BT FORKLIFT RRX35/45, RDX30, RSX40/50 SERVICE MANUAL 306756-000 July 1997 – PDF DOWNLOAD

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BT FORKLIFT RRX35/45, RDX30, RSX40/50 SERVICE MANUAL 306756-000 July 1997 – PDF DOWNLOAD

FILE DETAILS:

BT FORKLIFT RRX35/45, RDX30, RSX40/50 SERVICE MANUAL 306756-000 July 1997 – PDF DOWNLOAD

Language : English
Pages : 268
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

BT FORKLIFT RRX35/45, RDX30, RSX40/50 SERVICE MANUAL 306756-000 July 1997 – PDF DOWNLOAD

Front Cover.....................................................................  1
BT Standard Codes...............................................................  3
Table of Contents...............................................................  5
Warning Symbols.................................................................  7
	1. Warning Levels...........................................................  7
Prohibitory Symbols.............................................................  8
	1.1 Ordinance Symbols.......................................................  8
Introduction, Service Manual....................................................  9
Contents, Section M............................................................. 11
General Product Information..................................................... 13
	1. Presentation of the Rider Trucks......................................... 13
		1.1 Intended Application of the Trucks.................................. 13
		1.2 Forbidden Application of the Truck.................................. 14
		1.3 Truck Data.......................................................... 14
		1.4 RRX35 Dimensions.................................................... 15
		1.5 RRX45 Dimensions.................................................... 16
		1.6 RDX30 Dimensions.................................................... 17
		1.7 RSX40 Dimensions.................................................... 18
		1.8 RSX50 Dimensions.................................................... 19
		1.9 Data Plate.......................................................... 20
	2. Main Components.......................................................... 21
		Inch (SAE) and Metric Fasteners......................................... 23
		1. Introduction......................................................... 24
		2. Nomenclature, Threads................................................ 24
			Strength Identification............................................. 25
			Table #1 Bolts and Screws........................................... 26
			Table #2 Studs and Nuts............................................. 27
			Table #3 Torque Nuts................................................ 28
			Table #4 Torque Nuts with Nylon Insert.............................. 29
			Table #5 Conversion Table for Metric and English Units.............. 30
			Table #6............................................................ 32
		Technical Service Data.................................................. 33
		Ordering Spare Parts.................................................... 37
Contents, Section P............................................................. 39
Introduction, Maintenance....................................................... 41
	4. Safe Jacking Procedure................................................... 41
Service Schedule................................................................ 43
	5. Planned Maintenance Procedures........................................... 46
		5.1 Services to be Performed Daily or at Each 8 Hour Operating Shift.... 46
		5.2 Services to be Performed Monthly or Every 250 Operating Hours....... 48
		5.3 Services to be Performed Annually or Every 1200 Operating Hours..... 50
Lubrication Chart............................................................... 53
Oil and Grease Specifications................................................... 55
	6. Approved Oils and Grease................................................. 55
Contents, Section S............................................................. 57
Chassis......................................................................... 59
	1. General.................................................................. 59
	2. Door (#10)............................................................... 60
	3. Left Hand Side Panel (#1)................................................ 60
	4. Operator Compartment Panel (#2).......................................... 61
	5. Main Card Access Panel (#15)............................................. 61
Brake Pedal..................................................................... 63
	1. Pedal Removal............................................................ 64
	2. Pedal Bearing Replacement................................................ 64
	3. Pedal Adjustment......................................................... 65
Drive Motor..................................................................... 67
	1. General Information...................................................... 67
	2. Operating Conditions..................................................... 67
	3. Troubleshooting.......................................................... 68
		Table #1................................................................ 69
		Table #2................................................................ 72
	4. Component Repair......................................................... 76
	5. Inspection and Troubleshooting........................................... 78
		5.1 Drive End Head...................................................... 78
		5.2 Commutator End Head................................................. 78
		5.3 Bearings............................................................ 78
		5.4 Brush and Commutator................................................ 79
		5.5 Armature............................................................ 79
		5.6 Frame and Field Assembly............................................ 80
		5.7 Assembly............................................................ 82
	6. When Changing Brushes.................................................... 83
Electromagnetic Brake........................................................... 85
	1. Installation............................................................. 86
	2. Adjustments.............................................................. 87
	3. Coil Check on Brake...................................................... 87
	4. Electromagnetic Brake.  Armature and Magnetic Coil....................... 88
Drive Wheel..................................................................... 89
	1. Removal.................................................................. 89
	2. Installation............................................................. 90
Support/Swivel Wheel............................................................ 91
	1. Caster Pivot............................................................. 92
	2. Thrust Bearing........................................................... 95
	3. Caster Springs........................................................... 97
	4. Caster Axle.............................................................. 99
	5. Caster Spring............................................................100
	6. Caster Stops.............................................................101
	7. Caster Brake Assembly....................................................102
Tandem Load Wheels..............................................................105
	1. Replacement..............................................................106
Single Load Wheels..............................................................107
	1. Replacement..............................................................108
	2. Installation.............................................................108
Caster Wheels...................................................................109
	1. Removal..................................................................110
	2. Installation.............................................................110
Steering Arm/Wheel/Lever........................................................111
	1. Control Pod..............................................................112
	2. Steering Wheel...........................................................113
	3. Steering Tach............................................................114
Steering Bearing................................................................115
	1. Removal..................................................................116
	2. Installation.............................................................116
Electrical Functions............................................................117
	1. Operating Description....................................................117
	2. Start Up.................................................................119
	3. Direction Selection......................................................121
	4. Reverse Direction Selection..............................................123
	5. Forward Drive............................................................125
	6. Plug Braking.............................................................127
	7. Height Indicator and Preset Selector.....................................133
	8. Drive Motor Brush Indicator Switch.......................................134
	9. Pump Motor Brush Indicator Switch........................................135
	10. Safety Check............................................................136
	11. Shunt Wire..............................................................137
	12. Circuit Diagram 1(11)...................................................144
	13. Circuit Diagram 2(11)...................................................145
	14. Circuit Diagram 3(11)...................................................146
	15. Circuit Diagram 4(11)...................................................147
	16. Circuit Diagram 5(11)...................................................148
	17. Circuit Diagram 6(11)...................................................149
	18. Circuit Diagram 7(11)...................................................150
	19. Circuit Diagram 8(11)...................................................151
	20. Circuit Diagram 9(11)...................................................152
	21. Circuit Diagram 10(11)..................................................153
	22. Circuit Diagram 11(11)..................................................154
Transistor Regulator............................................................155
	1. Motor Connections........................................................156
	2. Safety Control...........................................................157
Electronic Card.................................................................159
	1. Display..................................................................165
	2. Time.....................................................................166
	3. Warning Codes............................................................167
	4. Error Codes..............................................................169
	5. Parameters...............................................................171
	6. Running Time.............................................................171
	7. Programming Parameters...................................................172
	8. Adjustment Procedures for Setting Brake Switch and Brake Transducer......174
Pump Motor......................................................................175
	1. Component Repair.........................................................176
	2. Inspection and Troubleshooting...........................................178
		2.1 Drive End Head......................................................178
		2.2 Commutator End Head.................................................178
		2.3 Bearings............................................................178
		2.4 Brush and Commutator................................................179
		2.5 Armature............................................................179
		2.6 Frame and Field Assembly............................................180
		2.7 Assembly............................................................182
	3. When Changing Brushes....................................................183
Hydraulic System................................................................185
	1. Operation................................................................185
		1.1 Supply..............................................................185
		1.2 Lifting.............................................................185
		1.3 Lowering............................................................185
		1.4 Reach...............................................................185
		1.5 Retract.............................................................186
		1.6 Tilt Up.............................................................186
		1.7 Tilt Down...........................................................186
		1.8 Sideshifting Right..................................................186
		1.9 Sideshifting Left...................................................187
	2. RRX35/45 Hydraulic Schematic.............................................189
	3. RDX30 Hydraulic Schematic................................................190
	4. RSX40/50 Hydraulic Schematic.............................................191
Mast, 3 Stage...................................................................201
	1. Shimming.................................................................202
		1.1 Shimming the Carriage/Reach.........................................202
		1.2 Shimming the Rails..................................................203
	2. Three Stage Mast.........................................................207
		2.1 Removal.............................................................207
		2.2 Installation........................................................208
		2.3 Disassembly.........................................................209
		2.4 Assembly............................................................210
Sideshifter.....................................................................213
	1. Mounting Instructions....................................................214
	2. Operation and Maintenance................................................215
Reach, Single...................................................................217
	1. Maintenance..............................................................217
	2. Reach Repair.............................................................218
Lift Cylinder, 3 Stage..........................................................223
	1. Freelift Cylinder Repair.................................................224
		1.1 Removal.............................................................224
		1.2 Disassembly.........................................................224
		1.3 Assembly............................................................224
		1.4 Installation........................................................225
Staging Cylinder, 3 Stage.......................................................227
	1.1 Removal.................................................................228
	1.2 Disassembly.............................................................228
	1.3 Assembly................................................................228
	1.4 Installation............................................................229
Tilt Cylinder...................................................................231
	1. Removal..................................................................232
	2. Disassembly..............................................................232
	3. Inspection...............................................................233
	4. Assembly.................................................................233
	5. Installation.............................................................234
Reach Cylinder..................................................................243
	1. Removal..................................................................244
	2. Disassembly..............................................................244
	3. Inspection...............................................................245
	4. Assembly.................................................................245
	5. Installation.............................................................246
Height Indicator................................................................249
	1. Pulse Sensor.............................................................250
		1.1 Repair..............................................................250
		1.2 Cable...............................................................250
		1.3 Pulley..............................................................250
Height Indication & Preset Height...............................................251
	1. General..................................................................252
	2. Operation................................................................252
	3. Preset Height............................................................253
	4. Display..................................................................254
	5. Description of the Display Symbols.......................................255
	6. Programming..............................................................256
		Programming a Level.....................................................256
		Collection Level........................................................256
		Leaving Level...........................................................256
		Erasing Programmed Levels...............................................257
		Automatic Operations....................................................257
		Collecting a Load.......................................................257
		Leaving a Load..........................................................258
		Parameters..............................................................259
		P1......................................................................259
		P2......................................................................259
		P3......................................................................260
		P5......................................................................260
		P7......................................................................260
		P8......................................................................261
		P9......................................................................261
Back Cover......................................................................268

DESCRIPTION:

BT FORKLIFT RRX35/45, RDX30, RSX40/50 SERVICE MANUAL 306756-000 July 1997 – PDF DOWNLOAD

• The information in this Service Manual covers models RRX35, RRX45. RDXSO. RSX40. and RSXSU.
• 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 Manual 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 06/01/2025