BT-Prime Mover RC-30B RC-40B RC-50B Electric Stand-up Rider Truck Repair Manual PDF

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BT-Prime Mover RC-30B RC-40B RC-50B Electric Stand-up Rider Truck Repair Manual – PDF DOWNLOAD

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BT-Prime Mover RC-30B RC-40B RC-50B Electric Stand-up Rider Truck Repair Manual – PDF DOWNLOAD

Language : English
Pages : 235
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

BT-Prime Mover RC-30B RC-40B RC-50B Electric Stand-up Rider Truck Repair Manual – PDF DOWNLOAD

Effective Serial Number 93-17290

Front Cover 1
Contents 3
Wiring Diagrams 3
Hydraulic Schematics 3
General Information 5
Troubleshooting 5
Maintenance 5
Specifications Tables 7
Torque Specifications 7
Introduction 11
The Service Manual 11
How to Use this Manual 11
The Equipment 12
Safety Precautions – Maintenance & Repair 13
Specifications Tables 17
General 17
Capacities 17
Steering System 17
Tires 17
Batteries 17
Travel Speeds & Current Draw 18
Lifting Speeds 18
Lift & Tilt System 18
Torque Specifications 19
Contents 21
Introduction 21
Maintenance Procedures 21
Introduction 23
General 23
Towing a Disabled Lift Truck 23
Lifting a Disabled Lift Truck 23
Putting the Lift Truck on Blocks 24
Scheduled Maintenance and Inspections 25
Scheduled Maintenance & Inspections Table 26
Maintenance Procedures Every 8 Hours or Daily 27
General 27
SRO Circuit 27
General Functions 27
Battery 27
Charging the Battery 28
Changing the Battery 28
Battery Connector 28
Inspection 28
Battery Gates 28
Inspection 28
Upright 29
Hydraulic System 30
Checking for Leaks 30
Drive Unit 30
Checking Operation 30
Forks 30
Inspection 30
Wheels & Tires 31
Inspection 31
Drive Wheel – Removal & Installation 31
Steer Wheel – Removal & Installation 31
Changing Tires 31
Brake Pedal 32
Inspect & Lubricate 32
Brake Switch 32
Check for Operation 32
Brakes 32
Check Operation 32
Controls/Horn 32
Check Operation 32
Steering System 32
Check Operation 32
Lights 32
Inspect 32
Decals 33
Inspect 33
Maintenance Procedures Every 40 Hours or 5 Days 34
Battery 34
Cleanliness 34
Water Level 34
Lift Chains 34
Inspect 35
Hydraulic System 35
Check Oil Level 35
Maintenance Procedures Every 350 Hours or 60 Days 36
Battery 36
Charging 36
Lift Chains 36
Lubrication 36
Check Tension 36
Upright 37
Lubrication 37
Hydraulic System 37
Breather Cap 37
Drive Unit 37
Check Fluid Level 37
Brakes 38
Check Fluid 38
Hinges & Levers 38
Steering 38
Motor Brushes 39
Drive Motors 39
Lift Pump Motor 39
Steering Pump Motor 40
Contactor Tips 40
Maintenance Procedures Every 2000 Hours or 360 Days 41
Hydraulic System 41
Change the Hydraulic Oil 41
Change the Hydraulic Oil Filter 41
Breather Cap 41
Drive Units 41
Wheels & Tires 42
Lubricate Wheel Bearings 42
Brakes 42
Brake Shoes 42
Contents 43
Wiring Diagrams 43
Contents 55
Introduction 55
Maintenance 55
Introduction 57
General 57
Safety 57
Maintenance 58
Installation 58
Removal 58
Charging the Battery 59
Normal Charge 59
Equalizing Charge 59
Cleaning the Battery 59
Hydrometer Use 60
Voltage Check 60
Adding Water 60
Battery History Record 60
Contents 63
Troubleshooting Tables 63
Power Section 65
Brake System 66
Steering System 68
Hydraulic System 69
Hydraulic Gear Pump 71
Uprights 73
Main Control Valve 74
Industrial Battery 75
Contents 77
Power Section 77
Brake System 77
Steering System 77
Controls Mechanical 77
Electrical System 77
Hydraulic System 77
Elevating Section 77
Contents 79
Drive Unit Assembly 79
Introduction 79
Repairs 79
Disassembly 79
Assembly 79
Installation 79
DC Motor Repair 79
Introduction 79
Repairs 79
Hydraulic Pump Motor 79
Power Steering Motor 80
DC Motor Maintenance 80
Introduction 80
Brush and Commutator Inspection 80
Brush Replacement 80
Tests for a Damaged Field and Armature 80
Brush Holder Test 80
Drive Unit Assembly 81
Introduction 81
Description 81
Repairs 81
Removal – General 81
Removal – Complete Drive Assembly 81
Removal – Final Drive Assembly 82
Disassembly 83
Single Stage Gear Housing 83
Final Drive Unit 83
Figure 3 5 – Drive Unit 84
Inspection 85
Assembly 85
Final Drive Unit 85
Single Stage Gear Housing 86
Final Drive Assembly 87
Installation 87
Complete Drive Assembly 87
Final Drive Assembly 88
DC Motor Repair 89
Introduction 89
Repairs 89
Drive Motor 89
Disassembly 91
Checks and Inspection 91
Assembly 91
Installation 91
Hydraulic Pump Motor 92
Removal 92
Disassembly 93
Checks and Inspection 93
Assembly 93
Installation 93
Power Steering Motor 93
Removal 93
Figure 3 14 – Hydraulic Pump Motor 94
Disassembly 95
Checks and Inspection 95
Assembly 95
Installation 96
DC Motor Maintenance 97
Introduction 97
Brush and Commutator Inspection 97
Figure 3 17 Normal Commutator Surfaces 98
Figure 3 18 Commutator Problems 99
Normal Commutator Surface 101
Brush Replacement 101
Tests for a Damaged Field and Armature 102
Armature Tests 102
Test for an Open Circuit 102
Test for Short Circuit – Armature Winding 102
Test for Short Circuit – Armature 102
Field Coil Tests 102
Test for an Open Circuit 102
Test for a Short Circuit in a Field 103
Test for a Short Circuit Between the Field and the Motor Case 103
Brush Holder Test 103
Contents 105
The Brake Assembly 105
Repairs 105
The Slave Cylinders 105
Repairs 105
The Master Cylinder 105
Repairs 105
Checks and Adjustments 105
The Brake Assembly 107
Description 107
Repairs 108
Removal and Disassembly 108
Cleaning and Inspection 109
Assembly and Installation 109
The Slave Cylinders 111
Repairs 111
Removal and Disassembly 111
Cleaning and Inspection 112
Assembly and Installation 112
The Master Cylinder 113
Repairs 113
Removal and Disassembly 113
Cleaning and Inspection 114
Assembly and Installation 114
Checks and Adjustments 115
Removing the Air from the Brake System 115
Adjusting the Brakes 115
Adjusting the Brake Pedal and Master Cylinder 116
Contents 117
Introduction 117
Repairs 117
Steering Fork Assembly 117
Steer Wheel 117
Steering Chain 117
Torque Generator 117
Additional Checks and Inspections 117
Steering System 119
Introduction 119
Description 119
Repairs 120
Steering Fork Assembly 120
Removal 120
Cleaning and Inspection 121
Installation 121
Steer Wheel 122
Removal 122
Installation 123
Steering Chain 123
Torque Generator 124
Removal 124
Disassembly 124
Cleaning 124
Assembly 124
Figure 3 7 Torque Generator and Gear Mount Assembly 125
Installation 126
Figure 3 8 The Torque Generator 126
Figure 3 9 Torque Generator Timing 127
Additional Checks and Inspections 128
Contents 129
Mechanical Controls 129
Control Handles 129
Battery Disconnect 129
Mechanical Controls 131
Control Handles 131
Control Linkage Adjustment 131
Figure 4 1 Control Handles 131
Multi-Function Control Handle and Switch Replacement 132
Battery Disconnect 132
Battery Disconnect Adjustment 132
Figure 4 2 Adjusting the Control Linkage 132
Contents 135
GE EV100 LXT Controls 135
General 135
Maintenance 135
Instructions EV100 LX/LXT SCR Controls 137
EV100 LX/LXT Dual Motor Control 139
Terminal Connections for LX/LXT Logic Cards 140
EV100 LX/LXT Specifications 141
Features 142
EV100 LX/LXT Current Limit Curves 145
Basics of Circuit Operation 146
Control Features 147
Oscillator 147
Current Limit 147
Plugging 148
Pedal Position Plug 148
Ramp Start 148
Full Power Transition 148
Control Acceleration and 1A Time 148
1A Current Drop Out 148
Static Return to Off 148
Accelerator Volts Hold-Off 148
Coil Driver Modules 149
1A Thermal Hold Off 149
Must Pulse to Time 149
Pulse Monitor Trip 149
Thermal Protector 149
Low Voltage 150
Field Weakening 150
Dual Motor Operation 150
Dual Motor In-Board Wheel Reversal 151
Dual Motor Two Speed Limit 151
Top Speed (Motor Volts) Limit 151
Steer Pump Contactor Time Delay 151
Constant Current Coil Drivers and Internal Coil Suppression 151
Hour Meter Readings 151
Internal Resistance Compensation 151
Truck Management Module (TMM1) 152
Truck Management Module (TMM2) 152
Stored Status Code 152
On Board Diagnostics 152
Battery Discharge Indication 152
Handset 152
General Maintenance Instructions 153
Troubleshooting Instructions 154
Instructions – Status Codes 155
Checking Components 173
Main Logic Card 173
Capacitor 1C 174
Potentiometer in Accelerator 174
SCR’s (1REC, 2REC, 5REC) 174
Rectifiers (3REC, 4REC, Diode Blocks) 175
Thermal Protector (TP) 175
Filter Block 176
1X Choke and Reactor T3 – T4 176
Replacement of EV-100 Components 177
Instructions – EV100 Handset 178
GE EV100 LXT BT Prime-Mover Factory Settings – All Models 183
Contents 185
Introduction 185
Repairs 185
Hydraulic Gear Pumps 185
The Lift Cylinders 185
The Tilt Cylinders 186
The Main Control Valve 186
The Hydraulic System 187
Introduction 187
Description 187
Operation 187
Multi-Lever Configuration 188
Multi-Function Handle Configuration 188
Repairs 189
Hydraulic Pump 189
Removal 189
Installation 189
Power Steering Pump 189
Installation 189
Multi-Lever Main Control Valve 190
Removal 190
Installation 190
Multi-Function Handle Main Control Valve 191
Removal 191
Installation 191
Multi-Function Solenoid Selector Valve 192
Removal 192
Installation 192
Hydraulic Pump Switches 192
Adjustment 192
Hydraulic Gear Pumps 194
Introduction 194
Description 194
Repairs 195
Seal Replacement – Power Steering Pump 195
Checking for Air in the System 195
The Lift Cylinders 196
Introduction 196
Description 196
Flow Control Valve & Flow Fuses 196
Repairs 197
Removal of the Lift Cylinder – Two Stage Uprights 197
Figure 6 7 Two Stage Upright 198
Figure 6 8 Three Stage Upright 199
Removal of the Lift Cylinders – Three Stage Uprights 200
Disassembly 201
Assembly 202
Figure 6 14 Lift Cylinder – Two Stage Upright 203
Figure 6 15 Inner Lift Cylinder – Three Stage Upright 203
Figure 6 16 Inner Lift Cylinder – Three Stage Upright 204
Figure 6 17 Outer Lift Cylinder – Three Stage Upright 204
Installation of the Lift Cylinder – Two Stage Uprights 205
Installation of the Lift Cylinders – Three Stage Uprights 205
The Tilt Cylinders 207
Introduction 207
Description 207
Repairs 207
Removal 207
Disassembly 207
Cleaning & Inspection 207
Assembly 208
Installation 208
Checks and Adjustments 209
Checking for Leakage 209
Adjusting the Tilt Angle 209
The Main Control Valve 210
Introduction 210
Description 210
Figure 6 21 Main Control Valve 211
Operation 212
Lift Section 212
Tilt Section 212
Solenoid Valve for Auxiliary Function 213
Relief Valve 213
Repairs 214
Removal & Disassembly 214
Cleaning & Inspection 215
Assembly 215
Checks & Adjustments 215
Primary Relief Valve 215
Auxiliary Function Relief Valve 216
Contents 217
Introduction 217
Uprights Repair 217
Forks 217
Carriage 217
Uprights 217
Side Shift Carriage 217
Side Shift Carriage – Checks and Adjustments 217
Hose Reel Assembly 217
Checks and Adjustments 217
The Elevating Section 219
Introduction 219
Description 219
Simplex Uprights 219
Triplex Uprights 219
Figure 7 1 Flow Control Valves and Flow Fuses 220
Figure 7 2 Two Stage Uprights 221
Figure 7 3 Three Stage Upright 222
Uprights Repair 223
Forks 223
Carriage 223
Removal 223
Installation 224
Uprights 225
Removal 225
Disassembly 226
Cleaning and Inspection 227
Assembly 229
Installation 229
Upright Adjustment 230
Carriage Adjustment 230
Sideshift Carriage 231
Removal 231
Repairs 231
Installation 231
Sideshift Carriage Checks and Adjustments 231
Adjusting the Restrictor Cartridge 231
Lower Hook Adjustment 232
Hose Reel Assembly 232
Removal 232
Installation 233
Checks and Adjustments 233
Leaks Outside the Hydraulic Lift System 233
Leaks Inside the Hydraulic Lift System 233
Adjusting the Tilt Angle 234
Lift Chain Adjustments 234

S.V 11/01/2025