Front Cover

Master Service Manual

RTX35/45, RTX30DR
Electric Stand-Up Rider Truck

Effective Serial Number RTX3530317001 - UP

+
11/2
0

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11/2
0

Warning

Read and observe all warnings on this unit

before operating it.

Warning

DO NOT operate this equipment unless all

factory installed guards and covers are
properly secured in place.

Part no: 310428-000

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Date: December 22, 2006

Table of Contents
Table of Contents
Ordering Spare Parts .................................................................................... 1
Standard Codes ............................................................................................. 3
Warning Symbols ......................................................................................... 17
Warning Levels ................................................................................................................. 17

Prohibitory Symbols .................................................................................... 18

Ordinance Symbols .......................................................................................................... 18

Safety ............................................................................................................ 19
General Safety .................................................................................................................. 19

Battery Safety ............................................................................................... 23

Static Discharge Precautions ..................................................................... 27
Welding Safety ............................................................................................. 29
Introduction, Service Manual ...................................................................... 31
Contents, Section M ..................................................................................... 33
Machine Information ......................................................................................................... 33

General Product Information ...................................................................... 35

Truck Presentation ............................................................................................................
Truck Side Views ....................................................................................................
Open Back Compartment ........................................................................................
Intended Truck Application ......................................................................................
Prohibited Truck Application ...................................................................................
Truck Data ...............................................................................................................
RTX35 Dimensions .................................................................................................
RTX45 Dimensions .................................................................................................
RTX30DR Dimensions ............................................................................................
Data Plate ...............................................................................................................
Main Components .............................................................................................................

35
35
36
36
37
37
38
39
40
41
42

Inch (SAE) and Metric Fasteners ................................................................ 45

Introduction .......................................................................................................................
Nomenclature, Threads ....................................................................................................
Strength Identification .......................................................................................................
Truck Torque Specifications .............................................................................................
Conversion of Metric and English Units ............................................................................

45
46
47
53
54

Technical Service Data ................................................................................ 57

Contents, Section P ..................................................................................... 61
Planned Maintenance ....................................................................................................... 61

Introduction, Maintenance .......................................................................... 63

Jacking Truck Off The Floor ............................................................................................. 64
Elevate Rear of Truck ............................................................................................. 64

BT Prime-Mover Inc.

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Master Service Manual

2004-03-22

Table of Contents
Extend Reach ......................................................................................................... 596
Arm Assembly ........................................................................................................ 596
Rear Frame ............................................................................................................ 605

Forks ............................................................................................................ 609

Theory of Operation .........................................................................................................
Maintenance ....................................................................................................................
Inspection ...............................................................................................................
Troubleshooting ...............................................................................................................
Repair and Rebuild ..........................................................................................................

609
609
609
610
610

Lights and Alarms (Optional) ..................................................................... 613

Theory of Operation .........................................................................................................
Maintenance ....................................................................................................................
Troubleshooting ...............................................................................................................
Repair and Rebuild ..........................................................................................................
Warning Lights .......................................................................................................
Working Lights .......................................................................................................
Travel/Back-up Alarm .............................................................................................

613
613
613
614
614
615
616

Height Indicator ........................................................................................... 617

Theory of Operation .........................................................................................................
Maintenance ....................................................................................................................
Troubleshooting ...............................................................................................................
Error Code 13 .........................................................................................................
Repair and Rebuild ..........................................................................................................
Pulse Sensor ..........................................................................................................
Cable ......................................................................................................................
Pulley .....................................................................................................................

617
617
617
617
618
621
622
622

Load Backrest ............................................................................................. 623

Theory of Operation .........................................................................................................
Maintenance ....................................................................................................................
Troubleshooting ...............................................................................................................
Repair and Rebuild ..........................................................................................................

623
623
623
624

Electrical Heater (Upper Chassis and Handle Assembly) ....................... 627

Theory of Operation .........................................................................................................
Maintenance ....................................................................................................................
Troubleshooting ...............................................................................................................
Repair and Rebuild ..........................................................................................................

627
627
627
628

Electrical Heater (Lower Chassis and Pedal Assembly) ......................... 631

Theory of Operation .........................................................................................................
Maintenance ....................................................................................................................
Troubleshooting ...............................................................................................................
Repair and Rebuild ..........................................................................................................

16

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631
631
631
632

2004-03-22

F-code

Section

C-code

RT
S3.4
3543
Braking Caster Assembly, RTX45/RTX30DR
Version no.

T-code

002

RTX45/30DR

6. Loosen adjusting nuts of the cable end at caster

assembly bell crank. Adjust cable threaded end to
allow for more engagement required by a worn
brake. At the 50 percent pedal up position, caster
wheels should stop rotating due to brakes making
contact with caster wheel drums.
7. When the cable can no longer be adjusted for
caster braking, the brake must be adjusted at the
caster wheels.
CAUTION Failure to determine battery compartment
size, battery weight, and mast height can
result in serious injury.

Adjuster nuts
Rod

Spring

8. Adjust the top stop bolts (12). The recommended

dimension between the stop bolts and the stop
block is 1/4 inch (6 mm). To determine if the
maximum dimension for the trucks can be
increased see table on page 188.
9. Run the cable adjustment back to the original
position, full threads toward the caster assembly.
10. Remove only one caster wheel (see page 204.)
11. Remove brake assembly from caster wheel.

Adjusting
nuts

12. Adjust double nuts at the brake rod up or down by

tightening the brake arm. Check brake at 50
percent pedal up position. The caster wheel should
stop rotating due to the brake starting to make
contact with the drums.
13. Lock double nuts together.
14. Reassemble and test for proper brake operation.

3. Troubleshooting
Lubricate caster and caster wheels every two months.

200

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Master Service Manual

2004-04-14

F-code

Section

C-code

RT
S6.0
Hydraulic System

6000

Version no.

T-code

002

RTX35/45/30DR

5. Reconnect the battery connector to the truck. Turn

key switch ON.
6. Lower forks all the way down to the floor.
7. Fully extend and retract the reach mechanism
several times.
8. When hydraulic fluid starts flowing from bleed
screw hole, securely tighten bleed screw.
9. If truck is equipped with tilt, lean carriage all the
way forward and backward several times.
10. If truck is equipped with sideshift, shift carriage all
the way to the left and right several times.
11. Thoroughly clean up any spilled hydraulic fluid.
12. Check hydraulic reservoir level and refill as
necessary.

2.5. Setting Lift/Auxiliary Pressure Relief

with a Rated Load

Relief Valve
Adjusting Screw

NOTE!

To set the system pressure, a calibrated

pressure gauge capable of measuring 3000
psi (2068 kPa) at mid-range is needed.

NOTE!

Call-outs in the following procedure refer to

illustration on page 454.

The lift/auxiliary pressure relief adjusting screw is located on

top of the main control valve, near solenoid Y10. The relief
pressure test port is on the side of the control valve, to the
right of hydraulic lines to the reservoir and pump.
1. Lift a rated load (maximum capacity listed on the
specification plate plus 10 percent).
2. Loosen lock nut (18) so adjuster screw (17) can be
turned. Turn adjuster screw counter-clockwise to
reduce pressure and clockwise to increase
pressure.
Relief Pressure
Test Port

(beneath main pressure hose)

450

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3. The pressure at rated load should be the truck

capacity weight plus 10 percent. Turn adjuster
screw until the load can be lifted through freelift/
staging transition.
Master Service Manual

2006-12-22