PRIME MOVER RTX35 RTX45 FORK Truck Workshop Service Repair M

Part no: 310428-000 Date: July 30, 2001 Master Service Manual Read and observe all warnings on this unit before operating it. DO NOT operate this equipment unless all factory installed guards and shields are properly secured in place. WARNING WARNING F RTX35/45 Electric Stand-Up Rider Truck Effective Serial Number RTX3530317001 - UP + - 1 0 1 /2 + - 1 0 1/2

BT Prime-Mover Standard Codes F-code Section C-code Version no T-code 000 © BT Prime-Mover Inc. 1 Service Manual 2001-03-15 BT Prime-Mover Standard Codes B-Code = Business area F-Code = Product family T-Code = Product type C-Code = Component function Worksheet standard W-Code = Working code R-Code = Reason code SO-Code = Assortment C-Code List No Function Group C-Code 0 Chassis 0000 1 Drive Motor 1000 2 Drive Gear / Transmission 2000 3 Brake / Wheel System 3000 4 Steering System 4000 5 Electrical System 5000 6 Hydraulic / Pneumatic System 6000 7 Operating Function-lifting Mast / Cylinders 7000 8 Peripheral / Installation Equipment 8000 9 Options / Attachments 9000

000 Version no T-code F-code Section C-code BT Prime-Mover Standard Codes 2 Service Manual 2001-03-15

© BT Prime-Mover Inc. 3 Table of Contents BT Prime-Mover Standard Codes ................................................................ 1 Warning Symbols ......................................................................................... 13 Warning Levels ......................................................................................... 13 Prohibitory Symbols .................................................................................... 14 Ordinance Symbols .................................................................................. 14 Safety ............................................................................................................ 15 General Safety .......................................................................................... 15 Battery Safety ............................................................................................... 19 Static Safety .................................................................................................. 23 Welding Safety ............................................................................................. 24 Introduction, Service Manual ...................................................................... 27 Contents, Section M ..................................................................................... 29 Machine Information ................................................................................. 29 General Product Information ...................................................................... 31 Truck Presentation .................................................................................... 31 Main Components ..................................................................................... 37 Grease Point Location .............................................................................. 40 Mast Adjustment Points ............................................................................ 41 Inch (SAE) and Metric Fasteners ............................................................... 43 Introduction ............................................................................................... 43 Nomenclature, Threads ............................................................................ 44 Strength Identification ............................................................................... 45 Conversion of Metric and English Units .................................................... 52 Technical Service Data ................................................................................ 55 Ordering Spare Parts ................................................................................... 59 Contents, Section P ..................................................................................... 61 Planned Maintenance ............................................................................... 61 Introduction, Maintenance .......................................................................... 63 Safe Jacking Procedure ............................................................................ 64 Lubricants ................................................................................................. 65

© BT Prime-Mover Inc. 4 Table of Contents Service Schedule ......................................................................................... 67 Planned Maintenance Schedule ............................................................... 67 Planned Maintenance Procedures ............................................................ 72 Lubrication Chart ......................................................................................... 79 Oil and Grease Specifications .................................................................... 81 Approved Oils and Grease ....................................................................... 81 Contents, Section S ..................................................................................... 83 Service Instructions .................................................................................. 83 Troubleshooting Guidelines ....................................................................... 85 General ..................................................................................................... 85 Electrical ................................................................................................... 87 Hydraulic ................................................................................................... 92 Definitions ................................................................................................. 93 Chassis ......................................................................................................... 95 General ..................................................................................................... 95 Top Console ............................................................................................. 96 Motor Compartment Door ......................................................................... 97 Left Side Panel (Exterior) .......................................................................... 98 Left Operator Compartment Panel ........................................................... 100 Main Electronic Card Panel ..................................................................... 101 Floor Board .............................................................................................. 102 Clipboard ................................................................................................. 103 Battery Retainer Plates and Rollers .......................................................... 105 Battery Retainer Plates ............................................................................ 106 Battery Rollers ......................................................................................... 106 Mounting Points .......................................................................................... 107 Drive Motor .............................................................................................. 107 Pump Motor ............................................................................................. 110 Transmission ........................................................................................... 114 Driver Controls ............................................................................................ 117 Handle Interface Module .......................................................................... 119 Control Handle ......................................................................................... 120 Brake Pedal (RTX35) ................................................................................... 123 Pedal Removal ........................................................................................ 124 Pedal Bearing Replacement .................................................................... 125 Pedal Adjustment ..................................................................................... 125

© BT Prime-Mover Inc. 5 Table of Contents Brake Pedal (RTX45) ................................................................................... 126 Pedal Removal ........................................................................................ 127 Pedal Bearing Replacement .................................................................... 128 Pedal Adjustment ..................................................................................... 128 Internal Fittings ........................................................................................... 129 Operator Fan ........................................................................................... 129 Guards .......................................................................................................... 131 Overhead Guard ...................................................................................... 131 Decals ........................................................................................................... 133 Decal with Protective Sheet ..................................................................... 133 Decal without Protective Sheet ................................................................ 133 Steering Motor ............................................................................................. 137 Removal ................................................................................................... 137 Installation ................................................................................................ 138 Steering Motor Gear Replacement .......................................................... 139 Fan Motor ..................................................................................................... 141 Upper Electrical Compartment Fan ......................................................... 141 Operator Fan ........................................................................................... 142 Motor Maintenance Schedule/Troubleshooting ......................................................................... 143 General Information ................................................................................. 143 Operating Conditions ............................................................................... 143 Troubleshooting ....................................................................................... 144 Pump Motor (RTX35) ................................................................................... 151 Component Repair ................................................................................... 152 Motor Inspection ...................................................................................... 154 Pump Motor (RTX 45) .................................................................................. 161 Component Repair ................................................................................... 162 Motor Inspection ...................................................................................... 164 Drive Motor .................................................................................................. 165 Motor Disassembly .................................................................................. 166 Motor Inspection ...................................................................................... 167 Transmission. .............................................................................................. 169 Axle Sealing Ring .................................................................................... 171 Leakage ................................................................................................... 173

© BT Prime-Mover Inc. 6 Table of Contents Wheel Bolt ............................................................................................... 175 Electromagnetic Brake ............................................................................... 177 Removal ................................................................................................... 177 Installation ................................................................................................ 179 Adjustments ............................................................................................. 180 Coil Check On Brake ............................................................................... 181 Electromagnetic Brake, Armature and Magnetic Coil .............................. 181 Brake Friction Plate ................................................................................. 182 Drive Wheel .................................................................................................. 183 Removal ................................................................................................... 183 Installation ................................................................................................ 184 Tire Pressing Procedure .......................................................................... 185 Non-Braking Caster Assembly .................................................................. 187 Caster Pivot ............................................................................................. 189 Thrust Bearing ......................................................................................... 191 Caster Springs ......................................................................................... 193 Caster Stops ............................................................................................ 195 Non-Braking Caster Wheels ....................................................................... 197 Removal ................................................................................................... 197 Installation ................................................................................................ 198 Braking Caster Assembly ........................................................................... 199 Removal ................................................................................................... 201 Braking Caster Wheel Assembly ............................................................... 203 Removal ................................................................................................... 204 Installation ................................................................................................ 205 Tandem Load Wheels ................................................................................. 207 Removal ................................................................................................... 208 Installation ................................................................................................ 209 Single Load Wheels .................................................................................... 211 Removal ................................................................................................... 212 Installation ................................................................................................ 213 Steering Wheel ............................................................................................ 215 Removal ................................................................................................... 215 Installation ................................................................................................ 216 Steer Tach .................................................................................................... 217

© BT Prime-Mover Inc. 7 Table of Contents Removal ................................................................................................... 217 Installation ................................................................................................ 218 Steering Bearing ......................................................................................... 219 Removal ................................................................................................... 220 Installation ................................................................................................ 220 Electrical Functions .................................................................................... 221 General .................................................................................................... 221 Start Up .................................................................................................... 225 Steering Components .............................................................................. 229 Brake Release ......................................................................................... 235 Travel Request, Forks First ..................................................................... 237 Travel Request, Forks Trailing ................................................................. 241 Plug Braking ............................................................................................ 245 12-Volt Power Supply .............................................................................. 249 7.35-Volt Power Supplies ........................................................................ 251 Limit Switches .......................................................................................... 253 Height Indicator ........................................................................................ 257 Drive Motor Brush Wear Indicator Switches ............................................ 259 Pump Motor Brush Wear Indicator Switches ........................................... 260 Safety Check ........................................................................................... 261 Shunt Power Cable .................................................................................. 263 Electrical Symbols ...................................................................................... 271 Electrical Schematics ................................................................................. 273 Circuit Diagram 1 (12) .............................................................................. 273 Circuit Diagram 2 (12) .............................................................................. 274 Circuit Diagram 3 (12) .............................................................................. 275 Circuit Diagram 4 (12) .............................................................................. 276 Circuit Diagram 5 (12) .............................................................................. 277 Circuit Diagram 6 (12) .............................................................................. 278 Circuit Diagram 7 (12) .............................................................................. 279 Circuit Diagram 8 (12) .............................................................................. 280 Circuit Diagram 9 (12) .............................................................................. 281 Circuit Diagram 10 (12) ............................................................................ 282 Circuit Diagram 11 (12) ............................................................................ 283 Circuit Diagram 12 (12) ............................................................................ 284 Battery .......................................................................................................... 285 Removal ................................................................................................... 285 Installation ................................................................................................ 285 Battery Maintenance ................................................................................ 286 Storage .................................................................................................... 288

© BT Prime-Mover Inc. 8 Table of Contents Battery History Record ............................................................................. 288 Light Assemblies ........................................................................................ 289 Overhead Guard Lights (Option) ............................................................. 289 Warning Lights (Option) ........................................................................... 290 Working Lights (Option) ........................................................................... 291 Travel/Back-up Alarm (Option) ................................................................ 292 Horn .............................................................................................................. 293 Removal ................................................................................................... 293 Installation ................................................................................................ 293 Battery Connector ....................................................................................... 295 Location ................................................................................................... 295 Inspection ................................................................................................ 296 Installation ................................................................................................ 296 Start/Stop Switches .................................................................................... 297 General .................................................................................................... 297 Key Switch (S17) ..................................................................................... 297 Emergency Disconnect Switch (S21) ...................................................... 299 Mast Switch (S31) ........................................................................................ 301 General .................................................................................................... 301 Adjustment ............................................................................................... 302 Removal ................................................................................................... 303 Installation ................................................................................................ 304 Control Cable and Harness ........................................................................ 305 Fuses ....................................................................................................... 305 Wiring ....................................................................................................... 306 Auxiliary Power Hook-up for On-board Terminal ................................................................................... 308 Contactors ................................................................................................... 309 General .................................................................................................... 309 Directional Contactors ............................................................................. 310 Lift Bypass Contactor ............................................................................... 312 Battery Cut-out Contactor ........................................................................ 314 Transistor Panel (Drive) .............................................................................. 317 Motor Connections ................................................................................... 317 Circuit Check. .......................................................................................... 319 Transistor Panel (Pump) ............................................................................. 320

PRIME MOVER RTX35 RTX45 FORK Truck Workshop Service Repair M

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