Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
BT Prime-Mover RCX25,RCX30C,RCX30,RCX35,RCX40,RCX45 Service Manual – PDF
$28.95
BT Prime-Mover RCX25,RCX30C,RCX30,RCX35,RCX40,RCX45,RCX50 Service Manual – PDF DOWNLOAD
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
BT Prime-Mover RCX25,RCX30C,RCX30,RCX35,RCX40,RCX45,RCX50 Service Manual – PDF DOWNLOAD
FILE DETAILS:
BT Prime-Mover RCX25,RCX30C,RCX30,RCX35,RCX40,RCX45,RCX50 Service Manual – PDF DOWNLOAD
Language : English
Pages : 493
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
BT Prime-Mover RCX25,RCX30C,RCX30,RCX35,RCX40,RCX45,RCX50 Service Manual – PDF DOWNLOAD
Front Cover......................................................................................... 2 Foreword............................................................................................ 4 Contents............................................................................................ 6 Group SA - Safe Maintenance......................................................................... 10 Section 1 - Safety.............................................................................. 12 Safety Signs and Messages................................................................... 13 Safety Maintenance Practices................................................................ 13 General Shop Precautions.................................................................... 15 Section 2 - Machine Jacking and Blocking........................................................ 18 Raising Drive Wheels........................................................................ 19 Blocking the Upright in Raised Position..................................................... 20 Raising Rear of Truck....................................................................... 20 Raising Truck with a Hoist.................................................................. 21 Group PS - Periodic Service......................................................................... 22 Section 1 - Maintenance Schedules............................................................... 24 Maintenance Schedules....................................................................... 25 Lubrication Points.......................................................................... 26 Lubrication Chart Key....................................................................... 27 Miscellaneous Lubricants.................................................................... 28 Section 2 - Planned Maintenance................................................................. 30 Use PM Report Form.......................................................................... 31 How to Perform the PM Periodic Inspections and Maintenance.................................. 31 Visual Inspection....................................................................... 31 Functional Checks....................................................................... 34 Test Drive Truck with Load.................................................................. 37 Lift Mechanism and Controls............................................................. 38 Battery Compartment Inspection.......................................................... 39 Motor SCR Control Inspection............................................................ 40 Control and Hydraulic Compartment Inspection............................................ 40 Control Levers and Linkage Inspection................................................... 40 Air Cleaning................................................................................ 40 Critical Fastener Torque Checks............................................................. 40 Lubrication, Fluids and Filters............................................................. 41 Hydraulic Sump.......................................................................... 41 Hydraulic Fluid and Filter Change....................................................... 41 Hydraulic Oil Filter.................................................................... 41 Sump Tank Breather Maintenance.......................................................... 41 Access to the Drive Axle................................................................ 41 Drive Axle Fluid........................................................................ 41 Drive Axle Fluid Change................................................................. 42 Truck Chassis Inspection and Lubrication................................................ 42 Uprights and Tilt Cylinder Lubrication.................................................. 42 Lift Chains............................................................................. 42 Group 12 - Battery.................................................................................. 44 Section 1 - Battery Handling.................................................................... 46 Typical Battery Service Area................................................................ 47 Battery Handling............................................................................ 48 Battery Maintenance......................................................................... 51 How to Get Maximum Life Out of Your Battery............................................. 51 Battery Vents........................................................................... 52 Battery Cleaning........................................................................ 52 Battery Charging........................................................................ 52 Battery Electrolyte..................................................................... 52 Clean Battery Compartment............................................................... 52 Replacement Battery..................................................................... 52 Install Battery............................................................................. 53 Keeping Battery Records..................................................................... 53 Group 13 - Electrical Handle Switch................................................................. 54 Section 1 - Control Handle Switch............................................................... 56 Tilt, Auxiliary 1 and Auxiliary 2 (Attachment) Switches..................................... 59 Remove and Install...................................................................... 59 Up and Down Switches........................................................................ 60 Remove and Install...................................................................... 60 Forward and Reverse Switches, Transducer (Speed Control).................................... 61 Remove and Install Switches............................................................. 61 Remove and Install Transducer........................................................... 61 Group 16 - Electrical Motors........................................................................ 62 Section 1 - General Information................................................................. 64 Safety...................................................................................... 65 Servicing Electric Motors................................................................... 65 Electric Motor Maintenance.................................................................. 66 Inspection Procedures................................................................... 66 Motor Cleanliness....................................................................... 66 Motor Inspection........................................................................ 66 Test for Motor Insulation "Resistance to Ground"............................................ 67 Using a 500 Volt Megger................................................................. 67 Using a Simpson 260-6p Volt Ohmmeter or Equivalent Calibrated on the Rx 10,000 Scale.... 67 Brush and Commutator Inspection............................................................. 68 Operating Conditions........................................................................ 68 Brush and Commutator Inspection......................................................... 68 Brush Inspection Chart...................................................................... 70 Section 2 - Drive Motors........................................................................ 72 Safety...................................................................................... 73 General Information......................................................................... 74 Operating Conditions........................................................................ 74 Drive Motor Description..................................................................... 75 Drive Motor Removal......................................................................... 75 Drive Motor................................................................................. 75 Drive Motor................................................................................. 77 Disassembly............................................................................. 77 Component Inspection and Troubleshooting................................................ 79 Testing................................................................................. 80 Frame and Field Service Notes........................................................... 80 Assembly................................................................................ 80 36 Volt Drive Motor Specifications.......................................................... 82 Brush Inspection Chart...................................................................... 83 Section 3 - Hydraulic Pump Motors............................................................... 84 Safety...................................................................................... 85 General Information......................................................................... 86 Operating Conditions........................................................................ 86 Hydraulic Pump Motor........................................................................ 87 Disassembly............................................................................. 87 Component Inspection and Troubleshooting................................................ 89 Testing................................................................................. 90 Frame and Field Service Notes........................................................... 90 Assembly................................................................................ 90 36 Volt Drive Motor Specifications.......................................................... 92 Brush Inspection Chart...................................................................... 93 Section 4 - Steer Pump Motor.................................................................... 94 Safety...................................................................................... 95 General Information......................................................................... 96 Operating Conditions........................................................................ 96 Steer Pump Motor (Permanent Magnet Type).................................................... 97 Troubleshooting Prior to Disassembly.................................................... 97 Disassembly............................................................................. 99 Component Inspection and Troubleshooting................................................101 Assembly................................................................................102 36 Volt Drive Motor Specifications..........................................................103 Motor Specifications....................................................................103 Brush Inspection Chart......................................................................104 Group 17 - Electrical Schematics....................................................................106 Section 1 - Wiring Schematics and Diagrams......................................................108 Standard Wiring Schematic...................................................................109 Standard Wiring Diagram.....................................................................110 Optional Wiring Schematic...................................................................111 Optional Wiring Diagram.....................................................................112 Lights Wiring Schematic.....................................................................113 Lights Wiring Diagram.......................................................................114 Strobe and Alarm Wiring Schematic...........................................................115 Strobe and Alarm Wiring Diagram.............................................................116 Group 19 - Electrical Controls......................................................................118 Section 1 - Control Panel.......................................................................120 Control Panel Description...................................................................121 Control Features........................................................................123 Control Panel Maintenance...................................................................124 Control Panel Troubleshooting...............................................................124 Troubleshooting Notes...................................................................125 Control and Contactor Panel Removal.........................................................125 Control and Contactor Panel Component Identification........................................127 Contactor Inspection........................................................................131 1A and Main Pump Contactors.............................................................131 Plugging and Power Steering Contactor...................................................133 Forward and Reverse Contactor...........................................................134 Oscillator Card.........................................................................138 Control and Contactor Panel Installation....................................................139 Section 2 - EV-100MK Troubleshooting............................................................144 Check #1, 2, 5 REC's (SCR's)................................................................145 Check Capacitor (1C)........................................................................149 Checking Component with VOM (Only)..........................................................150 #22, 23, 24 and 25 Filter Blocks........................................................150 #3 and 4 Rectifiers.....................................................................151 Filter Mounting Terminal Block..........................................................152 Sensor..................................................................................153 Thermal Protector.......................................................................154 Reactor/Choke Module....................................................................155 EV-100 MK Card Factory Settings.............................................................156 Oscillator Card Voltage Checks..............................................................157 Oscillator Card Wiring Schematic........................................................158 Solenoid Function Control Card Voltage Checks...............................................159 Solenoid Function Control Card Wiring Schematic.........................................160 Section 3 - Recommended Tests, Equipment, and Procedures........................................162 Recommended Tests...........................................................................163 Test Equipment..........................................................................163 Test Procedures.........................................................................163 Test Procedures.............................................................................163 Ground Fault Condition..................................................................163 Power Steer Idle Current................................................................164 SCR Current Limit.......................................................................164 1A Free-Wheeling Current................................................................164 1A Time Delay...........................................................................165 Creep Speed Motor Volts.................................................................165 Plugging................................................................................166 Section 4 - Drive Motor Cut-Out Switch Check and Adjustment.....................................168 Drive Motor Cut-Out Switch Check............................................................169 Drive Motor Cut-Out Switch Adjustment.......................................................170 Section 5 - Forward and Reverse Switches, Up and Down Switches, and Transducer Adjustments......172 Multi-Function Control Handle Connector Identification......................................173 Switches and Transducer Adjustments.........................................................174 Section 6 - Periodic Electrical Checks..........................................................184 Truck Preparation...........................................................................185 Electrical Connectors.......................................................................186 Power Cables............................................................................188 Fasteners...............................................................................189 Motor Connections.......................................................................190 Control Panel Connections...............................................................191 Cable Routing and Connections...........................................................192 Control Cards Connections...............................................................196 Section 7 - Battery Tests.......................................................................198 Battery Tests...............................................................................199 Section 8 - Solenoid Control Card Troubleshooting...............................................200 Indicator Lights............................................................................201 Troubleshooting Solenoid Control Card.......................................................202 Lift Function ONLY Disabled.................................................................204 Install New Solenoid Control Card...........................................................206 Section 14 - EV100 LXT Control Panel............................................................208 General.....................................................................................209 Operation...................................................................................209 Function Set-Up Procedures..................................................................210 Description of Function Numbers for:........................................................211 IC3645EVLXCDI1TT........................................................................211 IC3645EVLXCDI1TX........................................................................211 IC3645EVLXCDI1TK........................................................................211 IC3645EVLXCDI1MT........................................................................214 IC3645EVLXCDI1MX........................................................................214 IC3645EVLXCDI1MK........................................................................214 IC3645EVLXCDI1PX........................................................................217 Section 15 - EV100 LXT Control Panel Status Codes...............................................220 Section 16 - Checking Components................................................................254 Main Logic Card.............................................................................255 Capacitor...................................................................................256 Contactors F, R, 1A, SP, FW, D, Regen, and P................................................256 Potentiometer in Accelerator................................................................256 SCR's (1REC, 2REC, 3REC)....................................................................256 Rectifiers (3REC, 4REC, Diode Blocks).......................................................257 Thermal Protector (TP)......................................................................257 Filter Block (23FIL, etc.)..................................................................257 1X Choke and Reactor T3-T4..................................................................257 Replacement of EV-100 Components............................................................258 1REC, 2REC, or 5REC.....................................................................258 Capacitor...............................................................................258 22REC, 23REC, and 25REC.................................................................258 Group 20 - Drive Axle...............................................................................260 Section 1 - Drive Axle..........................................................................262 General Description.........................................................................263 Service Notes...............................................................................263 Drive Axle Maintenance......................................................................263 Fluid Level Checks......................................................................263 Fluid Change Procedure..................................................................263 Drive Axle Removal..........................................................................264 Drive Axle Special Tools....................................................................265 Drive Axle Disassembly......................................................................269 Drive Axle Notes........................................................................269 Drive Axle Assembly.....................................................................272 Drive Axle Installation.................................................................275 Group 22 - Wheels and Tires.........................................................................278 Section 1 - Cushion Wheels and Tires............................................................280 Cushion Drive and Steering Tire Specifications..............................................281 Cushion Drive Tire Removal..................................................................281 Cushion Drive Tire Inspection...............................................................281 Cushion Drive Tire Removal and Replacement..................................................282 Cushion Drive Wheel Installation............................................................282 Steering Wheel Removal......................................................................283 Steering Tire Inspection....................................................................284 Steering Wheel Installation.................................................................284 Section 2 - Pneumatic Drive Tire and Wheel Maintenance..........................................286 Pneumatic Tire Warning......................................................................287 Safety Procedures...........................................................................288 Pneumatic Drive Tire Specifications.........................................................289 Pneumatic Tire Maintenance..................................................................289 Pneumatic Drive Wheel and Tire Removal and Disassembly......................................290 Pneumatic Drive Tire Assembly...............................................................295 Filling Tires with Air..................................................................295 Filling Tires with Nitrogen.............................................................295 Procedures for Adding Air Pressure to Mounted Tire and Wheel Assembly...................297 Directional Thread Tires................................................................298 Pneumatic Drive Wheel and Tire Installation.................................................298 Group 23 - Brake System.............................................................................300 Section 1 - Brake System and Bleeding...........................................................302 Brake System Description....................................................................303 Bleeding the Brake System...................................................................304 Section 2 - Brake Adjustment....................................................................306 Brake Lining Wear Check.....................................................................307 Brake Lining Wear Adjustment................................................................308 Minor Brake Adjustment..................................................................308 Major Brake Adjustment..................................................................309 Replacing Brake Linings.....................................................................310 Section 3 - Brake Slave Cylinder................................................................312 Brake Slave Cylinder........................................................................313 Removal.................................................................................313 Disassembly.............................................................................314 Inspection..............................................................................314 Assembly................................................................................314 Installation............................................................................315 Group 25 - Steering Gear............................................................................316 Section 1 - Steering Gear.......................................................................318 Steering Gear Description...................................................................319 Steering Gear Troubleshooting...............................................................320 Steering Gear Removal.......................................................................320 Steering Gear Disassembly...................................................................321 Steering Gear Parts Inspection..............................................................323 Steering Gear Assembly......................................................................323 Steering Gear Installation..................................................................326 Group 26 - Steering Axle............................................................................328 Section 1 - Steering Axle Repair................................................................330 Steering Axle Removal.......................................................................331 Steering Axle Installation..................................................................332 Section 2 - Power Steering Pump.................................................................334 Steering Pump Description...................................................................335 Steering Pump Troubleshooting...............................................................335 Steering Pump Removal.......................................................................335 Steering Pump Disassembly...................................................................337 Steering Pump Parts Inspection..............................................................338 Steering Pump Assembly......................................................................339 Steering Pump Installation..................................................................340 Steering Pump Installation Specifications...................................................341 Steering Lines Installation Specifications..................................................342 Reverse Steering Lines Installation Specifications..........................................344 Section 3 - Steering Torque Generator...........................................................346 Steering Torque Generator Description.......................................................347 Steering Torque Generator Removal...........................................................347 Steering Torque Generator Disassembly.......................................................349 Steering Torque Generator Parts Inspection..................................................350 Steering Torque Generator Assembly..........................................................351 Steering Torque Generator Installation......................................................352 Steering Torque Generator Assembly Specifications...........................................354 Steering Torque Generator Lines Installation Specifications.................................355 Group 29 - Hydraulic Pump, Sump and Filter..........................................................356 Section 1 - Hydraulic Pump......................................................................358 Main Hydraulic Pump.........................................................................359 Removal.................................................................................359 Preparation for Disassembly.............................................................359 Disassembly.............................................................................359 Parts Inspection........................................................................359 Assembly................................................................................361 Hydraulic Pump Installation.............................................................363 Hydraulic Pump Installation Specifications..............................................363 Section 2 - Hydraulic Sump and Filter...........................................................364 Hydraulic Sump and Filter Assembly..........................................................365 Section 3 - Hydraulic Schematics................................................................366 Hydraulic Diagram...........................................................................367 Group 30 - Hydraulic Control Valves.................................................................368 Section 1 - Main Control Valve..................................................................370 Servicing Main Control Valve................................................................371 Relief Valve Assembly.......................................................................373 Procedure for Cartridge Seal Replacement................................................373 Adjustable Relief Valve Seal Nut Replacement............................................374 Non-Adjustable Relief Valve.............................................................374 Load Check Valve............................................................................375 Disassembly.............................................................................375 Inspection..............................................................................375 Assembly................................................................................375 Main Control Valve End Cap and Components...................................................376 Disassembly.............................................................................376 Assembly................................................................................376 Main Control Valve..........................................................................378 Disassembly.............................................................................378 Assembly................................................................................379 Section 2 - Face Seal Fittings..................................................................380 Face Seal Fittings..........................................................................382 Assembly Suggestions....................................................................382 Hydraulic Hose or Tube Installation.................................................382 Section 3 - Hydraulic System Pressure Checks - Lift Circuit.....................................384 Test Ports..................................................................................385 Hydraulic Lift Circuits Pressure Checks.....................................................386 Check Lift Circuit Relief Valve Setting.................................................386 Relief Valve Adjustment.................................................................386 Section 4 - Hydraulic System Pressure Checks - Steering Circuit.................................388 Test Ports..................................................................................389 Hydraulic Steering Circuit Pressure Checks..................................................390 Check Steering Circuit Relief Valve Setting.............................................390 Relief Valve Adjustment.................................................................390 Section 5 - Hydraulic System Pressure Checks - Auxiliary and Tilt Circuits......................392 Test Ports..................................................................................393 Hydraulic Pressure Checks...................................................................394 Check Auxiliary and Tilt Circuits Relief Valve Setting..................................394 Relief Valve Adjustment.................................................................395 Section 6 - Flow Controls - Selector Solenoid Valve.............................................396 Valve Identification........................................................................397 Hydraulic Solenoid Valves...................................................................398 Cartridge Valve Installation Procedure..................................................398 Service Specifications..................................................................399 Optional Auxiliary 2 Valve Specifications...............................................400 Group 31 - Hydraulic Supply System..................................................................402 Section 1 - Hydraulic System....................................................................404 General Description.........................................................................405 Hydraulic Fluid and Filter Change...........................................................405 Remote Pump Method......................................................................405 Truck Pump Method.......................................................................406 Hydraulic Sump Tank.........................................................................408 Group 32 - Cylinders................................................................................410 Section 1 - Tilt Cylinder.......................................................................412 Tilt Cylinder Components....................................................................413 Tilt Cylinder Plumbing Layout...............................................................414 Tilt Cylinder Drift Test....................................................................415 Tilt Cylinder Removal.......................................................................415 Tilt Cylinder Rod End Removal...............................................................417 Tilt Cylinder Disassembly...................................................................417 Tilt Cylinder Inspection....................................................................417 Tilt Cylinder Assembly......................................................................419 Tilt Cylinder Installation..................................................................419 Face Seal Fittings..........................................................................421 Assembly Suggestions....................................................................421 Tilt Check and Adjustment...................................................................423 Group 33 - Selector Solenoid Valve..................................................................426 Section 1 - Selector Solenoid Valve.............................................................428 Selector Solenoid Valve Description.........................................................429 Selector Solenoid Valve Troubleshooting.....................................................429 Selector Solenoid Valve Removal.............................................................430 Selector Solenoid Valve Repair..............................................................430 Selector Solenoid Valve Installation........................................................430 Device Selector Solenoid Valve..............................................................431 Group 34 - Uprights.................................................................................432 Section 1 - Upright.............................................................................434 Upright Maintenance.........................................................................435 Triple Stage Upright........................................................................435 Upright Rail Shim Inspection............................................................435 Carriage Shim Inspection................................................................437 Disassembly for Shim Adjustments........................................................437 Assembly for Shim Adjustments...........................................................443 Lift Cylinder Drift Check...............................................................444 Hydraulic Cylinder Repair...............................................................445 Standard (Two Stage) Upright................................................................447 Upright Rail Shim Inspection............................................................447 Carriage Shim Inspection................................................................449 Disassembly for Shim Adjustments........................................................449 Assembly for Shim Adjustment............................................................453 Lift Cylinder Drift Check...............................................................454 Upright Cylinder Repair.................................................................454 Section 2 - Chain Inspection, Adjustment, and Replacement.......................................460 Periodic Inspection.........................................................................463 Elongation..............................................................................463 Edge Wear...............................................................................463 Turning or Protruding Pins..............................................................463 Cracked Plate...........................................................................463 Ultimate Strength Failure...............................................................464 Tight Joints............................................................................464 Chain Length Adjustments....................................................................464 Standard Upright Chain Length Adjustments...............................................465 Triple-Stage Upright (TSU) Chain Length Adjustment......................................465 Chain Lubrication...........................................................................467 Chain Removal and Replacement...............................................................467 General Guidelines......................................................................467 Lift Chains (Standard and TSUs).........................................................468 Carriage Chains (TSUs)..................................................................468 Other Chain Service Notes...................................................................469 Group 40 - Specifications...........................................................................470 Section 1 - Specifications......................................................................472 Group 12 - Battery..........................................................................473 Group 16 - Motors...........................................................................474 Group 19 - Electrical Controls..............................................................474 Group 20 - Drive Axle.......................................................................475 Group 22 - Wheels and Tires.................................................................475 Group 23 - Brakes...........................................................................475 Group 25/26 - Steering System...............................................................475 Group 29/30 - Hydraulic System..............................................................475 Group 32 - Tilt Cylinder....................................................................476 Group 34 - Uprights.........................................................................477 Group 40 - Specifications...................................................................478 Section 2 - Data Plate..........................................................................480 How to Read Data Plate......................................................................481 Battery Weight Chart........................................................................483 Section 3 - Lubricants and Shop Supplies........................................................484 Lubricants and Shop Supplies................................................................485 Lubricants..............................................................................485 Sealants................................................................................487 Gasket Materials........................................................................488 Threadlocks and Threadsealers...........................................................489 Cleaners................................................................................490 Back Cover..........................................................................................493
S.S 06/24
