BT FORKLIFT RRX35/45, RDX30, RSX40/50 MASTER SERVICE MANUAL 306756-000 – PDF DOWNLOAD

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BT FORKLIFT RRX35/45, RDX30, RSX40/50 MASTER SERVICE MANUAL 306756-000 – PDF DOWNLOAD

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BT FORKLIFT RRX35/45, RDX30, RSX40/50 MASTER SERVICE MANUAL 306756-000 – PDF DOWNLOAD

Language : English
Pages : 690
Downloadable : Yes
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TABLE OF CONTENTS:

BT FORKLIFT RRX35/45, RDX30, RSX40/50 MASTER SERVICE MANUAL 306756-000 – PDF DOWNLOAD

BT Standard Codes...............................................................  3
Warning Symbols................................................................. 17
	1. Warning Levels........................................................... 17
Prohibitory Symbols............................................................. 18
	1. Ordinance Symbols........................................................ 18
Safety.......................................................................... 19
	1. General Safety........................................................... 19
Battery Safety.................................................................. 23
Static Safety................................................................... 28
Welding Safety.................................................................. 29
Introduction, Service Manual.................................................... 31
Contents, Section M............................................................. 33
	1. Machine Information...................................................... 33
General Product Information..................................................... 35
	1. Presentation of the Rider Trucks......................................... 35
		1.1. Truck Side Views................................................... 35
		1.2. Open Back Compartment.............................................. 36
		1.3. Intended Truck Application......................................... 36
		1.4. Prohibited Truck Application....................................... 37
		1.5. Truck Data......................................................... 37
		1.6. RRX35 Dimensions................................................... 38
		1.7. RRX45 Dimensions................................................... 39
		1.8. RDX30 Dimensions................................................... 40
		1.9. RSX40 Dimensions................................................... 41
		1.10. RSX50 Dimensions.................................................. 42
		1.11. Data Plate........................................................ 43
	2. Main Components.......................................................... 44
Inch (SAE) and Metric Fasteners................................................. 47
	1. Introduction............................................................. 47
	2. Nomenclature, Threads.................................................... 48
	3. Strength Identification.................................................. 49
	4. Conversion of Metric and English Units................................... 57
Technical Service Data.......................................................... 59
Ordering Spare Parts............................................................ 63
Contents, Section P............................................................. 65
	1. Planned Maintenance...................................................... 65
Introduction, Maintenance....................................................... 67
	1. Safe Jacking Procedure................................................... 68
		1.1. Elevate Rear of Truck.............................................. 68
		1.1. Elevate Either Side of Truck....................................... 69
	2. Lubricants............................................................... 70
		2.1. Cold Storage Conditioning.......................................... 70
		2.2. Electrical Component Cold Storage Conditioning..................... 70
Service Schedule................................................................ 71
	1. Planned Maintenance Schedule............................................. 71
	2. Planned Maintenance Procedures........................................... 76
		2.1. Services Performed Daily or Every 8 Operating Hours................ 76
			2.1.1. Battery Discharge Indicator with slow down................... 76
			2.1.2. Hydraulic System............................................. 76
			2.1.3. Frame/Sheet Metal............................................ 77
			2.1.4. Wheels/Tires................................................. 77
			2.1.5. Functions/Operations......................................... 77
		2.2. Services Performed Monthly or Every 120 Operating Hours............ 77
			2.2.1. Inspection................................................... 77
			2.2.2. Transmission................................................. 77
			2.2.3. Brakes....................................................... 77
			2.2.4. Battery...................................................... 78
			2.2.5. Electrical Connections....................................... 78
			2.2.6. Contactor Tips (NOT Sealed).................................. 78
			2.2.7. Motor Brushes................................................ 78
			2.2.8. Drive Motor.................................................. 78
			2.2.9. Hydraulic Reservoir.......................................... 79
			2.2.10. Frame Lube.................................................. 79
			2.2.11. Pivot Points................................................ 79
		2.3. Services Performed Every 480 or 960 Operating Hours................ 79
			2.3.1. Drive Motor.................................................. 79
		2.4. Services Performed Annually or Every 1440 Operating Hours.......... 80
			2.4.1. Inspection................................................... 80
			2.4.2. Transmission................................................. 80
			2.4.3. Battery...................................................... 80
			2.4.4. Hydraulic System............................................. 80
			2.4.5. Brakes....................................................... 81
			2.4.6. Lift and Carriage Chains..................................... 81
Lubrication Chart............................................................... 83
Oil and Grease Specifications................................................... 84
	1. Approved Oils and Grease................................................. 84
	2. Grease Location Points................................................... 85
	3. Mast Adjustment Points................................................... 86
Contents, Section S............................................................. 87
	1. Service Instructions..................................................... 87
Troubleshooting Guidelines...................................................... 89
	1. General.................................................................. 89
	2. Electrical............................................................... 91
		2.1. Shorts to Frame Test............................................... 91
	3. Hydraulic................................................................ 96
	4. Definitions.............................................................. 97
Chassis......................................................................... 99
	1. General.................................................................. 99
	2. Dash.....................................................................100
		2.1. Removal............................................................100
		2.1. Removal............................................................101
	3. Motor Compartment Door...................................................101
		3.1. Removal............................................................101
		3.2. Installation.......................................................101
	4. Left-Hand Side Panel.....................................................102
		4.1. Removal............................................................102
	5. Operator Compartment Panel...............................................103
		5.1. Removal............................................................103
	6. Main Card Access Panel...................................................103
		6.1. Removal............................................................103
Battery Compartment.............................................................105
	1. Battery Retainer Plates..................................................106
		1.1. Inspection.........................................................106
		1.2. Removal............................................................106
		1.3. Installation.......................................................106
	2. Battery Rollers..........................................................106
		2.1. Inspection.........................................................106
		2.2. Replacement........................................................106
Mounting Points.................................................................107
	1. Drive Motor..............................................................107
		1.1. Removal............................................................108
		1.2. Installation.......................................................109
	2. Pump Motor...............................................................110
		2.1. Removal............................................................111
		2.2. Installation.......................................................112
	3. Transmission.............................................................114
		3.1. Fluid Changing Procedure...........................................115
		3.2. Removal............................................................115
		3.3. Installation.......................................................116
Driver Controls.................................................................119
Brake Pedal, RSX40/RRX35........................................................121
	1. Pedal Removal............................................................122
	2. Pedal Bearing Replacement................................................123
	3. Pedal Adjustment.........................................................123
Brake Pedal, RSX50/RRX45/ RDX30.................................................124
	1. Pedal Removal............................................................125
	2. Pedal Bearing Replacement................................................126
	3. Pedal Adjustment.........................................................126
Overhead Guard..................................................................127
Decals..........................................................................129
	1. Decal with Protective Sheet..............................................129
	2. Decal without Protective Sheet...........................................129
Steering Motor..................................................................133
	1. Removal..................................................................133
	2. Installation.............................................................133
	3. Steering Motor Gear Replacement..........................................134
		3.1. Removal............................................................134
		3.2. Installation.......................................................134
Fan Motor.......................................................................135
	1. Upper Electrical Compartment Fan.........................................135
		1.1. Removal............................................................135
		1.2. Removal............................................................135
		1.3. Installation.......................................................136
	2. Operator Fan.............................................................136
Motor Maintenance Schedule/Troubleshooting......................................137
	1. General Information......................................................137
	2. Operating Conditions.....................................................137
	3. Troubleshooting..........................................................138
Pump Motor, RRX35/RSX40.........................................................145
	1. Component Repair.........................................................147
		1.1. Disassembly........................................................147
	2. Inspection and Troubleshooting...........................................149
		2.1. Drive End head.....................................................149
		2.2. Commutator End head................................................149
		2.3. Bearings...........................................................149
		2.4. Brush and Commutator...............................................150
		2.5. Armature...........................................................152
		2.6. Frame and Field Assembly...........................................153
			2.6.1. Testing......................................................153
		2.7. Assembly...........................................................154
			2.7.1. Bearing Installation.........................................154
			2.7.2. Testing......................................................154
Pump Motor, RRX45/RDX30/RSX50...................................................155
	1. Component Repair.........................................................156
		1.1. Disassembly........................................................156
	2. Motor Inspection.........................................................158
		2.1. External Motor.....................................................158
		2.2. Brush and Commutator...............................................159
		2.3. Bearings...........................................................161
		2.4. Armature Electrical Check..........................................161
		2.5. Frame & Field Service Recommendation...............................162
		2.6. Assembly/Testing...................................................163
Drive Motor.....................................................................165
	1. Disassembly..............................................................167
	2. Inspection...............................................................168
		2.1. Drive End Head.....................................................168
		2.2. Commutator End Head................................................168
		2.3. Bearings...........................................................168
		2.4. Brush and Commutator...............................................169
		2.5. Armature...........................................................171
		2.6. Frame and Field Assembly...........................................172
			2.6.1. Testing......................................................172
		2.7. Assembly...........................................................172
			2.7.1. Bearing Installation.........................................172
			2.7.2. Testing......................................................173
	3. Temperature Sensors......................................................173
		3.1. Removal............................................................173
		3.2. Installation.......................................................173
	4. Brush Wear Sensors.......................................................174
Transmission....................................................................175
	1. Disassemble..............................................................177
	2. Assembly.................................................................181
	3. Axle Sealing Ring........................................................190
		3.1. Disassembly........................................................190
		3.2. Assembly...........................................................191
	4. Leakage..................................................................192
		4.1. Top Cover..........................................................192
		4.2. Lower Cover........................................................193
	5. Wheel Bolt...............................................................194
Electromagnetic Brake...........................................................195
	1. Removal..................................................................195
	2. Installation.............................................................197
	3. Adjustments..............................................................198
	4. Coil Check On Brake......................................................199
	5. Electromagnetic Brake, Armature and Magnetic Coil........................199
		5.1. Removal............................................................199
		5.2. Installation.......................................................200
	6. Brake Friction Plate.....................................................200
		6.1. Inspection.........................................................200
		6.2. Replacement........................................................200
Drive Wheel.....................................................................201
	1. Removal..................................................................202
	2. Installation.............................................................202
	3. Tire Pressing Procedure..................................................203
Non-Braking Caster Wheel, RRX35/RSX40...........................................205
	1. Caster Pivot.............................................................207
		1.1. Removal............................................................207
		1.2. Installation.......................................................208
	2. Thrust Bearing...........................................................209
		2.1. Removal............................................................209
		2.2. Installation.......................................................210
	3. Caster Springs...........................................................211
		3.1. Adjustment.........................................................211
		3.2. Removal............................................................211
		3.3. Installation.......................................................212
	4. Caster Stops.............................................................213
		4.1. Adjustment.........................................................213
Non-Braking Caster Assembly, RRX35/RSX40........................................215
	1. Removal..................................................................216
	2. Installation.............................................................216
Braking Caster Wheel, RRX45/RDX30/RSX50.........................................217
	1. Removal..................................................................219
		1.1. Caster Brake Adjustment............................................219
Braking Caster Assembly, RRX45/RDX30/RSX50......................................221
	1. Removal..................................................................223
	2. Installation.............................................................224
Load Wheels, Sizes 4 X 3, 5 X 4, and 5 X 3......................................225
	1. Removal..................................................................227
	2. Installation.............................................................228
Load Wheels, Size 10.5 X 3.5....................................................229
	1. Removal..................................................................230
	2. Installation.............................................................230
Steering Arm / Wheel / Lever....................................................231
	1. Control Pod..............................................................233
		1.1. Removal............................................................233
		1.2. Installation.......................................................233
	2. Steering Wheel...........................................................234
		2.1. Removal............................................................234
		2.2. Installation.......................................................234
	3. Steering Tach............................................................235
		3.1. Removal............................................................235
		3.2. Installation.......................................................235
Steering Bearing................................................................237
	1. Removal..................................................................238
	2. Installation.............................................................238
Electrical Functions............................................................239
	1. General..................................................................239
		1.1. Directional/Speed Control Lever....................................239
		1.2. Main Electronic Card...............................................240
	2. Start Up.................................................................243
	3. Steering Components......................................................247
		3.1. Steering System....................................................247
		3.2. Wheel Direction Sensors............................................251
	4. Brake Release............................................................253
	5. Direction Selection......................................................255
	6. Travel Request, Forks First..............................................257
	7. Travel Request, Forks Trailing...........................................261
	8. Plug Braking.............................................................265
		8.1. Directional/Speed Control Lever Method.............................265
		8.2. Brake Pedal Method.................................................266
	9. 12-Volt Power Supply.....................................................269
	10. 7.35-Volt Power Supplies................................................270
	11. Limit Switches..........................................................273
		11.1. Truck Travel Speed Limiting.......................................273
		11.2. Mast Staging Speed Limiting.......................................275
	12. Height Indicator........................................................277
		12.1. Height Preset Selector............................................278
	13. Drive Motor Brush Wear Indicator Switches...............................279
	14. Pump Motor Brush Indicator Switch.......................................280
	15. Safety Check............................................................281
	16. Shunt Power Cable.......................................................283
Electrical Symbols..............................................................291
Electrical Schematics (P5-04 Serial numbers 27163000-28105000)..................293
	1. Circuit Diagram 1(11)....................................................293
	2. Circuit Diagram 2(11)....................................................294
	3. Circuit Diagram 3(11)....................................................295
	4. Circuit Diagram 4(11)....................................................296
	5. Circuit Diagram 5(11)....................................................297
	6. Circuit Diagram 6(11)....................................................298
	7. Circuit Diagram 7(11)....................................................299
	8. Circuit Diagram 8(11)....................................................300
	9. Circuit Diagram 9(11)....................................................301
	10. Circuit Diagram 10(11)..................................................302
	11. Circuit Diagram 11(11)..................................................303
Electrical Schematics (P5-04 Serial numbers 2810500-28126000)...................305
	1. Circuit Diagram 1(12)....................................................305
	2. Circuit Diagram 2(12)....................................................306
	3. Circuit Diagram 3(12)....................................................307
	4. Circuit Diagram 4(12)....................................................308
	5. Circuit Diagram 5(12)....................................................309
	6. Circuit Diagram 6(12)....................................................310
	7. Circuit Diagram 7(12)....................................................311
	8. Circuit Diagram 8(12)....................................................312
	9. Circuit Diagram 9(12)....................................................313
	10. Circuit Diagram 10(12)..................................................314
	11. Circuit Diagram 11(12)..................................................315
	12. Circuit Diagram 12(12)..................................................316
Electrical Schematics (P5-05/06/07 Serial number 28126001-UP)...................317
	1. Circuit Diagram 1(12)....................................................317
	2. Circuit Diagram 2(12)....................................................318
	3. Circuit Diagram 3(12)....................................................319
	4. Circuit Diagram 4(12)....................................................320
	5. Circuit Diagram 5(12)....................................................321
	6. Circuit Diagram 6(12)....................................................322
	7. Circuit Diagram 7(12)....................................................323
	8. Circuit Diagram 8(12)....................................................324
	9. Circuit Diagram 9(12)....................................................325
	10. Circuit Diagram 10(12)..................................................326
	11. Circuit Diagram 11(12)..................................................327
	12. Circuit Diagram 12(12)..................................................328
Battery.........................................................................329
	1. Removal..................................................................329
	2. Installation.............................................................329
	3. Battery Maintenance......................................................330
		3.1. Battery Inspection and Care........................................330
		3.2. Battery Exterior Cleaning..........................................331
		3.3. Charging...........................................................331
	4. Storage..................................................................332
	5. Battery History Record...................................................332
Light Assemblies................................................................333
	1. Overhead Guard Lights (Option)...........................................333
		1.1. Removal............................................................333
		1.2. Installation.......................................................333
	2. Warning Lights (Option)..................................................334
		2.1. Removal............................................................334
		2.2. Installation.......................................................335
	3. Working Lights (Option)..................................................335
		3.1. Removal............................................................335
		3.2. Installation.......................................................335
	4. Travel Alarm (Option)....................................................336
		4.1. Removal............................................................336
		4.2. Installation.......................................................336
	5. Operator Fan (Option)....................................................337
		5.1. Removal............................................................338
		5.2. Installation.......................................................338
Horn............................................................................339
	1. Removal..................................................................339
	2. Installation.............................................................339
Battery Connector...............................................................341
	1. Location.................................................................341
	2. Inspection...............................................................341
	3. Installation.............................................................342
Start/Stop Switches.............................................................343
	1. General..................................................................343
		1.1. Test/Inspection....................................................343
	2. Key Switch (S17).........................................................343
		2.1. Inspection.........................................................343
		2.2. Removal............................................................344
		2.3. Installation.......................................................344
	3. Emergency Disconnect Switch (S21)........................................345
		3.1. Inspection.........................................................345
		3.2. Removal............................................................345
		3.3. Installation.......................................................346
Mast Switch (S31)...............................................................347
	1. General..................................................................347
		1.1. Test/Inspection....................................................347
		1.2. Adjustment.........................................................349
		1.3. Removal............................................................350
		1.4. Installation.......................................................350
Control Cable and Harness.......................................................351
	1. Fuses....................................................................351
	2. Wiring...................................................................352
		2.1. Harness............................................................352
		2.2. Power Cables.......................................................353
Contactors......................................................................355
	1. General..................................................................355
		1.1. Resistance Testing.................................................355
		1.2. Contactor Tip Inspection...........................................355
	2. Direction Contactors.....................................................356
		2.1. Removal............................................................357
		2.2. Installation.......................................................357
	3. Lift Bypass Contactor (RRX45/RSX50/RDX30)................................358
		3.1. Removal............................................................359
		3.2. Installation.......................................................359
	4. Battery Cut-out Contactor................................................360
		4.1. Removal............................................................361
		4.2. Installation.......................................................361
Transistor Panel (Drive)........................................................363
Transistor Panel (Lift).........................................................364
	1. Motor Connections........................................................365
		1.1. Connections for controls...........................................365
	2. Circuit Check............................................................366
Micro Switches..................................................................367
	1. General..................................................................367
	2. Lift Limit Override Switch (S33).........................................368
		2.1. Removal............................................................368
		2.2. Installation.......................................................368
	3. Optional Light and Fan Switches (S96, S97 and S99).......................369
		3.1. Removal............................................................369
		3.2. Installation.......................................................369
Main Electronic Card............................................................371
	1. Connectivity to Truck....................................................371
	2. Transistor Controller Replacement........................................372
	3. Removal..................................................................376
	4. Installation.............................................................376
	5. Display..................................................................382
	6. Time.....................................................................383
	7. Effect on Truck..........................................................383
	8. Running time.............................................................384
	9. RV2 Adjustment Procedure.................................................384
	10. Adjustment Procedures for Setting Brake Switch and Brake Transducer.....385
	11. Battery Discharge Indicator Parameter Adjustment........................386
	12. A5 Jumper Harness Kit Installation (Serial numbers 28126000 - below)....392
	13. Warning\Caution Codes...................................................395
	14. Error Codes.............................................................397
		14.1. E102 Troubleshooting Procedures...................................399
			14.1.1. Power Circuit Checks........................................399
			14.1.2. Reference Circuit Value Checks (LED #4).....................401
	15. Programming Parameter...................................................402
Switches and Sensors............................................................413
	1. General..................................................................413
		1.1. Test/Inspection....................................................413
	2. Platform (Right Foot) Switch (S108)......................................413
		2.1. Removal............................................................414
		2.2. Installation.......................................................414
	3. Staging Switch (S45).....................................................415
		3.1. Adjustment.........................................................416
		3.2. Removal............................................................416
		3.3. Installation.......................................................416
	4. Wheel Direction Sensor...................................................417
		4.1. Adjustment.........................................................417
		4.2. Removal............................................................418
		4.3. Installation.......................................................418
	5. Steer Proximity Sensors A and B (S66 and S67)............................419
		5.1. Adjustment.........................................................419
		5.2. Removal............................................................420
		5.3. Installation.......................................................420
	6. Drive Motor Speed(S64)/Direction Sensors (S125)..........................421
		6.1. Removal............................................................421
		6.2. Installation.......................................................422
Hydraulic System................................................................423
	1. Operation................................................................423
		1.1. Supply.............................................................423
		1.2. Lifting............................................................425
		1.3. Lowering...........................................................426
		1.4. Reach..............................................................429
		1.5. Retract............................................................432
		1.6. Reach Relief (RRX35)...............................................433
		1.7. Reach Impact (RRX35)...............................................434
		1.8. Tilt Up............................................................437
		1.9. Tilt Down..........................................................440
		1.10. Side Shifting Right...............................................443
		1.11. Side Shifting Left................................................445
	2. RRX35 Hydraulic Schematic................................................448
	3. RRX45 Hydraulic Schematic................................................449
	4. RDX30 Hydraulic Schematic................................................450
	5. RSX40 Hydraulic Schematic................................................451
	6. RSX50 Hydraulic Schematic................................................452
Hydraulic Fluid.................................................................453
	1. Hydraulic Fluid Selection................................................453
	2. Changing Hydraulic System Fluid..........................................453
	3. System Draining..........................................................454
	4. Refilling System.........................................................455
	5. Bleeding Hydraulic System................................................456
Hydraulic Tank..................................................................458
	1. Removal..................................................................459
	2. Installation.............................................................460
Hydraulic Filter Assembly.......................................................461
	1. Hydraulic Filter.........................................................462
		1.1. Removal............................................................462
		1.2. Installation.......................................................462
	2. Hydraulic Filter Adapter.................................................463
		2.1. Removal............................................................463
		2.2. Installation.......................................................463
Hydraulic Pump..................................................................465
	1. Removal..................................................................465
	2. Repair...................................................................465
Control Valve...................................................................467
	1. Removal..................................................................467
	2. Installation.............................................................467
Control Valve Assembly..........................................................472
	3. Repair...................................................................474
		3.1. Proportional Pre-Pressure Reducing Valve...........................474
		3.2. Valve Assembly SWR14...............................................474
		3.3. Pressure Limiting Valve Assembly...................................475
		3.4. Setting Lift/Auxiliary Pressure Relief with a Rated Load...........475
		3.5. Rated Load Pressure Settings.......................................476
		3.6. Hydraulic Lowering Rate Adjustment.................................476
		3.7. Recondition Seal Kit...............................................477
Staging Cylinder, Three Stage Mast, RRX35/RSX40.................................479
	1. Removal..................................................................480
	2. Disassembly..............................................................481
	3. Assembly.................................................................481
	4. Installation.............................................................481
Staging Cylinder, Three Stage Mast, RRX45/RDX30/RSX50...........................483
	1. Removal..................................................................485
	2. Disassembly..............................................................486
	3. Assembly.................................................................486
	4. Installation.............................................................486
Freelift Cylinder, Three Stage Mast.............................................487
	1. Removal..................................................................489
	2. Disassembly..............................................................490
	3. Assembly.................................................................490
	4. Installation.............................................................490
Reach Cylinder Assembly, RRX35..................................................491
	1. Removal..................................................................493
	2. Disassembly..............................................................494
	3. Inspection...............................................................495
	4. Assembly.................................................................496
	5. Installation.............................................................497
Reach Cylinder Assembly, RRX45..................................................499
	1. Removal..................................................................501
	2. Disassembly..............................................................502
	3. Inspection...............................................................503
	4. Assembly.................................................................504
	5. Installation.............................................................505
Reach Cylinder Assembly, RDX30..................................................507
	1. Removal..................................................................509
	2. Disassembly..............................................................510
	3. Inspection...............................................................511
	4. Assembly.................................................................512
	5. Installation.............................................................513
Tilt Cylinder Assembly, RRX35/RSX40.............................................515
	1. Removal..................................................................517
	2. Disassembly..............................................................518
	3. Inspection...............................................................519
	4. Assembly.................................................................520
	5. Installation.............................................................521
Tilt Cylinder Assembly, RSX50...................................................523
	1. Removal..................................................................525
	2. Disassembly..............................................................526
	3. Inspection...............................................................527
	4. Assembly.................................................................528
	5. Installation.............................................................529
Tilt Cylinder Assembly, RRX45/RDX30.............................................531
	1. Removal..................................................................533
	2. Disassembly..............................................................534
	3. Inspection...............................................................535
	4. Assembly.................................................................536
	5. Installation.............................................................537
Mast, 3 Stage, RRX35/RSX40......................................................539
	1. Shimming Carriage with Mast on Truck.....................................541
	2. Three Stage Mast.........................................................543
		2.1. Removal............................................................543
		2.2. Disassembly........................................................544
		2.3. Assembly...........................................................545
		2.4. Installation.......................................................547
Mast, 3 Stage, RRX45/RSX50/RDX30................................................548
	1. Shimming Carriage with Mast on Truck.....................................550
	2. Three Stage Mast.........................................................552
		2.1. Removal............................................................552
		2.2. Disassembly........................................................553
		2.3. Assembly...........................................................554
		2.4. Installation.......................................................556
	3. Lift Chain...............................................................557
		3.1. Lift Chain Adjustment..............................................557
		3.2. Lift Chain Maintenance.............................................557
		3.3. Lift Chain Inspection..............................................557
			3.3.1. Wear.........................................................558
			3.3.2. Rust and Corrosion...........................................558
			3.3.3. Cracked Plates...............................................559
			3.3.4. Protruding or Turned Pins....................................561
			3.3.5. Chain Side Wear..............................................562
			3.3.6. Chain Anchors and Sheaves....................................562
			3.3.7. Lift Chain Lubrication.......................................562
		3.4. Lift Chain Replacement.............................................564
Lifting Gear (Crosshead), RRX35/ RSX40..........................................565
	1. Lifting Gear Repair......................................................566
		1.1. Removal............................................................566
		1.2. Disassembly........................................................567
		1.3. Assembly...........................................................567
		1.4. Installation.......................................................567
Lifting Gear (Crosshead), RRX45/ RSX50/RDX30....................................568
	1. Lifting Gear Repair......................................................569
		1.1. Removal............................................................569
		1.2. Disassembly........................................................570
		1.3. Assembly...........................................................570
		1.4. Installation.......................................................571
Sideshifter, RRX35/45/RDX30.....................................................573
	1. Mounting Instructions....................................................575
		1.1. Installation.......................................................575
	2. Operation and Maintenance................................................576
		2.1. Lower Slides.......................................................576
		2.2. Upper Slides.......................................................577
		2.3. Cylinder...........................................................577
Sideshifter, RRX35/45/RSX40/50/RDX30............................................579
	1. Mounting Instructions....................................................581
		1.1. Installation.......................................................581
	2. Operation................................................................582
	3. Maintenance..............................................................582
		3.1. Carriage Removal...................................................583
		3.2. Upper Pad Replacement..............................................583
		3.3. Lower Pad Replacement..............................................584
		3.4. Cylinder...........................................................585
	4. Troubleshooting..........................................................587
		4.1. No Sideshifting....................................................587
		4.2. Sideshifting Very Slow.............................................587
		4.3. Irregular Sideshifting.............................................588
Single Reach, RRX35.............................................................589
	1. Maintenance..............................................................595
		1.1. Inspection.........................................................595
		1.2. Adjustment.........................................................596
	2. Repair...................................................................600
		2.1. Disassembly........................................................601
	3. Rear Frame...............................................................606
		3.1. Inspection and Maintenance.........................................606
			3.1.1. Rear Frame Removal...........................................608
			3.1.2. Rear Frame Installation......................................609
	4. Carriage Roller Bearings.................................................610
		4.1. Removal............................................................610
		4.2. Installation.......................................................610
Single Reach, RRX45.............................................................611
	1. Maintenance..............................................................611
	2. Reach Repair.............................................................619
		2.1. Disassembly (for item call out identification see page613)........619
			2.1.1. Forward Frame Removal........................................619
			2.1.2. Outer Arm Removal............................................619
			2.1.3. Inner Arm Removal............................................620
			2.1.4. Rear Frame Removal...........................................620
			2.1.5. Reach Cylinder Removal.......................................621
		2.2. Assembly...........................................................621
			2.2.1. Reach Cylinder Installation..................................621
			2.2.2. Rear Frame Installation......................................621
			2.2.3. Inner Arm Installation.......................................622
			2.2.4. Outer Arm Installation.......................................622
			2.2.5. Front Frame Installation.....................................623
	3. Fork Carriage Pivot Pins.................................................623
	4. Carriage Roller Bearings.................................................624
		4.1. Removal............................................................624
		4.2. Installation.......................................................624
Double Reach, RDX30.............................................................625
	1. Maintenance..............................................................625
	2. Fork Frame Removal.......................................................631
		2.1. Fork Frame Assembly................................................632
		2.2. Forward Frame Removal..............................................632
		2.3. Forward Frame Installation.........................................633
		2.4. Rear Frame.........................................................634
		2.5. Rear Frame Removal.................................................637
		2.6. Rear Frame Installation............................................637
Double Reach Arm Assembly, RDX30................................................641
	1. Arm (2) and (13) Removal.................................................643
		1.1. Inner Arm (5) Removal..............................................644
		1.2. Arm Assembly Installation..........................................645
Forks...........................................................................655
	1. Removal..................................................................657
	2. Inspection...............................................................657
	3. Installation.............................................................658
Load Indicator..................................................................659
Load Indicator..................................................................661
	1. Pulse Sensor.............................................................663
		1.1. Repair.............................................................663
		1.2. Cable..............................................................663
			1.2.1. Removal......................................................663
			1.2.2. Installation.................................................663
		1.3. Pulley.............................................................663
			1.3.1. Removal......................................................663
Height Indicator and Preset Selector............................................665
	1. General..................................................................666
	2. Operation................................................................666
	3. Preset Height............................................................667
	4. Display..................................................................668
	5. Display Symbols Description..............................................669
	6. Programming..............................................................670
		6.1. Programming a Level................................................670
			6.1.1. Collection Level.............................................670
			6.1.2. Leaving Level................................................670
		6.2. Erasing Programmed Levels..........................................671
			6.2.1. Automatic Operations.........................................671
			6.2.2. Collecting a Load............................................671
			6.2.3. Leaving a Load...............................................672
		6.3. Parameters.........................................................673
Load Backrest...................................................................679
	1. Removal..................................................................682
	2. Installation.............................................................682
	A...........................................................................683
	B...........................................................................683
	C...........................................................................683
	D...........................................................................684
	E...........................................................................684
	F...........................................................................684
	G...........................................................................684
	H...........................................................................684
	I...........................................................................685
	K...........................................................................685
	L...........................................................................685
	M...........................................................................685
	N...........................................................................685
	O...........................................................................686
	P...........................................................................686
	R...........................................................................686
	S...........................................................................686
	T...........................................................................686
	V...........................................................................687
	W...........................................................................687

DESCRIPTION:

BT FORKLIFT RRX35/45, RDX30, RSX40/50 MASTER SERVICE MANUAL 306756-000 – PDF DOWNLOAD

• The information in this Service Manual covers models RRX35, RRX45, RDX30, RSX40, and RSX50.
• Federal and State laws require that operators be completely trained in the safe operation of trucks in accordance with OSHA regulation 1910.178.
• An Operator’s Manual is sent with 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 the truck.
• The Service Manual is divided into four separate sections, which cover needed information for servicing the truck types. The main subject for each of the sections are as described below.

S.S 07/01/2025