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BT FORKLIFT RCX25 RCX30C RCX30 RCX35 RCX40 RCX45 RCX50 SERVICE MANUAL – PDF DOWNLOAD
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BT FORKLIFT RCX25 RCX30C RCX30 RCX35 RCX40 RCX45 RCX50 SERVICE MANUAL – PDF DOWNLOAD
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Description
BT FORKLIFT RCX25 RCX30C RCX30 RCX35 RCX40 RCX45 RCX50 SERVICE MANUAL – PDF DOWNLOAD
FILE DETAILS:
BT FORKLIFT RCX25 RCX30C RCX30 RCX35 RCX40 RCX45 RCX50 SERVICE MANUAL – PDF DOWNLOAD
Language : English
Pages : 492
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
BT FORKLIFT RCX25 RCX30C RCX30 RCX35 RCX40 RCX45 RCX50 SERVICE MANUAL – PDF DOWNLOAD
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 Back Cover..........................................................................................492
DESCRIPTION:
BT FORKLIFT RCX25 RCX30C RCX30 RCX35 RCX40 RCX45 RCX50 SERVICE MANUAL – PDF DOWNLOAD
- 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.S 06/01/2025
