BT Forklift RRX35/45, RDX30, RSX40/50 Service Manual 306756-000 May 1997 – PDF DOWNLOAD

Description

BT Forklift RRX35/45, RDX30, RSX40/50 Service Manual 306756-000 May 1997 – PDF DOWNLOAD

FILE DETAILS:

BT Forklift RRX35/45, RDX30, RSX40/50 Service Manual 306756-000 May 1997 – PDF DOWNLOAD

Language : English
Pages : 228
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

BT Forklift RRX35/45, RDX30, RSX40/50 Service Manual 306756-000 May 1997 – PDF DOWNLOAD

Front Cover.................................................................  1
Table of Contents...........................................................  3
Warning Symbols.............................................................  5
	1. Warning Levels.......................................................  5
Prohibitory Symbols.........................................................  6
	1.1 Ordinance Symbols...................................................  6
Introduction, Service Manual................................................  7
Contents, Section M.........................................................  9
General Product Information................................................. 11
	1. Presentation of the Rider Trucks..................................... 11
		1.1 Intended Application of the Trucks.............................. 11
		1.2 Forbidden Application of the Truck.............................. 12
		1.3 Truck Data...................................................... 12
		1.4 RRX35 Dimensions................................................ 13
		1.5 RRX45 Dimensions................................................ 14
		1.6 RDX30 Dimensions................................................ 15
		1.7 RSX40 Dimensions................................................ 16
		1.8 RSX50 Dimensions................................................ 17
		1.9 Data Plate...................................................... 18
	2. Main Components...................................................... 19
		Inch (SAE) and Metric Fasteners..................................... 21
		Introduction........................................................ 22
		Nomenclature, Threads............................................... 22
		Strength Identification............................................. 23
		Table #1 Bolts and Screws........................................... 24
		Table #2 Studs and Nuts............................................. 25
		Table #3 Torque Nuts................................................ 26
		Table #4 Torque Nuts with Nylon Insert.............................. 27
		Table #5 Conversion Table for Metric and English Units.............. 28
		Table #6............................................................ 30
Technical Service Data...................................................... 31
Ordering Spare Parts........................................................ 35
Contents, Section P......................................................... 37
Introduction, Maintenance................................................... 39
	Safe Jacking Procedure.................................................. 39
Service Schedule............................................................ 41
	1. Planned Maintenance Schedule......................................... 41
	2. Planned Maintenance Procedures....................................... 44
		Services to be Performed Daily or at Each 8 Hour Operating Shift.... 44
			Battery Guard................................................... 44
			Hydraulic System................................................ 44
			Frame/Sheet Metal............................................... 45
			Wheels/Tires.................................................... 45
			Functions/Operations............................................ 45
		Services to be Performed Monthly or Every 250 Operating Hours....... 45
			Inspection...................................................... 45
			Transmission.................................................... 45
			Brakes.......................................................... 45
			Battery......................................................... 46
			Electrical Connections.......................................... 46
			Contactor Tips (NOT Sealed)..................................... 46
			Motor Brushes................................................... 46
			Drive Motor..................................................... 47
			Hydraulic Reservoir............................................. 47
			Frame Lube...................................................... 47
			Pivot Points.................................................... 47
		Services to be Performed Annually or Every 1200 Operating Hours..... 47
			Inspection...................................................... 48
			Transmission.................................................... 48
			Battery......................................................... 48
			Hydraulic System................................................ 48
			Brakes.......................................................... 49
			Lift and Carriage Chains........................................ 49
Lubrication Chart........................................................... 51
Oil and Grease Specifications............................................... 53
	3. Approved Oils and Grease............................................. 53
Contents, Section S......................................................... 55
Chassis..................................................................... 57
	1. General.............................................................. 57
	2. Door................................................................. 58
		2.1 Removal......................................................... 58
		2.2 Installation.................................................... 58
	3. Left Hand Side Panel................................................. 58
		3.1 Removal......................................................... 58
	4. Operator Compartment Panel........................................... 59
		4.1 Removal......................................................... 59
	5. Main Card Access Panel............................................... 59
		5.1 Removal......................................................... 59
Brake Pedal................................................................. 61
	1. Pedal Removal........................................................ 62
	2. Pedal Bearing Replacement............................................ 62
	3. Pedal Adjustment..................................................... 62
Drive Motor................................................................. 63
	1. General Information.................................................. 63
	2. Operating Conditions................................................. 63
	3. Troubleshooting...................................................... 63
		Table #1............................................................ 65
		Table #2............................................................ 68
	4. Component Repair..................................................... 72
	5. Inspection and Troubleshooting....................................... 74
		5.1 Drive End Head.................................................. 74
		5.2 Commutator End Head............................................. 74
		5.3 Bearings........................................................ 74
		5.4 Brush and Commutator............................................ 75
		5.5 Armature........................................................ 75
		5.6 Frame and Field Assembly........................................ 76
		5.7 Assembly........................................................ 78
	6. When Changing Brushes................................................ 79
Electromagnetic Brake....................................................... 81
	1. Installation......................................................... 82
	2. Adjustments.......................................................... 83
	3. Coil Check on Brake.................................................. 83
	4. Electromagnetic Brake. Armature and Magnetic Coil.................... 84
Drive Wheel................................................................. 85
	1. Removal.............................................................. 85
	2. Installation......................................................... 86
Support/Swivel Wheel........................................................ 87
	1. Caster Pivot......................................................... 88
	2. Thrust Bearing....................................................... 90
	3. Caster Springs....................................................... 91
	4. Caster Spring........................................................ 92
	5. Caster Stops......................................................... 93
	6. Caster Axle.......................................................... 94
	7. Caster Brake Assembly................................................ 95
Tandem Load Wheels.......................................................... 97
	1. Replacement.......................................................... 98
Single Load Wheels.......................................................... 99
	1. Replacement..........................................................100
	2. Installation.........................................................100
Caster Wheels...............................................................101
	1. Removal..............................................................102
	2. Installation.........................................................102
Steering Arm/Wheel/Lever....................................................103
	1. Control Pod..........................................................104
	2. Steering Wheel.......................................................105
	3. Steering Tach........................................................106
Steering Bearing............................................................107
	1. Removal..............................................................108
	2. Installation.........................................................108
Electrical Functions........................................................109
	1. Operating Description................................................109
	2. Ignition Key in the OFF Position.....................................110
	3. Ignition Key in the ON Position......................................110
	4. Selection of the Travel Direction....................................111
	5. Driving..............................................................112
	6. Steering.............................................................113
	7. Steering Wheel Indicator.............................................113
	8. Braking..............................................................114
		8.1 Motor Brake (electric)..........................................114
		8.2 Foot Brake......................................................114
		8.3 Parking Brake...................................................114
	9. Fork Lift............................................................115
		9.1 Maximum Height Switch (optional)................................115
		9.2 Pulse Counter...................................................115
		9.3 Fork Lowering...................................................115
	10. Reach Out...........................................................116
		10.1 Fork Tilt Up/Down..............................................116
		10.2 Sideshifter....................................................116
		10.3 Parallel Hydraulic Functions...................................116
	11. Reach In............................................................117
		11.1 Height Indication..............................................117
		11.2 Height Selector................................................117
	12. Circuit Diagram 1(11)...............................................124
	13. Circuit Diagram 2(11)...............................................125
	14. Circuit Diagram 3(11)...............................................126
	15. Circuit Diagram 4(11)...............................................127
	16. Circuit Diagram 5(11)...............................................128
	17. Circuit Diagram 6(11)...............................................129
	18. Circuit Diagram 7(11)...............................................130
	19. Circuit Diagram 8(11)...............................................131
	20. Circuit Diagram 9(11)...............................................132
	21. Circuit Diagram 10(11)..............................................133
	22. Circuit Diagram 11(11)..............................................134
Transistor Regulator........................................................135
	1. Motor Connections....................................................136
	2. Safety Control.......................................................137
Electronic Card.............................................................139
	1. Display..............................................................145
	2. Time.................................................................146
	3. Warning Codes........................................................147
	4. Error Codes..........................................................149
	5. Parameters...........................................................150
	6. Running Time.........................................................151
	7. Programming Parameters...............................................152
Pump Motor..................................................................155
	1. Component Repair.....................................................156
	2. Inspection and Troubleshooting.......................................158
		2.1 Drive End Head..................................................158
		2.2 Commutator End Head.............................................158
		2.3 Bearings........................................................158
		2.4 Brush and Commutator............................................159
		2.5 Armature........................................................159
		2.6 Frame and Field Assembly........................................160
		2.7 Assembly........................................................162
	3. When Changing Brushes................................................163
Hydraulic System............................................................165
	1. Operation............................................................165
		1.1 Supply..........................................................165
		1.2 Lifting.........................................................165
		1.3 Lowering........................................................165
		1.4 Reach...........................................................165
		1.5 Retract.........................................................166
		1.6 Tilt Up.........................................................166
		1.7 Tilt Down.......................................................166
		1.8 Sideshifting Right..............................................166
		1.9 Sideshifting Left...............................................167
	2. RRX35/45 Hydraulic Schematic.........................................169
	3. RDR30 Hydraulic Schematic............................................170
	4. RSC40/50 Hydraulic Schematic.........................................171
Mast, 3 Stage...............................................................173
	1. Shimming.............................................................174
		1.1 Shimming the Carriage/Reach.....................................174
		1.2 Shimming the Rails..............................................175
	2. Three Stage Mast.....................................................179
		2.1 Removal.........................................................179
		2.2 Installation....................................................179
		2.3 Disassembly.....................................................180
		2.4 Assembly........................................................181
Reach.......................................................................185
	1. Maintenance..........................................................185
	2. Reach Repair.........................................................186
Lift Cylinder, 3 Stage......................................................191
	1. Freelift Cylinder Repair.............................................192
		1.1 Removal.........................................................192
		1.2 Disassembly.....................................................192
		1.3 Assembly........................................................192
		1.4 Installation....................................................193
Staging Cylinder, 3 Stage...................................................195
	1.1 Removal.............................................................196
	1.2 Disassembly.........................................................196
	1.3 Assembly............................................................196
	1.4 Installation........................................................197
Tilt Cylinder...............................................................199
	1. Removal..............................................................200
	2. Disassembly..........................................................200
	3. Inspection...........................................................201
	4. Assembly.............................................................201
	5. Installation.........................................................202
Reach Cylinder..............................................................205
	1. Removal..............................................................206
	2. Disassembly..........................................................206
	3. Inspection...........................................................207
	4. Assembly.............................................................207
	5. Installation.........................................................208
Load Indicator..............................................................211
	1. Pulse Sensor.........................................................212
		1.1 Repair..........................................................212
		1.2 Cable...........................................................212
		1.3 Pulley..........................................................212
Height Indication & Preset Height...........................................213
	1. General..............................................................214
	2. Operation............................................................214
	3. Preset Height........................................................215
	4. Display..............................................................216
	5. Description of the Display Symbols...................................217
	6. Programming..........................................................218
		Programming a Level.................................................218
		Collection Level....................................................218
		Leaving Level.......................................................218
		Erasing Programmed Levels...........................................219
		Automatic Operations................................................219
		Collecting a Load...................................................219
		Leaving a Load......................................................220
		Parameters..........................................................221
		P1..................................................................221
		P2..................................................................221
		P3..................................................................222
		P5..................................................................222
		P7..................................................................222
		P8..................................................................223
		P9..................................................................223
		Error Codes.........................................................226
Back Cover..................................................................228

DESCRIPTION:

BT Forklift RRX35/45, RDX30, RSX40/50 Service Manual 306756-000 May 1997 – PDF DOWNLOAD

• The information in this Service Manual covers models RRX35, RRX45. RDX30, RSX40, and RSXSO. Federal and State laws require that operators be completely trained in the safe operation of lift trucks.
• An Operator’s Manual is attached to every BT Prime Mover lift 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 Mamet is divided into four separate sections which cover different kinds of information needed for servicing these truck types. The main subject for each of these sections are as described below.

S.S 07/01/2025