BT Prime-Mover RR-30B Reach Truck Repair Manual – PDF DOWNLOAD

Description

BT Prime-Mover RR-30B Reach Truck Repair Manual – PDF DOWNLOAD

FILE DETAILS:

BT Prime-Mover RR-30B Reach Truck Repair Manual – PDF DOWNLOAD 

Language : English
Pages : 376
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

BT Prime-Mover RR-30B Reach Truck Repair Manual – PDF DOWNLOAD 

Front Cover 1
Introduction 3
Important Notice 3
Preliminary Service 3
Index 4
Warning 5
Operating Rules and Instructions 6
Operator Qualifications 6
Operator Training 6
Operator Responsibility 6
General Rules and Practices 6
Traveling 7
Loading 8
Operator of the Truck 8
Arrival and Pre-Delivery Check List 9
Parts Ordering Instructions 10
Field Modifications 10
Dealers Owners Record 11
Frame Index 13
05:01 General Description 14
05:02 Auxiliary Door 14
05:03 Battery Retainer 14
05:04 Battery Rollers 14
Routine Maintenance 14
Disassembly 14
Assembly 15
05:05 Load Wheel Assembly 15
05:06 Caster Assembly 15
Routine Maintenance 15
Removal 15
Installation 15
Main Frame and Load Wheel Assembly 16
Instruments and Dash Controls Index 19
10:01 General Description 20
10:02 Emergency Disconnect 21
Disassembly 21
Inspection 21
Assembly 22
Emergency Disconnect Assembly 22
10:03 Auxiliary Control 24
Disassembly 24
Inspection 24
Assembly 25
Auxiliary Control Assembly 25
10:04 Hand Lift and Speed Control 26
Master Control Switch 26
Disassembly 26
Hand Lift and Speed Control Assembly 26
Assembly 27
10:05 Steering 29
Theory of Operation 29
Hydraulic 29
Electrical 29
Mechanical 29
Routine Maintenance 29
Torque Generator 29
Disassembly 29
Inspection 30
Assembly 30
Steering Assembly 32
Steering Troubleshooting 33
10:06 Brake 36
Theory of Operation 36
Brake Adjustments 36
Disassembly 36
Assembly 37
Brake Assembly 38
Brake Assembly Troubleshooting 39
Transmission Index 41
15:01 General Description 42
15:02 Transmission 42
Theory of Operation 42
Drive Motor 42
Electrical 42
Mechanical 42
Lubrication 42
Drive Motor Removal and Installation 43
Disassembly 43
Assembly 43
Transmission and Drive Motor Installation 43
Transmission Assembly 44
Drive Wheel Removal and Installation 46
Assembly 46
Transmission Installation 46
Transmission Disassembly 47
Inspection 58
Assembly 58
Install Transmission in Truck 77
Troubleshooting Transmission 78
Electrical System Index 81
20:01 General Description 82
Electrical Wiring 83
SCR Control System 83
Direction Control 83
Diode Test 84
Contactor Coil Test 85
20:02 Battery 86
Delivery 86
Specific Gravity as Related to Open Cell Voltage 88
Understanding Volts, Watts and Ampes 89
Battery Selection 89
Battery Troubleshooting Chart 90
Relay Wiring Harness Assembly 94
Switch Relay Assembly 95
Wiring Harness Assembly 96
Wiring Assembly for Cold Storage 98
Two Stage Mast Cable Assembly 99
Three Stage Mast Cable Assembly 100
Reach Cable Assembly 101
Power Component Wiring 102
SCR and Contactor Panel Assembly 103
EV-1 SCR Control 104
Transformer Assembly 105
Rectifier Heat Sink Assembly 106
Connector Assembly 107
Warning Light Assembly 108
20:03 Contactor 110
EV-1 Panel Contactors 110
Disassembly 110
Assembly 110
Single-Pole, Double-Throw Type 110
Contactors 110
Connections 110
Maintenance and Adjustment 111
Power Contacts 111
Disassembly 111
Inspection 111
Coils 111
Assembly 111
G E Contactor Assembly 112
Single-Pole, Double-Throw Type 113
Contactors 113
Connections 113
Maintenance and Adjustment 113
Power Contacts 113
Disassembly 113
Inspection 113
Coils 113
Assembly 114
G E Contactor Assembly 114
Contactor Assembly 115
Connections 115
Maintenance and Adjustment 115
Disassembly 115
Inspection 115
Assembly 115
Contactor Assembly 116
Component Symbol Explanation 118
Typical Physical Arrangement and Identification of Components 121
Circuit Operation 122
Control Features 122
General Maintenance Instructions 124
Troubleshooting the GE EV-1 SCR System 124
EV-1 Circuit Analyzer 125
SCR’s 125
To Prepare Truck for Troubleshooting 126
Preliminary Check List 126
Quick Check 126
Failures Which Cause Reduced or No Motor Torque 127
Failures Which Cause Full Motor Torque with SCR Control 134
Misoperation of Other Features 135
Checking Components 140
Replacement of EV-1 Components 144
Tuneup for New or Mistuned Card 1 145
Function of EV-1 Card Terminals as Used on Prime-Mover Stand-Up End Controlled and Order Selector Units 146
20:04 Prestolite Motor Service Instructions 148
Cleaning 148
Visual Inspection 148
Testing 148
Frame and Field Assembly 148
Armature 149
Frame and Field Service Notes 149
Field Coil Installation 149
Assembly and Testing 150
Electric Motor Repair 150
Service Procedures 150
Disassembly 150
Cleaning 152
Visual Inspection 152
Lift Motor Assembly 154
Auxiliary Motor Assembly 155
Drive Motor Assembly 156
Motor Troubleshooting 157
20:05 Master Control Switch 158
Disassembly 158
Assembly 159
Master Control Switch Troubleshooting 161
Hydraulic Index 163
30:01 General Description 164
Hydraulic System – Theory of Operation 164
General 164
Auxiliary Pump 164
Power Steering 165
Auxiliary Control Valve 165
Lift System Pump Motor 165
Lift System 165
Hydraulic Pump/Motor 165
To Drain the Reservoir Tank 166
Installing a Seal Kit 166
Oil Filter 166
Oil Filter Cartridge – To Remove 166
Filter Cartridge – To Fit 166
Reservoir Filling 167
Piping Leaks 167
The Basic Causes of 37 Degree Flare Leakage 167
Cures 167
Joint Leaks After Tightening Properly 167
The Basic Causes of O-Ring Seal Leakage 167
Cures 168
Pipe Threads Leaks 168
Causes/Cures 168
Flareless Connections 169
Installation 169
Installation O-Ring Fittings 169
Hydraulic Reservoir Assembly 170
Routine Maintenance 170
30:02 Lift Pump 171
Routine Maintenance 171
Removal 171
Installation 171
Cessna Lift Pump 172
Routine Maintenance 172
Disassembly 172
Inspection 172
Gear 172
Front and Back Plate 173
Body 173
24 Volt Lift Pump Assembly 173
Assembly 173
Running Test 174
Cessna Lift Pump Troubleshooting 175
Dowty Pump Assembly 176
Routine Maintenance 176
Disassembly 176
Inspecting the Parts 176
Body 176
Bushes 176
Gear 177
End Cover 177
Mounting Flange 177
36 Volt Lift Pump Assembly 177
Seal and Tie Bolts 177
Assembly 177
Running Test 178
Dowty Lift Pump Troubleshooting 179
30:03 Auxiliary Pump 180
Routine Maintenance 180
Removal 180
Installation 180
Auxiliary Pump and Motor Assembly 180
Cessna Auxiliary Pump 181
Routine Maintenance 181
Disassembly 181
Inspection 181
Gear 181
Housing 181
Assembly 182
Cessna Auxiliary Pump Troubleshooting 183
30:04 Torque Generator 184
Steering – Theory of Operation 184
Hydraulic 184
Electrical 184
Mechanical 184
Routine Maintenance 184
Cleaning 184
Removal 184
Installation 184
Steering Assembly 185
Torque Generator 186
Operation 186
Disassembly 186
Assembly 187
Lubrication 187
Inspection 187
Assembly 187
Steering Troubleshooting 191
30:05 Lift Valve 192
Lift Control Valve (Removal/Installation 192
Routine Maintenance 192
Cleaning 192
Removal 192
Installation 192
Valve Information 192
Hand Lift and Speed Assembly 193
Theory of Operation 194
Hydraulic Valve Switch (Cessna Valves) 194
Cessna Lift Control Valve Assembly 194
Disassembly 194
Inspection 194
Assembly 195
Cessna Valve Switch Adjustment 195
Troubleshooting Cessna Lift Control Valve Assembly 197
30:06 Auxiliary Valve 199
Routine Maintenance 199
Cleaning 199
Removal 199
Installation 199
Cessna Auxiliary Control Valve Assembly 199
Disassembly 199
Inspection 200
Assembly 200
Cessna Valve Switch Adjustment 200
Auxiliary Control Valve Troubleshooting 202
30:07 Solenoid Valve 204
Routine Maintenance 204
Cleaning 204
Removal 204
Installation 204
Disassembly 204
Assembly 204
Reach with Tilt Manifold Valve Assembly 205
Sideshifter Manifold Valve Assembly 205
Solenoid Valve Troubleshooting 206
30:08 Deep Reach Solenoid Valve 208
Routine Maintenance 208
Cleaning 208
Removal 208
Installation 208
Disassembly 208
Assembly 209
Deep Reach Manifold Valve Assembly 209
2 Stage Cylinder and Reservoir Assembly 210
2 Stage Cylinder Assembly 211
30:09 2 Stage Cylinder 212
Removal 212
Installation 212
Two Stage Cylinder Assembly 212
Routine Maintenance 212
Disassembly 212
Inspection 213
Assembly 213
Two Stage Cylinder Assembly Troubleshooting 214
Three Stage Cylinders and Reservoir Assembly 216
Three Stage Freelift Cylinder Assembly 217
30:10 3 Stage Freelift Cylinder 218
Routine Maintenance 218
Removal 218
Installation 218
Disassembly 218
Inspection 219
Assembly 219
Freelift Cylinder Troubleshootiong 220
30:11 3 Stage Staging Cylinder 222
Routine Maintenance 222
Removal 222
Installation 222
Disassembly 222
Inspection 222
Assembly 223
3 Stage Staging Cylinder Assembly 223
Staging Assembly Troubleshooting 224
Standard Reach Hose Assembly 226
Reach and Tilt Cylinder Assembly 227
30:12 Single Reach, Reach Cylinder 228
Single Reach, Reach Cylinder 228
Routine Maintenance 228
Reach Cylinder 228
Removal 228
Installation 228
Routine Maintenance 228
Disassembly 228
Inspection 229
Assembly 229
Single Reach, Reach Cylinder Troubleshooting 230
30:13 Single Reach, Tilt Cylinder 232
Routine Maintenance 232
Tilt Cylinder(s) 232
Removal 232
Installation 232
Routine Maintenance 232
Disassembly 232
Inspection 233
Assembly 233
Single Reach, Tilt Cylinder Troubleshooting 234
Deep Reach, Reach Cylinder and Hose Assembly 236
Deep Reach, Reach Cylinder Assembly 237
30:14 Deep Reach, Reach Cylinder 238
Routine Maintenance 238
HMC Reach Cylinders 238
Removal 238
Installation 238
Disassembly 238
Inspection 239
Assembly 239
Deep Reach, Reach Cylinder Troubleshooting 240
Deep Reach, Tilt Cylinder and Hose Assembly 242
Deep Reach, Tilt Cylinder Assembly 243
30:15 Deep Reach Tilt Cylinder 244
Routine Maintenance 244
Removal 244
Installation 244
Disassembly 244
Inspection 245
Assembly 245
Deep Reach, Tilt Cylinder Troubleshooting 246
Sideshifter Hose Assembly 248
Deep Reach Sideshifter Hose Assembly 249
30:16 Sideshifter Cylinder 250
Routine Maintenance 250
Removal 250
Installation 250
Sideshifter Cylinder Assembly 250
Routine Maintenance 250
Disassembly 250
Inspection 250
Assembly 251
30:17 Flow Divider 252
Routine Maintenance 252
Removal 252
Installation 252
Disassembly 252
Assembly 252
Flow Divider Assembly 253
Tires Index 255
35:01 General Description 256
35:02 Caster Assembly 256
Routine Maintenance 256
Disassembly 256
Inspection 257
Assembly 257
Caster Troubleshooting 259
35:03 Load Wheel Assembly 260
Articulating Wheels 260
Assembly 260
Single Load Wheel 262
Disassembly 262
Assembly 262
Single Load Wheel Assembly 263
Four Inch High Outriggers Articulating Load Wheel Assembly 264
Routine Maintenance 264
Disassembly 264
Assembly 264
Four Inch High Outriggers Articulating Load Wheel Assembly 265
Shielding Index 267
40:01 General Description 268
40:02 Shielding 268
40:03 Padding 268
Installation 268
Shielding Assembly 269
Jacking and Hoisting Index 271
41:01 General Description 272
41:02 Elevating the Truck 272
Elevating and Blocking 273
Mast System Index 275
45:01 General Description 276
Upright Maintenance 276
Reach Assembly Removal 276
Reach Cylinder (Removal from Machine) 277
Tilt Cylinder 277
Mast 277
Two Stage Mast Installation Assembly 278
45:02 Two Stage Mast 279
Shimming of Mast Bearings on Unit 279
Shimming Reach 279
Routine Maintenance 280
Removal 281
Installation 281
Disassembly 281
Two Stage Inner Column Assembly 281
Two Stage Outer Column Assembly 282
Assembly 282
Two Stage Cylinder and Related Parts 283
Routine Maintenance 283
Cylinder 283
Sheave Shaft 283
Lift Chain 283
Disassembly 283
Two Stage Cylinder Assembly and Related Parts 283
Assembly 284
Two Stage Mast Assembly Troubleshooting 285
Three Stage Mast Installation Assembly 286
45:03 Three Stage Mast 287
Shimming of Mast Bearings on Unit 287
Shimming Reach 287
Shimming Mast with Reach Removed 287
Routine Maintenance 289
Removal 289
Installation 290
Disassembly 290
Three Stage Outer Column Assembly 291
Three Stage Inner Column Assembly 292
Assembly 292
Freelift Cylinder Assembly 293
Routine Maintenance 293
Cylinder 293
Sheave Shaft 293
Lift Chain 294
Three Stage Cylinder Assembly and Related Parts 294
Disassembly 294
Assembly 294
Three Stage Freelift Cylinder Assembly and Related Parts 295
Three Stage Mast Assembly Troubleshooting 296
45:04 Single Reach Cylinder 298
Routine Maintenance 298
Removal 298
Installation 298
Single Reach Assembly 298
Routine Maintenance 298
Cleaning 298
Visual Inspection 298
Disassembly 299
Assembly 300
Single Reach Assembly 301
Single Reach Standard Front Frame Assembly 302
Routine Maintenance 302
Cleaning 302
Visual Inspection 302
Removal 302
Single Reach Standard Front Frame Assembly 303
Tilt Cylinder 304
Routine Maintenance 304
Routine Maintenance 304
Disassembly 304
Assembly 304
Single Reach Tilt Front Frame Assembly 304
Routine Maintenance 304
Cleaning 304
Visual Inspection 304
Disassembly 305
Assembly 305
Single Reach Tilt Front Frame Assembly 306
Deep Reach Assembly 308
45:05 Double Reach Removal 309
HMC Reach Cylinder Assembly 309
Routine Maintenance 309
HMC Reach Cylinders 309
Removal 309
Installation 309
Sideshifter Assembly 310
45:06 Sideshifter Removal 310
Routine Maintenance 310
Cleaning 310
Visual Inspection 310
Disassembly 311
Assembly 311
Fork Assembly 312
45:07 Fork Removal/Repair 312
Routine Maintenance 312
Disassembly 312
Assembly 312
45:08 Lift Chain 313
Lift Chain Maintenance 313
Lift Chain Inspection 313
Rust and Corrosion 314
Cracked Plates 314
Ultimate Strength Failure 314
Tight Joints 315
Protruding or Turned Pins 315
Chain Side Wear 315
Chain Anchors and Sheaves 315
Lift Chain Lubrication 316
Lift Chain Replacement 317
Specification Tables and Charts Index 319
50:01 General Description 320
50:02 Data Plate and Decals 320
50:03 Bolt Torque Data 321
50:04 RR-30B Specifications on 24 Volts 322
50:05 RR-30B Specifications on 36 Volts 323
50:06 Periodic Maintenance Chart 324
50:07 Lubrication Chart 325
RR30B Electric Reach Truck Specifications 326
RR30B Electric Deep Reach Truck Specifications 327
50:10 Shim Thickness 328
Maintenance 328
50:11 Serial Number 328
Electrical Schematic – Reach with Tilt Fork and Side Shifter 330
Electrical Schematic Symbols 331
Hydraulic Schematic 332
Hydraulic Schematic Symbols 333
Decal and Part Assembly 334
50:17 Special Tools 335
Flush Grease Fitting 335
Transmission Nut Tightening Tool 335
Seal Installation Tool 335
Troubleshooting Index 337
99:01 General Description 338
Cylinders 339
Auxiliary Pump 340
Lift Pump (Cessna and Dowty) 341
Steering 342
Transmission 345
Brakes 346
Lift 349
Lower 353
Reach Extend 354
Reach Retract 358
Side Shift Left 361
Side Shift Right 364
Tilt Back 367
Tilt Forward 370
Back Cover 376

DESCRIPTION:

BT Prime-Mover RR-30B Reach Truck Repair Manual – PDF DOWNLOAD 

INTRODUCTION:

• This manual is intended for the service mechanic who is seeking information about  maintenance and service. It contains a section on troubleshooting which will enable a qualified mechanic to locate and solve problems which may occur.
• This manual does not contain operationinstructions or parts information. For  operation instructions or parts information,refer to The Prime-Mover Co. Product Support Department. An index for this manual is located on the following page. The manual is arranged according to major sections.
• The first part of the page number indicates the section it belongs in, and the second number identifies the page number.  The higher the number of the section. the farther in the manual it is located. The sectional breakdown is as follows:

Section O 5 Frame
Section 10 Controls
Section 15 Transmission
Section 20 Electrical System
Section 30 Hydraulic System
Section 35 Tires
Section 40 Shielding
Section 41 Jacking and Hoisting
Section 45 Mast
Seetion 50 Speeifieation Table and Charts
Section 99 Troubleshooting

Although information in this manual is based on industry sources and is as complete as it was possible to make it at time of publication, the possiblity exists that some made later have changes, which could not be included here. Such information would appear in next edition of this manual and in updated pages.

S.V 31/01/2025