BT RC-30B, RC-40B, RC-50B Electric Stand-Up Rider Counterbalanced Truck Repair Manual 301981-000

BT RC-30B, RC-40B, RC-50B Electric Stand-Up Rider Counterbalanced Truck Repair Manual 301981-000 - Image 2

BT RC-30B, RC-40B, RC-50B Electric Stand-Up Rider Counterbalanced Truck Repair Manual 301981-000 - Image 3

BT RC-30B, RC-40B, RC-50B Electric Stand-Up Rider Counterbalanced Truck Repair Manual 301981-000 - Image 4

BT RC-30B, RC-40B, RC-50B Electric Stand-Up Rider Counterbalanced Truck Repair Manual 301981-000 - Image 5

bt rc 30b rc 40b rc 50b electric stand up rider counterbalanced truck repair manual 301981 000 2

bt rc 30b rc 40b rc 50b electric stand up rider counterbalanced truck repair manual 301981 000 3

BT RC-30B, RC-40B, RC-50B Electric Stand-Up Rider Counterbalanced Truck Repair Manual 301981-000

$30.00

Type Of Manual: Repair Manual
Manual ID: 301981-000
: Service Manual PDF
Number of Pages: 238
Size: 16.8MB
Format: PDF

Category: BT Service Manual PDF

Model List:
- RC-30B, RC-40B, RC-50B Electric Stand-Up Rider Counterbalanced Truck

1. Front Cover
2. Contents
2.1. Wiring Diagrams
2.2. Hydraulic Schematics
2.3. General Information
2.4. Troubleshooting
2.5. Maintenance
2.6. Specifications Tables
2.7. Torque Specifications
3. Introduction
3.1. The Service Manual
3.2. How to Use this Manual
3.3. The Equipment
4. Safety Precautions – Maintenance Repair
5. Specifications Tables
5.1. General
5.2. Capacities
5.3. Steering System
5.4. Batteries
5.5. Travel Speeds Current Draw
5.6. Lifting Speeds
5.7. Lift Tilt System
6. Torque Specifications
7. Contents
7.1. Introduction
7.2. Maintenance Procedures
8. Introduction
8.1. General
8.2. Towing a Disabled Lift Truck
8.3. Lifting a Disabled Lift Truck
8.4. Putting the Lift Truck on Blocks
8.5. Scheduled Maintenance and Inspections
8.6. Scheduled Maintenance Inspections Table
9. Maintenance Procedures Every 8 Hours or Daily
9.1. General
9.1.1. SRO Circuit
9.1.2. General Functions
9.2. Battery
9.2.1. Charging the Battery
9.2.2. Changing the Battery
9.3. Battery Connector
9.3.1. Inspection
9.4. Battery Gates
9.4.1. Inspection
9.5. Upright
9.6. Hydraulic System
9.6.1. Checking for Leaks
9.7. Drive Unit
9.7.1. Checking Operation
9.7.2. Inspection
9.8. Wheels Tires
9.8.1. Inspection
9.8.2. Drive Wheel – Removal Installation
9.8.3. Steer Wheel – Removal Installation
9.8.4. Changing Tires
9.9. Brake Pedal
9.9.1. Inspect Lubricate
9.10. Brake Switch
9.10.1. Check for Operation
9.10.2. Check Operation
9.11. Controls/Horn
9.11.1. Check Operation
9.12. Steering System
9.12.1. Check Operation
9.12.2. Inspect
9.12.3. Inspect
10. Maintenance Procedures Every 40 Hours or 5 Days
10.1. Battery
10.1.1. Cleanliness
10.1.2. Water Level
10.2. Lift Chains
10.2.1. Inspect
10.3. Hydraulic System
10.3.1. Check Oil Level
11. Maintenance Procedures Every 350 Hours or 60 Days
11.1. Battery
11.1.1. Charging
11.2. Lift Chains
11.2.1. Lubrication
11.2.2. Check Tension
11.3. Upright
11.3.1. Lubrication
11.4. Hydraulic System
11.4.1. Breather Cap
11.5. Drive Unit
11.5.1. Check Fluid Level
11.5.2. Check Fluid
11.6. Hinges Levers
11.7. Steering
11.8. Motor Brushes
11.8.1. Drive Motors
11.8.2. Lift Pump Motor
11.8.3. Steering Pump Motor
11.9. Contactor Tips
12. Maintenance Procedures Every 2000 Hours or 360 Days
12.1. Hydraulic System
12.1.1. Change the Hydraulic Oil
12.1.2. Change the Hydraulic Oil Filter
12.1.3. Breather Cap
12.2. Drive Units
12.3. Wheels Tires
12.3.1. Lubricate Wheel Bearings
12.3.2. Brake Shoes
13. Contents
13.1. Wiring Diagrams
14. Contents
14.1. Introduction
14.2. Maintenance
15. Introduction
15.1. General
16. Maintenance
16.1. Installation
16.2. Removal
16.3. Charging the Battery
16.3.1. Normal Charge
16.3.2. Equalizing Charge
16.4. Cleaning the Battery
16.5. Hydrometer Use
16.6. Voltage Check
16.7. Adding Water
16.8. Battery History Record
17. Contents
17.1. Troubleshooting Tables
17.1.1. Power Section
17.1.2. Brake System
17.1.3. Steering System
17.1.4. Hydraulic System
17.1.5. Hydraulic Gear Pump
17.1.6. Uprights
17.1.7. Main Control Valve
17.1.8. Industrial Battery
18. Contents
18.1. Power Section
18.2. Brake System
18.3. Steering System
18.4. Controls Mechanical
18.5. Electrical System
18.6. Hydraulic System
18.7. Elevating Section
19. Contents
19.1. Drive Unit Assembly
19.1.1. Introduction
19.1.2. Repairs
19.1.3. Disassembly
19.1.4. Assembly
19.1.5. Installation
19.2. DC Motor Repair
19.2.1. Introduction
19.2.2. Repairs
19.2.3. Hydraulic Pump Motor
19.2.4. Power Steering Motor
19.3. DC Motor Maintenance
19.3.1. Introduction
19.3.2. Brush and Commutator Inspection
19.3.3. Brush Replacement
19.3.4. Tests for a Damaged Field and Armature
19.3.5. Brush Holder Test
20. Drive Unit Assembly
20.1. Introduction
20.1.1. Description
20.2. Repairs
20.2.1. Removal – General
20.2.2. Removal – Complete Drive Assembly
20.2.3. Removal – Final Drive Assembly
20.3. Disassembly
20.3.1. Single Stage Gear Housing
20.3.2. Final Drive Unit
20.3.3. Figure 3.5 – Drive Unit
20.3.4. Inspection
20.4. Assembly
20.4.1. Final Drive Unit
20.4.2. Single Stage Gear Housing
20.4.3. Final Drive Assembly
20.5. Installation
20.5.1. Complete Drive Assembly
20.5.2. Final Drive Assembly
21. DC Motor Repair
21.1. Introduction
21.2. Repairs
21.2.1. Drive Motor
21.2.2. Hydraulic Pump Motor
21.2.3. Power Steering Motor
22. DC Motor Maintenance
22.1. Introduction
22.2. Brush and Commutator Inspection
22.2.1. Figure 3.17 Normal Commutator Surfaces
22.2.2. Figure 3.18 Commutator Problems
22.2.3. Normal Commutator Surface
22.3. Brush Replacement
22.4. Tests for a Damaged Field and Armature
22.4.1. Armature Tests
22.4.2. Field Coil Tests
22.4.3. Brush Holder Test
23. Contents
23.1. The Brake Assembly
23.1.1. Repairs
23.2. The Slave Cylinders
23.2.1. Repairs
23.3. The Master Cylinder
23.3.1. Repairs
23.4. Checks and Adjustments
24. The Brake Assembly
24.1. Description
24.2. Repairs
24.2.1. Removal and Disassembly
24.2.2. Cleaning and Inspection
24.2.3. Assembly and Installation
25. The Slave Cylinders
25.1. Repairs
25.1.1. Removal and Disassembly
25.1.2. Cleaning and Inspection
25.1.3. Assembly and Installation
26. The Master Cylinder
26.1. Repairs
26.1.1. Removal and Disassembly
26.1.2. Cleaning and Inspection
26.1.3. Assembly and Installation
27. Checks and Adjustments
27.1. Removing the Air from the Brake System
27.2. Adjusting the Brakes
27.3. Adjusting the Brake Pedal and Master Cylinder
28. Contents
28.1. Introduction
28.2. Repairs
28.3. Steering Fork Assembly
28.4. Steer Wheel
28.5. Steering Chain
28.6. Torque Generator
28.7. Additional Checks and Inspections
29. Steering System
29.1. Introduction
29.1.1. Description
29.2. Repairs
29.2.1. Steering Fork Assembly
29.2.2. Steer Wheel
29.2.3. Steering Chain
29.2.4. Torque Generator
30. Contents
30.1. Mechanical Controls
30.1.1. Control Handles
30.1.2. Battery Disconnect
31. Mechanical Controls
31.1. Control Handles
31.1.1. Control Linkage Adjustment
31.1.2. Figure 4.1 Control Handles
31.1.3. Multi-Function Control Handle and Switch Replacement
31.2. Battery Disconnect
31.2.1. Battery Disconnect Adjustment
31.2.2. Figure 4.2 Adjusting the Control Linkage
32. Contents
32.1. GE EV100 LXT Controls
32.1.1. General
32.1.2. Maintenance
33. Instructions EV100 LX/LXT SCR Controls
34. EV100 LX/LXT Dual Motor Control
35. Terminal Connections for LX/LXT Logic Cards
36. EV100 LX/LXT Specifications
37. Features
38. EV100 LX/LXT Current Limit Curves
39. Basics of Circuit Operation
39.1. Control Features
39.1.1. Oscillator
39.1.2. Current Limit
39.1.3. Plugging
39.1.4. Pedal Position Plug
39.1.5. Ramp Start
39.1.6. Full Power Transition
39.1.7. Control Acceleration and 1A Time
39.1.8. Current Drop Out
39.1.9. Static Return to Off
39.1.10. Accelerator Volts Hold-Off
39.1.11. Coil Driver Modules
39.1.12. Thermal Hold Off
39.1.13. Must Pulse to Time
39.1.14. Pulse Monitor Trip
39.1.15. Thermal Protector
39.1.16. Low Voltage
39.1.17. Field Weakening
39.1.18. Dual Motor Operation
39.1.19. Dual Motor In-Board Wheel Reversal
39.1.20. Dual Motor Two Speed Limit
39.1.21. Top Speed (Motor Volts) Limit
39.1.22. Steer Pump Contactor Time Delay
39.1.23. Constant Current Coil Drivers and Internal Coil Suppression
39.1.24. Hour Meter Readings
39.1.25. Internal Resistance Compensation
39.1.26. Truck Management Module (TMM1)
39.1.27. Truck Management Module (TMM2)
39.1.28. Stored Status Code
39.1.29. On Board Diagnostics
39.1.30. Battery Discharge Indication
39.1.31. Handset
40. General Maintenance Instructions
40.1. Troubleshooting Instructions
40.2. Instructions – Status Codes
40.3. Checking Components
40.3.1. Main Logic Card
40.3.2. Capacitor 1C
40.3.3. Potentiometer in Accelerator
40.3.4. SCRs (1REC, 2REC, 5REC)
40.3.5. Rectifiers (3REC, 4REC, Diode Blocks)
40.3.6. Thermal Protector (TP)
40.3.7. Filter Block
40.3.8. Choke and Reactor T3 – T4
40.4. Replacement of EV-100 Components
40.5. Instructions – EV100 Handset
40.6. GE EV100 LXT BT Prime-Mover Factory Settings – All Models
41. Contents
41.1. Introduction
41.2. Repairs
41.3. Hydraulic Gear Pumps
41.4. The Lift Cylinders
41.5. The Tilt Cylinders
41.6. The Main Control Valve
42. The Hydraulic System
42.1. Introduction
42.1.1. Description
42.1.2. Operation
42.1.3. Multi-Lever Configuration
42.1.4. Multi-Function Handle Configuration
42.2. Repairs
42.3. Hydraulic Pump
42.3.1. Removal
42.3.2. Installation
42.4. Power Steering Pump
42.4.1. Installation
42.5. Multi-Lever Main Control Valve
42.5.1. Removal
42.5.2. Installation
42.6. Multi-Function Handle Main Control Valve
42.6.1. Removal
42.6.2. Installation
42.7. Multi-Function Solenoid Selector Valve
42.7.1. Removal
42.7.2. Installation
42.8. Hydraulic Pump Switches
42.8.1. Adjustment
43. Hydraulic Gear Pumps
43.1. Introduction
43.1.1. Description
43.1.2. Repairs
44. The Lift Cylinders
44.1. Introduction
44.1.1. Description
44.1.2. Flow Control Valve Flow Fuses
44.2. Repairs
44.2.1. Removal of the Lift Cylinder – Two Stage Uprights
44.2.2. Figure 6.7 Two Stage Upright
44.2.3. Figure 6.8 Three Stage Upright
44.2.4. Removal of the Lift Cylinders – Three Stage Uprights
44.2.5. Disassembly
44.2.6. Assembly
44.2.7. Figure 6.14 Lift Cylinder – Two Stage Upright
44.2.8. Figure 6.15 Inner Lift Cylinder – Three Stage Upright
44.2.9. Figure 6.16 Inner Lift Cylinder – Three Stage Upright
44.2.10. Figure 6.17 Outer Lift Cylinder – Three Stage Upright
44.2.11. Installation of the Lift Cylinder – Two Stage Uprights
44.2.12. Installation of the Lift Cylinders – Three Stage Uprights
45. The Tilt Cylinders
45.1. Introduction
45.1.1. Description
45.2. Repairs
45.2.1. Removal
45.2.2. Disassembly
45.2.3. Cleaning Inspection
45.2.4. Assembly
45.2.5. Installation
45.3. Checks and Adjustments
45.3.1. Checking for Leakage
45.3.2. Adjusting the Tilt Angle
46. The Main Control Valve
46.1. Introduction
46.1.1. Description
46.1.2. Figure 6.21 Main Control Valve
46.2. Operation
46.3. Lift Section
46.4. Tilt Section
46.5. Solenoid Valve for Auxiliary Function
46.6. Relief Valve
46.7. Repairs
46.7.1. Removal Disassembly
46.7.2. Cleaning Inspection
46.7.3. Assembly
46.8. Checks Adjustments
46.8.1. Primary Relief Valve
46.8.2. Auxiliary Function Relief Valve
47. Contents
47.1. Introduction
47.2. Uprights Repair
47.2.1. Carriage
47.2.2. Uprights
47.2.3. Side Shift Carriage
47.2.4. Side Shift Carriage – Checks and Adjustments
47.2.5. Hose Reel Assembly
47.2.6. Checks and Adjustments
48. The Elevating Section
48.1. Introduction
48.1.1. Description
48.1.2. Simplex Uprights
48.1.3. Triplex Uprights
48.1.4. Figure 7.1 Flow Control Valves and Flow Fuses
48.1.5. Figure 7.2 Two Stage Uprights
48.1.6. Figure 7.3 Three Stage Upright
49. Uprights Repair
49.1. Carriage
49.1.1. Removal
49.1.2. Installation
49.2. Uprights
49.2.1. Removal
49.2.2. Disassembly
49.2.3. Cleaning and Inspection
49.2.4. Assembly
49.2.5. Installation
49.2.6. Upright Adjustment
49.2.7. Carriage Adjustment
49.3. Sideshift Carriage
49.3.1. Removal
49.3.2. Repairs
49.3.3. Installation
49.4. Sideshift Carriage Checks and Adjustments
49.4.1. Adjusting the Restrictor Cartridge
49.4.2. Lower Hook Adjustment
49.5. Hose Reel Assembly
49.5.1. Removal
49.5.2. Installation
49.6. Checks and Adjustments
49.6.1. Leaks Outside the Hydraulic Lift System

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