BT Forklift RRX35/45, RDX30, RSX40/50 Service Manual 306756-000 April 1998 – PDF DOWNLOAD

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BT Forklift RRX35/45, RDX30, RSX40/50 Service Manual 306756-000 April 1998 – PDF DOWNLOAD

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BT Forklift RRX35/45, RDX30, RSX40/50 Service Manual 306756-000 April 1998 – PDF DOWNLOAD

Language : English
Pages : 282
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

BT Forklift RRX35/45, RDX30, RSX40/50 Service Manual 306756-000 April 1998 – PDF DOWNLOAD

Front Cover..........................................................  1
BT Standard Codes....................................................  3
	Worksheet standard...............................................  3
	C-Code List......................................................  3
Warning Symbols...................................................... 11
	1. Warning Levels................................................ 11
		DANGER....................................................... 11
		WARNING...................................................... 11
		CAUTION...................................................... 11
		NOTE!........................................................ 11
Prohibitory Symbols.................................................. 12
	NO SMOKING....................................................... 12
	OPEN FLAMES PROHIBITED........................................... 12
	GENERAL PROHIBITION.............................................. 12
	1. Ordinance Symbols............................................. 12
		SAFETY SHOES................................................. 12
		PROTECTIVE GLASSES........................................... 12
Introduction, Service Manual......................................... 13
Contents, Section M.................................................. 15
	1. Machine Information........................................... 15
General Product Information.......................................... 17
	1. Presentation of the Rider Trucks RRX35/45, RDX3............... 17
		1.1. Intended Application of the Trucks...................... 17
		1.2. Forbidden Application of the Truck...................... 18
		1.3. Truck Data.............................................. 18
		1.4. RRX35 Dimensions........................................ 19
		1.5. RRX45 Dimensions........................................ 20
		1.6. RDX30 Dimensions........................................ 21
		1.7. RSX40 Dimensions........................................ 22
		1.8. RSX50 Dimensions........................................ 23
		1.9. Data Plate.............................................. 24
			Legend................................................... 24
				1 Truck model number................................. 24
				2 Truck serial number................................ 24
				3 Weight less battery................................ 24
				4 Maximum battery weight............................. 24
				5 Minimum battery weight............................. 24
				6 Truck voltage DC................................... 24
				7 Battery type UL class.............................. 24
				8 Battery maximum AMP hours.......................... 24
				9 Truck type......................................... 24
				10 Mast serial number................................ 24
				11 Attachment........................................ 24
				12 Maximum degree rear tilt.......................... 24
				13 Truck capacity.................................... 24
	2. Main Components............................................... 25
		1 Hydraulic valve:........................................... 25
		2 Battery:................................................... 25
		3 Battery connector:......................................... 25
		4 Hydraulic unit:............................................ 25
		5 Drive unit with brake:..................................... 25
		6 Electrical steering:....................................... 25
		7 Data plate:................................................ 25
		8 Cover:..................................................... 25
		9 Pedal:..................................................... 25
		10 Control console:.......................................... 25
		11 Instrument panel:......................................... 25
		12 Mast:..................................................... 25
		13 Electronics:.............................................. 25
		14 Control circuit fuse:..................................... 26
		15 Steering circuit fuse:.................................... 26
		16 Drive motor fuse:......................................... 26
		17 Pump motor fuse:.......................................... 26
		18 Right foot pedal.......................................... 26
		19 Emergency stop............................................ 26
		Main Components of Truck..................................... 26
	3. Grease Point Location......................................... 27
	4. Mast Adjustment Points........................................ 28
Inch (SAE) and Metric Fasteners...................................... 29
	1. Introduction.................................................. 29
	2. Nomenclature, Threads......................................... 30
	3. Strength Identification....................................... 31
	4. Conversion of Metric and English Units........................ 37
Technical Service Data............................................... 39
Ordering Spare Parts................................................. 43
	1. Locate the fault on the truck................................. 43
	2. Find out the machine model and serial number.................. 43
	3. Locate the page with the exploded diagram and f............... 43
	4. Locate the position number in the table. Select............... 43
	5. Note the part number.......................................... 43
	6. Call the local BT dealer and state the part num............... 43
Contents, Section P.................................................. 45
	1. Planned Maintenance........................................... 45
Introduction, Maintenance............................................ 47
	1. Safe Jacking Procedure........................................ 47
Service Schedule..................................................... 49
	1. Planned Maintenance Schedule.................................. 49
		ITEM......................................................... 49
		WORK REQUIRED................................................ 49
			Interval in Hours........................................ 49
			5........................................................ 49
			25....................................................... 49
			100...................................................... 49
			250...................................................... 49
			300...................................................... 49
			600...................................................... 49
			1200..................................................... 49
			3600..................................................... 49
			Interval in Days/Weeks/Months............................ 49
			1 d...................................................... 49
			1w....................................................... 49
			1 m...................................................... 49
			2 m...................................................... 49
			3 m...................................................... 49
			6 m...................................................... 49
			12 m..................................................... 49
			36 m..................................................... 49
	2. Planned Maintenance Procedures................................ 52
		2.1. Services to be performed daily or at each 8 h........... 52
			2.1.1. Battery Discharge Indicator with slow down........ 52
			2.1.2. Hydraulic System.................................. 52
			2.1.3. Frame/Sheet Metal................................. 53
			2.1.4. Wheels/Tires...................................... 53
			2.1.5. Functions/Operations.............................. 53
		2.2. Services to be performed monthly or every 250........... 53
			2.2.1. Inspection........................................ 53
			2.2.2. Transmission...................................... 53
			2.2.3. Brakes............................................ 53
			2.2.4. Battery........................................... 53
			2.2.5. Electrical Connections............................ 54
			2.2.6. Contactor Tips (NOT Sealed)....................... 54
			2.2.7. Motor Brushes..................................... 54
			2.2.8. Drive Motor....................................... 54
			2.2.9. Hydraulic Reservoir............................... 55
			2.2.10. Frame Lube (“Lubrication Chart” on page55....... 55
			2.2.11. Pivot Points..................................... 55
		2.3. Services to be performed annually or every 12........... 55
			2.3.1. Inspection........................................ 55
			2.3.2. Transmission...................................... 55
			2.3.3. Battery........................................... 56
			2.3.4. Hydraulic System.................................. 56
			2.3.5. Brakes............................................ 56
			2.3.6. Lift and Carriage Chains.......................... 56
Lubrication Chart.................................................... 59
	Pos. No.......................................................... 59
	Service Point.................................................... 59
	Interval/Running Hours........................................... 59
	Lubricant (See Chart in Section 6 for Code)...................... 59
		300 h........................................................ 59
		600 h........................................................ 59
		1200 h....................................................... 59
			Truck Lubrication Points................................. 59
Oil and Grease Specifications........................................ 61
	1. Approved Oils and Grease...................................... 61
		Lubricant.................................................... 61
		Specification................................................ 61
		Application area............................................. 61
		>14F(-10C)................................................. 61
		<14F(-10C)................................................. 61
		<-13F(-25C)................................................ 61
Contents, Section S.................................................. 63
	1. Service Instructions.......................................... 63
Chassis.............................................................. 65
	1. General....................................................... 65
		Removal/Installation of Chassis Panels & Covers.............. 65
	2. Door.......................................................... 66
		2.1. Removal................................................. 66
		2.2. Installation............................................ 66
	3. Left-Hand Side Panel.......................................... 67
		3.1. Removal................................................. 67
	4. Operator Compartment Panel.................................... 67
		4.1. Removal................................................. 67
	5. Main Card Access Panel........................................ 68
		5.1. Removal................................................. 68
Brake Pedal.......................................................... 69
	1. Pedal Removal................................................. 70
	2. Pedal Bearing Replacement..................................... 71
	3. Pedal Adjustment.............................................. 71
Drive Motor.......................................................... 73
	1. General Information........................................... 73
	2. Operating Conditions.......................................... 73
	3. Troubleshooting............................................... 74
		TABLE 1...................................................... 75
		TABLE 1. Continued........................................... 76
		TABLE 1. Continued........................................... 77
		TABLE 2...................................................... 78
		Primary Sources of Unsatisfactory Brush Performanc........... 78
			20. Poor preparation of commutator surface............... 78
			21. High mica............................................ 78
			22. Feather-edge mica.................................... 78
			23. Bar edges not chamfered after undercutting........... 78
			24. Need for periodic cleaning........................... 78
			25. Clogged ventilating ducts............................ 78
			26. Brushes in wrong position............................ 78
			27. Unequal brush spacing................................ 78
			28. Poor alignment of brush holders...................... 78
			29. Incorrect brush angle................................ 78
			30. Incorrect spring tension............................. 78
			31. Interpoles improperly adjusted....................... 78
			32. Series field improperly adjusted..................... 78
			33. Brushes tight in holders............................. 78
			34. Brushes too loose in holders......................... 78
			35. Brush holders loose at mounting...................... 78
			36. Commutator loose..................................... 78
			37. Loose pole pieces or pole-face shoes................. 78
			38. Loose or worn bearings............................... 78
			39. Unequal air gaps..................................... 78
			40. Unequal pole spacing................................. 78
			41. Dynamic unbalance.................................... 78
			42. Variable angular velocity............................ 78
			43. Commutator too small................................. 78
			44. Open or high resistance connection at commutat....... 78
			45. Poor connection at shunt terminal.................... 78
			46. Short circuit in field or armature winding........... 78
			47. Ground in field or armature winding.................. 78
			48. Reversed polarity on main pole or interpole.......... 78
		TABLE 2. Continued........................................... 79
			49. Commutating zone too narrow.......................... 79
			50. Commutating zone too wide............................ 79
			51. Brushes too thin..................................... 79
			52. Brushes too thick.................................... 79
			53. Magnetic saturation of interpoles.................... 79
			54. High bar-to-bar voltage.............................. 79
			55. High ratio of brush contact to commutator surf....... 79
			56. Insufficient cross connection of armature coil....... 79
			57. Overload............................................. 79
			58. Rapid change of load................................. 79
			59. Reversing operation of non-interpole machine......... 79
			60. Plugging............................................. 79
			61. Dynamic braking...................................... 79
			62. Low average current density in brushes............... 79
			63. Contaminated atmosphere.............................. 79
			64. “Contact poisons”.................................... 79
			65. Oil on commutator or oil mist in air................. 79
			66. Abrasive dust in air................................. 79
			67. Humidity too high.................................... 79
			68. Humidity too low..................................... 79
			69. Silicone contamination............................... 79
			70. Loose or unstable foundation......................... 79
			71. External source of vibration......................... 79
			72. External short circuit or very heavy load surg....... 79
			73. “Commutation factor” too high........................ 79
			74. “Commutation factor” too low......................... 79
			75. Contact drop of brushes too high..................... 79
			76. Contact drop of brushes too low...................... 79
			77. Coefficient of friction too high..................... 79
			78. Lack of film forming properties in brush............. 79
			79. Lack of polishing action in brush.................... 79
			80. Brushes too abrasive................................. 79
			81. Lack of carrying capacity............................ 79
Drive Motor.......................................................... 81
	1. Disassembly................................................... 83
	2. Inspection and Troubleshooting................................ 84
		2.1. Drive End Head.......................................... 84
		2.2. Commutator End Head..................................... 84
		2.3. Bearings................................................ 84
		2.4. Brush and Commutator.................................... 85
		2.5. Armature................................................ 85
		2.6. Frame and Field Assembly................................ 86
			2.6.1. Testing........................................... 86
			2.6.2. Frame and Field Service Notes..................... 87
		2.7. Assembly................................................ 88
			2.7.1. Field Coil Installation........................... 88
			2.7.2. Bearing Installation.............................. 88
			2.7.3. After Assembly.................................... 89
	3. When Changing Brushes......................................... 89
Caster Brake Assembly................................................ 91
	1. Removal....................................................... 92
		1.1. Caster Brake Adjustment................................. 92
Electromagnetic Brake................................................ 95
	1. Installation.................................................. 96
	2. Adjustments................................................... 97
	3. Coil Check On Brake........................................... 97
	4. Electromagnetic Brake, Armature and Magnetic Co............... 98
		4.1. Removal................................................. 98
		4.2. Installation............................................ 98
Drive Wheel.......................................................... 99
	1. Removal....................................................... 99
	2. Installation..................................................100
Support / Swivel Wheel...............................................101
	1. Caster Pivot..................................................102
		1.1. Removal.................................................102
		1.2. Installation............................................104
	2. Thrust Bearing................................................105
		2.1. Removal.................................................105
		2.2. Installation............................................106
	3. Caster Springs................................................107
		3.1. Removal.................................................107
		3.2. Installation............................................108
	4. Caster Spring.................................................109
		4.1. Adjustments.............................................109
	5. Caster Stops..................................................110
		5.1. Adjustment..............................................110
Tandem Load Wheels...................................................113
	1. Removal.......................................................114
Single Load Wheels...................................................115
	1. Removal.......................................................116
	2. Installation..................................................116
Caster Wheels........................................................117
	1. Removal.......................................................118
	2. Installation..................................................118
	3. Caster Axle...................................................119
		3.1. Removal.................................................119
		3.2. Installation............................................119
Caster Wheels........................................................121
	1. Removal.......................................................122
	2. Installation..................................................123
	3. Caster Axle...................................................124
		3.1. Removal.................................................124
		3.2. Installation............................................124
Steering Arm / Wheel / Lever.........................................125
	1. Control Pod...................................................126
		1.1. Removal.................................................126
		1.2. Installation............................................126
	2. Steering Wheel................................................127
		2.1. Removal.................................................127
		2.2. Installation............................................127
	3. Steering Tach.................................................128
		3.1. Removal.................................................128
		3.2. Installation............................................128
Steering Bearing.....................................................129
	1. Removal.......................................................130
	2. Installation..................................................130
Electrical Functions.................................................131
	1. Operating Description.........................................131
	2. Start Up......................................................133
	3. Direction Selection...........................................135
	4. Reverse Direction Selection...................................137
	5. Forward Drive.................................................139
	6. Plug Braking..................................................141
	7. Steering Componets............................................143
	8. 12-Volt Power Supply..........................................144
	9. Driving speed reduction switch................................145
	10. Height Indicator and Preset Selector.........................147
		10.1. Height Indicator.......................................147
		10.2. Height Preset Selector.................................147
	11. Drive Motor Brush Indicator Switch...........................148
	12. Pump Motor Brush Indicator Switch............................149
	13. Safety Check.................................................150
	14. Shunt Wire...................................................151
		Component Location (Figure 1 of 2)...........................156
	15. Circuit Diagram 1(11)........................................158
	16. Circuit Diagram 2(11)........................................159
	17. Circuit Diagram 3(11)........................................160
	18. Circuit Diagram 4(11)........................................161
	19. Circuit Diagram 5(11)........................................162
	20. Circuit Diagram 6(11)........................................163
	21. Circuit Diagram 7(11)........................................164
	22. Circuit Diagram 8(11)........................................165
	23. Circuit Diagram 9(11)........................................166
	24. Circuit Diagram 10(11).......................................167
	25. Circuit Diagram 11(11).......................................168
Transistor Regulator.................................................169
	1. Motor Connections.............................................170
		1.1. Connections for controls................................170
	2. Safety Control................................................171
		2.1. Checking Transistor Regulator’s Safety Circui...........171
Electronic Card......................................................173
	1. Display.......................................................179
	2. Time..........................................................180
	3. Warning Codes.................................................181
	4. Error Codes...................................................183
	5. Effect on the Truck...........................................185
	6. Parameters....................................................185
	7. Running time..................................................185
	8. Programming Parameters........................................186
	9. Adjustment Procedures for Setting Brake Switch ...............189
Pump Motor...........................................................191
	1. Component Repair..............................................192
		1.1. Motor Disassembly.......................................192
	2. Inspection and Troubleshooting................................194
		2.1. Drive End Head..........................................194
		2.2. Commutator End Head.....................................194
		2.3. Bearings................................................194
		2.4. Brush and Commutator....................................195
		2.5. Armature................................................195
		2.6. Frame and Field Assembly................................196
			2.6.1. Testing...........................................196
			2.6.2. Frame and Field Service Notes.....................197
		2.7. Assembly................................................198
			2.7.1. Field Coil Installation...........................198
			2.7.2. Bearing Installation..............................198
			2.7.3. After Assembly....................................199
	3. When Changing Brushes.........................................199
Hydraulic System.....................................................201
	Valid from machine number: 27091001 to 27135000..................201
	1. Operation.....................................................201
		1.1. Supply..................................................201
		1.2. Lifting.................................................201
		1.3. Lowering................................................201
		1.4. Reach...................................................201
		1.5. Retract.................................................202
		1.6. Tilt Up.................................................202
		1.7. Tilt Down...............................................202
		1.8. Sideshifting Right......................................203
		1.9. Sideshifting Left.......................................203
	2. RRX35/45 Hydraulic Schematic..................................205
Hydraulic System.....................................................207
	Valid from machine number: 27135001 and UP.......................207
	1. Operation.....................................................207
		1.1. Supply..................................................207
		1.2. Lifting.................................................207
		1.3. Lowering................................................208
		1.4. Reach...................................................208
		1.5. Retract.................................................208
		1.6. Tilt Up.................................................208
		1.7. Tilt Down...............................................209
		1.8. Sideshifting Right......................................209
		1.9. Sideshifting Left.......................................209
	2. RRX35/45 Hydraulic Schematic..................................211
	3. RDX30 Hydraulic Schematic.....................................212
	4. RSX40/50 Hydraulic Schematic..................................213
Mast, 3 Stage........................................................215
	1. Shimming Mast on Truck........................................216
		1.1. Shimming the Carriage/Reach.............................216
		1.2. Shimming the Rails......................................217
	2. Three Stage Mast..............................................221
		2.1. Removal.................................................221
		2.2. Installation............................................222
		2.3. Disassembly.............................................223
		2.4. Assembly................................................224
Sideshifter..........................................................227
	1. Mounting Instructions.........................................229
		1.1. Installation............................................229
			1. Remove lower hooks (8) from sideshifter assembl.......229
			2. Lift sideshifter onto the truck’s carriage whil.......229
			3. Make sure the centering lug (X) on the cylinder.......229
			4. Remount the lower hooks (8) with a minimum clea.......229
			5. Secure the lower hook (8) in place by tightenin.......229
			6. Connect the hydraulic fittings (4) to the sides.......229
	2. Operation and Maintenance.....................................230
		Every 1000 hours:............................................230
			1. Inspect hydraulic hoses for wear......................230
			2. Inspect the cylinder (15) and fittings (4) for .......230
			3. Clean the lower slides (6) and truck carriage l.......230
			4. Inspect and adjust the lower hooks (8) for the .......230
			5. Check the torque on the lower hook mounting bol.......230
		2.1. Lower Slides............................................231
			1. The original thickness of a lower slide is appr.......231
			2. Replace the lower slide if contamination is pre.......231
		2.2. Upper Slides............................................231
			1. The original thickness of upper slide (1) is ap.......231
			2. Replace the upper slides (1) if there is an una.......231
			3. When replacing the upper slides (1), always rep.......231
		2.3. Cylinder................................................231
			1. The hydraulic cylinder (15) is basically a non-.......231
			2. If the cylinder rod becomes scored, a minimal a.......232
Reach, Single........................................................233
	1. Maintenance...................................................233
	2. Reach Repair..................................................235
		2.1. Disassembly.............................................235
			2.1.1. Front Frame Removal...............................235
			2.1.2. Outer Arm Removal.................................235
			2.1.3. Inner Arm Removal.................................235
			2.1.4. Rear Frame Removal................................236
			2.1.5. Reach Cylinder Removal............................236
		2.2. Assembly................................................237
			2.2.1. Reach Cylinder Installation.......................237
			2.2.2. Rear Frame Installation...........................237
			2.2.3. Inner Arm Installation............................237
			2.2.4. Outer Arm Installation............................238
Freelift Cylinder, 3 Stage...........................................239
	1. Freelift Cylinder Repair......................................240
		1.1. Removal.................................................240
		1.2. Disassembly.............................................241
		1.3. Assembly................................................241
		1.4. Installation............................................241
Staging Cylinder, 3 Stage............................................243
	1.1. Removal.....................................................244
	1.2. Disassembly.................................................244
	1.3. Assembly....................................................244
	1.4. Installation................................................245
Tilt Cylinder........................................................247
	1. Removal.......................................................248
	2. Disassembly...................................................248
	3. Inspection....................................................249
	4. Assembly......................................................249
	5. Installation..................................................250
Tilt Cylinder........................................................253
	1. Removal.......................................................254
	2. Disassembly...................................................255
	3. Inspection....................................................256
	4. Assembly......................................................256
	5. Installation..................................................258
Reach Cylinder.......................................................259
	1. Removal.......................................................260
	2. Disassembly...................................................261
	3. Inspection....................................................262
	4. Assembly......................................................263
	5. Installation..................................................264
Height Indicator.....................................................265
	1. Pulse sensor..................................................266
		1.1. Repair..................................................266
		1.2. Cable...................................................266
			1.2.1. Removal...........................................266
			1.2.2. Installation......................................266
		1.3. Pulley..................................................266
			1.3.1. Removal...........................................266
Height Indication & Preset Height....................................267
	1. General.......................................................268
	2. Operation.....................................................268
	3. Preset Height.................................................269
	4. Display.......................................................270
	5. Description of the display symbols............................271
	6. Programming...................................................272
		6.1. Programming a Level.....................................272
			6.1.1. Collection Level..................................272
			6.1.2. Leaving Level.....................................272
		6.2. Erasing Programmed Levels...............................273
			6.2.1. Automatic Operations..............................273
			6.2.2. Collecting a Load.................................273
			6.2.3. Leaving a Load....................................274
		6.3. Parameters..............................................275
			P1.......................................................275
			P2.......................................................275
			P3.......................................................276
			P5.......................................................276
			P7.......................................................276
			P8.......................................................277
			P9.......................................................277
Back Cover...........................................................282

DESCRIPTION:

BT Forklift RRX35/45, RDX30, RSX40/50 Service Manual 306756-000 April 1998 – PDF DOWNLOAD

 Presentation of the Rider Trucks
RRX35/45, RDX30, and RSX40/50.
The RRX35/45 are battery powered reach trucks.
The RDX30 is a battery powered deep reach truck.
The RSX40/50 are battery powered straddle arm trucks.
These trucks are intended solely to be operated handling pallets or similar load carriers indoors.
In their standard design, the trucks are equipped with a steering wheel with all the controls for operating within easy access.
The trucks have various maximum lifting capacities (review data plate on the truck to note the maximum lifting capacity). These trucks are equipped with a 24V or 36V electrical system and the speed is regulated by means of a transistor controller to provide infinite control of acceleration and speed while driving.
The forks and auxiliary functions are controlled by means of a transistor controller. The control of the lift and auxiliary functions are done electrically with the levers on the control pod. Control of the speed and positioning of the forks when stacking is done by the position of the levers.
The trucks can be fitted with different accessories including sideshifter, warning light, lights/fan package, travel alarm, and adjustable driving lights. The trucks can be specially equipped to work in cold conditions

S.S 07/01/2025