BT-Prime Mover RCX25 RCX30C RCX30 RCX35 RCX40 RCX45 RCX50 Truck Service Manual – PDF DOWNLOAD

Description

BT-Prime Mover RCX25 RCX30C RCX30 RCX35 RCX40 RCX45 RCX50 Truck Service Manual – PDF DOWNLOAD

FILE DETAILS:

BT-Prime Mover RCX25 RCX30C RCX30 RCX35 RCX40 RCX45 RCX50 Truck Service Manual – PDF DOWNLOAD

Language : English
Pages : 489
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

BT-Prime Mover RCX25 RCX30C RCX30 RCX35 RCX40 RCX45 RCX50 Truck Service Manual – PDF DOWNLOAD

Manual Part Number 304421-000
Effective Serial Number RCX__2604001

Front Cover 1
Foreword 3
Contents 5
Group SA – Safe Maintenance 9
Section 1 – Safety 11
Safety Signs and Messages 12
Safety Maintenance Practices 12
General Shop Precautions 14
Section 2 – Machine Jacking and Blocking 17
Raising Drive Wheels 18
Blocking the Upright in Raised Position 19
Raising Rear of Truck 19
Raising Truck with a Hoist 20
Group PS – Periodic Service 21
Section 1 – Maintenance Schedules 23
Maintenance Schedules 24
Lubrication Points 25
Lubrication Chart Key 26
Miscellaneous Lubricants 27
Section 2 – Planned Maintenance 29
Use PM Report Form 30
How to Perform the PM Periodic Inspections and Maintenance 30
Visual Inspection 30
Functional Checks 33
Test Drive Truck with Load 36
Lift Mechanism and Controls 37
Battery Compartment Inspection 38
Motor SCR Control Inspection 39
Control and Hydraulic Compartment Inspection 39
Control Levers and Linkage Inspection 39
Air Cleaning 39
Critical Fastener Torque Checks 39
Lubrication, Fluids and Filters 40
Hydraulic Sump 40
Hydraulic Fluid and Filter Change 40
Hydraulic Oil Filter 40
Sump Tank Breather Maintenance 40
Access to the Drive Axle 40
Drive Axle Fluid 40
Drive Axle Fluid Change 41
Truck Chassis Inspection and Lubrication 41
Uprights and Tilt Cylinder Lubrication 41
Lift Chains 41
Group 12 – Battery 43
Section 1 – Battery Handling 45
Typical Battery Service Area 46
Battery Handling 47
Battery Maintenance 50
How to Get Maximum Life Out of Your Battery 50
Battery Vents 51
Battery Cleaning 51
Battery Charging 51
Battery Electrolyte 51
Clean Battery Compartment 51
Replacement Battery 51
Install Battery 52
Keeping Battery Records 52
Group 13 – Electrical Handle Switch 53
Section 1 – Control Handle Switch 55
Tilt, Auxiliary 1 and Auxiliary 2 (Attachment) Switches 58
Remove and Install 58
Up and Down Switches 59
Remove and Install 59
Forward and Reverse Switches, Transducer (Speed Control) 60
Remove and Install Switches 60
Remove and Install Transducer 60
Group 16 – Electrical Motors 61
Section 1 – General Information 63
Safety 64
Servicing Electric Motors 64
Electric Motor Maintenance 65
Inspection Procedures 65
Motor Cleanliness 65
Motor Inspection 65
Test for Motor Insulation “Resistance to Ground” 66
Using a 500 Volt Megger 66
Using a Simpson 260-6p Volt Ohmmeter or Equivalent Calibrated on the Rx 10,000 Scale 66
Brush and Commutator Inspection 67
Operating Conditions 67
Brush and Commutator Inspection 67
Brush Inspection Chart 69
Section 2 – Drive Motors 71
Safety 72
General Information 73
Operating Conditions 73
Drive Motor Description 74
Drive Motor Removal 74
Drive Motor 74
Drive Motor 76
Disassembly 76
Component Inspection and Troubleshooting 78
Testing 79
Frame and Field Service Notes 79
Assembly 79
36 Volt Drive Motor Specifications 81
Brush Inspection Chart 82
Section 3 – Hydraulic Pump Motors 83
Safety 84
General Information 85
Operating Conditions 85
Hydraulic Pump Motor 86
Disassembly 86
Component Inspection and Troubleshooting 88
Testing 89
Frame and Field Service Notes 89
Assembly 89
36 Volt Drive Motor Specifications 91
Brush Inspection Chart 92
Section 4 – Steer Pump Motor 93
Safety 94
General Information 95
Operating Conditions 95
Steer Pump Motor (Permanent Magnet Type) 96
Troubleshooting Prior to Disassembly 96
Disassembly 98
Component Inspection and Troubleshooting 100
Assembly 101
36 Volt Drive Motor Specifications 102
Motor Specifications 102
Brush Inspection Chart 103
Group 17 – Electrical Schematics 105
Section 1 – Wiring Schematics and Diagrams 107
Standard Wiring Schematic 108
Standard Wiring Diagram 109
Optional Wiring Schematic 110
Optional Wiring Diagram 111
Lights Wiring Schematic 112
Lights Wiring Diagram 113
Strobe and Alarm Wiring Schematic 114
Strobe and Alarm Wiring Diagram 115
Group 19 – Electrical Controls 117
Section 1 – Control Panel 119
Control Panel Description 120
Control Features 122
Control Panel Maintenance 123
Control Panel Troubleshooting 123
Troubleshooting Notes 124
Control and Contactor Panel Removal 124
Control and Contactor Panel Component Identification 126
Contactor Inspection 130
1A and Main Pump Contactors 130
Plugging and Power Steering Contactor 132
Forward and Reverse Contactor 133
Oscillator Card 137
Control and Contactor Panel Installation 138
Section 2 – EV-100MK Troubleshooting 143
Check #1, 2, 5 REC’s (SCR’s) 144
Check Capacitor (1C) 148
Checking Component with VOM (Only) 149
#22, 23, 24 and 25 Filter Blocks 149
#3 and 4 Rectifiers 150
Filter Mounting Terminal Block 151
Sensor 152
Thermal Protector 153
Reactor/Choke Module 154
EV-100 MK Card Factory Settings 155
Oscillator Card Voltage Checks 156
Oscillator Card Wiring Schematic 157
Solenoid Function Control Card Voltage Checks 158
Solenoid Function Control Card Wiring Schematic 159
Section 3 – Recommended Tests, Equipment, and Procedures 161
Recommended Tests 162
Test Equipment 162
Test Procedures 162
Test Procedures 162
Ground Fault Condition 162
Power Steer Idle Current 163
SCR Current Limit 163
1A Free-Wheeling Current 163
1A Time Delay 164
Creep Speed Motor Volts 164
Plugging 165
Section 4 – Drive Motor Cut-Out Switch Check and Adjustment 167
Drive Motor Cut-Out Switch Check 168
Drive Motor Cut-Out Switch Adjustment 169
Section 5 – Forward and Reverse Switches, Up and Down Switches, and Transducer Adjustments 171
Multi-Function Control Handle Connector Identification 172
Switches and Transducer Adjustments 173
Section 6 – Periodic Electrical Checks 183
Truck Preparation 184
Electrical Connectors 185
Power Cables 187
Fasteners 188
Motor Connections 189
Control Panel Connections 190
Cable Routing and Connections 191
Control Cards Connections 195
Section 7 – Battery Tests 197
Battery Tests 198
Section 8 – Solenoid Control Card Troubleshooting 199
Indicator Lights 200
Troubleshooting Solenoid Control Card 201
Lift Function ONLY Disabled 203
Install New Solenoid Control Card 205
Section 14 – EV100 LXT Control Panel 207
General 208
Operation 208
Function Set-Up Procedures 209
Description of Function Numbers for: 210
IC3645EVLXCDI1TT 210
IC3645EVLXCDI1TX 210
IC3645EVLXCDI1TK 210
IC3645EVLXCDI1MT 213
IC3645EVLXCDI1MX 213
IC3645EVLXCDI1MK 213
IC3645EVLXCDI1PX 216
Section 15 – EV100 LXT Control Panel Status Codes 219
Section 16 – Checking Components 253
Main Logic Card 254
Capacitor 255
Contactors F, R, 1A, SP, FW, D, Regen, and P 255
Potentiometer in Accelerator 255
SCR’s (1REC, 2REC, 3REC) 255
Rectifiers (3REC, 4REC, Diode Blocks) 256
Thermal Protector (TP) 256
Filter Block (23FIL, etc ) 256
1X Choke and Reactor T3-T4 256
Replacement of EV-100 Components 257
1REC, 2REC, or 5REC 257
Capacitor 257
22REC, 23REC, and 25REC 257
Group 20 – Drive Axle 259
Section 1 – Drive Axle 261
General Description 262
Service Notes 262
Drive Axle Maintenance 262
Fluid Level Checks 262
Fluid Change Procedure 262
Drive Axle Removal 263
Drive Axle Special Tools 264
Drive Axle Disassembly 268
Drive Axle Notes 268
Drive Axle Assembly 271
Drive Axle Installation 274
Group 22 – Wheels and Tires 277
Section 1 – Cushion Wheels and Tires 279
Cushion Drive and Steering Tire Specifications 280
Cushion Drive Tire Removal 280
Cushion Drive Tire Inspection 280
Cushion Drive Tire Removal and Replacement 281
Cushion Drive Wheel Installation 281
Steering Wheel Removal 282
Steering Tire Inspection 283
Steering Wheel Installation 283
Section 2 – Pneumatic Drive Tire and Wheel Maintenance 285
Pneumatic Tire Warning 286
Safety Procedures 287
Pneumatic Drive Tire Specifications 288
Pneumatic Tire Maintenance 288
Pneumatic Drive Wheel and Tire Removal and Disassembly 289
Pneumatic Drive Tire Assembly 294
Filling Tires with Air 294
Filling Tires with Nitrogen 294
Procedures for Adding Air Pressure to Mounted Tire and Wheel Assembly 296
Directional Thread Tires 297
Pneumatic Drive Wheel and Tire Installation 297
Group 23 – Brake System 299
Section 1 – Brake System and Bleeding 301
Brake System Description 302
Bleeding the Brake System 303
Section 2 – Brake Adjustment 305
Brake Lining Wear Check 306
Brake Lining Wear Adjustment 307
Minor Brake Adjustment 307
Major Brake Adjustment 308
Replacing Brake Linings 309
Section 3 – Brake Slave Cylinder 311
Brake Slave Cylinder 312
Removal 312
Disassembly 313
Inspection 313
Assembly 313
Installation 314
Group 25 – Steering Gear 315
Section 1 – Steering Gear 317
Steering Gear Description 318
Steering Gear Troubleshooting 319
Steering Gear Removal 319
Steering Gear Disassembly 320
Steering Gear Parts Inspection 322
Steering Gear Assembly 322
Steering Gear Installation 325
Group 26 – Steering Axle 327
Section 1 – Steering Axle Repair 329
Steering Axle Removal 330
Steering Axle Installation 331
Section 2 – Power Steering Pump 333
Steering Pump Description 334
Steering Pump Troubleshooting 334
Steering Pump Removal 334
Steering Pump Disassembly 336
Steering Pump Parts Inspection 337
Steering Pump Assembly 338
Steering Pump Installation 339
Steering Pump Installation Specifications 340
Steering Lines Installation Specifications 341
Reverse Steering Lines Installation Specifications 343
Section 3 – Steering Torque Generator 345
Steering Torque Generator Description 346
Steering Torque Generator Removal 346
Steering Torque Generator Disassembly 348
Steering Torque Generator Parts Inspection 349
Steering Torque Generator Assembly 350
Steering Torque Generator Installation 351
Steering Torque Generator Assembly Specifications 353
Steering Torque Generator Lines Installation Specifications 354
Group 29 – Hydraulic Pump, Sump and Filter 355
Section 1 – Hydraulic Pump 357
Main Hydraulic Pump 358
Removal 358
Preparation for Disassembly 358
Disassembly 358
Parts Inspection 358
Assembly 360
Hydraulic Pump Installation 362
Hydraulic Pump Installation Specifications 362
Section 2 – Hydraulic Sump and Filter 363
Hydraulic Sump and Filter Assembly 364
Section 3 – Hydraulic Schematics 365
Hydraulic Diagram 366
Group 30 – Hydraulic Control Valves 367
Section 1 – Main Control Valve 369
Servicing Main Control Valve 370
Relief Valve Assembly 372
Procedure for Cartridge Seal Replacement 372
Adjustable Relief Valve Seal Nut Replacement 373
Non-Adjustable Relief Valve 373
Load Check Valve 374
Disassembly 374
Inspection 374
Assembly 374
Main Control Valve End Cap and Components 375
Disassembly 375
Assembly 375
Main Control Valve 377
Disassembly 377
Assembly 378
Section 2 – Face Seal Fittings 379
Face Seal Fittings 381
Assembly Suggestions 381
Hydraulic Hose or Tube Installation 381
Section 3 – Hydraulic System Pressure Checks – Lift Circuit 383
Test Ports 384
Hydraulic Lift Circuits Pressure Checks 385
Check Lift Circuit Relief Valve Setting 385
Relief Valve Adjustment 385
Section 4 – Hydraulic System Pressure Checks – Steering Circuit 387
Test Ports 388
Hydraulic Steering Circuit Pressure Checks 389
Check Steering Circuit Relief Valve Setting 389
Relief Valve Adjustment 389
Section 5 – Hydraulic System Pressure Checks – Auxiliary and Tilt Circuits 391
Test Ports 392
Hydraulic Pressure Checks 393
Check Auxiliary and Tilt Circuits Relief Valve Setting 393
Relief Valve Adjustment 394
Section 6 – Flow Controls – Selector Solenoid Valve 395
Valve Identification 396
Hydraulic Solenoid Valves 397
Cartridge Valve Installation Procedure 397
Service Specifications 398
Optional Auxiliary 2 Valve Specifications 399
Group 31 – Hydraulic Supply System 401
Section 1 – Hydraulic System 403
General Description 404
Hydraulic Fluid and Filter Change 404
Remote Pump Method 404
Truck Pump Method 405
Hydraulic Sump Tank 407
Group 32 – Cylinders 409
Section 1 – Tilt Cylinder 411
Tilt Cylinder Components 412
Tilt Cylinder Plumbing Layout 413
Tilt Cylinder Drift Test 414
Tilt Cylinder Removal 414
Tilt Cylinder Rod End Removal 416
Tilt Cylinder Disassembly 416
Tilt Cylinder Inspection 416
Tilt Cylinder Assembly 418
Tilt Cylinder Installation 418
Face Seal Fittings 420
Assembly Suggestions 420
Tilt Check and Adjustment 422
Group 33 – Selector Solenoid Valve 425
Section 1 – Selector Solenoid Valve 427
Selector Solenoid Valve Description 428
Selector Solenoid Valve Troubleshooting 428
Selector Solenoid Valve Removal 429
Selector Solenoid Valve Repair 429
Selector Solenoid Valve Installation 429
Device Selector Solenoid Valve 430
Group 34 – Uprights 431
Section 1 – Upright 433
Upright Maintenance 434
Triple Stage Upright 434
Upright Rail Shim Inspection 434
Carriage Shim Inspection 436
Disassembly for Shim Adjustments 436
Assembly for Shim Adjustments 442
Lift Cylinder Drift Check 443
Hydraulic Cylinder Repair 444
Standard (Two Stage) Upright 446
Upright Rail Shim Inspection 446
Carriage Shim Inspection 448
Disassembly for Shim Adjustments 448
Assembly for Shim Adjustment 452
Lift Cylinder Drift Check 453
Upright Cylinder Repair 453
Section 2 – Chain Inspection, Adjustment, and Replacement 459
Periodic Inspection 462
Elongation 462
Edge Wear 462
Turning or Protruding Pins 462
Cracked Plate 462
Ultimate Strength Failure 463
Tight Joints 463
Chain Length Adjustments 463
Standard Upright Chain Length Adjustments 464
Triple-Stage Upright (TSU) Chain Length Adjustment 464
Chain Lubrication 466
Chain Removal and Replacement 466
General Guidelines 466
Lift Chains (Standard and TSUs) 467
Carriage Chains (TSUs) 467
Other Chain Service Notes 468
Group 40 – Specifications 469
Section 1 – Specifications 471
Group 12 – Battery 472
Group 16 – Motors 473
Group 19 – Electrical Controls 473
Group 20 – Drive Axle 474
Group 22 – Wheels and Tires 474
Group 23 – Brakes 474
Group 25/26 – Steering System 474
Group 29/30 – Hydraulic System 474
Group 32 – Tilt Cylinder 475
Group 34 – Uprights 476
Group 40 – Specifications 477
Section 2 – Data Plate 479
How to Read Data Plate 480
Battery Weight Chart 482
Section 3 – Lubricants and Shop Supplies 483
Lubricants and Shop Supplies 484
Lubricants 484
Sealants 486
Gasket Materials 487
Threadlocks and Threadsealers 488
Cleaners 489

DESCRIPTION:

BT-Prime Mover RCX25 RCX30C RCX30 RCX35 RCX40 RCX45 RCX50 Truck Service Manual – PDF DOWNLOAD

Manual Part Number 304421-000
Effective Serial Number RCX__2604001

FOREWORD:

• This Service Publication provides information covering normal service, maintenance and repair of the BT Prime-Mover lift truck noted on the cover. It has been specifically prepared to help owners and service personnel maintain these trucks in efficient and safe operating condition.
• This Manual is intended for use by persons who are trained and authorized to do lift truck maintenance. It is designed to provide essential information about the correct and safe service maintenance and repair of the truck by trained mechanics or service technicians.
• The Pictorial Contents list components or systems by Basic Group Number of Major Parts. Additional content listings are placed at the beginning of each Section in the manual.
• General and detailed service and repair procedures are outlined (as required) for each component or subsystem. Some procedures include explanations that are common to several components or subsystems.
• Procedures have been easier to use by providing specific steps only when necessary and general instructions required to explain the activity, component, assembly, or process being worked on.
• The technician is expected to include obvious additional steps of standard procedure for removal, disassembly, cleaning, inspection, reassembly, installation, etc., as needed.
• To be better prepared to do the necessary service work, take time to completely read the entire procedure, including any special instructions, before starting any work.

S.V 11/01/2025