BT-Prime Mover RRX35/45 RDX30 RSX40/50 Rider Up Service Manual PDF

Description

BT-Prime Mover RRX35/45 RDX30 RSX40/50 Electric Electrical Stand-up Rider Up Service Manual – PDF DOWNLOAD

FILE DETAILS:

BT-Prime Mover RRX35/45 RDX30 RSX40/50 Electric Electrical Stand-up Rider Up Service Manual – PDF DOWNLOAD

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

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TABLE OF CONTENTS:

BT-Prime Mover RRX35/45 RDX30 RSX40/50 Electric Electrical Stand-up Rider Up Service Manual – PDF DOWNLOAD

Manual Part no: 306756-000
Effective Serial Number R_X0027135001

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-Prime Mover RRX35 45 RDX30 RSX40 50 Electric Electrical Stand-up Rider Up Service Manual – PDF DOWNLOAD

Manual Part no: 306756-000
Effective Serial Number R_X0027135001

General Product Information
1. 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.V 11/01/2025