BT RTX35, RTX45 Electric Stand-Up Rider Truck Service Manual 310428-000

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BT RTX35, RTX45 Electric Stand-Up Rider Truck Service Manual 310428-000

$30.00

Type Of Manual: Service Manual
Manual ID: 310428-000
: Service Manual PDF
Number of Pages: 542
Size: 26.7MB
Format: PDF

Category: BT Service Manual PDF

Model List:
- RTX35, RTX45 Electric Stand-Up Rider Truck

1. BT Prime-Mover Standard Codes
1.1. Worksheet standard
1.2. C-Code List
2. Warning Symbols
2.1. Warning Levels
3. Prohibitory Symbols
3.1. NO SMOKING
3.2. OPEN FLAMES PROHIBITED
3.3. GENERAL PROHIBITION
3.4. Ordinance Symbols
3.5. General Safety
4. Battery Safety
5. Static Safety
5.1. Place a static discharge wrist strap around your wrist. Connect the ground lead to the wrist s…
5.2. Connect the ground clamp to an unpainted, grounded surface on the truck frame.
5.3. If removing or installing static-sensitive components, place them on a properly grounded stati…
5.4. To transport static-sensitive components, including failed components being returned, place th…
6. Welding Safety
7. Introduction, Service Manual
8. Contents, Section M
8.1. Machine Information
9. General Product Information
9.1. Truck Presentation
9.2. Main Components
9.3. Grease Point Location
9.4. Mast Adjustment Points
10. Inch (SAE) and Metric Fasteners
10.1. Introduction
10.2. Nomenclature, Threads
10.3. Strength Identification
10.4. Conversion of Metric and English Units
11. Technical Service Data
11.1. RTX35 (192 inch mast)
11.2. RTX45 (210 inch mast)
11.3. Series – DC
11.4. Series – DC
11.5. 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…
11.6. hour continuous
11.7. hour continuous
11.8. inch (20 mm)
11.9. inch (20 mm)
11.10. inches (74 mm)
11.11. inches (74 mm)
11.12. oz. (180 grams)
11.13. oz. (180 grams)
11.14. Vertical motor spiral-bevel output
11.15. Vertical motor spiral-bevel output
11.16. gallons (3.79 liters)
11.17. gallons (3.79 liters)
11.18. SAE 80W90
11.19. SAE 80W/90
11.20. SAE 80W90
11.21. SAE 80W/90
11.22. x 5.5 x 10.0 inches (343 x 140 x 254 mm)
11.23. x 5.5 x 10.0 inches (343 x 140 x 254 mm)
11.24. lb battery 14.5 BC – 6735 (3054) 2000 lb battery 16.5 BC – 4315 (1959)
11.25. lb battery 16.5 BC – 4750 (2156) 2400 lb battery 21 BC – 4910 (2229)
11.26. lb battery 14.5 BC – 3240 (1471) 2000 lb battery 16.5 BC – 3430 (1557)
11.27. lb battery 16.5 BC – 3780 (1716) 2400 lb battery 21 BC – 4025 (1827)
11.28. ft-lb (130 Nm)
11.29. ft-lb (130 Nm)
11.30. x 3.6 inches (127 x 91 mm)
11.31. x 3.6 inches (127 x 91 mm)
11.32. lb battery 14.5 BC – 6860 (3114 2000 lb battery 16.5 BC – 7145 (3244)
11.33. lb battery 16.5 BC – 8595 (3902) 2400 lb battery 21 BC – 8690 (3945)
11.34. Amp 400 Amp
11.35. Not Applicable (N/A) 425 Amp
11.36. empty-750 loaded 36V – 2100 empty-1500 loaded
11.37. empty-1450 loaded
11.38. volt 11.6 HP with 20 duty cycle
11.39. on 5 minute cycles
11.40. inch (20 mm)
11.41. inch (16 mm)
11.42. inches (74 mm)
11.43. inches (72 mm)
11.44. oz (180 grams)
11.45. oz (1120 grams)
11.46. psi (16890 kPa)
11.47. psi (16890 kPa)
11.48. cc upper/4 cc lower
11.49. cc upper/4 cc lower 8 cc upper/4 cc lower
11.50. cc upper/4 cc lower 11 cc upper/4 cc lower
11.51. gallons (19 liters)
11.52. gallons (19 liters)
11.53. Sunoco TH
11.54. Texaco 15
11.55. Sunoco TH
11.56. Texaco 15
11.57. Amp
11.58. Amp
11.59. Amp
11.60. Amp
11.61. Amp
11.62. x 38.8 x 32.0 inches
11.63. (366 x 986 x 813 mm)
11.64. x 38.8 x 32.0 inches
11.65. (417 x 986 x 813 mm)
11.66. x 38.8 x 32.0 inches
11.67. (417 x 986 x 813 mm)
11.68. x 38.8 x 32.0 inches
11.69. (531 x 986 x 813 mm)
11.70. Amp hours
11.71. Amp hours 875 Amp hours
11.72. Amp hours 875 Amp hours
11.73. inches (368 mm) 1600 lb (726 kg)
11.74. (2300 lb / 1044 kg)
11.75. inches (419 mm) 2000 lb (908 kg)
11.76. (2300 lb / 1044 kg)
11.77. inches (419 mm) 2000 lb (908 kg)
11.78. (2300 lb / 1044 kg)
11.79. inches (533 mm) 2400 lb (1089 kg)
11.80. (2900 lb (1317 kg)
11.81. mph (9.65 kph)
11.82. mph (10.46 kph)
11.83. mph (10.46 kph)
11.84. mph (8.85 kph)
11.85. mph (9.65 kph)
11.86. mph (9.65 kph)
11.87. fpm (17.37 m/min.)
11.88. fpm (24.4 m/min.)
11.89. fpm (29 m/min.)
11.90. fpm (10.4 m/min.)
11.91. fpm (18.3 m/min.)
11.92. fpm (18.3 m/min.)
11.93. fpm (24.4 m/min.)
11.94. fpm (27.5 m/min.)
11.95. fpm (24.4 m/min.)
11.96. fpm (29 m/min.)
11.97. Amps
11.98. Amps
11.99. N/A 90 Amps
11.100. Amps
11.101. Amps
11.102. Amps
11.103. Amps
11.104. Amps
11.105. Amps
11.106. Amps
11.107. Amps
11.108. Amps
11.109. Amps
11.110. Amps
11.111. Amps
11.112. Amps
11.113. Amps
11.114. Amps
11.115. Amps
11.116. Amps
11.117. Amps
11.118. Amps
11.119. Amps
11.120. Amps
11.121. Amps
11.122. Amps
12. Ordering Spare Parts
12.1. Locate the fault on the truck.
12.2. Identify truck model, serial number, and battery voltage.
12.3. Locate the page with the exploded diagram and find the item number for the part required.
12.4. Locate the item number in the table. Select the column for the actual truck model and serial n…
12.5. Note the part number.
12.6. Call your local BT Prime-Mover Dealer and indicate the part number.
12.7. If the model, serial number, or the article number cannot be found on the truck, call your loc…
13. Contents, Section P
13.1. Planned Maintenance
14. Introduction, Maintenance
14.1. Safe Jacking Procedure
14.2. Lubricants
15. Service Schedule
15.1. Planned Maintenance Schedule
15.2. Planned Maintenance Procedures
16. Lubrication Chart
16.1. Interval/Running Hours
16.2. Lubricant
17. Oil and Grease Specifications
17.1. Approved Oils and Grease
18. Contents, Section S
18.1. Service Instructions
19. Troubleshooting Guidelines
19.1. General
19.2. Electrical
19.3. Hydraulic
19.4. Definitions
20. Chassis
20.1. General
20.2. Top Console
20.3. Motor Compartment Door
20.4. Left Side Panel (Exterior)
20.5. Left Operator Compartment Panel
20.6. Main Electronic Card Panel
20.7. Floor Board
20.8. Clipboard
21. Battery Retainer Plates and Rollers
21.1. Battery Retainer Plates
21.2. Battery Rollers
22. Mounting Points
22.1. Drive Motor
22.2. Pump Motor
22.3. Transmission
23. Driver Controls
23.1. Handle Interface Module
23.2. Control Handle
24. Brake Pedal (RTX35)
24.1. Pedal Removal
24.2. Pedal Bearing Replacement
24.3. Pedal Adjustment
25. Brake Pedal (RTX45)
25.1. Pedal Removal
25.2. Pedal Bearing Replacement
25.3. Pedal Adjustment
26. Internal Fittings
26.1. Operator Fan
26.2. Overhead Guard
26.3. Decal with Protective Sheet
26.4. Decal without Protective Sheet
27. Steering Motor
27.1. Removal
27.2. Installation
27.3. Steering Motor Gear Replacement
28. Fan Motor
28.1. Upper Electrical Compartment Fan
28.2. Operator Fan
29. Motor Maintenance Schedule/Troubleshooting
29.1. General Information
29.2. Operating Conditions
29.3. Troubleshooting
30. Pump Motor (RTX35)
30.1. Component Repair
30.2. Motor Inspection
31. Pump Motor (RTX 45)
31.1. Component Repair
31.2. Motor Inspection
32. Drive Motor
32.1. Motor Disassembly
32.2. Motor Inspection
33. Transmission.
33.1. Axle Sealing Ring
33.2. Leakage
33.3. Wheel Bolt
34. Electromagnetic Brake
34.1. Removal
34.2. Installation
34.3. Adjustments
34.4. Coil Check On Brake
34.5. Electromagnetic Brake, Armature and Magnetic Coil
34.6. Brake Friction Plate
35. Drive Wheel
35.1. Removal
35.2. Installation
35.3. Tire Pressing Procedure
36. Non-Braking Caster Assembly
36.1. Caster Pivot
36.2. Thrust Bearing
36.3. Caster Springs
36.4. Caster Stops
37. Non-Braking Caster Wheels
37.1. Removal
37.2. Installation
38. Braking Caster Assembly
38.1. Removal
39. Braking Caster Wheel Assembly
39.1. Removal
39.2. Installation
40. Tandem Load Wheels
40.1. Removal
40.2. Installation
41. Single Load Wheels
41.1. Removal
41.2. Installation
42. Steering Wheel
42.1. Removal
42.2. Installation
43. Steer Tach
43.1. Removal
43.2. Installation
44. Steering Bearing
44.1. Removal
44.2. Installation
45. Electrical Functions
45.1. General
45.2. Start Up
45.3. Steering Components
45.4. Brake Release
45.5. Travel Request, Forks First
45.6. Travel Request, Forks Trailing
45.7. Plug Braking
45.8. Volt Power Supply
45.9. Volt Power Supplies
45.10. Limit Switches
45.11. Height Indicator
45.12. Drive Motor Brush Wear Indicator Switches
45.13. Pump Motor Brush Wear Indicator Switches
45.14. Safety Check
45.15. Shunt Power Cable
46. Electrical Symbols
47. Electrical Schematics
47.1. Circuit Diagram 1 (12)
47.2. Circuit Diagram 2 (12)
47.3. Circuit Diagram 3 (12)
47.4. Circuit Diagram 4 (12)
47.5. Circuit Diagram 5 (12)
47.6. Circuit Diagram 6 (12)
47.7. Circuit Diagram 7 (12)
47.8. Circuit Diagram 8 (12)
47.9. Circuit Diagram 9 (12)
47.10. Circuit Diagram 10 (12)
47.11. Circuit Diagram 11 (12)
47.12. Circuit Diagram 12 (12)
48. Battery
48.1. Removal
48.2. Installation
48.3. Battery Maintenance
48.4. Storage
48.5. Battery History Record
49. Light Assemblies
49.1. Overhead Guard Lights (Option)
49.2. Warning Lights (Option)
49.3. Working Lights (Option)
49.4. Travel/Back-up Alarm (Option)
49.5. Removal
49.6. Installation
50. Battery Connector
50.1. Location
50.2. Inspection
50.3. Installation
51. Start/Stop Switches
51.1. General
51.2. Key Switch (S17)
51.3. Emergency Disconnect Switch (S21)
52. Mast Switch (S31)
52.1. General
52.2. Adjustment
52.3. Removal
52.4. Installation
53. Control Cable and Harness
53.1. Fuses
53.2. Wiring
53.3. Auxiliary Power Hook-up for On-board Terminal
54. Contactors
54.1. General
54.2. Directional Contactors
54.3. Lift Bypass Contactor
54.4. Battery Cut-out Contactor
55. Transistor Panel (Drive)
55.1. Motor Connections
55.2. Circuit Check.
56. Transistor Panel (Pump)
56.1. Motor Connections
57. Micro Switches
57.1. General
57.2. Lift Limit Override Switch (S33)
57.3. Optional Light and Fan Switches (S96, S97 and S99)
58. Main Electronic Card
58.1. Removal
58.2. Installation
58.3. Connectivity to Truck
58.4. Display
58.5. Warning/Caution codes
58.6. Error codes
58.7. Parameters
58.8. Running time
58.9. Programming Parameters
58.10. RV2 Adjustment Procedure
58.11. Adjustment Procedures for Setting Brake Switch and Brake Transducer
59. Switches and Sensors
59.1. General
59.2. Platform (Right Foot) Switch (S23)
59.3. Staging Switch (S45)
59.4. Wheel Direction Sensor
59.5. Steer Stop Proximity Sensor A and Sensor B
59.6. Drive Motor Speed/Direction Sensors
60. Hydraulic System
60.1. Operation
60.2. RTX35 Hydraulic Schematic
60.3. RTX45 Hydraulic Schematic
61. Hydraulic Fluid
61.1. Hydraulic Fluid Selection
61.2. Changing Hydraulic System Fluid
61.3. System Draining
61.4. System Refilling
61.5. Bleeding Hydraulic System
62. Hydraulic Tank
62.1. Removal
62.2. Installation
63. Hydraulic Filter and Adapter
63.1. Hydraulic Filter
63.2. Hydraulic Filter Adapter
64. Hydraulic Pump
64.1. Removal
64.2. Pump Disassembly
64.3. Parts Inspection
64.4. Pump Reassembly
64.5. Testing
65. Control Valve
65.1. Removal
65.2. Installation
65.3. Repair
66. Staging Cylinder, 3 Stage
66.1. Staging Cylinder Repair
67. Freelift Cylinder, 3 Stage
67.1. Freelift Cylinder Repair
68. Reach Cylinder (RTX35)
68.1. Removal
68.2. Disassembly
68.3. Inspection
68.4. Assembly
68.5. Installation
69. Reach Cylinder (RTX45)
69.1. Removal
69.2. Disassembly
69.3. Inspection
69.4. Assembly
69.5. Installation
70. Tilt Cylinder (RTX35)
70.1. Removal
71. Tilt Cylinder (RTX45)
71.1. Removal
72. Mast, 3 Stage (RTX35)
72.1. Shimming Carriage with Mast on Truck
72.2. Three Stage Mast
73. Mast, 3 Stage (RTX45)
73.1. Shimming Carriage with Mast on Truck
73.2. Three Stage Mast
74. Lift Chain
74.1. Lift Chain Adjustment
74.2. Lift Chain Maintenance
74.3. Lift Chain Inspection

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