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BT Prime-Mover RRX35/45, RSX40/50, RDX30 Master Service Manual – PDF
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Description
BT Prime-Mover RRX35/45, RSX40/50, RDX30 Master Service Manual – PDF DOWNLOAD
FILE DETAILS:
BT Prime-Mover RRX35/45, RSX40/50, RDX30 Master Service Manual – PDF DOWNLOAD
Language : English
Pages : 2667
Downloadable : Yes
File Type : PDF
306756-000 1996_December
306756-000 1997_July
306756-000 1997_August
306756-000 1998_April
306756-000 2001_November
306756-000 2002_February
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
BT Prime-Mover RRX35/45, RSX40/50, RDX30 Master Service Manual – PDF DOWNLOAD
Front Cover..................................................................... 2 Table of Contents............................................................... 4 Warning Symbols................................................................. 6 1. Warning Levels........................................................... 6 Prohibitory Symbols............................................................. 7 1.1 Ordinance Symbols....................................................... 7 Introduction, Service Manual.................................................... 8 Contents, Section M............................................................. 10 General Product Information..................................................... 12 1. Presentation of the Rider Trucks......................................... 12 1.1 Intended Application of the Trucks.................................. 12 1.2 Forbidden Application of the Truck.................................. 13 1.3 Truck Data.......................................................... 13 1.4 RRX35 Dimensions.................................................... 14 1.5 RRX45 Dimensions.................................................... 15 1.6 RDX30 Dimensions.................................................... 16 1.7 RSX40 Dimensions.................................................... 17 1.8 RSX50 Dimensions.................................................... 18 1.9 Data Plate.......................................................... 19 2. Main Components.......................................................... 20 Inch (SAE) and Metric Fasteners......................................... 22 Introduction............................................................ 23 Nomenclature, Threads................................................... 23 Strength Identification................................................. 24 Table #1 Bolts and Screws............................................... 25 Table #2 Studs and Nuts................................................. 26 Table #3 Torque Nuts.................................................... 27 Table #4 Torque Nuts with Nylon Insert.................................. 28 Table #5 Conversion Table for Metric and English Units.................. 29 Table #6................................................................ 31 Technical Service Data.......................................................... 32 Ordering Spare Parts............................................................ 36 Contents, Section P............................................................. 38 Introduction, Maintenance....................................................... 40 Safe Jacking Procedure...................................................... 40 Service Schedule................................................................ 42 1. Planned Maintenance Schedule............................................. 42 2. Planned Maintenance Procedures........................................... 45 Services to be Performed Daily or at Each 8 Hour Operating Shift........ 45 Battery Guard....................................................... 45 Hydraulic System.................................................... 45 Frame/Sheet Metal................................................... 46 Wheels/Tires........................................................ 46 Functions/Operations................................................ 46 Services to be Performed Monthly or Every 250 Operating Hours........... 46 Inspection.......................................................... 46 Transmission........................................................ 46 Brakes.............................................................. 46 Battery............................................................. 47 Electrical Connections.............................................. 47 Contactor Tips (NOT Sealed)......................................... 47 Motor Brushes....................................................... 47 Drive Motor......................................................... 48 Hydraulic Reservoir................................................. 48 Frame Lube.......................................................... 48 Pivot Points........................................................ 48 Services to be Performed Annually or Every 1200 Operating Hours......... 48 Inspection.......................................................... 49 Transmission........................................................ 49 Battery............................................................. 49 Hydraulic System.................................................... 49 Brakes.............................................................. 50 Lift and Carriage Chains............................................ 50 Lubrication Chart............................................................... 52 Oil and Grease Specifications................................................... 54 3. Approved Oils and Grease................................................. 54 Contents, Section S............................................................. 56 Chassis......................................................................... 58 1. General.................................................................. 58 2. Door..................................................................... 59 2.1 Removal............................................................. 59 2.2 Installation........................................................ 59 3. Left Hand Side Panel..................................................... 59 3.1 Removal............................................................. 59 4. Operator Compartment Panel............................................... 60 4.1 Removal............................................................. 60 5. Main Card Access Panel................................................... 60 5.1 Removal............................................................. 60 Brake Pedal..................................................................... 62 1. Pedal Removal............................................................ 63 2. Pedal Bearing Replacement................................................ 63 3. Pedal Adjustment......................................................... 63 Drive Motor..................................................................... 64 1. General Information...................................................... 64 2. Operating Conditions..................................................... 64 3. Troubleshooting.......................................................... 64 Table #1................................................................ 66 Table #2................................................................ 69 4. Component Repair......................................................... 73 5. Inspection and Troubleshooting........................................... 75 5.1 Drive End Head...................................................... 75 5.2 Commutator End Head................................................. 75 5.3 Bearings............................................................ 75 5.4 Brush and Commutator................................................ 76 5.5 Armature............................................................ 76 5.6 Frame and Field Assembly............................................ 77 5.7 Assembly............................................................ 79 6. When Changing Brushes.................................................... 80 Electromagnetic Brake........................................................... 82 1. Installation............................................................. 83 2. Adjustments.............................................................. 84 3. Coil Check on Brake...................................................... 84 4. Electromagnetic Brake. Armature and Magnetic Coil........................ 85 Drive Wheel..................................................................... 86 1. Removal.................................................................. 86 2. Installation............................................................. 87 Support/Swivel Wheel............................................................ 88 1. Caster Pivot............................................................. 89 2. Thrust Bearing........................................................... 91 3. Caster Springs........................................................... 92 4. Caster Spring............................................................ 93 5. Caster Stops............................................................. 94 6. Caster Axle.............................................................. 95 7. Caster Brake Assembly.................................................... 96 Tandem Load Wheels.............................................................. 98 1. Replacement.............................................................. 99 Single Load Wheels.............................................................. 100 1. Replacement.............................................................. 101 2. Installation............................................................. 101 Caster Wheels................................................................... 102 1. Removal.................................................................. 103 2. Installation............................................................. 103 Steering Arm/Wheel/Lever........................................................ 104 1. Control Pod.............................................................. 105 2. Steering Wheel........................................................... 106 3. Steering Tach............................................................ 107 Steering Bearing................................................................ 108 1. Removal.................................................................. 109 2. Installation............................................................. 109 Electrical Functions............................................................ 110 1. Operating Description.................................................... 110 2. Ignition Key in the OFF Position......................................... 111 3. Ignition Key in the ON Position.......................................... 111 4. Selection of the Travel Direction........................................ 112 5. Driving.................................................................. 113 6. Steering................................................................. 114 7. Steering Wheel Indicator................................................. 114 8. Braking.................................................................. 115 8.1 Motor Brake (electric).............................................. 115 8.2 Foot Brake.......................................................... 115 8.3 Parking Brake....................................................... 115 9. Fork Lift................................................................ 116 9.1 Maximum Height Switch (optional).................................... 116 9.2 Pulse Counter....................................................... 116 9.3 Fork Lowering....................................................... 116 10. Reach Out............................................................... 117 10.1 Fork Tilt Up/Down.................................................. 117 10.2 Sideshifter........................................................ 117 10.3 Parallel Hydraulic Functions....................................... 117 11. Reach In................................................................ 118 11.1 Height Indication.................................................. 118 11.2 Height Selector.................................................... 118 12. Circuit Diagram 1(11)................................................... 125 13. Circuit Diagram 2(11)................................................... 126 14. Circuit Diagram 3(11)................................................... 127 15. Circuit Diagram 4(11)................................................... 128 16. Circuit Diagram 5(11)................................................... 129 17. Circuit Diagram 6(11)................................................... 130 18. Circuit Diagram 7(11)................................................... 131 19. Circuit Diagram 8(11)................................................... 132 20. Circuit Diagram 9(11)................................................... 133 21. Circuit Diagram 10(11).................................................. 134 22. Circuit Diagram 11(11).................................................. 135 Transistor Regulator............................................................ 136 1. Motor Connections........................................................ 137 2. Safety Control........................................................... 138 Electronic Card................................................................. 140 1. Display.................................................................. 146 2. Time..................................................................... 147 3. Warning Codes............................................................ 148 4. Error Codes.............................................................. 150 5. Parameters............................................................... 151 6. Running Time............................................................. 152 7. Programming Parameters................................................... 153 Pump Motor...................................................................... 156 1. Component Repair......................................................... 157 2. Inspection and Troubleshooting........................................... 159 2.1 Drive End Head...................................................... 159 2.2 Commutator End Head................................................. 159 2.3 Bearings............................................................ 159 2.4 Brush and Commutator................................................ 160 2.5 Armature............................................................ 160 2.6 Frame and Field Assembly............................................ 161 2.7 Assembly............................................................ 163 3. When Changing Brushes.................................................... 164 Hydraulic System................................................................ 166 1. Operation................................................................ 166 1.1 Supply.............................................................. 166 1.2 Lifting............................................................. 166 1.3 Lowering............................................................ 166 1.4 Reach............................................................... 166 1.5 Retract............................................................. 167 1.6 Tilt Up............................................................. 167 1.7 Tilt Down........................................................... 167 1.8 Sideshifting Right.................................................. 167 1.9 Sideshifting Left................................................... 168 2. RRX35/45 Hydraulic Schematic............................................. 170 3. RDR30 Hydraulic Schematic................................................ 171 4. RSC40/50 Hydraulic Schematic............................................. 172 Mast, 3 Stage................................................................... 174 1. Shimming................................................................. 175 1.1 Shimming the Carriage/Reach......................................... 175 1.2 Shimming the Rails.................................................. 176 2. Three Stage Mast......................................................... 180 2.1 Removal............................................................. 180 2.2 Installation........................................................ 180 2.3 Disassembly......................................................... 181 2.4 Assembly............................................................ 182 Reach........................................................................... 186 1. Maintenance.............................................................. 186 2. Reach Repair............................................................. 187 Lift Cylinder, 3 Stage.......................................................... 192 1. Freelift Cylinder Repair................................................. 193 1.1 Removal............................................................. 193 1.2 Disassembly......................................................... 193 1.3 Assembly............................................................ 193 1.4 Installation........................................................ 194 Staging Cylinder, 3 Stage....................................................... 196 1.1 Removal................................................................. 197 1.2 Disassembly............................................................. 197 1.3 Assembly................................................................ 197 1.4 Installation............................................................ 198 Tilt Cylinder................................................................... 200 1. Removal.................................................................. 201 2. Disassembly.............................................................. 201 3. Inspection............................................................... 202 4. Assembly................................................................. 202 5. Installation............................................................. 203 Reach Cylinder.................................................................. 206 1. Removal.................................................................. 207 2. Disassembly.............................................................. 207 3. Inspection............................................................... 208 4. Assembly................................................................. 208 5. Installation............................................................. 209 Load Indicator.................................................................. 212 1. Pulse Sensor............................................................. 213 1.1 Repair.............................................................. 213 1.2 Cable............................................................... 213 1.3 Pulley.............................................................. 213 Height Indication & Preset Height............................................... 214 1. General.................................................................. 215 2. Operation................................................................ 215 3. Preset Height............................................................ 216 4. Display.................................................................. 217 5. Description of the Display Symbols....................................... 218 6. Programming.............................................................. 219 Programming a Level..................................................... 219 Collection Level........................................................ 219 Leaving Level........................................................... 219 Erasing Programmed Levels............................................... 220 Automatic Operations.................................................... 220 Collecting a Load....................................................... 220 Leaving a Load.......................................................... 221 Parameters.............................................................. 222 P1...................................................................... 222 P2...................................................................... 222 P3...................................................................... 223 P5...................................................................... 223 P7...................................................................... 223 P8...................................................................... 224 P9...................................................................... 224 Error Codes............................................................. 227 Back Cover...................................................................... 229 Front Cover..................................................................... 230 BT Standard Codes............................................................... 232 Table of Contents............................................................... 234 Warning Symbols................................................................. 236 1. Warning Levels........................................................... 236 Prohibitory Symbols............................................................. 237 1.1 Ordinance Symbols....................................................... 237 Introduction, Service Manual.................................................... 238 Contents, Section M............................................................. 240 General Product Information..................................................... 242 1. Presentation of the Rider Trucks......................................... 242 1.1 Intended Application of the Trucks.................................. 242 1.2 Forbidden Application of the Truck.................................. 243 1.3 Truck Data.......................................................... 243 1.4 RRX35 Dimensions.................................................... 244 1.5 RRX45 Dimensions.................................................... 245 1.6 RDX30 Dimensions.................................................... 246 1.7 RSX40 Dimensions.................................................... 247 1.8 RSX50 Dimensions.................................................... 248 1.9 Data Plate.......................................................... 249 2. Main Components.......................................................... 250 Inch (SAE) and Metric Fasteners......................................... 252 1. Introduction......................................................... 253 2. Nomenclature, Threads................................................ 253 Strength Identification............................................. 254 Table #1 Bolts and Screws........................................... 255 Table #2 Studs and Nuts............................................. 256 Table #3 Torque Nuts................................................ 257 Table #4 Torque Nuts with Nylon Insert.............................. 258 Table #5 Conversion Table for Metric and English Units.............. 259 Table #6............................................................ 261 Technical Service Data.................................................. 262 Ordering Spare Parts.................................................... 266 Contents, Section P............................................................. 268 Introduction, Maintenance....................................................... 270 4. Safe Jacking Procedure................................................... 270 Service Schedule................................................................ 272 5. Planned Maintenance Procedures........................................... 275 5.1 Services to be Performed Daily or at Each 8 Hour Operating Shift.... 275 5.2 Services to be Performed Monthly or Every 250 Operating Hours....... 277 5.3 Services to be Performed Annually or Every 1200 Operating Hours..... 279 Lubrication Chart............................................................... 282 Oil and Grease Specifications................................................... 284 6. Approved Oils and Grease................................................. 284 Contents, Section S............................................................. 286 Chassis......................................................................... 288 1. General.................................................................. 288 2. Door (#10)............................................................... 289 3. Left Hand Side Panel (#1)................................................ 289 4. Operator Compartment Panel (#2).......................................... 290 5. Main Card Access Panel (#15)............................................. 290 Brake Pedal..................................................................... 292 1. Pedal Removal............................................................ 293 2. Pedal Bearing Replacement................................................ 293 3. Pedal Adjustment......................................................... 294 Drive Motor..................................................................... 296 1. General Information...................................................... 296 2. Operating Conditions..................................................... 296 3. Troubleshooting.......................................................... 297 Table #1................................................................ 298 Table #2................................................................ 301 4. Component Repair......................................................... 305 5. Inspection and Troubleshooting........................................... 307 5.1 Drive End Head...................................................... 307 5.2 Commutator End Head................................................. 307 5.3 Bearings............................................................ 307 5.4 Brush and Commutator................................................ 308 5.5 Armature............................................................ 308 5.6 Frame and Field Assembly............................................ 309 5.7 Assembly............................................................ 311 6. When Changing Brushes.................................................... 312 Electromagnetic Brake........................................................... 314 1. Installation............................................................. 315 2. Adjustments.............................................................. 316 3. Coil Check on Brake...................................................... 316 4. Electromagnetic Brake. Armature and Magnetic Coil....................... 317 Drive Wheel..................................................................... 318 1. Removal.................................................................. 318 2. Installation............................................................. 319 Support/Swivel Wheel............................................................ 320 1. Caster Pivot............................................................. 321 2. Thrust Bearing........................................................... 324 3. Caster Springs........................................................... 326 4. Caster Axle.............................................................. 328 5. Caster Spring............................................................ 329 6. Caster Stops............................................................. 330 7. Caster Brake Assembly.................................................... 331 Tandem Load Wheels.............................................................. 334 1. Replacement.............................................................. 335 Single Load Wheels.............................................................. 336 1. Replacement.............................................................. 337 2. Installation............................................................. 337 Caster Wheels................................................................... 338 1. Removal.................................................................. 339 2. Installation............................................................. 339 Steering Arm/Wheel/Lever........................................................ 340 1. Control Pod.............................................................. 341 2. Steering Wheel........................................................... 342 3. Steering Tach............................................................ 343 Steering Bearing................................................................ 344 1. Removal.................................................................. 345 2. Installation............................................................. 345 Electrical Functions............................................................ 346 1. Operating Description.................................................... 346 2. Start Up................................................................. 348 3. Direction Selection...................................................... 350 4. Reverse Direction Selection.............................................. 352 5. Forward Drive............................................................ 354 6. Plug Braking............................................................. 356 7. Height Indicator and Preset Selector..................................... 362 8. Drive Motor Brush Indicator Switch....................................... 363 9. Pump Motor Brush Indicator Switch........................................ 364 10. Safety Check............................................................ 365 11. Shunt Wire.............................................................. 366 12. Circuit Diagram 1(11)................................................... 373 13. Circuit Diagram 2(11)................................................... 374 14. Circuit Diagram 3(11)................................................... 375 15. Circuit Diagram 4(11)................................................... 376 16. Circuit Diagram 5(11)................................................... 377 17. Circuit Diagram 6(11)................................................... 378 18. Circuit Diagram 7(11)................................................... 379 19. Circuit Diagram 8(11)................................................... 380 20. Circuit Diagram 9(11)................................................... 381 21. Circuit Diagram 10(11).................................................. 382 22. Circuit Diagram 11(11).................................................. 383 Transistor Regulator............................................................ 384 1. Motor Connections........................................................ 385 2. Safety Control........................................................... 386 Electronic Card................................................................. 388 1. Display.................................................................. 394 2. Time..................................................................... 395 3. Warning Codes............................................................ 396 4. Error Codes.............................................................. 398 5. Parameters............................................................... 400 6. Running Time............................................................. 400 7. Programming Parameters................................................... 401 8. Adjustment Procedures for Setting Brake Switch and Brake Transducer...... 403 Pump Motor...................................................................... 404 1. Component Repair......................................................... 405 2. Inspection and Troubleshooting........................................... 407 2.1 Drive End Head...................................................... 407 2.2 Commutator End Head................................................. 407 2.3 Bearings............................................................ 407 2.4 Brush and Commutator................................................ 408 2.5 Armature............................................................ 408 2.6 Frame and Field Assembly............................................ 409 2.7 Assembly............................................................ 411 3. When Changing Brushes.................................................... 412 Hydraulic System................................................................ 414 1. Operation................................................................ 414 1.1 Supply.............................................................. 414 1.2 Lifting............................................................. 414 1.3 Lowering............................................................ 414 1.4 Reach............................................................... 414 1.5 Retract............................................................. 415 1.6 Tilt Up............................................................. 415 1.7 Tilt Down........................................................... 415 1.8 Sideshifting Right.................................................. 415 1.9 Sideshifting Left................................................... 416 2. RRX35/45 Hydraulic Schematic............................................. 418 3. RDX30 Hydraulic Schematic................................................ 419 4. RSX40/50 Hydraulic Schematic............................................. 420 Mast, 3 Stage................................................................... 430 1. Shimming................................................................. 431 1.1 Shimming the Carriage/Reach......................................... 431 1.2 Shimming the Rails.................................................. 432 2. Three Stage Mast......................................................... 436 2.1 Removal............................................................. 436 2.2 Installation........................................................ 437 2.3 Disassembly......................................................... 438 2.4 Assembly............................................................ 439 Sideshifter..................................................................... 442 1. Mounting Instructions.................................................... 443 2. Operation and Maintenance................................................ 444 Reach, Single................................................................... 446 1. Maintenance.............................................................. 446 2. Reach Repair............................................................. 447 Lift Cylinder, 3 Stage.......................................................... 452 1. Freelift Cylinder Repair................................................. 453 1.1 Removal............................................................. 453 1.2 Disassembly......................................................... 453 1.3 Assembly............................................................ 453 1.4 Installation........................................................ 454 Staging Cylinder, 3 Stage....................................................... 456 1.1 Removal................................................................. 457 1.2 Disassembly............................................................. 457 1.3 Assembly................................................................ 457 1.4 Installation............................................................ 458 Tilt Cylinder................................................................... 460 1. Removal.................................................................. 461 2. Disassembly.............................................................. 461 3. Inspection............................................................... 462 4. Assembly................................................................. 462 5. Installation............................................................. 463 Reach Cylinder.................................................................. 472 1. Removal.................................................................. 473 2. Disassembly.............................................................. 473 3. Inspection............................................................... 474 4. Assembly................................................................. 474 5. Installation............................................................. 475 Height Indicator................................................................ 478 1. Pulse Sensor............................................................. 479 1.1 Repair.............................................................. 479 1.2 Cable............................................................... 479 1.3 Pulley.............................................................. 479 Height Indication & Preset Height............................................... 480 1. General.................................................................. 481 2. Operation................................................................ 481 3. Preset Height............................................................ 482 4. Display.................................................................. 483 5. Description of the Display Symbols....................................... 484 6. Programming.............................................................. 485 Programming a Level..................................................... 485 Collection Level........................................................ 485 Leaving Level........................................................... 485 Erasing Programmed Levels............................................... 486 Automatic Operations.................................................... 486 Collecting a Load....................................................... 486 Leaving a Load.......................................................... 487 Parameters.............................................................. 488 P1...................................................................... 488 P2...................................................................... 488 P3...................................................................... 489 P5...................................................................... 489 P7...................................................................... 489 P8...................................................................... 490 P9...................................................................... 490 Back Cover...................................................................... 497 Front Cover..................................................................... 498 BT Standard Codes............................................................... 500 Table of Contents............................................................... 502 Warning Symbols................................................................. 506 1. Warning Levels.......................................................... 506 Prohibitory Symbols............................................................. 507 1. Ordinance Symbols....................................................... 507 Introduction, Service Manual.................................................... 508 Contents, Section M............................................................. 510 General Product Information..................................................... 512 1. Presentation of the Rider Trucks........................................ 512 1.1 Intended Application of the Trucks.................................. 512 1.2 Forbidden Application of the Truck.................................. 513 1.3 Truck Data.......................................................... 513 1.4 RRX35 Dimensions.................................................... 514 1.5 RRX45 Dimensions.................................................... 515 1.6 RDX30 Dimensions.................................................... 516 1.7 RSX40 Dimensions.................................................... 517 1.8 RSX50 Dimensions.................................................... 518 1.9 Data Plate.......................................................... 519 2. Main Components.......................................................... 520 Inch (SAE) and Metric Fasteners................................................. 522 1. Introduction............................................................. 522 2. Nomenclature, Threads.................................................... 523 3. Strength Identification.................................................. 524 Table 1 - Bolt and Screw Designations....................................... 525 Table 2 - Stud and Nut Designations......................................... 526 Table 3 - Torque Nut Designations........................................... 527 Table 4 - Torque Nut with Nylon Insert Designations......................... 528 Table 5 - Fastener Torque Values............................................ 529 4. Conversion of Metric and English Units................................... 530 Technical Service Data.......................................................... 532 Ordering Spare Parts............................................................ 536 Contents, Section P............................................................. 538 Introduction, Maintenance....................................................... 540 1. Safe Jacking Procedure................................................... 540 Service Schedule................................................................ 542 1. Planned Maintenance Schedule............................................. 542 2. Planned Maintenance Procedures........................................... 546 2.1 Services to be Performed Daily or at Each 8 Hour Operating Shift.... 546 2.2 Services to be Performed Monthly or Every 250 Operating Hours....... 548 2.3 Services to be Performed Annually or Every 1200 Operating Hours..... 550 Lubrication Chart............................................................... 552 Oil and Grease Specifications................................................... 554 1. Approved Oils and Grease................................................. 554 Contents, Section S............................................................. 556 Chassis......................................................................... 558 1. General.................................................................. 558 2. Door..................................................................... 559 3. Left-Hand Side Panel..................................................... 560 4. Operator Compartment Panel............................................... 560 5. Main Card Access Panel................................................... 561 Brake Pedal..................................................................... 562 1. Pedal Removal............................................................ 563 2. Pedal Bearing Replacement................................................ 564 3. Pedal Adjustment......................................................... 564 Drive Motor..................................................................... 566 1. General Information...................................................... 566 2. Operating Conditions..................................................... 566 3. Troubleshooting.......................................................... 567 Drive Motor..................................................................... 574 1. Disassembly.............................................................. 576 2. Inspection and Troubleshooting........................................... 577 2.1 Drive End Head...................................................... 577 2.2 Commutator End Head................................................. 577 2.3 Bearings............................................................ 577 2.4 Brush and Commutator................................................ 578 2.5 Armature............................................................ 578 2.6 Frame and Field Assembly............................................ 579 2.7 Assembly............................................................ 581 3. When Changing Brushes.................................................... 582 Caster Brake Assembly........................................................... 584 1. Removal.................................................................. 585 Electromagnetic Brake........................................................... 588 1. Installation............................................................. 589 2. Adjustments.............................................................. 590 3. Coil Check on Brake...................................................... 590 4. Electromagnetic Brake, Armature and Magnetic Coil........................ 591 Drive Wheel..................................................................... 592 1. Removal.................................................................. 592 2. Installation............................................................. 593 Support/Swivel Wheel............................................................ 594 1. Caster Pivot............................................................. 595 2. Thrust Bearing........................................................... 598 3. Caster Springs........................................................... 600 4. Caster Axle.............................................................. 602 5. Caster Spring............................................................ 603 6. Caster Stops............................................................. 604 Tandem Load Wheels.............................................................. 606 1. Removal.................................................................. 607 Single Load Wheels.............................................................. 608 1. Removal.................................................................. 609 2. Installation............................................................. 609 Caster Wheels................................................................... 610 1. Removal.................................................................. 611 2. Installation............................................................. 611 Steering Arm/Wheel/Lever........................................................ 616 1. Control Pod.............................................................. 617 2. Steering Wheel........................................................... 618 3. Steering Tach............................................................ 619 Steering Bearing................................................................ 620 1. Removal.................................................................. 621 2. Installation............................................................. 621 Electrical Functions............................................................ 622 1. Operating Description.................................................... 622 2. Start Up................................................................. 624 3. Direction Selection...................................................... 626 4. Reverse Direction Selection.............................................. 628 5. Forward Drive............................................................ 630 6. Plug Braking............................................................. 632 7. Steering Components...................................................... 634 8. 12 Volt Power Supply..................................................... 635 9. Driving Speed Reduction Switch........................................... 636 10. Height Indicator and Preset Selector.................................... 638 11. Drive Motor Brush Indicator Switch...................................... 639 12. Pump Motor Brush Indicator Switch....................................... 640 13. Safety Check............................................................ 641 14. Shunt Wire.............................................................. 642 Component Location.......................................................... 647 Diagrams.................................................................... 649 Transistor Regulator............................................................ 660 1. Motor Connections........................................................ 661 2. Safety Control........................................................... 662 Electronic Card................................................................. 664 1. Display.................................................................. 670 2. Time..................................................................... 671 3. Warning Codes............................................................ 672 4. Error Codes.............................................................. 674 5. Effect on the Truck...................................................... 676 6. Parameters............................................................... 676 7. Running Time............................................................. 676 8. Programming Parameters................................................... 677 9. Adjustment Procedures for Setting Brake Switch and Brake Transducer...... 679 Pump Motor...................................................................... 680 1. Component Repair......................................................... 681 2. Inspection and Troubleshooting........................................... 683 3. When Changing Brushes.................................................... 688 Hydraulic System................................................................ 690 1. Operation................................................................ 690 2. RRX35/45 Hydraulic Schematic............................................. 694 3. RDX30 Hydraulic Schematic................................................ 701 4. RSX40/50 Hydraulic Schematic............................................. 702 Mast, 3 Stage................................................................... 704 1. Shimming Mast on Truck................................................... 705 2. Three Stage Mast......................................................... 710 Sideshifter..................................................................... 716 1. Mounting Instructions.................................................... 718 2. Operation and Maintenance................................................ 719 Reach, Single................................................................... 722 1. Maintenance.............................................................. 722 2. Reach Repair............................................................. 724 Freelift Cylinder, 3 Stage...................................................... 728 1. Freelift Cylinder Repair................................................. 729 Staging Cylinder, 3 Stage....................................................... 732 Tilt Cylinder................................................................... 736 1. Removal.................................................................. 737 2. Disassembly.............................................................. 737 3. Inspection............................................................... 738 4. Assembly................................................................. 738 5. Installation............................................................. 739 Reach Cylinder.................................................................. 748 1. Removal.................................................................. 749 2. Disassembly.............................................................. 750 3. Inspection............................................................... 751 4. Assembly................................................................. 752 5. Installation............................................................. 753 Height Indicator................................................................ 754 1. Pulse Sensor............................................................. 755 Height Indication & Preset Height............................................... 756 1. General.................................................................. 757 2. Operation................................................................ 757 3. Preset Height............................................................ 758 4. Display.................................................................. 759 5. Description of the Display Symbols....................................... 760 6. Programming.............................................................. 761 Back Cover...................................................................... 771 Front Cover..................................................................... 772 BT Standard Codes............................................................... 774 Worksheet standard.......................................................... 774 C-Code List................................................................. 774 Warning Symbols................................................................. 782 1. Warning Levels........................................................... 782 DANGER.................................................................. 782 WARNING................................................................. 782 CAUTION................................................................. 782 NOTE!................................................................... 782 Prohibitory Symbols............................................................. 783 NO SMOKING.................................................................. 783 OPEN FLAMES PROHIBITED...................................................... 783 GENERAL PROHIBITION......................................................... 783 1. Ordinance Symbols........................................................ 783 SAFETY SHOES............................................................ 783 PROTECTIVE GLASSES...................................................... 783 Introduction, Service Manual.................................................... 784 Contents, Section M............................................................. 786 1. Machine Information...................................................... 786 General Product Information..................................................... 788 1. Presentation of the Rider Trucks RRX35/45, RDX3.......................... 788 1.1. Intended Application of the Trucks................................. 788 1.2. Forbidden Application of the Truck................................. 789 1.3. Truck Data......................................................... 789 1.4. RRX35 Dimensions................................................... 790 1.5. RRX45 Dimensions................................................... 791 1.6. RDX30 Dimensions................................................... 792 1.7. RSX40 Dimensions................................................... 793 1.8. RSX50 Dimensions................................................... 794 1.9. Data Plate......................................................... 795 Legend.............................................................. 795 1 Truck model number............................................ 795 2 Truck serial number........................................... 795 3 Weight less battery........................................... 795 4 Maximum battery weight........................................ 795 5 Minimum battery weight........................................ 795 6 Truck voltage DC.............................................. 795 7 Battery type UL class......................................... 795 8 Battery maximum AMP hours..................................... 795 9 Truck type.................................................... 795 10 Mast serial number........................................... 795 11 Attachment................................................... 795 12 Maximum degree rear tilt..................................... 795 13 Truck capacity............................................... 795 2. Main Components.......................................................... 796 1 Hydraulic valve:...................................................... 796 2 Battery:.............................................................. 796 3 Battery connector:.................................................... 796 4 Hydraulic unit:....................................................... 796 5 Drive unit with brake:................................................ 796 6 Electrical steering:.................................................. 796 7 Data plate:........................................................... 796 8 Cover:................................................................ 796 9 Pedal:................................................................ 796 10 Control console:..................................................... 796 11 Instrument panel:.................................................... 796 12 Mast:................................................................ 796 13 Electronics:......................................................... 796 14 Control circuit fuse:................................................ 797 15 Steering circuit fuse:............................................... 797 16 Drive motor fuse:.................................................... 797 17 Pump motor fuse:..................................................... 797 18 Right foot pedal..................................................... 797 19 Emergency stop....................................................... 797 Main Components of Truck................................................ 797 3. Grease Point Location.................................................... 798 4. Mast Adjustment Points................................................... 799 Inch (SAE) and Metric Fasteners................................................. 800 1. Introduction............................................................. 800 2. Nomenclature, Threads.................................................... 801 3. Strength Identification.................................................. 802 4. Conversion of Metric and English Units................................... 808 Technical Service Data.......................................................... 810 Ordering Spare Parts............................................................ 814 1. Locate the fault on the truck............................................ 814 2. Find out the machine model and serial number............................. 814 3. Locate the page with the exploded diagram and f.......................... 814 4. Locate the position number in the table. Select.......................... 814 5. Note the part number..................................................... 814 6. Call the local BT dealer and state the part num.......................... 814 Contents, Section P............................................................. 816 1. Planned Maintenance...................................................... 816 Introduction, Maintenance....................................................... 818 1. Safe Jacking Procedure................................................... 818 Service Schedule................................................................ 820 1. Planned Maintenance Schedule............................................. 820 ITEM.................................................................... 820 WORK REQUIRED........................................................... 820 Interval in Hours................................................... 820 5................................................................... 820 25.................................................................. 820 100................................................................. 820 250................................................................. 820 300................................................................. 820 600................................................................. 820 1200................................................................ 820 3600................................................................ 820 Interval in Days/Weeks/Months....................................... 820 1 d................................................................. 820 1w.................................................................. 820 1 m................................................................. 820 2 m................................................................. 820 3 m................................................................. 820 6 m................................................................. 820 12 m................................................................ 820 36 m................................................................ 820 2. Planned Maintenance Procedures........................................... 823 2.1. Services to be performed daily or at each 8 h...................... 823 2.1.1. Battery Discharge Indicator with slow down................... 823 2.1.2. Hydraulic System............................................. 823 2.1.3. Frame/Sheet Metal............................................ 824 2.1.4. Wheels/Tires................................................. 824 2.1.5. Functions/Operations......................................... 824 2.2. Services to be performed monthly or every 250...................... 824 2.2.1. Inspection................................................... 824 2.2.2. Transmission................................................. 824 2.2.3. Brakes....................................................... 824 2.2.4. Battery...................................................... 824 2.2.5. Electrical Connections....................................... 825 2.2.6. Contactor Tips (NOT Sealed).................................. 825 2.2.7. Motor Brushes................................................ 825 2.2.8. Drive Motor.................................................. 825 2.2.9. Hydraulic Reservoir.......................................... 826 2.2.10. Frame Lube (“Lubrication Chart” on page55.................. 826 2.2.11. Pivot Points................................................ 826 2.3. Services to be performed annually or every 12...................... 826 2.3.1. Inspection................................................... 826 2.3.2. Transmission................................................. 826 2.3.3. Battery...................................................... 827 2.3.4. Hydraulic System............................................. 827 2.3.5. Brakes....................................................... 827 2.3.6. Lift and Carriage Chains..................................... 827 Lubrication Chart............................................................... 830 Pos. No..................................................................... 830 Service Point............................................................... 830 Interval/Running Hours...................................................... 830 Lubricant (See Chart in Section 6 for Code)................................. 830 300 h................................................................... 830 600 h................................................................... 830 1200 h.................................................................. 830 Truck Lubrication Points............................................ 830 Oil and Grease Specifications................................................... 832 1. Approved Oils and Grease................................................. 832 Lubricant............................................................... 832 Specification........................................................... 832 Application area........................................................ 832 >14 F(-10 C)............................................................ 832 <14 F(-10 C)............................................................ 832 <-13 F(-25 C)........................................................... 832 Contents, Section S............................................................. 834 1. Service Instructions..................................................... 834 Chassis......................................................................... 836 1. General.................................................................. 836 Removal/Installation of Chassis Panels & Covers......................... 836 2. Door..................................................................... 837 2.1. Removal............................................................ 837 2.2. Installation....................................................... 837 3. Left-Hand Side Panel..................................................... 838 3.1. Removal............................................................ 838 4. Operator Compartment Panel............................................... 838 4.1. Removal............................................................ 838 5. Main Card Access Panel................................................... 839 5.1. Removal............................................................ 839 Brake Pedal..................................................................... 840 1. Pedal Removal............................................................ 841 2. Pedal Bearing Replacement................................................ 842 3. Pedal Adjustment......................................................... 842 Drive Motor..................................................................... 844 1. General Information...................................................... 844 2. Operating Conditions..................................................... 844 3. Troubleshooting.......................................................... 845 TABLE 1................................................................. 846 TABLE 1. Continued...................................................... 847 TABLE 1. Continued...................................................... 848 TABLE 2................................................................. 849 Primary Sources of Unsatisfactory Brush Performanc...................... 849 20. Poor preparation of commutator surface.......................... 849 21. High mica....................................................... 849 22. Feather-edge mica............................................... 849 23. Bar edges not chamfered after undercutting...................... 849 24. Need for periodic cleaning...................................... 849 25. Clogged ventilating ducts....................................... 849 26. Brushes in wrong position....................................... 849 27. Unequal brush spacing........................................... 849 28. Poor alignment of brush holders................................. 849 29. Incorrect brush angle........................................... 849 30. Incorrect spring tension........................................ 849 31. Interpoles improperly adjusted.................................. 849 32. Series field improperly adjusted................................ 849 33. Brushes tight in holders........................................ 849 34. Brushes too loose in holders.................................... 849 35. Brush holders loose at mounting................................. 849 36. Commutator loose................................................ 849 37. Loose pole pieces or pole-face shoes............................ 849 38. Loose or worn bearings.......................................... 849 39. Unequal air gaps................................................ 849 40. Unequal pole spacing............................................ 849 41. Dynamic unbalance............................................... 849 42. Variable angular velocity....................................... 849 43. Commutator too small............................................ 849 44. Open or high resistance connection at commutat.................. 849 45. Poor connection at shunt terminal............................... 849 46. Short circuit in field or armature winding...................... 849 47. Ground in field or armature winding............................. 849 48. Reversed polarity on main pole or interpole..................... 849 TABLE 2. Continued...................................................... 850 49. Commutating zone too narrow..................................... 850 50. Commutating zone too wide....................................... 850 51. Brushes too thin................................................ 850 52. Brushes too thick............................................... 850 53. Magnetic saturation of interpoles............................... 850 54. High bar-to-bar voltage......................................... 850 55. High ratio of brush contact to commutator surf.................. 850 56. Insufficient cross connection of armature coil.................. 850 57. Overload........................................................ 850 58. Rapid change of load............................................ 850 59. Reversing operation of non-interpole machine.................... 850 60. Plugging........................................................ 850 61. Dynamic braking................................................. 850 62. Low average current density in brushes.......................... 850 63. Contaminated atmosphere......................................... 850 64. “Contact poisons”............................................... 850 65. Oil on commutator or oil mist in air............................ 850 66. Abrasive dust in air............................................ 850 67. Humidity too high............................................... 850 68. Humidity too low................................................ 850 69. Silicone contamination.......................................... 850 70. Loose or unstable foundation.................................... 850 71. External source of vibration.................................... 850 72. External short circuit or very heavy load surg.................. 850 73. “Commutation factor” too high................................... 850 74. “Commutation factor” too low.................................... 850 75. Contact drop of brushes too high................................ 850 76. Contact drop of brushes too low................................. 850 77. Coefficient of friction too high................................ 850 78. Lack of film forming properties in brush........................ 850 79. Lack of polishing action in brush............................... 850 80. Brushes too abrasive............................................ 850 81. Lack of carrying capacity....................................... 850 Drive Motor..................................................................... 852 1. Disassembly.............................................................. 854 2. Inspection and Troubleshooting........................................... 855 2.1. Drive End Head..................................................... 855 2.2. Commutator End Head................................................ 855 2.3. Bearings........................................................... 855 2.4. Brush and Commutator............................................... 856 2.5. Armature........................................................... 856 2.6. Frame and Field Assembly........................................... 857 2.6.1. Testing...................................................... 857 2.6.2. Frame and Field Service Notes................................ 858 2.7. Assembly........................................................... 859 2.7.1. Field Coil Installation...................................... 859 2.7.2. Bearing Installation......................................... 859 2.7.3. After Assembly............................................... 860 3. When Changing Brushes.................................................... 860 Caster Brake Assembly........................................................... 862 1. Removal.................................................................. 863 1.1. Caster Brake Adjustment............................................ 863 Electromagnetic Brake........................................................... 866 1. Installation............................................................. 867 2. Adjustments.............................................................. 868 3. Coil Check On Brake...................................................... 868 4. Electromagnetic Brake, Armature and Magnetic Co.......................... 869 4.1. Removal............................................................ 869 4.2. Installation....................................................... 869 Drive Wheel..................................................................... 870 1. Removal.................................................................. 870 2. Installation............................................................. 871 Support / Swivel Wheel.......................................................... 872 1. Caster Pivot............................................................. 873 1.1. Removal............................................................ 873 1.2. Installation....................................................... 875 2. Thrust Bearing........................................................... 876 2.1. Removal............................................................ 876 2.2. Installation....................................................... 877 3. Caster Springs........................................................... 878 3.1. Removal............................................................ 878 3.2. Installation....................................................... 879 4. Caster Spring............................................................ 880 4.1. Adjustments........................................................ 880 5. Caster Stops............................................................. 881 5.1. Adjustment......................................................... 881 Tandem Load Wheels.............................................................. 884 1. Removal.................................................................. 885 Single Load Wheels.............................................................. 886 1. Removal.................................................................. 887 2. Installation............................................................. 887 Caster Wheels................................................................... 888 1. Removal.................................................................. 889 2. Installation............................................................. 889 3. Caster Axle.............................................................. 890 3.1. Removal............................................................ 890 3.2. Installation....................................................... 890 Caster Wheels................................................................... 892 1. Removal.................................................................. 893 2. Installation............................................................. 894 3. Caster Axle.............................................................. 895 3.1. Removal............................................................ 895 3.2. Installation....................................................... 895 Steering Arm / Wheel / Lever.................................................... 896 1. Control Pod.............................................................. 897 1.1. Removal............................................................ 897 1.2. Installation....................................................... 897 2. Steering Wheel........................................................... 898 2.1. Removal............................................................ 898 2.2. Installation....................................................... 898 3. Steering Tach............................................................ 899 3.1. Removal............................................................ 899 3.2. Installation....................................................... 899 Steering Bearing................................................................ 900 1. Removal.................................................................. 901 2. Installation............................................................. 901 Electrical Functions............................................................ 902 1. Operating Description.................................................... 902 2. Start Up................................................................. 904 3. Direction Selection...................................................... 906 4. Reverse Direction Selection.............................................. 908 5. Forward Drive............................................................ 910 6. Plug Braking............................................................. 912 7. Steering Componets....................................................... 914 8. 12-Volt Power Supply..................................................... 915 9. Driving speed reduction switch........................................... 916 10. Height Indicator and Preset Selector.................................... 918 10.1. Height Indicator.................................................. 918 10.2. Height Preset Selector............................................ 918 11. Drive Motor Brush Indicator Switch...................................... 919 12. Pump Motor Brush Indicator Switch....................................... 920 13. Safety Check............................................................ 921 14. Shunt Wire.............................................................. 922 Component Location (Figure 1 of 2)...................................... 927 15. Circuit Diagram 1(11)................................................... 929 16. Circuit Diagram 2(11)................................................... 930 17. Circuit Diagram 3(11)................................................... 931 18. Circuit Diagram 4(11)................................................... 932 19. Circuit Diagram 5(11)................................................... 933 20. Circuit Diagram 6(11)................................................... 934 21. Circuit Diagram 7(11)................................................... 935 22. Circuit Diagram 8(11)................................................... 936 23. Circuit Diagram 9(11)................................................... 937 24. Circuit Diagram 10(11).................................................. 938 25. Circuit Diagram 11(11).................................................. 939 Transistor Regulator............................................................ 940 1. Motor Connections........................................................ 941 1.1. Connections for controls........................................... 941 2. Safety Control........................................................... 942 2.1. Checking Transistor Regulator’s Safety Circui...................... 942 Electronic Card................................................................. 944 1. Display.................................................................. 950 2. Time..................................................................... 951 3. Warning Codes............................................................ 952 4. Error Codes.............................................................. 954 5. Effect on the Truck...................................................... 956 6. Parameters............................................................... 956 7. Running time............................................................. 956 8. Programming Parameters................................................... 957 9. Adjustment Procedures for Setting Brake Switch .......................... 960 Pump Motor...................................................................... 962 1. Component Repair......................................................... 963 1.1. Motor Disassembly.................................................. 963 2. Inspection and Troubleshooting........................................... 965 2.1. Drive End Head..................................................... 965 2.2. Commutator End Head................................................ 965 2.3. Bearings........................................................... 965 2.4. Brush and Commutator............................................... 966 2.5. Armature........................................................... 966 2.6. Frame and Field Assembly........................................... 967 2.6.1. Testing...................................................... 967 2.6.2. Frame and Field Service Notes................................ 968 2.7. Assembly........................................................... 969 2.7.1. Field Coil Installation...................................... 969 2.7.2. Bearing Installation......................................... 969 2.7.3. After Assembly............................................... 970 3. When Changing Brushes.................................................... 970 Hydraulic System................................................................ 972 Valid from machine number: 27091001 to 27135000............................. 972 1. Operation................................................................ 972 1.1. Supply............................................................. 972 1.2. Lifting............................................................ 972 1.3. Lowering........................................................... 972 1.4. Reach.............................................................. 972 1.5. Retract............................................................ 973 1.6. Tilt Up............................................................ 973 1.7. Tilt Down.......................................................... 973 1.8. Sideshifting Right................................................. 974 1.9. Sideshifting Left.................................................. 974 2. RRX35/45 Hydraulic Schematic............................................. 976 Hydraulic System................................................................ 978 Valid from machine number: 27135001 and UP.................................. 978 1. Operation................................................................ 978 1.1. Supply............................................................. 978 1.2. Lifting............................................................ 978 1.3. Lowering........................................................... 979 1.4. Reach.............................................................. 979 1.5. Retract............................................................ 979 1.6. Tilt Up............................................................ 979 1.7. Tilt Down.......................................................... 980 1.8. Sideshifting Right................................................. 980 1.9. Sideshifting Left.................................................. 980 2. RRX35/45 Hydraulic Schematic............................................. 982 3. RDX30 Hydraulic Schematic................................................ 983 4. RSX40/50 Hydraulic Schematic............................................. 984 Mast, 3 Stage................................................................... 986 1. Shimming Mast on Truck................................................... 987 1.1. Shimming the Carriage/Reach........................................ 987 1.2. Shimming the Rails................................................. 988 2. Three Stage Mast......................................................... 992 2.1. Removal............................................................ 992 2.2. Installation....................................................... 993 2.3. Disassembly........................................................ 994 2.4. Assembly........................................................... 995 Sideshifter..................................................................... 998 1. Mounting Instructions....................................................1000 1.1. Installation.......................................................1000 1. Remove lower hooks (8) from sideshifter assembl..................1000 2. Lift sideshifter onto the truck’s carriage whil..................1000 3. Make sure the centering lug (X) on the cylinder..................1000 4. Remount the lower hooks (8) with a minimum clea..................1000 5. Secure the lower hook (8) in place by tightenin..................1000 6. Connect the hydraulic fittings (4) to the sides..................1000 2. Operation and Maintenance................................................1001 Every 1000 hours:.......................................................1001 1. Inspect hydraulic hoses for wear.................................1001 2. Inspect the cylinder (15) and fittings (4) for ..................1001 3. Clean the lower slides (6) and truck carriage l..................1001 4. Inspect and adjust the lower hooks (8) for the ..................1001 5. Check the torque on the lower hook mounting bol..................1001 2.1. Lower Slides.......................................................1002 1. The original thickness of a lower slide is appr..................1002 2. Replace the lower slide if contamination is pre..................1002 2.2. Upper Slides.......................................................1002 1. The original thickness of upper slide (1) is ap..................1002 2. Replace the upper slides (1) if there is an una..................1002 3. When replacing the upper slides (1), always rep..................1002 2.3. Cylinder...........................................................1002 1. The hydraulic cylinder (15) is basically a non-..................1002 2. If the cylinder rod becomes scored, a minimal a..................1003 Reach, Single...................................................................1004 1. Maintenance..............................................................1004 2. Reach Repair.............................................................1006 2.1. Disassembly........................................................1006 2.1.1. Front Frame Removal..........................................1006 2.1.2. Outer Arm Removal............................................1006 2.1.3. Inner Arm Removal............................................1006 2.1.4. Rear Frame Removal...........................................1007 2.1.5. Reach Cylinder Removal.......................................1007 2.2. Assembly...........................................................1008 2.2.1. Reach Cylinder Installation..................................1008 2.2.2. Rear Frame Installation......................................1008 2.2.3. Inner Arm Installation.......................................1008 2.2.4. Outer Arm Installation.......................................1009 Freelift Cylinder, 3 Stage......................................................1010 1. Freelift Cylinder Repair.................................................1011 1.1. Removal............................................................1011 1.2. Disassembly........................................................1012 1.3. Assembly...........................................................1012 1.4. Installation.......................................................1012 Staging Cylinder, 3 Stage.......................................................1014 1.1. Removal................................................................1015 1.2. Disassembly............................................................1015 1.3. Assembly...............................................................1015 1.4. Installation...........................................................1016 Tilt Cylinder...................................................................1018 1. Removal..................................................................1019 2. Disassembly..............................................................1019 3. Inspection...............................................................1020 4. Assembly.................................................................1020 5. Installation.............................................................1021 Tilt Cylinder...................................................................1024 1. Removal..................................................................1025 2. Disassembly..............................................................1026 3. Inspection...............................................................1027 4. Assembly.................................................................1027 5. Installation.............................................................1029 Reach Cylinder..................................................................1030 1. Removal..................................................................1031 2. Disassembly..............................................................1032 3. Inspection...............................................................1033 4. Assembly.................................................................1034 5. Installation.............................................................1035 Height Indicator................................................................1036 1. Pulse sensor.............................................................1037 1.1. Repair.............................................................1037 1.2. Cable..............................................................1037 1.2.1. Removal......................................................1037 1.2.2. Installation.................................................1037 1.3. Pulley.............................................................1037 1.3.1. Removal......................................................1037 Height Indication & Preset Height...............................................1038 1. General..................................................................1039 2. Operation................................................................1039 3. Preset Height............................................................1040 4. Display..................................................................1041 5. Description of the display symbols.......................................1042 6. Programming..............................................................1043 6.1. Programming a Level................................................1043 6.1.1. Collection Level.............................................1043 6.1.2. Leaving Level................................................1043 6.2. Erasing Programmed Levels..........................................1044 6.2.1. Automatic Operations.........................................1044 6.2.2. Collecting a Load............................................1044 6.2.3. Leaving a Load...............................................1045 6.3. Parameters.........................................................1046 P1..................................................................1046 P2..................................................................1046 P3..................................................................1047 P5..................................................................1047 P7..................................................................1047 P8..................................................................1048 P9..................................................................1048 Back Cover......................................................................1053 Front Cover.....................................................................1054 BT Standard Codes...............................................................1056 Worksheet standard..........................................................1056 C-Code List.................................................................1056 Warning Symbols.................................................................1064 1. Warning Levels...........................................................1064 DANGER..................................................................1064 WARNING.................................................................1064 CAUTION.................................................................1064 NOTE!...................................................................1064 Prohibitory Symbols.............................................................1065 NO SMOKING..................................................................1065 OPEN FLAMES PROHIBITED......................................................1065 GENERAL PROHIBITION.........................................................1065 1. Ordinance Symbols........................................................1065 SAFETY SHOES............................................................1065 PROTECTIVE GLASSES......................................................1065 Introduction, Service Manual....................................................1066 Contents, Section M.............................................................1068 1. Machine Information......................................................1068 General Product Information.....................................................1070 1. Presentation of the Rider Trucks RRX35/45, RDX3..........................1070 1.1. Intended Application of the Trucks.................................1070 1.2. Forbidden Application of the Truck.................................1071 1.3. Truck Data.........................................................1071 1.4. RRX35 Dimensions...................................................1072 1.5. RRX45 Dimensions...................................................1073 1.6. RDX30 Dimensions...................................................1074 1.7. RSX40 Dimensions...................................................1075 1.8. RSX50 Dimensions...................................................1076 1.9. Data Plate.........................................................1077 Legend..............................................................1077 1 Truck model number............................................1077 2 Truck serial number...........................................1077 3 Weight less battery...........................................1077 4 Maximum battery weight........................................1077 5 Minimum battery weight........................................1077 6 Truck voltage DC..............................................1077 7 Battery type UL class.........................................1077 8 Battery maximum AMP hours.....................................1077 9 Truck type....................................................1077 10 Mast serial number...........................................1077 11 Attachment...................................................1077 12 Maximum degree rear tilt.....................................1077 13 Truck capacity...............................................1077 2. Main Components..........................................................1078 1 Hydraulic valve:......................................................1078 2 Battery:..............................................................1078 3 Battery connector:....................................................1078 4 Hydraulic unit:.......................................................1078 5 Drive unit with brake:................................................1078 6 Electrical steering:..................................................1078 7 Data plate:...........................................................1078 8 Cover:................................................................1078 9 Pedal:................................................................1078 10 Control console:.....................................................1078 11 Instrument panel:....................................................1078 12 Mast:................................................................1078 13 Electronics:.........................................................1078 14 Control circuit fuse:................................................1079 15 Steering circuit fuse:...............................................1079 16 Drive motor fuse:....................................................1079 17 Pump motor fuse:.....................................................1079 18 Right foot pedal.....................................................1079 19 Emergency stop.......................................................1079 Main Components of Truck................................................1079 3. Grease Point Location....................................................1080 4. Mast Adjustment Points...................................................1081 Inch (SAE) and Metric Fasteners.................................................1082 1. Introduction.............................................................1082 2. Nomenclature, Threads....................................................1083 3. Strength Identification..................................................1084 4. Conversion of Metric and English Units...................................1090 Technical Service Data..........................................................1092 Ordering Spare Parts............................................................1096 1. Locate the fault on the truck............................................1096 2. Find out the machine model and serial number.............................1096 3. Locate the page with the exploded diagram and f..........................1096 4. Locate the position number in the table. Select..........................1096 5. Note the part number.....................................................1096 6. Call the local BT dealer and state the part num..........................1096 Contents, Section P.............................................................1098 1. Planned Maintenance......................................................1098 Introduction, Maintenance.......................................................1100 1. Safe Jacking Procedure...................................................1100 Service Schedule................................................................1102 1. Planned Maintenance Schedule.............................................1102 ITEM....................................................................1102 WORK REQUIRED...........................................................1102 Interval in Hours...................................................1102 5...................................................................1102 25..................................................................1102 100.................................................................1102 250.................................................................1102 300.................................................................1102 600.................................................................1102 1200................................................................1102 3600................................................................1102 Interval in Days/Weeks/Months.......................................1102 1 d.................................................................1102 1w..................................................................1102 1 m.................................................................1102 2 m.................................................................1102 3 m.................................................................1102 6 m.................................................................1102 12 m................................................................1102 36 m................................................................1102 2. Planned Maintenance Procedures...........................................1105 2.1. Services to be performed daily or at each 8 h......................1105 2.1.1. Battery Discharge Indicator with slow down...................1105 2.1.2. Hydraulic System.............................................1105 2.1.3. Frame/Sheet Metal............................................1106 2.1.4. Wheels/Tires.................................................1106 2.1.5. Functions/Operations.........................................1106 2.2. Services to be performed monthly or every 250......................1106 2.2.1. Inspection...................................................1106 2.2.2. Transmission.................................................1106 2.2.3. Brakes.......................................................1106 2.2.4. Battery......................................................1106 2.2.5. Electrical Connections.......................................1107 2.2.6. Contactor Tips (NOT Sealed)..................................1107 2.2.7. Motor Brushes................................................1107 2.2.8. Drive Motor..................................................1107 2.2.9. Hydraulic Reservoir..........................................1108 2.2.10. Frame Lube (“Lubrication Chart” on page55..................1108 2.2.11. Pivot Points................................................1108 2.3. Services to be performed annually or every 12......................1108 2.3.1. Inspection...................................................1108 2.3.2. Transmission.................................................1108 2.3.3. Battery......................................................1109 2.3.4. Hydraulic System.............................................1109 2.3.5. Brakes.......................................................1109 2.3.6. Lift and Carriage Chains.....................................1109 Lubrication Chart...............................................................1112 Pos. No.....................................................................1112 Service Point...............................................................1112 Interval/Running Hours......................................................1112 Lubricant (See Chart in Section 6 for Code).................................1112 300 h...................................................................1112 600 h...................................................................1112 1200 h..................................................................1112 Truck Lubrication Points............................................1112 Oil and Grease Specifications...................................................1114 1. Approved Oils and Grease.................................................1114 Lubricant...............................................................1114 Specification...........................................................1114 Application area........................................................1114 >14 F(-10 C)............................................................1114 <14 F(-10 C)............................................................1114 <-13 F(-25 C)...........................................................1114 Contents, Section S.............................................................1116 1. Service Instructions.....................................................1116 Chassis.........................................................................1118 1. General..................................................................1118 Removal/Installation of Chassis Panels & Covers.........................1118 2. Door.....................................................................1119 2.1. Removal............................................................1119 2.2. Installation.......................................................1119 3. Left-Hand Side Panel.....................................................1120 3.1. Removal............................................................1120 4. Operator Compartment Panel...............................................1120 4.1. Removal............................................................1120 5. Main Card Access Panel...................................................1121 5.1. Removal............................................................1121 Brake Pedal.....................................................................1122 1. Pedal Removal............................................................1123 2. Pedal Bearing Replacement................................................1124 3. Pedal Adjustment.........................................................1124 Drive Motor.....................................................................1126 1. General Information......................................................1126 2. Operating Conditions.....................................................1126 3. Troubleshooting..........................................................1127 TABLE 1.................................................................1128 TABLE 1. Continued......................................................1129 TABLE 1. Continued......................................................1130 TABLE 2.................................................................1131 Primary Sources of Unsatisfactory Brush Performanc......................1131 20. Poor preparation of commutator surface..........................1131 21. High mica.......................................................1131 22. Feather-edge mica...............................................1131 23. Bar edges not chamfered after undercutting......................1131 24. Need for periodic cleaning......................................1131 25. Clogged ventilating ducts.......................................1131 26. Brushes in wrong position.......................................1131 27. Unequal brush spacing...........................................1131 28. Poor alignment of brush holders.................................1131 29. Incorrect brush angle...........................................1131 30. Incorrect spring tension........................................1131 31. Interpoles improperly adjusted..................................1131 32. Series field improperly adjusted................................1131 33. Brushes tight in holders........................................1131 34. Brushes too loose in holders....................................1131 35. Brush holders loose at mounting.................................1131 36. Commutator loose................................................1131 37. Loose pole pieces or pole-face shoes............................1131 38. Loose or worn bearings..........................................1131 39. Unequal air gaps................................................1131 40. Unequal pole spacing............................................1131 41. Dynamic unbalance...............................................1131 42. Variable angular velocity.......................................1131 43. Commutator too small............................................1131 44. Open or high resistance connection at commutat..................1131 45. Poor connection at shunt terminal...............................1131 46. Short circuit in field or armature winding......................1131 47. Ground in field or armature winding.............................1131 48. Reversed polarity on main pole or interpole.....................1131 TABLE 2. Continued......................................................1132 49. Commutating zone too narrow.....................................1132 50. Commutating zone too wide.......................................1132 51. Brushes too thin................................................1132 52. Brushes too thick...............................................1132 53. Magnetic saturation of interpoles...............................1132 54. High bar-to-bar voltage.........................................1132 55. High ratio of brush contact to commutator surf..................1132 56. Insufficient cross connection of armature coil..................1132 57. Overload........................................................1132 58. Rapid change of load............................................1132 59. Reversing operation of non-interpole machine....................1132 60. Plugging........................................................1132 61. Dynamic braking.................................................1132 62. Low average current density in brushes..........................1132 63. Contaminated atmosphere.........................................1132 64. “Contact poisons”...............................................1132 65. Oil on commutator or oil mist in air............................1132 66. Abrasive dust in air............................................1132 67. Humidity too high...............................................1132 68. Humidity too low................................................1132 69. Silicone contamination..........................................1132 70. Loose or unstable foundation....................................1132 71. External source of vibration....................................1132 72. External short circuit or very heavy load surg..................1132 73. “Commutation factor” too high...................................1132 74. “Commutation factor” too low....................................1132 75. Contact drop of brushes too high................................1132 76. Contact drop of brushes too low.................................1132 77. Coefficient of friction too high................................1132 78. Lack of film forming properties in brush........................1132 79. Lack of polishing action in brush...............................1132 80. Brushes too abrasive............................................1132 81. Lack of carrying capacity.......................................1132 Drive Motor.....................................................................1134 1. Disassembly..............................................................1136 2. Inspection and Troubleshooting...........................................1137 2.1. Drive End Head.....................................................1137 2.2. Commutator End Head................................................1137 2.3. Bearings...........................................................1137 2.4. Brush and Commutator...............................................1138 2.5. Armature...........................................................1138 2.6. Frame and Field Assembly...........................................1139 2.6.1. Testing......................................................1139 2.6.2. Frame and Field Service Notes................................1140 2.7. Assembly...........................................................1141 2.7.1. Field Coil Installation......................................1141 2.7.2. Bearing Installation.........................................1141 2.7.3. After Assembly...............................................1142 3. When Changing Brushes....................................................1142 Caster Brake Assembly...........................................................1144 1. Removal..................................................................1145 1.1. Caster Brake Adjustment............................................1145 Electromagnetic Brake...........................................................1148 1. Installation.............................................................1149 2. Adjustments..............................................................1150 3. Coil Check On Brake......................................................1150 4. Electromagnetic Brake, Armature and Magnetic Co..........................1151 4.1. Removal............................................................1151 4.2. Installation.......................................................1151 Drive Wheel.....................................................................1152 1. Removal..................................................................1152 2. Installation.............................................................1153 Support / Swivel Wheel..........................................................1154 1. Caster Pivot.............................................................1155 1.1. Removal............................................................1155 1.2. Installation.......................................................1157 2. Thrust Bearing...........................................................1158 2.1. Removal............................................................1158 2.2. Installation.......................................................1159 3. Caster Springs...........................................................1160 3.1. Removal............................................................1160 3.2. Installation.......................................................1161 4. Caster Spring............................................................1162 4.1. Adjustments........................................................1162 5. Caster Stops.............................................................1163 5.1. Adjustment.........................................................1163 Tandem Load Wheels..............................................................1166 1. Removal..................................................................1167 Single Load Wheels..............................................................1168 1. Removal..................................................................1169 2. Installation.............................................................1169 Caster Wheels...................................................................1170 1. Removal..................................................................1171 2. Installation.............................................................1171 3. Caster Axle..............................................................1172 3.1. Removal............................................................1172 3.2. Installation.......................................................1172 Caster Wheels...................................................................1174 1. Removal..................................................................1175 2. Installation.............................................................1176 3. Caster Axle..............................................................1177 3.1. Removal............................................................1177 3.2. Installation.......................................................1177 Steering Arm / Wheel / Lever....................................................1178 1. Control Pod..............................................................1179 1.1. Removal............................................................1179 1.2. Installation.......................................................1179 2. Steering Wheel...........................................................1180 2.1. Removal............................................................1180 2.2. Installation.......................................................1180 3. Steering Tach............................................................1181 3.1. Removal............................................................1181 3.2. Installation.......................................................1181 Steering Bearing................................................................1182 1. Removal..................................................................1183 2. Installation.............................................................1183 Electrical Functions............................................................1184 1. Operating Description....................................................1184 2. Start Up.................................................................1186 3. Direction Selection......................................................1188 4. Reverse Direction Selection..............................................1190 5. Forward Drive............................................................1192 6. Plug Braking.............................................................1194 7. Steering Componets.......................................................1196 8. 12-Volt Power Supply.....................................................1197 9. Driving speed reduction switch...........................................1198 10. Height Indicator and Preset Selector....................................1200 10.1. Height Indicator..................................................1200 10.2. Height Preset Selector............................................1200 11. Drive Motor Brush Indicator Switch......................................1201 12. Pump Motor Brush Indicator Switch.......................................1202 13. Safety Check............................................................1203 14. Shunt Wire..............................................................1204 Component Location (Figure 1 of 2)......................................1209 15. Circuit Diagram 1(11)...................................................1211 16. Circuit Diagram 2(11)...................................................1212 17. Circuit Diagram 3(11)...................................................1213 18. Circuit Diagram 4(11)...................................................1214 19. Circuit Diagram 5(11)...................................................1215 20. Circuit Diagram 6(11)...................................................1216 21. Circuit Diagram 7(11)...................................................1217 22. Circuit Diagram 8(11)...................................................1218 23. Circuit Diagram 9(11)...................................................1219 24. Circuit Diagram 10(11)..................................................1220 25. Circuit Diagram 11(11)..................................................1221 Transistor Regulator............................................................1222 1. Motor Connections........................................................1223 1.1. Connections for controls...........................................1223 2. Safety Control...........................................................1224 2.1. Checking Transistor Regulator’s Safety Circui......................1224 Electronic Card.................................................................1226 1. Display..................................................................1232 2. Time.....................................................................1233 3. Warning Codes............................................................1234 4. Error Codes..............................................................1236 5. Effect on the Truck......................................................1238 6. Parameters...............................................................1238 7. Running time.............................................................1238 8. Programming Parameters...................................................1239 9. Adjustment Procedures for Setting Brake Switch ..........................1242 Pump Motor......................................................................1244 1. Component Repair.........................................................1245 1.1. Motor Disassembly..................................................1245 2. Inspection and Troubleshooting...........................................1247 2.1. Drive End Head.....................................................1247 2.2. Commutator End Head................................................1247 2.3. Bearings...........................................................1247 2.4. Brush and Commutator...............................................1248 2.5. Armature...........................................................1248 2.6. Frame and Field Assembly...........................................1249 2.6.1. Testing......................................................1249 2.6.2. Frame and Field Service Notes................................1250 2.7. Assembly...........................................................1251 2.7.1. Field Coil Installation......................................1251 2.7.2. Bearing Installation.........................................1251 2.7.3. After Assembly...............................................1252 3. When Changing Brushes....................................................1252 Hydraulic System................................................................1254 Valid from machine number: 27091001 to 27135000.............................1254 1. Operation................................................................1254 1.1. Supply.............................................................1254 1.2. Lifting............................................................1254 1.3. Lowering...........................................................1254 1.4. Reach..............................................................1254 1.5. Retract............................................................1255 1.6. Tilt Up............................................................1255 1.7. Tilt Down..........................................................1255 1.8. Sideshifting Right.................................................1256 1.9. Sideshifting Left..................................................1256 2. RRX35/45 Hydraulic Schematic.............................................1258 Hydraulic System................................................................1260 Valid from machine number: 27135001 and UP..................................1260 1. Operation................................................................1260 1.1. Supply.............................................................1260 1.2. Lifting............................................................1260 1.3. Lowering...........................................................1261 1.4. Reach..............................................................1261 1.5. Retract............................................................1261 1.6. Tilt Up............................................................1261 1.7. Tilt Down..........................................................1262 1.8. Sideshifting Right.................................................1262 1.9. Sideshifting Left..................................................1262 2. RRX35/45 Hydraulic Schematic.............................................1264 3. RDX30 Hydraulic Schematic................................................1265 4. RSX40/50 Hydraulic Schematic.............................................1266 Mast, 3 Stage...................................................................1268 1. Shimming Mast on Truck...................................................1269 1.1. Shimming the Carriage/Reach........................................1269 1.2. Shimming the Rails.................................................1270 2. Three Stage Mast.........................................................1274 2.1. Removal............................................................1274 2.2. Installation.......................................................1275 2.3. Disassembly........................................................1276 2.4. Assembly...........................................................1277 Sideshifter.....................................................................1280 1. Mounting Instructions....................................................1282 1.1. Installation.......................................................1282 1. Remove lower hooks (8) from sideshifter assembl..................1282 2. Lift sideshifter onto the truck’s carriage whil..................1282 3. Make sure the centering lug (X) on the cylinder..................1282 4. Remount the lower hooks (8) with a minimum clea..................1282 5. Secure the lower hook (8) in place by tightenin..................1282 6. Connect the hydraulic fittings (4) to the sides..................1282 2. Operation and Maintenance................................................1283 Every 1000 hours:.......................................................1283 1. Inspect hydraulic hoses for wear.................................1283 2. Inspect the cylinder (15) and fittings (4) for ..................1283 3. Clean the lower slides (6) and truck carriage l..................1283 4. Inspect and adjust the lower hooks (8) for the ..................1283 5. Check the torque on the lower hook mounting bol..................1283 2.1. Lower Slides.......................................................1284 1. The original thickness of a lower slide is appr..................1284 2. Replace the lower slide if contamination is pre..................1284 2.2. Upper Slides.......................................................1284 1. The original thickness of upper slide (1) is ap..................1284 2. Replace the upper slides (1) if there is an una..................1284 3. When replacing the upper slides (1), always rep..................1284 2.3. Cylinder...........................................................1284 1. The hydraulic cylinder (15) is basically a non-..................1284 2. If the cylinder rod becomes scored, a minimal a..................1285 Reach, Single...................................................................1286 1. Maintenance..............................................................1286 2. Reach Repair.............................................................1288 2.1. Disassembly........................................................1288 2.1.1. Front Frame Removal..........................................1288 2.1.2. Outer Arm Removal............................................1288 2.1.3. Inner Arm Removal............................................1288 2.1.4. Rear Frame Removal...........................................1289 2.1.5. Reach Cylinder Removal.......................................1289 2.2. Assembly...........................................................1290 2.2.1. Reach Cylinder Installation..................................1290 2.2.2. Rear Frame Installation......................................1290 2.2.3. Inner Arm Installation.......................................1290 2.2.4. Outer Arm Installation.......................................1291 Freelift Cylinder, 3 Stage......................................................1292 1. Freelift Cylinder Repair.................................................1293 1.1. Removal............................................................1293 1.2. Disassembly........................................................1294 1.3. Assembly...........................................................1294 1.4. Installation.......................................................1294 Staging Cylinder, 3 Stage.......................................................1296 1.1. Removal................................................................1297 1.2. Disassembly............................................................1297 1.3. Assembly...............................................................1297 1.4. Installation...........................................................1298 Tilt Cylinder...................................................................1300 1. Removal..................................................................1301 2. Disassembly..............................................................1301 3. Inspection...............................................................1302 4. Assembly.................................................................1302 5. Installation.............................................................1303 Tilt Cylinder...................................................................1306 1. Removal..................................................................1307 2. Disassembly..............................................................1308 3. Inspection...............................................................1309 4. Assembly.................................................................1309 5. Installation.............................................................1311 Reach Cylinder..................................................................1312 1. Removal..................................................................1313 2. Disassembly..............................................................1314 3. Inspection...............................................................1315 4. Assembly.................................................................1316 5. Installation.............................................................1317 Height Indicator................................................................1318 1. Pulse sensor.............................................................1319 1.1. Repair.............................................................1319 1.2. Cable..............................................................1319 1.2.1. Removal......................................................1319 1.2.2. Installation.................................................1319 1.3. Pulley.............................................................1319 1.3.1. Removal......................................................1319 Height Indication & Preset Height...............................................1320 1. General..................................................................1321 2. Operation................................................................1321 3. Preset Height............................................................1322 4. Display..................................................................1323 5. Description of the display symbols.......................................1324 6. Programming..............................................................1325 6.1. Programming a Level................................................1325 6.1.1. Collection Level.............................................1325 6.1.2. Leaving Level................................................1325 6.2. Erasing Programmed Levels..........................................1326 6.2.1. Automatic Operations.........................................1326 6.2.2. Collecting a Load............................................1326 6.2.3. Leaving a Load...............................................1327 6.3. Parameters.........................................................1328 P1..................................................................1328 P2..................................................................1328 P3..................................................................1329 P5..................................................................1329 P7..................................................................1329 P8..................................................................1330 P9..................................................................1330 Back Cover......................................................................1363 RRX, RSX, RDX Circuit Diagram 1(12).........................................1335 RRX, RSX, RDX Circuit Diagram 2(12).........................................1336 RRX, RSX, RDX Circuit Diagram 3(12).........................................1337 RRX, RSX, RDX Circuit Diagram 4(12).........................................1338 RRX, RSX, RDX Circuit Diagram 5(12).........................................1339 RRX, RSX, RDX Circuit Diagram 6(12).........................................1340 RRX, RSX, RDX Circuit Diagram 7(12).........................................1341 RRX, RSX, RDX Circuit Diagram 8(12).........................................1342 RRX, RSX, RDX Circuit Diagram 9(12).........................................1343 RRX, RSX, RDX Circuit Diagram 10(12)........................................1344 RRX, RSX, RDX Circuit Diagram 11(12)........................................1345 RRX, RSX, RDX Circuit Diagram 12(12)........................................1346 List of Symbols.............................................................1347 BT Standard Codes...............................................................1366 Warning Symbols.................................................................1380 1. Warning Levels...........................................................1380 Prohibitory Symbols.............................................................1381 1. Ordinance Symbols........................................................1381 Safety..........................................................................1382 1. General Safety...........................................................1382 Battery Safety..................................................................1386 Static Safety...................................................................1391 Welding Safety..................................................................1392 Introduction, Service Manual....................................................1394 Contents, Section M.............................................................1396 1. Machine Information......................................................1396 General Product Information.....................................................1398 1. Presentation of the Rider Trucks.........................................1398 1.1. Truck Side Views...................................................1398 1.2. Open Back Compartment..............................................1399 1.3. Intended Truck Application.........................................1399 1.4. Prohibited Truck Application.......................................1400 1.5. Truck Data.........................................................1400 1.6. RRX35 Dimensions...................................................1401 1.7. RRX45 Dimensions...................................................1402 1.8. RDX30 Dimensions...................................................1403 1.9. RSX40 Dimensions...................................................1404 1.10. RSX50 Dimensions..................................................1405 1.11. Data Plate........................................................1406 2. Main Components..........................................................1407 Inch (SAE) and Metric Fasteners.................................................1410 1. Introduction.............................................................1410 2. Nomenclature, Threads....................................................1411 3. Strength Identification..................................................1412 4. Conversion of Metric and English Units...................................1420 Technical Service Data..........................................................1422 Ordering Spare Parts............................................................1426 Contents, Section P.............................................................1428 1. Planned Maintenance......................................................1428 Introduction, Maintenance.......................................................1430 1. Safe Jacking Procedure...................................................1431 1.1. Elevate Rear of Truck..............................................1431 1.1. Elevate Either Side of Truck.......................................1432 2. Lubricants...............................................................1433 2.1. Cold Storage Conditioning..........................................1433 2.2. Electrical Component Cold Storage Conditioning.....................1433 Service Schedule................................................................1434 1. Planned Maintenance Schedule.............................................1434 2. Planned Maintenance Procedures...........................................1439 2.1. Services Performed Daily or Every 8 Operating Hours................1439 2.1.1. Battery Discharge Indicator with slow down...................1439 2.1.2. Hydraulic System.............................................1439 2.1.3. Frame/Sheet Metal............................................1440 2.1.4. Wheels/Tires.................................................1440 2.1.5. Functions/Operations.........................................1440 2.2. Services Performed Monthly or Every 120 Operating Hours............1440 2.2.1. Inspection...................................................1440 2.2.2. Transmission.................................................1440 2.2.3. Brakes.......................................................1440 2.2.4. Battery......................................................1441 2.2.5. Electrical Connections.......................................1441 2.2.6. Contactor Tips (NOT Sealed)..................................1441 2.2.7. Motor Brushes................................................1441 2.2.8. Drive Motor..................................................1441 2.2.9. Hydraulic Reservoir..........................................1442 2.2.10. Frame Lube..................................................1442 2.2.11. Pivot Points................................................1442 2.3. Services Performed Every 480 or 960 Operating Hours................1442 2.3.1. Drive Motor..................................................1442 2.4. Services Performed Annually or Every 1440 Operating Hours..........1443 2.4.1. Inspection...................................................1443 2.4.2. Transmission.................................................1443 2.4.3. Battery......................................................1443 2.4.4. Hydraulic System.............................................1443 2.4.5. Brakes.......................................................1444 2.4.6. Lift and Carriage Chains.....................................1444 Lubrication Chart...............................................................1446 Oil and Grease Specifications...................................................1447 1. Approved Oils and Grease.................................................1447 2. Grease Location Points...................................................1448 3. Mast Adjustment Points...................................................1449 Contents, Section S.............................................................1450 1. Service Instructions.....................................................1450 Troubleshooting Guidelines......................................................1452 1. General..................................................................1452 2. Electrical...............................................................1454 2.1. Shorts to Frame Test...............................................1454 3. Hydraulic................................................................1459 4. Definitions..............................................................1460 Chassis.........................................................................1462 1. General..................................................................1462 2. Dash.....................................................................1463 2.1. Removal............................................................1463 2.1. Removal............................................................1464 3. Motor Compartment Door...................................................1464 3.1. Removal............................................................1464 3.2. Installation.......................................................1464 4. Left-Hand Side Panel.....................................................1465 4.1. Removal............................................................1465 5. Operator Compartment Panel...............................................1466 5.1. Removal............................................................1466 6. Main Card Access Panel...................................................1466 6.1. Removal............................................................1466 Battery Compartment.............................................................1468 1. Battery Retainer Plates..................................................1469 1.1. Inspection.........................................................1469 1.2. Removal............................................................1469 1.3. Installation.......................................................1469 2. Battery Rollers..........................................................1469 2.1. Inspection.........................................................1469 2.2. Replacement........................................................1469 Mounting Points.................................................................1470 1. Drive Motor..............................................................1470 1.1. Removal............................................................1471 1.2. Installation.......................................................1472 2. Pump Motor...............................................................1473 2.1. Removal............................................................1474 2.2. Installation.......................................................1475 3. Transmission.............................................................1477 3.1. Fluid Changing Procedure...........................................1478 3.2. Removal............................................................1478 3.3. Installation.......................................................1479 Driver Controls.................................................................1482 Brake Pedal, RSX40/RRX35........................................................1484 1. Pedal Removal............................................................1485 2. Pedal Bearing Replacement................................................1486 3. Pedal Adjustment.........................................................1486 Brake Pedal, RSX50/RRX45/ RDX30.................................................1487 1. Pedal Removal............................................................1488 2. Pedal Bearing Replacement................................................1489 3. Pedal Adjustment.........................................................1489 Overhead Guard..................................................................1490 Decals..........................................................................1492 1. Decal with Protective Sheet..............................................1492 2. Decal without Protective Sheet...........................................1492 Steering Motor..................................................................1496 1. Removal..................................................................1496 2. Installation.............................................................1496 3. Steering Motor Gear Replacement..........................................1497 3.1. Removal............................................................1497 3.2. Installation.......................................................1497 Fan Motor.......................................................................1498 1. Upper Electrical Compartment Fan.........................................1498 1.1. Removal............................................................1498 1.2. Removal............................................................1498 1.3. Installation.......................................................1499 2. Operator Fan.............................................................1499 Motor Maintenance Schedule/Troubleshooting......................................1500 1. General Information......................................................1500 2. Operating Conditions.....................................................1500 3. Troubleshooting..........................................................1501 Pump Motor, RRX35/RSX40.........................................................1508 1. Component Repair.........................................................1510 1.1. Disassembly........................................................1510 2. Inspection and Troubleshooting...........................................1512 2.1. Drive End head.....................................................1512 2.2. Commutator End head................................................1512 2.3. Bearings...........................................................1512 2.4. Brush and Commutator...............................................1513 2.5. Armature...........................................................1515 2.6. Frame and Field Assembly...........................................1516 2.6.1. Testing......................................................1516 2.7. Assembly...........................................................1517 2.7.1. Bearing Installation.........................................1517 2.7.2. Testing......................................................1517 Pump Motor, RRX45/RDX30/RSX50...................................................1518 1. Component Repair.........................................................1519 1.1. Disassembly........................................................1519 2. Motor Inspection.........................................................1521 2.1. External Motor.....................................................1521 2.2. Brush and Commutator...............................................1522 2.3. Bearings...........................................................1524 2.4. Armature Electrical Check..........................................1524 2.5. Frame & Field Service Recommendation...............................1525 2.6. Assembly/Testing...................................................1526 Drive Motor.....................................................................1528 1. Disassembly..............................................................1530 2. Inspection...............................................................1531 2.1. Drive End Head.....................................................1531 2.2. Commutator End Head................................................1531 2.3. Bearings...........................................................1531 2.4. Brush and Commutator...............................................1532 2.5. Armature...........................................................1534 2.6. Frame and Field Assembly...........................................1535 2.6.1. Testing......................................................1535 2.7. Assembly...........................................................1535 2.7.1. Bearing Installation.........................................1535 2.7.2. Testing......................................................1536 3. Temperature Sensors......................................................1536 3.1. Removal............................................................1536 3.2. Installation.......................................................1536 4. Brush Wear Sensors.......................................................1537 Transmission....................................................................1538 1. Disassemble..............................................................1540 2. Assembly.................................................................1544 3. Axle Sealing Ring........................................................1553 3.1. Disassembly........................................................1553 3.2. Assembly...........................................................1554 4. Leakage..................................................................1555 4.1. Top Cover..........................................................1555 4.2. Lower Cover........................................................1556 5. Wheel Bolt...............................................................1557 Electromagnetic Brake...........................................................1558 1. Removal..................................................................1558 2. Installation.............................................................1560 3. Adjustments..............................................................1561 4. Coil Check On Brake......................................................1562 5. Electromagnetic Brake, Armature and Magnetic Coil........................1562 5.1. Removal............................................................1562 5.2. Installation.......................................................1563 6. Brake Friction Plate.....................................................1563 6.1. Inspection.........................................................1563 6.2. Replacement........................................................1563 Drive Wheel.....................................................................1564 1. Removal..................................................................1565 2. Installation.............................................................1565 3. Tire Pressing Procedure..................................................1566 Non-Braking Caster Wheel, RRX35/RSX40...........................................1568 1. Caster Pivot.............................................................1570 1.1. Removal............................................................1570 1.2. Installation.......................................................1571 2. Thrust Bearing...........................................................1572 2.1. Removal............................................................1572 2.2. Installation.......................................................1573 3. Caster Springs...........................................................1574 3.1. Adjustment.........................................................1574 3.2. Removal............................................................1574 3.3. Installation.......................................................1575 4. Caster Stops.............................................................1576 4.1. Adjustment.........................................................1576 Non-Braking Caster Assembly, RRX35/RSX40........................................1578 1. Removal..................................................................1579 2. Installation.............................................................1579 Braking Caster Wheel, RRX45/RDX30/RSX50.........................................1580 1. Removal..................................................................1582 1.1. Caster Brake Adjustment............................................1582 Braking Caster Assembly, RRX45/RDX30/RSX50......................................1584 1. Removal..................................................................1586 2. Installation.............................................................1587 Load Wheels, Sizes 4 X 3, 5 X 4, and 5 X 3......................................1588 1. Removal..................................................................1590 2. Installation.............................................................1591 Load Wheels, Size 10.5 X 3.5....................................................1592 1. Removal..................................................................1593 2. Installation.............................................................1593 Steering Arm / Wheel / Lever....................................................1594 1. Control Pod..............................................................1596 1.1. Removal............................................................1596 1.2. Installation.......................................................1596 2. Steering Wheel...........................................................1597 2.1. Removal............................................................1597 2.2. Installation.......................................................1597 3. Steering Tach............................................................1598 3.1. Removal............................................................1598 3.2. Installation.......................................................1598 Steering Bearing................................................................1600 1. Removal..................................................................1601 2. Installation.............................................................1601 Electrical Functions............................................................1602 1. General..................................................................1602 1.1. Directional/Speed Control Lever....................................1602 1.2. Main Electronic Card...............................................1603 2. Start Up.................................................................1606 3. Steering Components......................................................1610 3.1. Steering System....................................................1610 3.2. Wheel Direction Sensors............................................1614 4. Brake Release............................................................1616 5. Direction Selection......................................................1618 6. Travel Request, Forks First..............................................1620 7. Travel Request, Forks Trailing...........................................1624 8. Plug Braking.............................................................1628 8.1. Directional/Speed Control Lever Method.............................1628 8.2. Brake Pedal Method.................................................1629 9. 12-Volt Power Supply.....................................................1632 10. 7.35-Volt Power Supplies................................................1633 11. Limit Switches..........................................................1636 11.1. Truck Travel Speed Limiting.......................................1636 11.2. Mast Staging Speed Limiting.......................................1638 12. Height Indicator........................................................1640 12.1. Height Preset Selector............................................1641 13. Drive Motor Brush Wear Indicator Switches...............................1642 14. Pump Motor Brush Indicator Switch.......................................1643 15. Safety Check............................................................1644 16. Shunt Power Cable.......................................................1646 Electrical Symbols..............................................................1654 Electrical Schematics (P5-04 Serial numbers 27163000-28105000)..................1656 1. Circuit Diagram 1(11)....................................................1656 2. Circuit Diagram 2(11)....................................................1657 3. Circuit Diagram 3(11)....................................................1658 4. Circuit Diagram 4(11)....................................................1659 5. Circuit Diagram 5(11)....................................................1660 6. Circuit Diagram 6(11)....................................................1661 7. Circuit Diagram 7(11)....................................................1662 8. Circuit Diagram 8(11)....................................................1663 9. Circuit Diagram 9(11)....................................................1664 10. Circuit Diagram 10(11)..................................................1665 11. Circuit Diagram 11(11)..................................................1666 Electrical Schematics (P5-04 Serial numbers 2810500-28126000)...................1668 1. Circuit Diagram 1(12)....................................................1668 2. Circuit Diagram 2(12)....................................................1669 3. Circuit Diagram 3(12)....................................................1670 4. Circuit Diagram 4(12)....................................................1671 5. Circuit Diagram 5(12)....................................................1672 6. Circuit Diagram 6(12)....................................................1673 7. Circuit Diagram 7(12)....................................................1674 8. Circuit Diagram 8(12)....................................................1675 9. Circuit Diagram 9(12)....................................................1676 10. Circuit Diagram 10(12)..................................................1677 11. Circuit Diagram 11(12)..................................................1678 12. Circuit Diagram 12(12)..................................................1679 Electrical Schematics (P5-05/06/07 Serial number 28126001-UP)...................1680 1. Circuit Diagram 1(12)....................................................1680 2. Circuit Diagram 2(12)....................................................1681 3. Circuit Diagram 3(12)....................................................1682 4. Circuit Diagram 4(12)....................................................1683 5. Circuit Diagram 5(12)....................................................1684 6. Circuit Diagram 6(12)....................................................1685 7. Circuit Diagram 7(12)....................................................1686 8. Circuit Diagram 8(12)....................................................1687 9. Circuit Diagram 9(12)....................................................1688 10. Circuit Diagram 10(12)..................................................1689 11. Circuit Diagram 11(12)..................................................1690 12. Circuit Diagram 12(12)..................................................1691 Battery.........................................................................1692 1. Removal..................................................................1692 2. Installation.............................................................1692 3. Battery Maintenance......................................................1693 3.1. Battery Inspection and Care........................................1693 3.2. Battery Exterior Cleaning..........................................1694 3.3. Charging...........................................................1694 4. Storage..................................................................1695 5. Battery History Record...................................................1695 Light Assemblies................................................................1696 1. Overhead Guard Lights (Option)...........................................1696 1.1. Removal............................................................1696 1.2. Installation.......................................................1696 2. Warning Lights (Option)..................................................1697 2.1. Removal............................................................1697 2.2. Installation.......................................................1698 3. Working Lights (Option)..................................................1698 3.1. Removal............................................................1698 3.2. Installation.......................................................1698 4. Travel Alarm (Option)....................................................1699 4.1. Removal............................................................1699 4.2. Installation.......................................................1699 5. Operator Fan (Option)....................................................1700 5.1. Removal............................................................1701 5.2. Installation.......................................................1701 Horn............................................................................1702 1. Removal..................................................................1702 2. Installation.............................................................1702 Battery Connector...............................................................1704 1. Location.................................................................1704 2. Inspection...............................................................1704 3. Installation.............................................................1705 Start/Stop Switches.............................................................1706 1. General..................................................................1706 1.1. Test/Inspection....................................................1706 2. Key Switch (S17).........................................................1706 2.1. Inspection.........................................................1706 2.2. Removal............................................................1707 2.3. Installation.......................................................1707 3. Emergency Disconnect Switch (S21)........................................1708 3.1. Inspection.........................................................1708 3.2. Removal............................................................1708 3.3. Installation.......................................................1709 Mast Switch (S31)...............................................................1710 1. General..................................................................1710 1.1. Test/Inspection....................................................1710 1.2. Adjustment.........................................................1712 1.3. Removal............................................................1713 1.4. Installation.......................................................1713 Control Cable and Harness.......................................................1714 1. Fuses....................................................................1714 2. Wiring...................................................................1715 2.1. Harness............................................................1715 2.2. Power Cables.......................................................1716 Contactors......................................................................1718 1. General..................................................................1718 1.1. Resistance Testing.................................................1718 1.2. Contactor Tip Inspection...........................................1718 2. Direction Contactors.....................................................1719 2.1. Removal............................................................1720 2.2. Installation.......................................................1720 3. Lift Bypass Contactor (RRX45/RSX50/RDX30)................................1721 3.1. Removal............................................................1722 3.2. Installation.......................................................1722 4. Battery Cut-out Contactor................................................1723 4.1. Removal............................................................1724 4.2. Installation.......................................................1724 Transistor Panel (Drive)........................................................1726 Transistor Panel (Lift).........................................................1727 1. Motor Connections........................................................1728 1.1. Connections for controls...........................................1728 2. Circuit Check............................................................1729 Micro Switches..................................................................1730 1. General..................................................................1730 2. Lift Limit Override Switch (S33).........................................1731 2.1. Removal............................................................1731 2.2. Installation.......................................................1731 3. Optional Light and Fan Switches (S96, S97 and S99).......................1732 3.1. Removal............................................................1732 3.2. Installation.......................................................1732 Main Electronic Card............................................................1734 1. Connectivity to Truck....................................................1734 2. Transistor Controller Replacement........................................1735 3. Removal..................................................................1739 4. Installation.............................................................1739 5. Display..................................................................1745 6. Time.....................................................................1746 7. Effect on Truck..........................................................1746 8. Running time.............................................................1747 9. RV2 Adjustment Procedure.................................................1747 10. Adjustment Procedures for Setting Brake Switch and Brake Transducer.....1748 11. Battery Discharge Indicator Parameter Adjustment........................1749 12. A5 Jumper Harness Kit Installation (Serial numbers 28126000 - below)....1755 13. Warning\Caution Codes...................................................1758 14. Error Codes.............................................................1760 14.1. E102 Troubleshooting Procedures...................................1762 14.1.1. Power Circuit Checks........................................1762 14.1.2. Reference Circuit Value Checks (LED #4).....................1764 15. Programming Parameter...................................................1765 Switches and Sensors............................................................1776 1. General..................................................................1776 1.1. Test/Inspection....................................................1776 2. Platform (Right Foot) Switch (S108)......................................1776 2.1. Removal............................................................1777 2.2. Installation.......................................................1777 3. Staging Switch (S45).....................................................1778 3.1. Adjustment.........................................................1779 3.2. Removal............................................................1779 3.3. Installation.......................................................1779 4. Wheel Direction Sensor...................................................1780 4.1. Adjustment.........................................................1780 4.2. Removal............................................................1781 4.3. Installation.......................................................1781 5. Steer Proximity Sensors A and B (S66 and S67)............................1782 5.1. Adjustment.........................................................1782 5.2. Removal............................................................1783 5.3. Installation.......................................................1783 6. Drive Motor Speed(S64)/Direction Sensors (S125)..........................1784 6.1. Removal............................................................1784 6.2. Installation.......................................................1785 Hydraulic System................................................................1786 1. Operation................................................................1786 1.1. Supply.............................................................1786 1.2. Lifting............................................................1788 1.3. Lowering...........................................................1789 1.4. Reach..............................................................1792 1.5. Retract............................................................1795 1.6. Reach Relief (RRX35)...............................................1796 1.7. Reach Impact (RRX35)...............................................1797 1.8. Tilt Up............................................................1800 1.9. Tilt Down..........................................................1803 1.10. Side Shifting Right...............................................1806 1.11. Side Shifting Left................................................1808 2. RRX35 Hydraulic Schematic................................................1811 3. RRX45 Hydraulic Schematic................................................1812 4. RDX30 Hydraulic Schematic................................................1813 5. RSX40 Hydraulic Schematic................................................1814 6. RSX50 Hydraulic Schematic................................................1815 Hydraulic Fluid.................................................................1816 1. Hydraulic Fluid Selection................................................1816 2. Changing Hydraulic System Fluid..........................................1816 3. System Draining..........................................................1817 4. Refilling System.........................................................1818 5. Bleeding Hydraulic System................................................1819 Hydraulic Tank..................................................................1821 1. Removal..................................................................1822 2. Installation.............................................................1823 Hydraulic Filter Assembly.......................................................1824 1. Hydraulic Filter.........................................................1825 1.1. Removal............................................................1825 1.2. Installation.......................................................1825 2. Hydraulic Filter Adapter.................................................1826 2.1. Removal............................................................1826 2.2. Installation.......................................................1826 Hydraulic Pump..................................................................1828 1. Removal..................................................................1828 2. Repair...................................................................1828 Control Valve...................................................................1830 1. Removal..................................................................1830 2. Installation.............................................................1830 Control Valve Assembly..........................................................1835 3. Repair...................................................................1837 3.1. Proportional Pre-Pressure Reducing Valve...........................1837 3.2. Valve Assembly SWR14...............................................1837 3.3. Pressure Limiting Valve Assembly...................................1838 3.4. Setting Lift/Auxiliary Pressure Relief with a Rated Load...........1838 3.5. Rated Load Pressure Settings.......................................1839 3.6. Hydraulic Lowering Rate Adjustment.................................1839 3.7. Recondition Seal Kit...............................................1840 Staging Cylinder, Three Stage Mast, RRX35/RSX40.................................1842 1. Removal..................................................................1843 2. Disassembly..............................................................1844 3. Assembly.................................................................1844 4. Installation.............................................................1844 Staging Cylinder, Three Stage Mast, RRX45/RDX30/RSX50...........................1846 1. Removal..................................................................1848 2. Disassembly..............................................................1849 3. Assembly.................................................................1849 4. Installation.............................................................1849 Freelift Cylinder, Three Stage Mast.............................................1850 1. Removal..................................................................1852 2. Disassembly..............................................................1853 3. Assembly.................................................................1853 4. Installation.............................................................1853 Reach Cylinder Assembly, RRX35..................................................1854 1. Removal..................................................................1856 2. Disassembly..............................................................1857 3. Inspection...............................................................1858 4. Assembly.................................................................1859 5. Installation.............................................................1860 Reach Cylinder Assembly, RRX45..................................................1862 1. Removal..................................................................1864 2. Disassembly..............................................................1865 3. Inspection...............................................................1866 4. Assembly.................................................................1867 5. Installation.............................................................1868 Reach Cylinder Assembly, RDX30..................................................1870 1. Removal..................................................................1872 2. Disassembly..............................................................1873 3. Inspection...............................................................1874 4. Assembly.................................................................1875 5. Installation.............................................................1876 Tilt Cylinder Assembly, RRX35/RSX40.............................................1878 1. Removal..................................................................1880 2. Disassembly..............................................................1881 3. Inspection...............................................................1882 4. Assembly.................................................................1883 5. Installation.............................................................1884 Tilt Cylinder Assembly, RSX50...................................................1886 1. Removal..................................................................1888 2. Disassembly..............................................................1889 3. Inspection...............................................................1890 4. Assembly.................................................................1891 5. Installation.............................................................1892 Tilt Cylinder Assembly, RRX45/RDX30.............................................1894 1. Removal..................................................................1896 2. Disassembly..............................................................1897 3. Inspection...............................................................1898 4. Assembly.................................................................1899 5. Installation.............................................................1900 Mast, 3 Stage, RRX35/RSX40......................................................1902 1. Shimming Carriage with Mast on Truck.....................................1904 2. Three Stage Mast.........................................................1906 2.1. Removal............................................................1906 2.2. Disassembly........................................................1907 2.3. Assembly...........................................................1908 2.4. Installation.......................................................1910 Mast, 3 Stage, RRX45/RSX50/RDX30................................................1911 1. Shimming Carriage with Mast on Truck.....................................1913 2. Three Stage Mast.........................................................1915 2.1. Removal............................................................1915 2.2. Disassembly........................................................1916 2.3. Assembly...........................................................1917 2.4. Installation.......................................................1919 3. Lift Chain...............................................................1920 3.1. Lift Chain Adjustment..............................................1920 3.2. Lift Chain Maintenance.............................................1920 3.3. Lift Chain Inspection..............................................1920 3.3.1. Wear.........................................................1921 3.3.2. Rust and Corrosion...........................................1921 3.3.3. Cracked Plates...............................................1922 3.3.4. Protruding or Turned Pins....................................1924 3.3.5. Chain Side Wear..............................................1925 3.3.6. Chain Anchors and Sheaves....................................1925 3.3.7. Lift Chain Lubrication.......................................1925 3.4. Lift Chain Replacement.............................................1927 Lifting Gear (Crosshead), RRX35/ RSX40..........................................1928 1. Lifting Gear Repair......................................................1929 1.1. Removal............................................................1929 1.2. Disassembly........................................................1930 1.3. Assembly...........................................................1930 1.4. Installation.......................................................1930 Lifting Gear (Crosshead), RRX45/ RSX50/RDX30....................................1931 1. Lifting Gear Repair......................................................1932 1.1. Removal............................................................1932 1.2. Disassembly........................................................1933 1.3. Assembly...........................................................1933 1.4. Installation.......................................................1934 Sideshifter, RRX35/45/RDX30.....................................................1936 1. Mounting Instructions....................................................1938 1.1. Installation.......................................................1938 2. Operation and Maintenance................................................1939 2.1. Lower Slides.......................................................1939 2.2. Upper Slides.......................................................1940 2.3. Cylinder...........................................................1940 Sideshifter, RRX35/45/RSX40/50/RDX30............................................1942 1. Mounting Instructions....................................................1944 1.1. Installation.......................................................1944 2. Operation................................................................1945 3. Maintenance..............................................................1945 3.1. Carriage Removal...................................................1946 3.2. Upper Pad Replacement..............................................1946 3.3. Lower Pad Replacement..............................................1947 3.4. Cylinder...........................................................1948 4. Troubleshooting..........................................................1950 4.1. No Sideshifting....................................................1950 4.2. Sideshifting Very Slow.............................................1950 4.3. Irregular Sideshifting.............................................1951 Single Reach, RRX35.............................................................1952 1. Maintenance..............................................................1958 1.1. Inspection.........................................................1958 1.2. Adjustment.........................................................1959 2. Repair...................................................................1963 2.1. Disassembly........................................................1964 3. Rear Frame...............................................................1969 3.1. Inspection and Maintenance.........................................1969 3.1.1. Rear Frame Removal...........................................1971 3.1.2. Rear Frame Installation......................................1972 4. Carriage Roller Bearings.................................................1973 4.1. Removal............................................................1973 4.2. Installation.......................................................1973 Single Reach, RRX45.............................................................1974 1. Maintenance..............................................................1974 2. Reach Repair.............................................................1982 2.1. Disassembly (for item call out identification see page613)........1982 2.1.1. Forward Frame Removal........................................1982 2.1.2. Outer Arm Removal............................................1982 2.1.3. Inner Arm Removal............................................1983 2.1.4. Rear Frame Removal...........................................1983 2.1.5. Reach Cylinder Removal.......................................1984 2.2. Assembly...........................................................1984 2.2.1. Reach Cylinder Installation..................................1984 2.2.2. Rear Frame Installation......................................1984 2.2.3. Inner Arm Installation.......................................1985 2.2.4. Outer Arm Installation.......................................1985 2.2.5. Front Frame Installation.....................................1986 3. Fork Carriage Pivot Pins.................................................1986 4. Carriage Roller Bearings.................................................1987 4.1. Removal............................................................1987 4.2. Installation.......................................................1987 Double Reach, RDX30.............................................................1988 1. Maintenance..............................................................1988 2. Fork Frame Removal.......................................................1994 2.1. Fork Frame Assembly................................................1995 2.2. Forward Frame Removal..............................................1995 2.3. Forward Frame Installation.........................................1996 2.4. Rear Frame.........................................................1997 2.5. Rear Frame Removal.................................................2000 2.6. Rear Frame Installation............................................2000 Double Reach Arm Assembly, RDX30................................................2004 1. Arm (2) and (13) Removal.................................................2006 1.1. Inner Arm (5) Removal..............................................2007 1.2. Arm Assembly Installation..........................................2008 Forks...........................................................................2018 1. Removal..................................................................2020 2. Inspection...............................................................2020 3. Installation.............................................................2021 Load Indicator..................................................................2022 Load Indicator..................................................................2024 1. Pulse Sensor.............................................................2026 1.1. Repair.............................................................2026 1.2. Cable..............................................................2026 1.2.1. Removal......................................................2026 1.2.2. Installation.................................................2026 1.3. Pulley.............................................................2026 1.3.1. Removal......................................................2026 Height Indicator and Preset Selector............................................2028 1. General..................................................................2029 2. Operation................................................................2029 3. Preset Height............................................................2030 4. Display..................................................................2031 5. Display Symbols Description..............................................2032 6. Programming..............................................................2033 6.1. Programming a Level................................................2033 6.1.1. Collection Level.............................................2033 6.1.2. Leaving Level................................................2033 6.2. Erasing Programmed Levels..........................................2034 6.2.1. Automatic Operations.........................................2034 6.2.2. Collecting a Load............................................2034 6.2.3. Leaving a Load...............................................2035 6.3. Parameters.........................................................2036 Load Backrest...................................................................2042 1. Removal..................................................................2045 2. Installation.............................................................2045 A...........................................................................2046 B...........................................................................2046 C...........................................................................2046 D...........................................................................2047 E...........................................................................2047 F...........................................................................2047 G...........................................................................2047 H...........................................................................2047 I...........................................................................2048 K...........................................................................2048 L...........................................................................2048 M...........................................................................2048 N...........................................................................2048 O...........................................................................2049 P...........................................................................2049 R...........................................................................2049 S...........................................................................2049 T...........................................................................2049 V...........................................................................2050 W...........................................................................2050 Standard Codes..................................................................2056 Warning Symbols.................................................................2070 1. Warning Levels...........................................................2070 Prohibitory Symbols.............................................................2071 1. Ordinance Symbols........................................................2071 Safety..........................................................................2072 1. General Safety...........................................................2072 Battery Safety..................................................................2076 Static Safety...................................................................2081 Welding Safety..................................................................2082 Introduction, Service Manual....................................................2084 Contents, Section M.............................................................2086 1. Machine Information......................................................2086 General Product Information.....................................................2088 1. Presentation of the Rider Trucks.........................................2088 1.1. Truck Side Views...................................................2088 1.2. Open Back Compartment..............................................2089 1.3. Intended Truck Application.........................................2089 1.4. Prohibited Truck Application.......................................2090 1.5. Truck Data.........................................................2090 1.6. RRX35 Dimensions...................................................2091 1.7. RRX45 Dimensions...................................................2092 1.8. RDX30 Dimensions...................................................2093 1.9. RSX40 Dimensions...................................................2094 1.10. RSX50 Dimensions..................................................2095 1.11. Data Plate........................................................2096 2. Main Components..........................................................2097 Inch (SAE) and Metric Fasteners.................................................2100 1. Introduction.............................................................2100 2. Nomenclature, Threads....................................................2101 3. Strength Identification..................................................2102 4. Conversion of Metric and English Units...................................2110 Technical Service Data..........................................................2112 Ordering Spare Parts............................................................2116 Contents, Section P.............................................................2118 1. Planned Maintenance......................................................2118 Introduction, Maintenance.......................................................2120 1. Jacking Truck Off The Floor..............................................2121 1.1. Elevate Rear of Truck..............................................2121 1.2. Elevate Either Side of Truck.......................................2122 2. Lubricants...............................................................2123 2.1. Standard...........................................................2123 2.2. Corrosion..........................................................2123 2.3. Cold Storage.......................................................2123 2.4. Freezer Storage....................................................2125 Service Schedule................................................................2126 1. Planned Maintenance Schedule.............................................2126 2. Planned Maintenance Procedures...........................................2131 2.1. Services Performed Daily or Every 8 Operating Hours................2131 2.1.1. Battery Discharge Indicator with slow down...................2131 2.1.2. Hydraulic System.............................................2131 2.1.3. Frame/Sheet Metal............................................2132 2.1.4. Wheels/Tires.................................................2132 2.1.5. Functions/Operations.........................................2132 2.2. Services Performed Monthly or Every 120 Operating Hours............2132 2.2.1. Inspection...................................................2132 2.2.2. Transmission.................................................2132 2.2.3. Brakes.......................................................2132 2.2.4. Battery......................................................2133 2.2.5. Electrical Connections.......................................2133 2.2.6. Contactor Tips (NOT Sealed)..................................2133 2.2.7. Motor Brushes................................................2133 2.2.8. Drive Motor..................................................2133 2.2.9. Hydraulic Reservoir..........................................2134 2.2.10. Frame Lube..................................................2134 2.2.11. Pivot Points................................................2134 2.3. Services Performed Every 480 or 960 Operating Hours................2135 2.3.1. Drive Motor..................................................2135 2.4. Services Performed Annually or Every 1440 Operating Hours..........2136 2.4.1. Inspection...................................................2136 2.4.2. Transmission.................................................2136 2.4.3. Battery......................................................2136 2.4.4. Hydraulic System.............................................2137 2.4.5. Brakes.......................................................2137 2.4.6. Lift and Carriage Chains.....................................2137 Lubrication Chart...............................................................2138 Oil and Grease Specifications...................................................2139 1. Approved Oils and Grease.................................................2139 2. Grease Location Points...................................................2140 3. Mast Adjustment Points...................................................2141 Contents, Section S.............................................................2142 1. Service Instructions.....................................................2142 Troubleshooting Guidelines......................................................2144 1. General..................................................................2144 2. Electrical...............................................................2146 2.1. Shorts to Frame Test...............................................2146 3. Hydraulic................................................................2151 4. Definitions..............................................................2152 Chassis.........................................................................2154 1. General..................................................................2154 2. Dash.....................................................................2155 2.1. Removal............................................................2155 2.2. Removal............................................................2156 3. Motor Compartment Door...................................................2156 3.1. Removal............................................................2156 3.2. Installation.......................................................2156 4. Left-Hand Side Panel.....................................................2157 4.1. Removal............................................................2157 5. Operator Compartment Panel...............................................2158 5.1. Removal............................................................2158 6. Main Card Access Panel...................................................2158 6.1. Removal............................................................2158 Battery Compartment.............................................................2160 1. Battery Retainer Plates..................................................2161 1.1. Inspection.........................................................2161 1.2. Removal............................................................2161 1.3. Installation.......................................................2161 2. Battery Rollers..........................................................2161 2.1. Inspection.........................................................2161 2.2. Replacement........................................................2161 Driver Controls.................................................................2162 Brake Pedal, RSX40/RRX35........................................................2164 1. Pedal Removal............................................................2165 2. Pedal Bearing Replacement................................................2166 3. Pedal Adjustment.........................................................2166 Brake Pedal, RSX50/RRX45/ RDX30.................................................2167 1. Pedal Removal............................................................2168 2. Pedal Bearing Replacement................................................2169 3. Pedal Adjustment.........................................................2169 Overhead Guard..................................................................2170 Decals..........................................................................2172 1. Decal with Protective Sheet..............................................2172 2. Decal without Protective Sheet...........................................2172 Steering Motor..................................................................2176 1. Removal..................................................................2176 2. Installation.............................................................2176 3. Steering Motor Gear Replacement..........................................2177 3.1. Removal............................................................2177 3.2. Installation.......................................................2177 Fan Motor.......................................................................2178 1. Upper Electrical Compartment Fan.........................................2178 1.1. Removal............................................................2178 1.2. Installation.......................................................2178 2. Operator Fan.............................................................2179 Motor Maintenance Schedule/Troubleshooting......................................2180 1. General Information......................................................2180 2. Operating Conditions.....................................................2180 3. Troubleshooting..........................................................2181 Motor Repair....................................................................2188 1. Disassembly..............................................................2188 2. Motor Inspection.........................................................2190 2.1. External Motor.....................................................2190 2.2. Brush and Commutator...............................................2190 2.3. Bearings...........................................................2193 2.4. Armature Electrical Check..........................................2193 2.5. Frame & Field Service Recommendation...............................2194 2.6. Assembly/Testing...................................................2195 Pump Motor......................................................................2196 1. Mounting Points..........................................................2196 1.1. Removal............................................................2197 1.2. Installation.......................................................2198 2. Repair...................................................................2200 Drive Motor.....................................................................2204 1. Mounting Points..........................................................2204 1.1. Removal............................................................2205 1.2. Installation.......................................................2206 2. Repair...................................................................2207 Transmission....................................................................2210 1. Mounting Points..........................................................2210 1.1. Fluid Changing Procedure...........................................2211 1.2. Removal............................................................2211 1.3. Installation.......................................................2212 2. Repair...................................................................2214 3. Disassemble..............................................................2216 4. Assembly.................................................................2220 5. Axle Sealing Ring........................................................2229 5.1. Disassembly........................................................2229 5.2. Assembly...........................................................2230 6. Leakage..................................................................2231 6.1. Top Cover..........................................................2231 6.2. Lower Cover........................................................2232 7. Wheel Bolt...............................................................2233 Electromagnetic Brake...........................................................2234 1. Removal..................................................................2234 2. Installation.............................................................2236 3. Adjustments..............................................................2237 4. Coil Check On Brake......................................................2238 5. Electromagnetic Brake, Armature and Magnetic Coil........................2238 5.1. Removal............................................................2238 5.2. Installation.......................................................2239 6. Brake Friction Plate.....................................................2239 6.1. Inspection.........................................................2239 6.2. Replacement........................................................2239 Drive Wheel.....................................................................2240 1. Removal..................................................................2241 2. Installation.............................................................2241 3. Tire Pressing Procedure..................................................2242 Non-Braking Caster Wheel, RRX35/ RSX40..........................................2244 1. Caster Pivot.............................................................2246 1.1. Removal............................................................2246 2. Thrust Bearing...........................................................2248 2.1. Removal............................................................2248 2.2. Installation.......................................................2249 3. Caster Springs...........................................................2250 3.1. Adjustment.........................................................2250 3.2. Removal............................................................2250 3.3. Installation.......................................................2251 4. Caster Stops.............................................................2252 4.1. Adjustment.........................................................2252 Non-Braking Caster Assembly, RRX35/RSX40........................................2254 1. Removal..................................................................2255 2. Installation.............................................................2255 Braking Caster Wheel, RRX45/RDX30/ RSX50........................................2256 1. Removal..................................................................2258 1.1. Caster Brake Adjustment............................................2258 Braking Caster Assembly, RRX45/ RDX30/RSX50.....................................2260 1. Removal..................................................................2262 2. Installation.............................................................2263 Load Wheels, Sizes 4 X 3, 5 X 4, and 5 X 3......................................2264 1. Removal..................................................................2266 2. Installation.............................................................2267 Load Wheels, Size 10.5 X 3.5....................................................2268 1. Removal..................................................................2269 2. Installation.............................................................2269 Steering Arm / Wheel / Lever....................................................2270 1. Control Pod..............................................................2272 1.1. Removal............................................................2272 1.2. Installation.......................................................2272 2. Steering Wheel...........................................................2273 2.1. Removal............................................................2273 2.2. Installation.......................................................2273 3. Steering Tach............................................................2274 3.1. Removal............................................................2274 3.2. Installation.......................................................2274 Steering Bearing................................................................2276 1. Removal..................................................................2277 2. Installation.............................................................2277 Electrical Functions............................................................2278 1. General..................................................................2278 1.1. Directional/Speed Control Lever....................................2278 1.2. Main Electronic Card...............................................2279 2. Start Up.................................................................2282 3. Steering Components......................................................2286 3.1. Steering System....................................................2286 3.2. Wheel Direction Sensors............................................2290 4. Brake Release............................................................2292 5. Direction Selection......................................................2294 6. Travel Request, Forks First..............................................2296 7. Travel Request, Forks Trailing...........................................2300 8. Plug Braking.............................................................2305 8.1. Directional/Speed Control Lever Method.............................2305 8.2. Brake Pedal Method.................................................2306 9. 12-Volt Power Supply.....................................................2309 10. 7.35-Volt Power Supplies................................................2310 11. Limit Switches..........................................................2313 11.1. Truck Travel Speed Limiting.......................................2313 11.2. Mast Staging Speed Limiting.......................................2315 12. Height Indicator........................................................2317 12.1. Height Preset Selector............................................2318 13. Drive Motor Brush Wear Indicator Switches...............................2319 14. Pump Motor Brush Indicator Switch.......................................2320 15. Safety Check............................................................2321 16. Shunt Power Cable.......................................................2323 Electrical Symbols..............................................................2330 Electrical Schematics (Serial numbers 27163000-28105000)........................2332 1. Circuit Diagram 1(11)....................................................2332 2. Circuit Diagram 2(11)....................................................2333 3. Circuit Diagram 3(11)....................................................2334 4. Circuit Diagram 4(11)....................................................2335 5. Circuit Diagram 5(11)....................................................2336 6. Circuit Diagram 6(11)....................................................2337 7. Circuit Diagram 7(11)....................................................2338 8. Circuit Diagram 8(11)....................................................2339 9. Circuit Diagram 9(11)....................................................2340 10. Circuit Diagram 10(11)..................................................2341 11. Circuit Diagram 11(11)..................................................2342 Electrical Schematics (Serial numbers 28105001-28126000)........................2344 1. Circuit Diagram 1(12)....................................................2344 2. Circuit Diagram 2(12)....................................................2345 3. Circuit Diagram 3(12)....................................................2346 4. Circuit Diagram 4(12)....................................................2347 5. Circuit Diagram 5(12)....................................................2348 6. Circuit Diagram 6(12)....................................................2349 7. Circuit Diagram 7(12)....................................................2350 8. Circuit Diagram 8(12)....................................................2351 9. Circuit Diagram 9(12)....................................................2352 10. Circuit Diagram 10(12)..................................................2353 11. Circuit Diagram 11(12)..................................................2354 12. Circuit Diagram 12(12)..................................................2355 Electrical Schematics (Serial numbers 28126001-31285000)........................2356 1. Circuit Diagram 1(12)....................................................2356 2. Circuit Diagram 2(12)....................................................2357 3. Circuit Diagram 3(12)....................................................2358 4. Circuit Diagram 4(12)....................................................2359 5. Circuit Diagram 5(12)....................................................2360 6. Circuit Diagram 6(12)....................................................2361 7. Circuit Diagram 7(12)....................................................2362 8. Circuit Diagram 8(12)....................................................2363 9. Circuit Diagram 9(12)....................................................2364 10. Circuit Diagram 10(12)..................................................2365 11. Circuit Diagram 11(12)..................................................2366 12. Circuit Diagram 12(12)..................................................2367 Electrical Schematics (Serial numbers 31285001-UP)..............................2368 1. Circuit Diagram 1(12)....................................................2368 2. Circuit Diagram 2(12)....................................................2369 3. Circuit Diagram 3(12)....................................................2370 4. Circuit Diagram 4(12)....................................................2371 5. Circuit Diagram 5(12)....................................................2372 6. Circuit Diagram 6(12)....................................................2373 7. Circuit Diagram 7(12)....................................................2374 8. Circuit Diagram 8(12)....................................................2375 9. Circuit Diagram 9(12)....................................................2376 10. Circuit Diagram 10(12)..................................................2377 11. Circuit Diagram 11(12)..................................................2378 12. Circuit Diagram 12(12)..................................................2379 Battery.........................................................................2380 1. Removal..................................................................2380 2. Installation.............................................................2380 3. Battery Maintenance......................................................2381 3.1. Battery Inspection and Care........................................2381 3.2. Battery Exterior Cleaning..........................................2382 3.3. Charging...........................................................2382 4. Storage..................................................................2383 5. Battery History Record...................................................2383 Light Assemblies................................................................2384 1. Overhead Guard Lights (Option)...........................................2384 1.1. Removal............................................................2384 1.2. Installation.......................................................2384 2. Warning Lights (Option)..................................................2385 2.1. Removal............................................................2385 2.2. Installation.......................................................2386 3. Working Lights (Option)..................................................2386 3.1. Removal............................................................2386 3.2. Installation.......................................................2386 4. Travel Alarm (Option)....................................................2387 4.1. Removal............................................................2387 4.2. Installation.......................................................2387 5. Operator Fan (Option)....................................................2388 5.1. Removal............................................................2389 5.2. Installation.......................................................2389 Horn............................................................................2390 1. Removal..................................................................2390 2. Installation.............................................................2390 Start/Stop Switches.............................................................2392 1. General..................................................................2392 1.1. Test/Inspection....................................................2392 2. Key Switch (S17).........................................................2392 2.1. Inspection.........................................................2392 2.2. Removal............................................................2393 2.3. Installation.......................................................2393 3. Emergency Disconnect Switch (S21)........................................2394 3.1. Inspection.........................................................2394 3.2. Removal............................................................2394 3.3. Installation.......................................................2395 Battery Connector...............................................................2396 1. Location.................................................................2396 2. Inspection...............................................................2396 3. Installation.............................................................2397 Mast Switch (S31)...............................................................2398 1. General..................................................................2398 1.1. Test/Inspection....................................................2398 1.2. Adjustment.........................................................2400 1.3. Removal............................................................2401 1.4. Installation.......................................................2401 Control Cable and Harness.......................................................2402 1. Fuses....................................................................2402 2. Wiring...................................................................2403 2.1. Harness............................................................2403 2.2. Power Cables.......................................................2404 Contactors......................................................................2406 1. General..................................................................2406 1.1. Resistance Testing.................................................2406 1.2. Contactor Tip Inspection...........................................2406 2. Direction Contactors.....................................................2407 2.1. Removal............................................................2408 2.2. Installation.......................................................2408 3. Lift Bypass Contactor (RRX45/RSX50/RDX30)................................2409 3.1. Removal............................................................2410 3.2. Installation.......................................................2410 4. Main Contactor...........................................................2411 4.1. Removal............................................................2412 4.2. Installation.......................................................2412 Transistor Panel (Drive)........................................................2414 1. Motor Connections........................................................2415 Transistor Panel (Lift).........................................................2416 2. Circuit Check, Drive Only................................................2418 Micro Switches..................................................................2420 1. General..................................................................2420 2. Lift Limit Override Switch (S33) Optional................................2421 2.1. Removal............................................................2421 2.2. Installation.......................................................2421 3. Optional Light and Fan Switches (S96, S97 and S99).......................2422 3.1. Removal............................................................2422 3.2. Installation.......................................................2422 Main Electronic Card............................................................2424 1. Connectivity to Truck....................................................2424 2. Transistor Controller Replacement........................................2425 3. Removal..................................................................2429 4. Installation.............................................................2429 5. Display..................................................................2435 6. Time.....................................................................2436 7. Effect on Truck..........................................................2436 8. Running time.............................................................2437 9. RV2 Adjustment Procedure.................................................2437 10. Adjustment Procedures for Setting Brake Switch and Brake Transducer.....2438 11. Battery Discharge Indicator Parameter Adjustment........................2439 12. A5 Jumper Harness Kit Installation (Serial numbers 28126000 - below)....2445 13. Warning\Caution Codes...................................................2448 14. Error Codes.............................................................2450 14.1. E102 Troubleshooting Procedures...................................2452 14.1.1. Power Circuit Checks........................................2452 14.1.2. Reference Circuit Value Checks (LED #4).....................2454 15. Programming Parameter...................................................2456 Switches and Sensors............................................................2466 1. General..................................................................2466 1.1. Test/Inspection....................................................2466 2. Platform (Right Foot) Switch (S108)......................................2466 2.1. Removal............................................................2467 2.2. Installation.......................................................2467 3. Staging Switch (S45).....................................................2468 3.1. Adjustment.........................................................2469 3.2. Removal............................................................2469 3.3. Installation.......................................................2469 4. Wheel Direction Sensor...................................................2470 4.1. Adjustment.........................................................2470 4.2. Removal............................................................2471 4.3. Installation.......................................................2471 5. Steer Proximity Sensors A and B (S66 and S67)............................2472 5.1. Adjustment.........................................................2472 5.2. Removal............................................................2473 5.3. Installation.......................................................2473 6. Drive Motor Speed(S64)/Direction Sensors (S125)..........................2474 6.1. Removal............................................................2474 6.2. Installation.......................................................2475 Hydraulic System................................................................2476 1. Operation................................................................2476 1.1. Supply.............................................................2478 1.2. Lifting............................................................2479 1.3. Lowering...........................................................2480 1.4. Reach..............................................................2482 1.5. Retract............................................................2484 1.6. Reach Relief (RRX35 Only)..........................................2485 1.7. Reach Impact (RRX35 Only)..........................................2486 1.8. Tilt Up............................................................2488 1.9. Tilt Down..........................................................2490 1.10. Side Shifting Right...............................................2492 1.11. Side Shifting Left................................................2494 2. RRX35 Hydraulic Schematic................................................2497 3. RRX45 Hydraulic Schematic................................................2498 4. RDX30 Hydraulic Schematic................................................2499 5. RSX40 Hydraulic Schematic................................................2500 6. RSX50 Hydraulic Schematic................................................2501 Hydraulic Fluid.................................................................2502 1. Hydraulic Fluid Selection................................................2502 2. Changing Hydraulic System Fluid..........................................2502 3. System Draining..........................................................2503 4. Refilling System.........................................................2504 5. Bleeding Hydraulic System................................................2505 Hydraulic Tank..................................................................2507 1. Removal..................................................................2508 2. Installation.............................................................2509 Hydraulic Filter Assembly.......................................................2511 1. Hydraulic Filter.........................................................2512 1.1. Removal............................................................2512 1.2. Installation.......................................................2512 2. Hydraulic Filter Adapter.................................................2513 2.1. Removal............................................................2513 2.2. Installation.......................................................2513 Hydraulic Pump..................................................................2515 1. Removal..................................................................2515 2. Repair...................................................................2515 Control Valve...................................................................2516 1. Removal..................................................................2516 2. Installation.............................................................2516 Control Valve Assembly..........................................................2521 3. Repair...................................................................2523 3.1. Proportional Pre-Pressure Reducing Valve...........................2523 3.2. Valve Assembly SWR14...............................................2523 3.3. Pressure Limiting Valve Assembly...................................2524 3.4. Setting Lift/Auxiliary Pressure Relief with a Rated Load...........2524 3.5. Hydraulic Lowering Rate Adjustment.................................2525 3.6. Recondition Seal Kit...............................................2526 Staging Cylinder, Three Stage Mast..............................................2528 1. Bearing Removal..........................................................2529 2. Disassembly..............................................................2530 3. Assembly.................................................................2530 4. Installation.............................................................2530 Freelift Cylinder, Three Stage Mast.............................................2532 1. Removal..................................................................2534 2. Disassembly..............................................................2535 3. Assembly.................................................................2535 4. Installation.............................................................2535 Reach Cylinder Assembly.........................................................2536 1. Removal..................................................................2538 2. Disassembly..............................................................2539 3. Inspection...............................................................2540 4. Assembly.................................................................2541 5. Installation.............................................................2542 Tilt Cylinder Assembly, RRX35/RSX40/ RSX50......................................2544 1. Removal..................................................................2545 2. Disassembly..............................................................2546 3. Inspection...............................................................2547 4. Assembly.................................................................2548 5. Installation.............................................................2549 Tilt Cylinder Assembly, RRX45/RDX30.............................................2550 1. Removal..................................................................2552 2. Disassembly..............................................................2553 3. Inspection...............................................................2554 4. Assembly.................................................................2555 5. Installation.............................................................2556 Mast, 3 Stage...................................................................2558 1. Shimming Carriage with Mast on Truck.....................................2562 2. Three Stage Mast.........................................................2564 2.1. Removal............................................................2564 2.2. Disassembly........................................................2565 2.3. Assembly...........................................................2566 2.4. Installation.......................................................2568 3. Lift Chain...............................................................2569 3.1. Lift Chain Adjustment..............................................2569 3.2. Lift Chain Maintenance.............................................2569 3.3. Lift Chain Inspection..............................................2569 3.3.1. Wear.........................................................2570 3.3.2. Rust and Corrosion...........................................2570 3.3.3. Cracked Plates...............................................2571 3.3.4. Protruding or Turned Pins....................................2573 3.3.5. Chain Side Wear..............................................2574 3.3.6. Chain Anchors and Sheaves....................................2574 3.3.7. Lift Chain Lubrication.......................................2574 3.4. Lift Chain Replacement.............................................2576 Lifting Gear (Crosshead)........................................................2578 1. Lifting Gear Repair......................................................2580 1.1. Removal............................................................2580 1.2. Disassembly........................................................2581 1.3. Assembly...........................................................2581 1.4. Installation.......................................................2581 Sideshifter, RRX35/45/RDX30.....................................................2582 1. Mounting Instructions....................................................2584 1.1. Installation.......................................................2584 2. Operation and Maintenance................................................2585 2.1. Lower Slides.......................................................2585 2.2. Upper Slides.......................................................2586 2.3. Cylinder...........................................................2586 Sideshifter, RRX35/45/RSX40/50/RDX30............................................2588 1. Mounting Instructions....................................................2590 1.1. Installation.......................................................2590 2. Operation................................................................2591 3. Maintenance..............................................................2591 3.1. Carriage Removal...................................................2592 3.2. Upper Pad Replacement..............................................2592 3.3. Lower Pad Replacement..............................................2593 3.4. Cylinder...........................................................2594 4. Troubleshooting..........................................................2595 4.1. No Sideshifting....................................................2595 4.2. Sideshifting Very Slow.............................................2595 4.3. Irregular Sideshifting.............................................2595 Single Reach, RRX35.............................................................2596 1. Maintenance..............................................................2602 1.1. Inspection.........................................................2602 1.2. Adjustment.........................................................2603 2. Reach Repair.............................................................2607 2.1. Removal............................................................2607 2.1. Disassembly........................................................2607 2.1.1. Front Frame Removal..........................................2607 2.1.2. Outer Arm Removal............................................2608 2.1.3. Inner Arm Removal............................................2608 2.1.4. Rear Frame Removal...........................................2608 2.1.5. Reach Cylinder Removal.......................................2609 2.2. Assembly...........................................................2609 2.2.1. Reach Cylinder Installation..................................2609 2.2.2. Rear Frame Installation......................................2609 2.2.3. Inner Arm Installation.......................................2610 2.2.4. Outer Arm Installation.......................................2610 2.2.5. Front Frame Installation.....................................2611 3. Carriage Bumpers.........................................................2611 3.1. Reach Adjustment...................................................2611 4. Fork Carriage Pivot Pins.................................................2613 5. Carriage Roller Bearings.................................................2613 5.1. Removal............................................................2613 5.2. Installation.......................................................2613 Single Reach, RRX45.............................................................2614 1. Maintenance..............................................................2614 2. Reach Repair.............................................................2622 2.1. Disassembly........................................................2622 2.1.1. Forward Frame Removal........................................2622 2.1.2. Outer Arm Removal............................................2622 2.1.3. Inner Arm Removal............................................2623 2.1.4. Rear Frame Removal...........................................2623 2.1.5. Reach Cylinder Removal.......................................2624 2.2. Assembly...........................................................2624 2.2.1. Reach Cylinder Installation..................................2624 2.2.2. Rear Frame Installation......................................2624 2.2.3. Inner Arm Installation.......................................2625 2.2.4. Outer Arm Installation.......................................2625 2.2.5. Front Frame Installation.....................................2626 3. Fork Carriage Pivot Pins.................................................2626 4. Carriage Roller Bearings.................................................2627 4.1. Removal............................................................2627 4.2. Installation.......................................................2627 Double Reach Mechanism, RDX30...................................................2628 1...........................................................................2629 Rod.........................................................................2629 24..........................................................................2629 Bearing.....................................................................2629 46..........................................................................2629 Bearing, 3 stage............................................................2629 2...........................................................................2629 Arm.........................................................................2629 25..........................................................................2629 Ring, Nilos.................................................................2629 47..........................................................................2629 Cap, bearing................................................................2629 3...........................................................................2629 Bearing, thrust.............................................................2629 26..........................................................................2629 Set, bearing................................................................2629 48..........................................................................2629 Screw.......................................................................2629 4...........................................................................2629 Bearing.....................................................................2629 27..........................................................................2629 Spacer......................................................................2629 49..........................................................................2629 Bearing.....................................................................2629 5...........................................................................2629 Arm.........................................................................2629 28..........................................................................2629 Tilt cylinder assembly......................................................2629 50..........................................................................2629 Cap.........................................................................2629 6...........................................................................2629 Pin, roll...................................................................2629 29..........................................................................2629 Screw.......................................................................2629 51..........................................................................2629 Screw.......................................................................2629 7...........................................................................2629 Pin.........................................................................2629 30..........................................................................2629 Pin.........................................................................2629 52..........................................................................2629 Block, bumper...............................................................2629 8...........................................................................2629 Frame, fork.................................................................2629 31..........................................................................2629 Screw, set..................................................................2629 53..........................................................................2629 Bumper......................................................................2629 9...........................................................................2629 Screw.......................................................................2629 32..........................................................................2629 Arm.........................................................................2629 54..........................................................................2629 Screw, socket head..........................................................2629 10..........................................................................2629 Frame, forward..............................................................2629 33..........................................................................2629 Nut, lock...................................................................2629 55..........................................................................2629 Screw, socket head..........................................................2629 11..........................................................................2629 Bearing.....................................................................2629 34..........................................................................2629 Arm.........................................................................2629 56..........................................................................2629 Lockwasher..................................................................2629 12..........................................................................2629 Shim........................................................................2629 35..........................................................................2629 Arm.........................................................................2629 57..........................................................................2629 Bushing.....................................................................2629 13..........................................................................2629 Arm.........................................................................2629 36..........................................................................2629 Pin.........................................................................2629 58..........................................................................2629 Bracket.....................................................................2629 14..........................................................................2629 Nut.........................................................................2629 37..........................................................................2629 Screw.......................................................................2629 59..........................................................................2629 Shield......................................................................2629 15..........................................................................2629 Pin, cotter.................................................................2629 38..........................................................................2629 Reach cylinder assembly.....................................................2629 60..........................................................................2629 Screw, cap..................................................................2629 16..........................................................................2629 Nut, slotted................................................................2629 39..........................................................................2629 Fitting, grease.............................................................2629 61..........................................................................2629 Manifold....................................................................2629 17..........................................................................2629 Washer......................................................................2629 40..........................................................................2629 Frame, rear.................................................................2629 62..........................................................................2629 Control valve...............................................................2629 18..........................................................................2629 Ring, Nilos.................................................................2629 41..........................................................................2629 Washer, shim................................................................2629 63..........................................................................2629 Cover.......................................................................2629 19..........................................................................2629 Cone, bearing...............................................................2629 42..........................................................................2629 Screw.......................................................................2629 64..........................................................................2629 Screw, cap..................................................................2629 20..........................................................................2629 Race, bearing...............................................................2629 43..........................................................................2629 Bar, wear...................................................................2629 65..........................................................................2629 Nut, flanged................................................................2629 21..........................................................................2629 Ring, retainer..............................................................2629 44..........................................................................2629 Shim........................................................................2629 66..........................................................................2629 Washer......................................................................2629 22..........................................................................2629 Shim........................................................................2629 45..........................................................................2629 Shim........................................................................2629 67..........................................................................2629 Shim........................................................................2629 23..........................................................................2629 Arm.........................................................................2629 1. Theory of Operation......................................................2630 2. Maintenance..............................................................2630 3. Troubleshooting..........................................................2630 4. Repair...................................................................2630 5. Rebuild..................................................................2630 Forks...........................................................................2632 1. Removal..................................................................2634 2. Inspection...............................................................2634 3. Installation.............................................................2635 Load Indicator..................................................................2636 Load Indicator..................................................................2638 1. Pulse Sensor.............................................................2640 1.1. Repair.............................................................2640 1.2. Cable..............................................................2640 1.2.1. Removal......................................................2640 1.2.2. Installation.................................................2640 1.3. Pulley.............................................................2641 1.3.1. Removal......................................................2641 Height Indicator and Preset Selector............................................2642 1. General..................................................................2643 2. Operation................................................................2643 3. Preset Height............................................................2644 4. Display..................................................................2645 5. Display Symbols Description..............................................2646 6. Programming..............................................................2647 6.1. Programming a Level................................................2647 6.1.1. Collection Level.............................................2647 6.1.2. Leaving Level................................................2647 6.2. Erasing Programmed Levels..........................................2648 6.2.1. Automatic Operations.........................................2648 6.2.2. Collecting a Load............................................2648 6.2.3. Leaving a Load...............................................2649 6.3. Parameters.........................................................2650 Load Backrest...................................................................2656 1. Removal..................................................................2659 2. Installation.............................................................2659 A...........................................................................2660 B...........................................................................2660 C...........................................................................2660 D...........................................................................2661 E...........................................................................2661 F...........................................................................2661 G...........................................................................2661 H...........................................................................2661 I...........................................................................2662 J...........................................................................2662 K...........................................................................2662 L...........................................................................2662 M...........................................................................2662 N...........................................................................2662 O...........................................................................2662 P...........................................................................2662 R...........................................................................2663 S...........................................................................2663 T...........................................................................2663 V...........................................................................2664 W...........................................................................2664
S.S 06/24
