
			2. To test the battery for shorts to case, connect a 12-volt test light to the battery case from ........... 90
			3. With the battery disconnected from the truck, use a digital volt/ohm/ammeter on the ampere fun........... 91
			4. With the battery disconnected (or removed and disconnected) from the truck, use a digital ohmm........... 91
			a. To identify the cause of the short to frame, disconnect circuit components until the low resis........... 91
				5. Reconnect the battery connector to the truck and turn the key switch ON. If the battery was pr....... 92
				6. Use a volt/ohm/ammeter on the current function meter to measure leakage current to the truck f....... 92
			a. To identify the cause of the short to frame, disconnect circuit components until the leakage c........... 92
				7. After all components are reconnected, and a reading is less than 0.001 ampere (1 mA) there is ....... 93
	3. Hydraulic........................................................................................................ 94
	4. Definitions...................................................................................................... 95
Chassis................................................................................................................. 97
	1. General.......................................................................................................... 97
		t............................................................................................................... 97
	2. Top Console...................................................................................................... 98
		2.1. Removal.................................................................................................... 98
			1. Park truck on a level surface and block.................................................................. 98
		2.2. Installation............................................................................................... 98
			1. Place the top console over the steering wheel and control handle......................................... 98
	3. Motor Compartment Door........................................................................................... 99
		3.1. Removal.................................................................................................... 99
			1. Use an Allen wrench to turn the latch screw clockwise one quarter turn................................... 99
		3.2. Installation............................................................................................... 99
			1. Set the door in place so the hinge pins are securely mounted in the panel hinge.......................... 99
	4. Left Side Panel (Exterior).......................................................................................100
		4.1. Removal....................................................................................................100
			1. Park truck on a level surface and block..................................................................100
				7. Remove four bolts securing the overhead guard post. Disconnect wiring harness at the post if a.......100
				8. Pull the left side panel outward and set aside.......................................................100
		4.2. Installation...............................................................................................101
			1. Lift left side panel up to align the three studs on the panel with the holes in the frame................101
	5. Left Operator Compartment Panel..................................................................................102
		5.1. Removal....................................................................................................102
			1. Park truck on a level surface and block..................................................................102
		5.2. Installation...............................................................................................102
			1. Slide left compartment panel into position...............................................................102
	6. Main Electronic Card Panel.......................................................................................103
		6.1. Removal....................................................................................................103
			1. Park truck on a level surface and block..................................................................103
		6.2. Installation...............................................................................................103
			1. Place slots along the lower edge of the main electronic card panel over the bottom two retaini...........103
	7. Floor Board......................................................................................................104
		7.1. Removal....................................................................................................104
			1. Park truck on a level surface and block..................................................................104
		7.2. Installation...............................................................................................104
			1. Truck must be properly blocked at this time..............................................................104
	8. Clipboard........................................................................................................105
		8.1. Removal....................................................................................................105
			1. Loosen top console to gain access to the clip mounting hardware..........................................105
		8.2. Installation...............................................................................................105
			1. Raise top console to allow reach of clipboard mounting holes from underside of the cover.................105
Battery Retainer Plates and Rollers.....................................................................................107
	f...................................................................................................................108
	1. Battery Retainer Plates..........................................................................................108
		1.1. Inspection.................................................................................................108
		1.2. Removal....................................................................................................108
			1. While lifting the battery retainer plate upward, tilt the edge toward the mast slightly forwar...........108
		1.3. Installation...............................................................................................108
			1. Position the battery retainer plate with tongued edges on the bottom and facing the operator c...........108
	2. Battery Rollers..................................................................................................108
		2.1. Inspection.................................................................................................108
		2.2. Replacement................................................................................................108
Mounting Points.........................................................................................................109
	1. Drive Motor......................................................................................................109
		1.1. Removal....................................................................................................110
			1. Park the truck on a level surface and make sure all wheels are blocked to prevent accidental m...........110
		1.2. Installation...............................................................................................111
			1. Remove cap from the top of transmission..................................................................111
				10. Add washers and nuts to terminal posts. Be sure nuts are tight using an 11/16 inch (17 mm) wr.......111
				11. Reconnect brush wear sensor, temperature sensor, and two speed/directional sensor connections.......111
	2. Pump Motor.......................................................................................................112
		2.1. Removal....................................................................................................113
			1. Park the truck on a level surface and make sure all wheels are blocked to prevent accidental m...........113
				10. Remove four bolts (4) attaching bracket to the truck frame using an 9/16 inch (13 mm) socket........113
				11. Loosen screws in hose clamp for hose connecting the pump to the reservoir. Slide hose clamp b.......113
				12. Disconnect brush wear indicator terminals at the back of the motor..................................114
				13. Remove motor and pump assembly from truck. If a hoist is available, attach a hoist to the bra.......114
		2.2. Installation...............................................................................................114
			1. Place lift pump and motor assembly with bracket onto truck frame. Make sure four rubber gromme...........114
	3. Transmission.....................................................................................................116
		3.1. Fluid Changing Procedure...................................................................................117
			1. Remove drain plug (item 28, page169) from drive unit and drain all the fluid............................117
		3.2. Removal....................................................................................................117
			1. Park the truck on a level surface........................................................................117
		3.3. Installation...............................................................................................118
			1. Place transmission in drive tire and slide transmission, in the tire cradle, beneath the truck...........118
Driver Controls.........................................................................................................119
	1. Handle Interface Module..........................................................................................121
		1.1. Removal....................................................................................................121
			1. Turn key switch OFF and disconnect battery connector.....................................................121
		1.2. Installation...............................................................................................121
			1. Position handle interface module at the contactor plate/bracket, aligning mounting holes.................121
	2. Control Handle...................................................................................................122
		2.1. Removal....................................................................................................122
			1. Turn key switch OFF and disconnect battery connector.....................................................122
		2.2. Installation...............................................................................................123
			1. Insert the shaft of the control handle assembly into the support bracket (3).............................123
		2.3. Recalibration..............................................................................................123
			1. Voltages at the main electronic card inputs greater than 6.75 volts and less than 0.6 volts in...........124
			2. The center and travel limits of the travel and lift/lower potentiometers are learned. Therefor...........124
Brake Pedal (RTX35).....................................................................................................125
	1. Pedal Removal....................................................................................................126
		1. Park truck on a flat surface.................................................................................126
	2. Pedal Bearing Replacement........................................................................................127
		1. To replace the bearing assemblies on the brake pedal (1), remove the brake pedal return spring...............127
	3. Pedal Adjustment.................................................................................................127
		1. See “Adjustment Procedures for Setting Brake Switch and Brake Transducer” on page355........................127
Brake Pedal (RTX45).....................................................................................................128
	1. Pedal Removal....................................................................................................129
		1. Park truck on a flat surface.................................................................................129
	2. Pedal Bearing Replacement........................................................................................130
		1. To replace bearing assemblies on brake pedal (1), remove the brake pedal return spring (5)...................130
	3. Pedal Adjustment.................................................................................................130
		1. See “Adjustment Procedures for Setting Brake Switch and Brake Transducer” on page355........................130
Internal Fittings.......................................................................................................131
	1. Operator Fan.....................................................................................................131
		1.1. Removal....................................................................................................132
			1. Turn key switch OFF and disconnect battery connector.....................................................132
		1.2. Installation...............................................................................................132
			1. Reassemble the light/fan console assembly. Be sure the clip nuts (3) are positioned over the m...........132
Guards..................................................................................................................133
	1. Overhead Guard...................................................................................................133
Decals..................................................................................................................135
	1. Decal with Protective Sheet......................................................................................135
	2. Decal without Protective Sheet...................................................................................135
Steering Motor..........................................................................................................139
	1. Removal..........................................................................................................139
		1. Park truck on a level surface. Block truck to prevent accidental movement....................................139
	2. Installation.....................................................................................................140
		1. Make sure the rubber spacer and two O-rings are on the end of the steering motor.............................140
			10. Return truck to service.................................................................................140
	3. Steering Motor Gear Replacement..................................................................................141
		3.1. Removal....................................................................................................141
			1. Remove steering motor following the procedure on page137................................................141
		3.2. Installation...............................................................................................141
			1. Slide steering gear onto the steering motor shaft........................................................141
Fan Motor...............................................................................................................143
	1. Upper Electrical Compartment Fan.................................................................................143
		1.1. Removal....................................................................................................143
			1. Turn key switch OFF and disconnect battery connector.....................................................143
		1.2. Installation...............................................................................................143
			1. Install fan assembly by inserting four screws (2) through the truck frame from the mast side.............143
	2. Operator Fan.....................................................................................................144
Motor Maintenance Schedule/Troubleshooting..............................................................................145
	1. General Information..............................................................................................145
	2. Operating Conditions.............................................................................................145
	3. Troubleshooting..................................................................................................146
		1...............................................................................................................150
		2...............................................................................................................150
		3...............................................................................................................150
		4...............................................................................................................150
		5...............................................................................................................150
		6...............................................................................................................150
		7...............................................................................................................150
		8...............................................................................................................150
		9...............................................................................................................150
		10..............................................................................................................150
		11..............................................................................................................150
		12..............................................................................................................150
		13..............................................................................................................150
		14..............................................................................................................150
		15..............................................................................................................150
		16..............................................................................................................150
		17..............................................................................................................150
		18..............................................................................................................150
		19..............................................................................................................150
		20..............................................................................................................150
		21..............................................................................................................150
		22..............................................................................................................150
		23..............................................................................................................150
		24..............................................................................................................151
		25..............................................................................................................151
		26..............................................................................................................151
		27..............................................................................................................151
		28..............................................................................................................151
		29..............................................................................................................151
		30..............................................................................................................151
		31..............................................................................................................151
		32..............................................................................................................151
		33..............................................................................................................151
		34..............................................................................................................151
		35..............................................................................................................151
		36..............................................................................................................151
		37..............................................................................................................151
		38..............................................................................................................151
		39..............................................................................................................151
		40..............................................................................................................151
		41..............................................................................................................151
		42..............................................................................................................151
		43..............................................................................................................151
		44..............................................................................................................151
		45..............................................................................................................151
		46..............................................................................................................151
		47..............................................................................................................151
		48..............................................................................................................152
		49..............................................................................................................152
		50..............................................................................................................152
		51..............................................................................................................152
		52..............................................................................................................152
		53..............................................................................................................152
		54..............................................................................................................152
		55..............................................................................................................152
		56..............................................................................................................152
		57..............................................................................................................152
		58..............................................................................................................152
		59..............................................................................................................152
		60..............................................................................................................152
		61..............................................................................................................152
		62..............................................................................................................152
Pump Motor (RTX35)......................................................................................................153
	1. Component Repair.................................................................................................154
		1.1. Motor Disassembly..........................................................................................154
			1. Remove pump motor from truck (see page111)..............................................................154
				10. After the motor has been separated into all its major subassemblies, the components should be.......155
	2. Motor Inspection.................................................................................................156
		2.1. External Motor.............................................................................................156
			1. Check for clean, tight terminal studs and mounting bolts.................................................156
		2.2. Brush and Commutator.......................................................................................157
		2.3. Bearings...................................................................................................159
		2.4. Armature Electrical Check..................................................................................159
			1. Check armature for grounded circuits by placing one test lead of a Dielectric Breakdown Tester...........159
		2.5. Frame & Field Service Recommendation.......................................................................160
		2.6. Assembly/Testing...........................................................................................161
			1. Press against the race that is absorbing the pressure....................................................161
Pump Motor (RTX 45).....................................................................................................163
	1. Component Repair.................................................................................................164
		1.1. Motor Disassembly..........................................................................................164
			1. Remove pump motor from truck (see page111)..............................................................164
				11. After the motor has been separated into all its major subassemblies, the components should be.......165
	2. Motor Inspection.................................................................................................166
Drive Motor.............................................................................................................167
	1. Motor Disassembly................................................................................................168
		1. Remove drive motor from truck (see page108).................................................................168
	2. Motor Inspection.................................................................................................169
Transmission............................................................................................................171
	1. Axle Sealing Ring................................................................................................173
		1.1. Disassembly................................................................................................173
			1. Remove transmission from the truck (see page115)........................................................173
		1.2. Assembly...................................................................................................174
			1. Place drive axle outer bearing (23) in the transmission case (38)........................................174
	2. Leakage..........................................................................................................175
		2.1. Top Cover..................................................................................................175
			1. Remove transmission from truck...........................................................................175
		2.2. Lower Cover................................................................................................176
			1. Drain transmission oil by removing drain plug (28). Remove washer (18) from drain plug (28)..............176
	3. Wheel Bolt.......................................................................................................177
		1. Drain transmission oil by removing drain plug (28)...........................................................177
Electromagnetic Brake...................................................................................................179
	1. Removal..........................................................................................................179
		1. Park the truck on a level surface and make sure all wheels are blocked to prevent accidental m...............179
	2. Installation.....................................................................................................181
		1. Be sure truck is securely blocked with key switch OFF and battery disconnected...............................181
	3. Adjustments......................................................................................................182
		1. Turn Allen head retaining screws (9) counter- clockwise to loosen one at a time, to allow adju...............182
	4. Coil Check On Brake..............................................................................................183
	5. Electromagnetic Brake, Armature and Magnetic Coil................................................................183
		5.1. Removal....................................................................................................183
			1. Park the truck on a level surface and make sure all wheels are blocked to prevent accidental m...........183
		5.2. Installation...............................................................................................184
			1. Set armature (3) and magnetic coil (2) on the base plate (6).............................................184
	6. Brake Friction Plate.............................................................................................184
		6.1. Inspection.................................................................................................184
		6.2. Replacement................................................................................................184
Drive Wheel.............................................................................................................185
	1. Removal..........................................................................................................185
		1. Park truck on a level surface................................................................................185
	2. Installation.....................................................................................................186
		1. Press drive tire on wheel hub. This is usually done while pressing off the old tire. Press hub...............186
	3. Tire Pressing Procedure..........................................................................................187
		1. Check the inside surface of the metal insert on the new tire. Remove any scaling or rust with ...............187
Non-Braking Caster Assembly.............................................................................................189
	1. Caster Pivot.....................................................................................................191
		1.1. Removal....................................................................................................191
			1. Park truck on a level surface............................................................................191
				10. Remove mounting bolts (20...........................................................................191
				11. Loosen nuts (5) to release spring tension...........................................................191
				12. Remove caster pivot (13). Inspect and replace bushings and bearings as needed.......................191
		1.2. Installation...............................................................................................192
			1. Install pivot block (16) closest to the battery compartment first........................................192
				10. Install main electronic card panel..................................................................192
				11. Test truck operation, then return to service........................................................192
	2. Thrust Bearing...................................................................................................193
		2.1. Removal....................................................................................................193
			1. Park truck on a level surface............................................................................193
		2.2. Installation...............................................................................................194
			1. The truck must be properly blocked at this time..........................................................194
	3. Caster Springs...................................................................................................195
		3.1. Adjustment.................................................................................................195
			1. Park truck on a level surface............................................................................195
		3.2. Removal....................................................................................................195
			1. Park truck on a level surface............................................................................195
		3.3. Installation...............................................................................................196
			1. Install caster springs...................................................................................196
	4. Caster Stops.....................................................................................................197
		4.1. Adjustment.................................................................................................197
			1. Park truck on a level surface. Turn key switch OFF and disconnect battery connector. Securely ...........197
				10. Test truck operation, then return to service........................................................197
Non-Braking Caster Wheels...............................................................................................199
	1. Removal..........................................................................................................199
		1. Park truck on a level surface................................................................................199
	2. Installation.....................................................................................................200
		1. Install Nilos ring (3) on the axle...........................................................................200
Braking Caster Assembly.................................................................................................201
	1. Removal..........................................................................................................203
		1.1. Caster Brake Adjustment....................................................................................203
			1. Park truck on a flat surface.............................................................................203
				9. Run the cable adjustment back to the original position, full threads toward the caster assembly......204
				10. Remove only one caster wheel. Refer to caster wheel removal, on page204............................204
				11. Remove brake assembly from caster wheel.............................................................204
				12. Adjust double nuts at the brake rod up or down by tightening the brake arm. Check brake at 50.......204
				13. Lock double nuts together...........................................................................204
				14. Reassemble and test for proper brake operation......................................................204
Braking Caster Wheel Assembly...........................................................................................205
	1. Removal..........................................................................................................206
		1. Park truck on a level surface................................................................................206
			10. Remove brake plunger (16) and spring (15)...............................................................206
	2. Installation.....................................................................................................207
		1. Slide spring (15) in the caster bracket (2) and install brake plunger (16)...................................207
			10. Back off locknut (6) until the caster wheel turns freely. The locknut (6) and lockwasher (5) ...........207
			11. Bend lockwasher (5) tab to secure locknut (6)...........................................................207
			12. Grease as needed........................................................................................207
			13. Replace wheel cap (8)...................................................................................207
Tandem Load Wheels......................................................................................................209
	1. Removal..........................................................................................................210
		1. Park truck on a level surface................................................................................210
	2. Installation.....................................................................................................211
		1. Pack bearings with grease....................................................................................211
Single Load Wheels......................................................................................................213
	1. Removal..........................................................................................................214
		1. Park truck on a level surface................................................................................214
	2. Installation.....................................................................................................215
		1. Inspect and replace bearing (4) as needed....................................................................215
Steering Wheel..........................................................................................................217
	1. Removal..........................................................................................................217
		1. Park truck on a level surface and block wheels...............................................................217
	2. Installation.....................................................................................................218
		1. Place steering wheel in the mounting bracket (10)............................................................218
Steer Tach..............................................................................................................219
	1. Removal..........................................................................................................219
		1. Park truck on a level surface and block wheels...............................................................219
	2. Installation.....................................................................................................220
		1. Attach steering tach (14) to the underside of mounting bracket (10) with two screws (9)......................220
Steering Bearing........................................................................................................221
	1. Removal..........................................................................................................222
		1. Park truck on a level surface................................................................................222
	2. Installation.....................................................................................................222
		1. Install new steer bearing (1)................................................................................222
Electrical Functions....................................................................................................223
	1. General..........................................................................................................223
		1.1. Directional/Speed Control Handle...........................................................................223
		1.2. Control Handle Interface Card..............................................................................224
		1.3. Main Electronic Card.......................................................................................224
	2. Start Up.........................................................................................................227
	3. Steering Components..............................................................................................231
		3.1. Steering System............................................................................................231
		3.2. Wheel Direction Sensors....................................................................................235
			Table 1: Sensor Sequence....................................................................................236
	4. Brake Release....................................................................................................237
	5. Travel Request, Forks First......................................................................................239
		1. A steering sensor failure (S65, S66 or S67). (See “Wheel Direction Sensors” on page233.)....................240
		2. A drive motor over temperature condition (S60)...............................................................240
		3. A steer controller over temperature (internal to the main electronic card (A5)...............................240
		4. The mast is extended above free lift height (S31). (See page252 and page254.)..............................240
		5. Mast switches (S31 and S45) sequence error. (See page252 and page254.).....................................240
		Travel Request, Forks Trailing..................................................................................242
	6. Travel Request, Forks Trailing...................................................................................243
		1. A steering sensor failure (S65, S66 or S67). (See “Wheel Direction Sensors” on page233.)....................244
		2. A drive motor over temperature condition (S60)...............................................................244
		3. A steer controller over temperature (internal to the main electronic card (A5)...............................244
		4. The mast is extended above free lift height (S31). (See page252 and page254.)..............................244
		5. Mast switches (S31 and S45) sequence error. (See page252 and page254.).....................................244
		Plug Braking....................................................................................................246
	7. Plug Braking.....................................................................................................247
		7.1. Directional/Speed Control Handle Method....................................................................247
		7.2. Brake Pedal Method.........................................................................................248
	8. 12-Volt Power Supply.............................................................................................251
		12-Volt Power Supply............................................................................................251
		7.35-Volt Power Supplies........................................................................................252
	9. 7.35-Volt Power Supplies.........................................................................................253
		9.1. 7.35-Volt Power Supply Main Electronic Card................................................................253
		9.2. 7.35-Volt Power Supply Control Handle Interface Card.......................................................253
		Speed Limit (S31) and Mast (S45) Switches.......................................................................254
	10. Limit Switches..................................................................................................255
		10.1. Truck Travel Speed Limiting...............................................................................255
		Speed Limit (S31) and Mast (S45) Switches.......................................................................256
			10.2. Mast Staging Speed Limiting...........................................................................257
		Height Indicator................................................................................................258
	11. Height Indicator................................................................................................259
	12. Drive Motor Brush Wear Indicator Switches.......................................................................261
		Drive Motor Brush Wear Indicator Switches.......................................................................261
	13. Pump Motor Brush Wear Indicator Switches........................................................................262
		Pump Motor Brush Wear Indicator Switches........................................................................262
	14. Safety Check....................................................................................................263
		Safety Check A..................................................................................................263
		Safety Check B..................................................................................................264
	15. Shunt Power Cable...............................................................................................265
		Shunt Power Cable...............................................................................................265
Electrical Symbols......................................................................................................273
Electrical Schematics...................................................................................................275
	1. Circuit Diagram 1 (12)...........................................................................................275
	2. Circuit Diagram 2 (12)...........................................................................................276
	3. Circuit Diagram 3 (12)...........................................................................................277
	4. Circuit Diagram 4 (12)...........................................................................................278
	5. Circuit Diagram 5 (12)...........................................................................................279
	6. Circuit Diagram 6 (12)...........................................................................................280
	7. Circuit Diagram 7 (12)...........................................................................................281
	8. Circuit Diagram 8 (12)...........................................................................................282
	9. Circuit Diagram 9 (12)...........................................................................................283
	10. Circuit Diagram 10 (12).........................................................................................284
	11. Circuit Diagram 11 (12).........................................................................................285
	12. Circuit Diagram 12 (12).........................................................................................286
Battery.................................................................................................................287
	1. Removal..........................................................................................................287
		1. After the truck is stopped and the brake pedal is returned to the full up position, turn key s...............287
	2. Installation.....................................................................................................287
		1. With a fully charged and tested battery on the lifting device, position the lifting device at ...............287
	3. Battery Maintenance..............................................................................................288
		3.1. Battery Inspection and Care................................................................................288
			1. The top of the battery becomes wet and stays wet, since the acid in the electrolyte does not e...........288
			1. Wet covers can indicate overfilling, leaky seals at posts, or excessive gassing during charge............288
		3.2. Battery Exterior Cleaning..................................................................................289
		3.3. Charging...................................................................................................289
	4. Storage..........................................................................................................290
	5. Battery History Record...........................................................................................290
Light Assemblies........................................................................................................291
	1. Overhead Guard Lights (Option)...................................................................................291
		1.1. Removal....................................................................................................291
			1. Turn key switch OFF and disconnect battery connector.....................................................291
		1.2. Installation...............................................................................................291
			1. Reassemble the light/fan console assembly. Be sure clip nuts are positioned over mounting hole...........291
	2. Warning Lights (Option)..........................................................................................292
		2.1. Removal....................................................................................................292
			1. Turn key switch OFF and disconnect battery connector.....................................................292
		2.2. Installation...............................................................................................292
			1. Secure light assembly to the overhead guard bracket (3) with two hex head screws (1).....................292
	3. Working Lights (Option)..........................................................................................293
		3.1. Removal....................................................................................................293
			1. Turn key switch OFF and disconnect battery connector.....................................................293
		3.2. Installation...............................................................................................293
			1. Secure light assembly to the overhead guard..............................................................293
	4. Travel/Back-up Alarm (Option)....................................................................................294
		4.1. Removal....................................................................................................294
			1. Turn key switch OFF and disconnect battery connector.....................................................294
		4.2. Installation...............................................................................................294
			1. Secure the travel/back-up alarm assembly to the overhead guard bracket (3) with two hex head s...........294
Horn....................................................................................................................295
	1. Removal..........................................................................................................295
		1. Turn key switch OFF and disconnect battery connector.........................................................295
	2. Installation.....................................................................................................295
		1. Attach the horn to the truck frame and tighten mounting bolt (2).............................................295
Battery Connector.......................................................................................................297
	1. Location.........................................................................................................297
		f...............................................................................................................297
	2. Inspection.......................................................................................................298
		1. Turn key switch OFF and disconnect battery connector.........................................................298
	3. Installation.....................................................................................................298
Start/Stop Switches.....................................................................................................299
	1. General..........................................................................................................299
		1.1. Test/Inspection............................................................................................299
	2. Key Switch (S17).................................................................................................299
		2.1. Inspection.................................................................................................299
		2.2. Removal....................................................................................................300
			1. Turn key switch OFF and disconnect battery connector.....................................................300
		2.3. Installation...............................................................................................300
			1. Install new key switch and tighten locking nut...........................................................300
	3. Emergency Disconnect Switch (S21)................................................................................301
		3.1. Inspection.................................................................................................301
		3.2. Removal....................................................................................................301
			1. Turn key switch OFF and disconnect battery connector.....................................................301
		3.3. Installation...............................................................................................302
			1. Place switch operator down through the opening in the top console........................................302
Mast Switch (S31).......................................................................................................303
	1. General..........................................................................................................303
		1.1. Test/Inspection............................................................................................303
	2. Adjustment.......................................................................................................304
		1. Raise the empty carriage until the bottom of the tie bar is even with the bottom of the mast s...............304
			10. Remove the load from forks..............................................................................304
			11. Test the truck operation to verify normal travel speed with the mast lowered............................304
	3. Removal..........................................................................................................305
		1. Raise the empty carriage until the bottom of the tie bar is even with the bottom of the mast s...............305
	4. Installation.....................................................................................................306
		1. Install new mast switch......................................................................................306
Control Cable and Harness...............................................................................................307
	1. Fuses............................................................................................................307
	2. Wiring...........................................................................................................308
		2.1. Harness....................................................................................................308
		2.2. Power Cables...............................................................................................309
	3. Auxiliary Power Hook-up for On-board Terminal....................................................................310
Contactors..............................................................................................................311
	1. General..........................................................................................................311
		1.1. Testing Resistance.........................................................................................311
			1. Turn truck’s key switch OFF and disconnect battery connector.............................................311
		1.2. Contactor Tip Inspection...................................................................................311
	2. Directional Contactors...........................................................................................312
		2.1. Removal....................................................................................................313
			1. Turn key switch OFF and disconnect battery connector.....................................................313
		2.2. Installation...............................................................................................313
			1. Position contactor over the holes in the mounting panel. Attach with screws..............................313
	3. Lift Bypass Contactor............................................................................................314
		3.1. Removal....................................................................................................315
			1. Turn key switch OFF and disconnect battery connector.....................................................315
		3.2. Installation...............................................................................................315
			1. Position contactor over the holes in the mounting panel. Attach with screws (3)..........................315
	4. Battery Cut-out Contactor........................................................................................316
		4.1. Removal....................................................................................................317
			1. Turn key switch OFF and disconnect battery connector.....................................................317
		4.2. Installation...............................................................................................317
			1. Position contactor over the holes in the mounting panel. Attach with screws (1)..........................317
Transistor Panel (Drive)................................................................................................319
	1. Motor Connections................................................................................................319
		1.1. Connections for controls...................................................................................320
	2. Circuit Check....................................................................................................321
		1. Jack up the rear of the truck (see “Safe Jacking Procedure” on page64)......................................321
Transistor Panel (Pump).................................................................................................322
	1. Motor Connections................................................................................................322
		1.1. Connections for controls...................................................................................323
Micro Switches..........................................................................................................325
	1. General..........................................................................................................325
	2. Lift Limit Override Switch (S33).................................................................................326
		2.1. Removal....................................................................................................326
			1. Turn key switch OFF and disconnect battery connector.....................................................326
		2.2. Installation...............................................................................................326
			1. Place new switch in the switch cluster...................................................................326
	3. Optional Light and Fan Switches (S96, S97 and S99)...............................................................327
		3.1. Removal....................................................................................................327
			1. Turn key switch OFF and disconnect battery connector.....................................................327
		3.2. Installation...............................................................................................327
			1. Place new switch in the switch cluster...................................................................327
Main Electronic Card....................................................................................................329
	1. Removal..........................................................................................................329
		1. Turn key switch OFF and disconnect battery connector.........................................................329
	2. Installation.....................................................................................................329
		1. Place main electronic card unit against the outside wall of the chassis. Align mounting holes................329
	3. Connectivity to Truck............................................................................................330
		L...............................................................................................................335
	4. Display..........................................................................................................336
		1. Remove main electronic card panel in the operator’s compartment..............................................336
		4.1. Time.......................................................................................................337
			1. Change the time by stepping up using SW2 or down using SW1...............................................337
	5. Warning/Caution codes............................................................................................338
	6. Error codes......................................................................................................341
		6.1. E102 Troubleshooting Procedures............................................................................343
			6.1.1. POWER CIRCUIT CHECKS (LED #3)........................................................................343
				1. Check the 250 amp drive fuse. A blown fuse will cause this error when the truck is powered up........343
				1. Check for battery voltage through the main contactor (K10), with respect to battery negative, .......345
			6.1.2. REFERENCE CIRCUIT VALUE CHECKS (LED #4)..............................................................345
				1. Check the voltage at the control plug on the drive transistor regulator (A1), pin #10, wire #3.......345
	7. Parameters.......................................................................................................346
	8. Running time.....................................................................................................346
	9. Programming Parameters...........................................................................................347
		1. Press SW3 on the electronic card at the same time as the key switch is turned ON.............................347
		Table 2: PARAMETER NUMBER 9.....................................................................................348
		Table 3: PARAMETER NUMBER 10....................................................................................349
		9.1. Parameter 13 “Battery Type” Adjustment.....................................................................349
			9.1.1. 24 Volt Unit Adjustment..............................................................................352
				1. Install a fully charged battery into the truck.......................................................353
			9.1.2. 36 Volt Unit Adjustment..............................................................................354
				1. Install a fully charged battery into the truck.......................................................354
	10. RV2 Adjustment Procedure........................................................................................356
		1. Remove main electronic card panel............................................................................356
	11. Adjustment Procedures for Setting Brake Switch and Brake Transducer.............................................357
		1. Remove main electronic card access panel (see page101)......................................................357
			10. The brake switch should be adjusted so it actuates between 45 and 52 on the display when depr...........357
			11. After making adjustments, go back into programming mode.................................................357
			12. Reinstall the floor plate and the main electrical card access panel.....................................358
Switches and Sensors....................................................................................................359
	1. General..........................................................................................................359
		1.1. Test/Inspection............................................................................................359
	2. Platform (Right Foot) Switch (S23)...............................................................................359
		2.1. Removal....................................................................................................360
			1. Turn key switch OFF and disconnect battery connector.....................................................360
		2.2. Installation...............................................................................................360
			f...........................................................................................................360
				1. Install two screws (1) through switch (2) into twin nut (3) on the opposite side of the switch.......360
	3. Staging Switch (S45).............................................................................................360
		3.1. Adjustment.................................................................................................360
			1. Raise the empty carriage until the top of the staging switch is even with the top of the stagi...........360
		3.2. Removal....................................................................................................361
			1. Raise empty carriage until the top of the staging switch is above the top of the staging column..........361
		3.3. Installation...............................................................................................361
			1. Install switch on the mounting bracket...................................................................361
	4. Wheel Direction Sensor...........................................................................................362
		4.1. Adjustment.................................................................................................362
			1. Position drive wheel with wheel nuts facing outward......................................................362
		4.2. Removal....................................................................................................363
			1. Turn key switch OFF and disconnect battery connector.....................................................363
		4.3. Installation...............................................................................................363
			1. Install sensor in the frame..............................................................................363
	5. Steer Stop Proximity Sensor A and Sensor B.......................................................................364
		5.1. Adjustment.................................................................................................364
			1. Position drive wheel with wheel nuts facing inward.......................................................364
		5.2. Removal....................................................................................................365
			1. Turn key switch OFF and disconnect battery connector.....................................................365
		5.3. Installation...............................................................................................365
			1. Place new sensors in the frame...........................................................................365
	6. Drive Motor Speed/Direction Sensors..............................................................................366
		6.1. Removal....................................................................................................366
			1. Turn key switch OFF and disconnect battery connector.....................................................366
		6.2. Installation...............................................................................................367
			1. Install sensor (7 or 5) in spacer (6). Be sure the style of the wire ends and location match t...........367
Hydraulic System........................................................................................................369
	1. Operation........................................................................................................369
		Control Handle Interface Schematic..............................................................................370
			1.1. Control Handle Interface, Hydraulic Control Operation..................................................371
				1. Voltages at the main electronic card (A5) inputs greater than 6.615 volts and less than 0.735 .......372
				2. Voltages at the main electronic card inputs other than the stated voltages will select no func.......372
				3. Voltages at the main electronic card inputs greater than 6.75 volts and less than 0.6 volts in.......372
				4. The center and travel limits of the travel and lift/lower potentiometers are learned. Therefor.......372
		Supply Schematic................................................................................................374
			1.2. Supply.................................................................................................375
		Lifting Schematic...............................................................................................376
			1.3. Lifting................................................................................................377
		Lowering Schematic..............................................................................................378
			1.4. Lowering...............................................................................................379
		Low Speed Extend Schematic......................................................................................380
			1.5. Low Speed Extend.......................................................................................381
		High Speed Extend Schematic.....................................................................................382
			1.6. High Speed Extend......................................................................................383
		Low Speed Retract Schematic.....................................................................................384
			1.7. Low Speed Retract......................................................................................385
		High Speed Retract Schematic....................................................................................386
			1.8. High Speed Retract.....................................................................................387
		Right Sideshift Schematic.......................................................................................388
			1.9. Right Sideshift........................................................................................389
		Left Sideshift Schematic........................................................................................390
			1.10. Left Sideshift........................................................................................391
		Fork Tilt Up Schematic..........................................................................................392
			1.11. Fork Tilt Up..........................................................................................393
		Fork Tilt Down Schematic........................................................................................394
			1.12. Fork Tilt Down........................................................................................395
	2. RTX35 Hydraulic Schematic........................................................................................398
	3. RTX45 Hydraulic Schematic........................................................................................399
Hydraulic Fluid.........................................................................................................401
	1. Hydraulic Fluid Selection........................................................................................401
	2. Changing Hydraulic System Fluid..................................................................................401
		1. Be sure the truck is in a clean area, away from any possible contaminating elements that could...............401
	3. System Draining..................................................................................................402
		1. Lower the carriage fully, tilt forks down completely and retract reach mechanism fully.......................402
			9. Remove female half of diagnostic fitting and hose........................................................402
			10. If it is necessary to flush the reservoir, remove reservoir.............................................402
			11. Dispose of old hydraulic fluid according to local regulations for hazardous materials...................402
	4. System Refilling.................................................................................................403
		1. If reservoir was removed for flushing, install reservoir.....................................................403
	5. Bleeding Hydraulic System........................................................................................403
		1. Elevate forks 2 to 3 inches (50 to 75 mm) off the floor......................................................403
			10. If truck is equipped with sideshift, shift the carriage all the way to the left and right sev...........404
			11. Thoroughly clean up any spilled hydraulic fluid.........................................................404
			12. Check hydraulic reservoir level and refill as necessary.................................................404
Hydraulic Tank..........................................................................................................405
	1. Removal..........................................................................................................405
		1. Lower carriage fully and retract reach mechanism fully.......................................................405
			10. Remove hydraulic filter adapter.........................................................................406
	2. Installation.....................................................................................................406
		1. Install hydraulic filter adapter.............................................................................406
			10. Test operate truck......................................................................................406
			11. Turn key switch OFF and disconnect battery connector. Install top console. Reconnect battery ...........406
Hydraulic Filter and Adapter............................................................................................407
	1. Hydraulic Filter.................................................................................................408
		1.1. Removal....................................................................................................408
			1. Lower carriage fully to ensure all hydraulic pressure is relieved........................................408
		1.2. Installation...............................................................................................408
			1. Snap filter onto blue cover (13).........................................................................408
	2. Hydraulic Filter Adapter.........................................................................................409
		2.1. Removal....................................................................................................409
			1. Turn key switch OFF and disconnect battery connector.....................................................409
		2.2. Installation...............................................................................................409
			1. Clean all parts thoroughly. Clean the mating surface of hydraulic tank...................................409
				10. Reconnect battery connector.........................................................................409
Hydraulic Pump..........................................................................................................411
	1. Removal..........................................................................................................412
	2. Pump Disassembly.................................................................................................412
		1. Scribe match mark on the bodies (9, 16), covers (12, 17), and spacer (4) to insure that the du...............412
	3. Parts Inspection.................................................................................................415
		1. Wash all parts and dry thoroughly............................................................................415
	4. Pump Reassembly..................................................................................................416
		1. Place the front cover (12) on a flat plate with the shaft seal bore up. Install new shaft seal...............416
	5. Testing..........................................................................................................418
		1. Mount pump on truck and operate for two minutes at minimum pressure and one-quarter engine speed.............418
Control Valve...........................................................................................................419
	1. Removal..........................................................................................................419
		1. Turn key switch OFF and disconnect battery connector.........................................................419
	2. Installation.....................................................................................................419
		1. Apply thread locking compound to three mounting bolts........................................................419
	3. Repair...........................................................................................................423
		3.1. Proportional Pre-Pressure Reducing Valve, (Items 3, 4, 4a, 4b):............................................423
			1. Remove three screws and lift off twin solenoid block (2) from valve block................................423
		3.2. Valve Assembly SWR14 (Item 38).............................................................................423
			1. Remove two screws (36) and washers (37). The SWR14 valve will separate from lift control valve...........423
		3.3. Pressure Limiting Valve Assembly (Items 17 to 28)..........................................................424
			1. Remove screw (19). Items 17 and 18 can remain intact. Inspect seal (20) for damage and replace...........424
		3.4. Setting Lift/Auxiliary Pressure Relief with a Rated Load...................................................424
			1. Lift a rated load (maximum capacity listed on the specification plate plus 10%)..........................424
		3.5. Hydraulic Lowering Rate Adjustment.........................................................................425
			1. Loosen sealed locknut (32) so that the adjusting screw (35) can be turned................................425
		3.6. Recondition Seal Kit for Lift/ Lower Valve (Items 3, 4a, 4b, 14, 18, 20, 31, 32, 33, and 34)...............425
			1. Refer to paragraph 3.1 for items 3, 4a, and 4b...........................................................425
				9. Loosen locknut (32) and remove adjustment screw (35). Replace locknut................................426
				10. Remove plug (29) and replace seal (20). Screw plug in two turns.....................................426
				11. Remove opposite screw (49) and replace seal (20). Install screw and tighten items 29 and 49.........426
				12. Remove plug (29a) and replace seal (20). Screw plug in two turns....................................426
				13. Remove plug (48) and replace seal (20). Install plug and tighten items 29a and 48...................426
				14. Remove plug (47) and replace seal (33). Install plug................................................426
				15. To replace O-rings (34), refer to Valve Assembly SWR 14.............................................426
Staging Cylinder, 3 Stage...............................................................................................427
	1. Staging Cylinder Repair..........................................................................................428
		1.1. Removal....................................................................................................428
			1. Park truck on a level surface and apply the brake........................................................428
		1.2. Disassembly................................................................................................428
			1. Remove cylinder rod (12) from cylinder tube..............................................................428
		1.3. Assembly...................................................................................................429
			1. Install new wear ring (9), seals, and rod wiper (16) in gland (14). The “lip” of the wiper mus...........429
		1.4. Installation...............................................................................................429
			1. Install lifting gear, chains, hoses, and electric cables.................................................429
Freelift Cylinder, 3 Stage..............................................................................................431
	1. Freelift Cylinder Repair.........................................................................................432
		1.1. Removal....................................................................................................432
			1. Park truck on a level surface and apply brake............................................................432
		1.2. Disassembly................................................................................................434
			1. Remove bearing (12) from cylinder tube (3)...............................................................434
		1.3. Assembly...................................................................................................434
			1. Install a new bearing, seals, and rod wiper in gland. The “lip” of the wiper must face outward...........434
		1.4. Installation...............................................................................................434
			1. Install lifting gear, chains, hoses, and electric cables.................................................434
Reach Cylinder (RTX35)..................................................................................................435
	1. Removal..........................................................................................................436
		1. Park truck on a level surface and apply brake................................................................436
	2. Disassembly......................................................................................................437
		1. Before disassembly, clean the exterior of reach cylinder in a cleaning solution to remove all ...............437
	3. Inspection.......................................................................................................438
		1. Carefully clean all parts in a cleaning solution and position parts on a clean work surface..................438
	4. Assembly.........................................................................................................439
		1. Install new O-rings and rod wiper (16) in bearing assembly (17). The “lip” of the wiper must f...............439
	5. Installation.....................................................................................................440
		1. Raise reach assembly to full freelift height. Install reach cylinder rear mounting pins (2). S...............440
Reach Cylinder (RTX45)..................................................................................................441
	1. Removal..........................................................................................................442
		1. Park truck on a level surface and apply brake................................................................442
	2. Disassembly......................................................................................................443
		1. Before disassembly, clean the exterior of reach cylinder in a cleaning solution to remove all ...............443
	3. Inspection.......................................................................................................444
		1. Carefully clean all parts in a cleaning solution and position them on a clean work surface...................444
	4. Assembly.........................................................................................................445
		1. Install new rod wiper (21) in bearing assembly. The “lip” of the wiper must face outward.....................445
			9. Install retainer (13)....................................................................................445
	5. Installation.....................................................................................................446
		1. Raise reach assembly to full freelift height. Install reach cylinder rear mounting pins (10). ...............446
Tilt Cylinder (RTX35)...................................................................................................447
	1. Removal..........................................................................................................448
		1. Park truck on a level surface and apply the brake............................................................448
		1. Before disassembly, clean the exterior of tilt cylinder (1) in a cleaning solution to remove a...............449
		1. Carefully clean all parts in a cleaning solution and position parts on a clean work surface..................450
		1. Install new packing and rod wipers in the bearing assembly. The “lip” of the wiper must face o...............451
			10. Install cylinder bearing (7) and bearing retainer (13)..................................................451
		1. Install cylinder on reach front frame........................................................................452
Tilt Cylinder (RTX45)...................................................................................................453
	1. Removal..........................................................................................................454
		1. Park truck on a level surface and apply brake................................................................454
		1. Before disassembly, clean the exterior of tilt cylinder (1) in a cleaning solution to remove a...............455
		1. Carefully clean all parts in a cleaning solution and position them on a clean work surface...................456
		1. Install new packing and rod wipers in bearing assembly. The “lip” of the wiper must face outward.............457
			10. Install cylinder bearing (8) and bearing retainer (14)..................................................457
		1. Install cylinder on reach front frame........................................................................458
Mast, 3 Stage (RTX35)...................................................................................................459
	1. Shimming Carriage with Mast on Truck.............................................................................461
		1. Turn key switch OFF and disconnect battery connector. Remove battery from truck..............................461
			10. Remove hoist from carriage and test operation of unit. Check operation first with no load, th...........462
	2. Three Stage Mast.................................................................................................463
		2.1. Removal....................................................................................................463
			1. Turn key switch OFF and disconnect battery connector. Remove battery from truck..........................463
		2.2. Disassembly................................................................................................464
			1. Lower mast assembly to a horizontal position before work can begin.......................................464
		2.3. Assembly...................................................................................................465
			1. Thoroughly clean all parts and air dry...................................................................465
				10. Extend inner column through the intermediate column as far as it will go under normal operati.......466
				11. Install staging lift cylinder assembly in outer column lower end....................................466
				12. Press roller bearings in lift chain sheaves. Grease roller bearings, then slide inner races i.......466
				13. Install shim washers on either side of lift chain sheaves and install in intermediate column........466
				14. Install a bearing in the electrical sheave. Grease bearing and install spacers on either side.......466
				15. Install electrical sheave in the proper location on intermediate column. Secure sheave with o.......466
				16. Push intermediate and outer columns together. Install a cap screw in intermediate column to s.......466
				17. Install lift chain anchors through outer column. Thread a wheel nut on each anchor and secure.......466
				18. Install lift chain on chain anchors and secure with chain pins. After chain pins have been in.......467
				19. Install freelift cylinder assembly on inner column. Secure with four cap screws and nuts............467
				20. Connect hydraulic lines to lift cylinder............................................................467
				21. Lubricate grease fittings using a standard lube gun (see “Oil and Grease Specifications” on p.......467
		2.4. Installation...............................................................................................467
			1. Install mast using a hoist...............................................................................467
Mast, 3 Stage (RTX45)...................................................................................................468
	1. Shimming Carriage with Mast on Truck.............................................................................470
		1. Turn key switch OFF and disconnect battery connector. Remove battery from truck..............................470
			10. Remove hoist from the carriage. Test operation of unit. Check operation first with no load, t...........471
	2. Three Stage Mast.................................................................................................472
		2.1. Removal....................................................................................................472
			1. Turn key switch OFF and disconnect battery connector. Remove battery from truck..........................472
		2.2. Disassembly................................................................................................473
			1. Lower mast assembly to a horizontal position before work can begin.......................................473
				9. Thoroughly clean all parts...........................................................................473
		2.3. Assembly...................................................................................................474
			1. Thoroughly clean all parts and air dry...................................................................474
				10. Extend inner column through the intermediate column as far as it will go under normal operati.......475
				11. Install staging lift cylinder assembly in the intermediate column lower end.........................475
				12. Press roller bearings in the lift chain sheaves. Grease roller bearings, then slide the inner.......475
				13. Install shim washers on either side of the lift chain sheaves. Install in the intermediate co.......475
				14. Install a bearing in the electrical sheave. Grease bearing and install spacers on either side.......475
				15. Install electrical sheave in the proper location on the intermediate column. Secure with one .......475
				16. Push intermediate and outer columns together. Install a cap screw in the intermediate column .......475
				17. Install lift chain anchors through the outer column. Thread a wheel nut on each anchor and se.......476
				18. Install lift chain on the chain anchors. Secure with chain pins. After chain pins have been i.......476
				19. Install freelift cylinder assembly on the inner column. Secure with four cap screws and nuts........476
				20. Connect hydraulic lines to the lift cylinder........................................................476
				21. Lubricate grease fittings using a standard lube gun (see “Oil and Grease Specifications” on p.......476
		2.4. Installation...............................................................................................476
			1. Install mast using a hoist...............................................................................476
Lift Chain..............................................................................................................478
	1. Lift Chain Adjustment............................................................................................478
		1. Loosen locking nuts on chain anchors.........................................................................478
	2. Lift Chain Maintenance...........................................................................................478
	3. Lift Chain Inspection............................................................................................478
		3.1. Wear.......................................................................................................479
		3.2. Rust and Corrosion.........................................................................................479
		3.3. Cracked Plates.............................................................................................480
		3.4. Protruding or Turned Pins..................................................................................482
		3.5. Chain Side Wear............................................................................................483
		3.6. Chain Anchors and Sheaves..................................................................................483
	4. Lift Chain Lubrication...........................................................................................484
	5. Lift Chain Replacement...........................................................................................486
		1. All chains should be replaced if any strand has wear elongation of 3% or if any of the conditi...............486
Lifting Gear (Crosshead) (RTX35)........................................................................................487
	1. Lifting Gear Repair..............................................................................................488
		1.1. Removal....................................................................................................488
			1. Park truck on a level surface and apply brake. Turn key switch OFF and disconnect battery conn...........488
		1.2. Disassembly................................................................................................489
			1. Remove retaining ring (2) from one end of the lifting gear assembly......................................489
		1.3. Assembly...................................................................................................489
			1. Place hydraulic/electric sheave (8) into the sheave head.................................................489
		1.4. Installation...............................................................................................490
			1. Place lifting gear assembly on top of freelift cylinder..................................................490
Lifting Gear (Crosshead) (RTX45)........................................................................................491
	1. Lifting Gear Repair..............................................................................................492
		1.1. Removal....................................................................................................492
			1. Park truck on a level surface and apply brake. Turn key switch OFF and disconnect battery conn...........492
		1.2. Disassembly................................................................................................493
			1. Remove retaining ring (2) from one end of the lifting gear assembly......................................493
		1.3. Assembly...................................................................................................493
			1. Place hydraulic/electric sheave (8) into the sheave head.................................................493
		1.4. Installation...............................................................................................493
			1. Place lifting gear assembly on the top of the freelift cylinder..........................................493
Sideshifter.............................................................................................................495
	1. Mounting Instructions............................................................................................497
		1.1. Installation...............................................................................................497
			1. Remove lower pads (12) from sideshift assembly. Grease lower pads and return to the sideshift ...........497
				10. Mount forks in the notches on the upper bar of the sideshift carriage...............................497
				11. Install fork stop bolt (7) with washer (9, 10) into the lower bar of the sideshift carriage.........497
				12. Sideshift the unit several times to insure there are no leaks. Check sideshift unit for smoot.......498
	2. Operation........................................................................................................498
	3. Maintenance......................................................................................................498
		3.1. Carriage Removal...........................................................................................499
			1. Remove fork stop bolt (7) from sideshift carriage........................................................499
		3.2. Upper Pad Replacement......................................................................................499
			1. Remove sideshift carriage from the truck. See paragraph 3.1 above........................................499
		3.3. Lower Pad Replacement......................................................................................500
			1. Remove fork stop bolt (7) from sideshift carriage........................................................500
				10. Remove blocking spacer and lower sideshift carriage to fork carriage................................500
				11. Lift lower hook (11), bringing plastic pad (12) in contact with underside of truck carriage. .......500
				12. Tighten set screw (8) to 21 ft-lb (30 N•m) torque...................................................500
				13. Install safety screw (28) into the hole with the set screw (8). Torque safety screw to 70 ft-.......501
				14. Connect hydraulic fittings to the sideshift cylinder. Tighten fittings to 56 ft-lb (80 N•m).........501
				15. Mount forks in the notches on the upper bar of sideshift carriage...................................501
				16. Install fork stop bolt (7) with washer (9, 10) into lower bar of the sideshift carriage.............501
				17. Sideshift the unit several times to insure there are no leaks. Check the sideshift unit for s.......501
		3.4. Cylinder...................................................................................................502
			1. Remove sideshift carriage from truck. See “Carriage Removal” on page497.................................502
	4. Troubleshooting..................................................................................................503
		4.1. No Sideshifting............................................................................................503
			1. Check that input pressure is not greater than 3200 psi (22060 kPa). Average working pressure s...........503
		4.2. Very Slow Sideshifting.....................................................................................503
			1. Check that input pressure is not greater than 3200 psi (22060 kPa). Average working pressure s...........503
		4.3. Irregular Sideshifting.....................................................................................504
			1. Check hydraulic system to be sure there is no air. Bleed hydraulic system if necessary...................504
Reach, Single (RTX35)...................................................................................................505
	1. Maintenance......................................................................................................505
	2. Reach Repair.....................................................................................................507
		2.1. Removal....................................................................................................507
			1. Remove forks.............................................................................................507
		2.1. Disassembly................................................................................................507
			2.1.1. Front Frame Removal..................................................................................507
				1. Disconnect hydraulic hoses from tilt and sideshift cylinders from the input side of junction b.......507
			2.1.2. Outer Arm Removal....................................................................................508
				1. Remove nut (28) and washer (27)......................................................................508
			2.1.3. Inner Arm Removal....................................................................................508
				1. Drive pins out of reach cylinder rod end pins........................................................508
			2.1.4. Rear Frame Removal...................................................................................508
				1. Lift rear frame (3) until all tension is removed from lift chains....................................508
			2.1.5. Reach Cylinder Removal...............................................................................509
				1. Disconnect hydraulic hoses. Plug to prevent contamination............................................509
		2.2. Assembly...................................................................................................509
			2.2.1. Reach Cylinder Installation..........................................................................509
				1. Install rear frame pins..............................................................................509
			2.2.2. Rear Frame Installation..............................................................................509
				1. Install shims (37) and rollers (32)..................................................................509
			2.2.3. Inner Arm Installation...............................................................................510
				1. Install upper end of inner arms (9) into rear frame (3)..............................................510
			2.2.4. Outer Arm Installation...............................................................................510
				1. Install rollers (32), caps (31) and screws (30) on outer arms (5 and 26).............................510
			2.2.5. Front Frame Installation.............................................................................511
				1. Install front frame (17) onto inner arm (9) rollers (46).............................................511
	3. Carriage Bumpers.................................................................................................511
		3.1. Reach Adjustment...........................................................................................511
			1. Install a 0.125 inch (3 mm) shim (36) behind each reach retract bumper (35)..............................511
				10. When proper adjustment is achieved, clean rod threads and apply Loctite 242® thread locking c.......513
	4. Fork Carriage Pivot Pins.........................................................................................513
	5. Carriage Roller Bearings.........................................................................................513
		5.1. Removal....................................................................................................513
			1. Remove carriage/reach....................................................................................513
		5.2. Installation...............................................................................................514
			1. Install new bearing on shaft.............................................................................514
Reach, Single (RTX45)...................................................................................................515
	1. Maintenance......................................................................................................515
	2. Reach Repair.....................................................................................................517
		1. Remove forks.................................................................................................517
		2.1. Disassembly................................................................................................517
			2.1.1. Front Frame Removal..................................................................................517
				1. Disconnect hydraulic hoses from the tilt and sideshift cylinders from the input side of the so.......517
			2.1.2. Outer Arm Removal....................................................................................517
				1. Remove nut (16) and lockwasher (17)..................................................................517
			2.1.3. Inner Arm Removal....................................................................................518
				1. Remove screws (20) and washer (22)...................................................................518
			2.1.4. Rear Frame Removal...................................................................................518
				1. Lift rear frame (31) until all tension is removed from the lift chains...............................518
			2.1.5. Reach Cylinder Removal...............................................................................519
				1. Disconnect hydraulic hoses. Plug to prevent contamination............................................519
		2.2. Assembly...................................................................................................519
			2.2.1. Reach Cylinder Installation..........................................................................519
				1. Install rear frame pins (27).........................................................................519
			2.2.2. Rear Frame Installation..............................................................................519
				1. Install shims (35) and rollers (36)..................................................................519
			2.2.3. Inner Arm Installation...............................................................................520
				1. Install bearing (6) in inner arm (10)................................................................520
			2.2.4. Outer Arm Installation...............................................................................520
				1. Install bearing (3), bearing cap (2) and screw (1) on the arms (4 and 15)............................520
			2.2.5. Front Frame Installation.............................................................................520
				1. Install front frame (42) onto inner arm (10) rollers (3).............................................520
	3. Reach Carriage Wear Strip........................................................................................521
		3.1. Removal....................................................................................................521
			1. Partially extend the carriage so that the end of the inner scissor arm (10) is midway down the...........521
		3.2. Installation...............................................................................................521
			1. Grease and wedge the new reach wear strip (57) between bearing (3) and track.............................521
	4. Fork Carriage Pivot Pins.........................................................................................522
	5. Carriage Bumpers.................................................................................................522
	6. Carriage Roller Bearings.........................................................................................522
		6.1. Removal....................................................................................................522
			1. Remove carriage/reach....................................................................................522
		6.2. Installation...............................................................................................523
			1. Install new bearing on shaft. Apply thread locking compound to socket head cap screw (38). Fas...........523
Height Indication.......................................................................................................525
	1. General..........................................................................................................526
	2. Operation........................................................................................................526
	3. Error Code 13....................................................................................................526
Height Indicator (RTX35)................................................................................................527
	1. Pulse sensor.....................................................................................................528
		1.1. Repair.....................................................................................................528
			1. Unplug wiring harness at the sensing unit................................................................528
		1.2. Cable......................................................................................................528
			1.2.1. Removal..............................................................................................528
				1. To replace cable (19), remove bolt from the bottom anchor (3) relieving spring tension...............528
			1.2.2. Installation.........................................................................................528
				1. Install a new cable (19) on the top anchor. Wrap cable once around the pulley wheel..................528
		1.3. Pulley.....................................................................................................529
			1.3.1. Removal..............................................................................................529
				1. To replace roller (5), remove cover (2), pulse sensor, and cable (19)................................529
Height Indicator (RTX45)................................................................................................530
	1. Pulse sensor.....................................................................................................531
		1.1. Repair.....................................................................................................531
			1. Unplug wiring harness at the sensing unit................................................................531
		1.2. Cable......................................................................................................531
			1.2.1. Removal..............................................................................................531
				1. To replace cable (19), remove bolt from the bottom anchor (3) relieving spring tension...............531
			1.2.2. Installation.........................................................................................531
				1. Install a new cable (19) on the top anchor. Wrap the cable once around the pulley wheel..............531
		1.3. Pulley.....................................................................................................532
			1.3.1. Removal..............................................................................................532
				1. To replace roller (5), remove cover (2), pulse sensor, and cable (19)................................532
Load Backrest...........................................................................................................533
	1. Removal..........................................................................................................534
		1. Park truck on a level surface. Turn key switch OFF and disconnect battery connector. Remove ba...............534
	2. Installation.....................................................................................................534
		1. Place load backrest on front fork frame......................................................................534

DESCRIPTION:

BT PRIME MOVER RTX35/45 MASTER SERVICE MANUAL 310428-000 July 2001 – PDF DOWNLOAD

• 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 OSHA191D.178.
• An Operator’s Manual is sent with every BT Prime-Mover truck when it is manufactured.
• 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 track types. The main subject for each of these sections are as described below.

S.S 07/01/2025