BT RCX 25-50 Electric Stand-Up Rider Truck Service Manual 304421-000
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BT RCX 25-50 Electric Stand-Up Rider Truck Service Manual 304421-000 - Image 4
BT RCX 25-50 Electric Stand-Up Rider Truck Service Manual 304421-000 - Image 5

BT RCX 25-50 Electric Stand-Up Rider Truck Service Manual 304421-000

$30.00

  • Type Of Manual: Service Manual
  • Manual ID: 304421-000
  • : Service Manual PDF
  • Number of Pages: 492
  • Size: 7.7MB
  • Format: PDF
Category:

Product details

  • Model List:

    • RCX 25, RCX 30C, RCX 30, RCX 35, RCX 40, RCX 45, RCX 50
  • 1. Front Cover
  • 2. Foreword
  • 3. Contents
  • 4. Group SA – Safe Maintenance
  • 4.1. Section 1 – Safety
  • 4.1.1. Safety Signs and Messages
  • 4.1.2. Safety Maintenance Practices
  • 4.1.3. General Shop Precautions
  • 4.2. Section 2 – Machine Jacking and Blocking
  • 4.2.1. Raising Drive Wheels
  • 4.2.2. Blocking the Upright in Raised Position
  • 4.2.3. Raising Rear of Truck
  • 4.2.4. Raising Truck with a Hoist
  • 5. Group PS – Periodic Service
  • 5.1. Section 1 – Maintenance Schedules
  • 5.1.1. Maintenance Schedules
  • 5.1.2. Lubrication Points
  • 5.1.3. Lubrication Chart Key
  • 5.1.4. Miscellaneous Lubricants
  • 5.2. Section 2 – Planned Maintenance
  • 5.2.1. Use PM Report Form
  • 5.2.2. How to Perform the PM Periodic Inspections and Maintenance
  • 5.2.3. Test Drive Truck with Load
  • 5.2.4. Air Cleaning
  • 5.2.5. Critical Fastener Torque Checks
  • 5.2.6. Lubrication, Fluids and Filters
  • 6. Group 12 – Battery
  • 6.1. Section 1 – Battery Handling
  • 6.1.1. Typical Battery Service Area
  • 6.1.2. Battery Handling
  • 6.1.3. Battery Maintenance
  • 6.1.4. Install Battery
  • 6.1.5. Keeping Battery Records
  • 7. Group 13 – Electrical Handle Switch
  • 7.1. Section 1 – Control Handle Switch
  • 7.1.1. Tilt, Auxiliary 1 and Auxiliary 2 (Attachment) Switches
  • 7.1.2. Up and Down Switches
  • 7.1.3. Forward and Reverse Switches, Transducer (Speed Control)
  • 8. Group 16 – Electrical Motors
  • 8.1. Section 1 – General Information
  • 8.1.1. Servicing Electric Motors
  • 8.1.2. Electric Motor Maintenance
  • 8.1.3. Test for Motor Insulation Resistance to Ground
  • 8.1.4. Brush and Commutator Inspection
  • 8.1.5. Operating Conditions
  • 8.1.6. Brush Inspection Chart
  • 8.2. Section 2 – Drive Motors
  • 8.2.1. General Information
  • 8.2.2. Operating Conditions
  • 8.2.3. Drive Motor Description
  • 8.2.4. Drive Motor Removal
  • 8.2.5. Drive Motor
  • 8.2.6. Drive Motor
  • 8.2.7. Volt Drive Motor Specifications
  • 8.2.8. Brush Inspection Chart
  • 8.3. Section 3 – Hydraulic Pump Motors
  • 8.3.1. General Information
  • 8.3.2. Operating Conditions
  • 8.3.3. Hydraulic Pump Motor
  • 8.3.4. Volt Drive Motor Specifications
  • 8.3.5. Brush Inspection Chart
  • 8.4. Section 4 – Steer Pump Motor
  • 8.4.1. General Information
  • 8.4.2. Operating Conditions
  • 8.4.3. Steer Pump Motor (Permanent Magnet Type)
  • 8.4.4. Volt Drive Motor Specifications
  • 8.4.5. Brush Inspection Chart
  • 9. Group 17 – Electrical Schematics
  • 9.1. Section 1 – Wiring Schematics and Diagrams
  • 9.1.1. Standard Wiring Schematic
  • 9.1.2. Standard Wiring Diagram
  • 9.1.3. Optional Wiring Schematic
  • 9.1.4. Optional Wiring Diagram
  • 9.1.5. Lights Wiring Schematic
  • 9.1.6. Lights Wiring Diagram
  • 9.1.7. Strobe and Alarm Wiring Schematic
  • 9.1.8. Strobe and Alarm Wiring Diagram
  • 10. Group 19 – Electrical Controls
  • 10.1. Section 1 – Control Panel
  • 10.1.1. Control Panel Description
  • 10.1.2. Control Panel Maintenance
  • 10.1.3. Control Panel Troubleshooting
  • 10.1.4. Control and Contactor Panel Removal
  • 10.1.5. Control and Contactor Panel Component Identification
  • 10.1.6. Contactor Inspection
  • 10.1.7. Control and Contactor Panel Installation
  • 10.2. Section 2 – EV-100MK Troubleshooting
  • 10.2.1. Check 1, 2, 5 RECs (SCRs)
  • 10.2.2. Check Capacitor (1C)
  • 10.2.3. Checking Component with VOM (Only)
  • 10.2.4. EV-100 MK Card Factory Settings
  • 10.2.5. Oscillator Card Voltage Checks
  • 10.2.6. Solenoid Function Control Card Voltage Checks
  • 10.3. Section 3 – Recommended Tests, Equipment, and Procedures
  • 10.3.1. Recommended Tests
  • 10.3.2. Test Procedures
  • 10.4. Section 4 – Drive Motor Cut-Out Switch Check and Adjustment
  • 10.4.1. Drive Motor Cut-Out Switch Check
  • 10.4.2. Drive Motor Cut-Out Switch Adjustment
  • 10.5. Section 5 – Forward and Reverse Switches, Up and Down Switches, and Transducer Adjustments
  • 10.5.1. Multi-Function Control Handle Connector Identification
  • 10.5.2. Switches and Transducer Adjustments
  • 10.6. Section 6 – Periodic Electrical Checks
  • 10.6.1. Truck Preparation
  • 10.6.2. Electrical Connectors
  • 10.7. Section 7 – Battery Tests
  • 10.7.1. Battery Tests
  • 10.8. Section 8 – Solenoid Control Card Troubleshooting
  • 10.8.1. Indicator Lights
  • 10.8.2. Troubleshooting Solenoid Control Card
  • 10.8.3. Lift Function ONLY Disabled
  • 10.8.4. Install New Solenoid Control Card
  • 10.9. Section 14 – EV100 LXT Control Panel
  • 10.9.1. General
  • 10.9.2. Operation
  • 10.9.3. Function Set-Up Procedures
  • 10.9.4. Description of Function Numbers for
  • 10.10. Section 15 – EV100 LXT Control Panel Status Codes
  • 10.11. Section 16 – Checking Components
  • 10.11.1. Main Logic Card
  • 10.11.2. Capacitor
  • 10.11.3. Contactors F, R, 1A, SP, FW, D, Regen, and P
  • 10.11.4. Potentiometer in Accelerator
  • 10.11.5. SCRs (1REC, 2REC, 3REC)
  • 10.11.6. Rectifiers (3REC, 4REC, Diode Blocks)
  • 10.11.7. Thermal Protector (TP)
  • 10.11.8. Filter Block (23FIL, etc.)
  • 10.11.9. Choke and Reactor T3-T4
  • 10.11.10. Replacement of EV-100 Components
  • 11. Group 20 – Drive Axle
  • 11.1. Section 1 – Drive Axle
  • 11.1.1. General Description
  • 11.1.2. Service Notes
  • 11.1.3. Drive Axle Maintenance
  • 11.1.4. Drive Axle Removal
  • 11.1.5. Drive Axle Special Tools
  • 11.1.6. Drive Axle Disassembly
  • 12. Group 22 – Wheels and Tires
  • 12.1. Section 1 – Cushion Wheels and Tires
  • 12.1.1. Cushion Drive and Steering Tire Specifications
  • 12.1.2. Cushion Drive Tire Removal
  • 12.1.3. Cushion Drive Tire Inspection
  • 12.1.4. Cushion Drive Tire Removal and Replacement
  • 12.1.5. Cushion Drive Wheel Installation
  • 12.1.6. Steering Wheel Removal
  • 12.1.7. Steering Tire Inspection
  • 12.1.8. Steering Wheel Installation
  • 12.2. Section 2 – Pneumatic Drive Tire and Wheel Maintenance
  • 12.2.1. Pneumatic Tire Warning
  • 12.2.2. Safety Procedures
  • 12.2.3. Pneumatic Drive Tire Specifications
  • 12.2.4. Pneumatic Tire Maintenance
  • 12.2.5. Pneumatic Drive Wheel and Tire Removal and Disassembly
  • 12.2.6. Pneumatic Drive Tire Assembly
  • 12.2.7. Pneumatic Drive Wheel and Tire Installation
  • 13. Group 23 – Brake System
  • 13.1. Section 1 – Brake System and Bleeding
  • 13.1.1. Brake System Description
  • 13.1.2. Bleeding the Brake System
  • 13.2. Section 2 – Brake Adjustment
  • 13.2.1. Brake Lining Wear Check
  • 13.2.2. Brake Lining Wear Adjustment
  • 13.2.3. Replacing Brake Linings
  • 13.3. Section 3 – Brake Slave Cylinder
  • 13.3.1. Brake Slave Cylinder
  • 14. Group 25 – Steering Gear
  • 14.1. Section 1 – Steering Gear
  • 14.1.1. Steering Gear Description
  • 14.1.2. Steering Gear Troubleshooting
  • 14.1.3. Steering Gear Removal
  • 14.1.4. Steering Gear Disassembly
  • 14.1.5. Steering Gear Parts Inspection
  • 14.1.6. Steering Gear Assembly
  • 14.1.7. Steering Gear Installation
  • 15. Group 26 – Steering Axle
  • 15.1. Section 1 – Steering Axle Repair
  • 15.1.1. Steering Axle Removal
  • 15.1.2. Steering Axle Installation
  • 15.2. Section 2 – Power Steering Pump
  • 15.2.1. Steering Pump Description
  • 15.2.2. Steering Pump Troubleshooting
  • 15.2.3. Steering Pump Removal
  • 15.2.4. Steering Pump Disassembly
  • 15.2.5. Steering Pump Parts Inspection
  • 15.2.6. Steering Pump Assembly
  • 15.2.7. Steering Pump Installation
  • 15.2.8. Steering Pump Installation Specifications
  • 15.2.9. Steering Lines Installation Specifications
  • 15.2.10. Reverse Steering Lines Installation Specifications
  • 15.3. Section 3 – Steering Torque Generator
  • 15.3.1. Steering Torque Generator Description
  • 15.3.2. Steering Torque Generator Removal
  • 15.3.3. Steering Torque Generator Disassembly
  • 15.3.4. Steering Torque Generator Parts Inspection
  • 15.3.5. Steering Torque Generator Assembly
  • 15.3.6. Steering Torque Generator Installation
  • 15.3.7. Steering Torque Generator Assembly Specifications
  • 15.3.8. Steering Torque Generator Lines Installation Specifications
  • 16. Group 29 – Hydraulic Pump, Sump and Filter
  • 16.1. Section 1 – Hydraulic Pump
  • 16.1.1. Main Hydraulic Pump
  • 16.2. Section 2 – Hydraulic Sump and Filter
  • 16.2.1. Hydraulic Sump and Filter Assembly
  • 16.3. Section 3 – Hydraulic Schematics
  • 16.3.1. Hydraulic Diagram
  • 17. Group 30 – Hydraulic Control Valves
  • 17.1. Section 1 – Main Control Valve
  • 17.1.1. Servicing Main Control Valve
  • 17.1.2. Relief Valve Assembly
  • 17.1.3. Load Check Valve
  • 17.1.4. Main Control Valve End Cap and Components
  • 17.1.5. Main Control Valve
  • 17.2. Section 2 – Face Seal Fittings
  • 17.2.1. Face Seal Fittings
  • 17.3. Section 3 – Hydraulic System Pressure Checks – Lift Circuit
  • 17.3.1. Test Ports
  • 17.3.2. Hydraulic Lift Circuits Pressure Checks
  • 17.4. Section 4 – Hydraulic System Pressure Checks – Steering Circuit
  • 17.4.1. Test Ports
  • 17.4.2. Hydraulic Steering Circuit Pressure Checks
  • 17.5. Section 5 – Hydraulic System Pressure Checks – Auxiliary and Tilt Circuits
  • 17.5.1. Test Ports
  • 17.5.2. Hydraulic Pressure Checks
  • 17.6. Section 6 – Flow Controls – Selector Solenoid Valve
  • 17.6.1. Valve Identification
  • 17.6.2. Hydraulic Solenoid Valves
  • 18. Group 31 – Hydraulic Supply System
  • 18.1. Section 1 – Hydraulic System
  • 18.1.1. General Description
  • 18.1.2. Hydraulic Fluid and Filter Change
  • 18.1.3. Hydraulic Sump Tank
  • 19. Group 32 – Cylinders
  • 19.1. Section 1 – Tilt Cylinder
  • 19.1.1. Tilt Cylinder Components
  • 19.1.2. Tilt Cylinder Plumbing Layout
  • 19.1.3. Tilt Cylinder Drift Test
  • 19.1.4. Tilt Cylinder Removal
  • 19.1.5. Tilt Cylinder Rod End Removal
  • 19.1.6. Tilt Cylinder Disassembly
  • 19.1.7. Tilt Cylinder Inspection
  • 19.1.8. Tilt Cylinder Assembly
  • 19.1.9. Tilt Cylinder Installation
  • 19.1.10. Face Seal Fittings
  • 19.1.11. Tilt Check and Adjustment
  • 20. Group 33 – Selector Solenoid Valve
  • 20.1. Section 1 – Selector Solenoid Valve
  • 20.1.1. Selector Solenoid Valve Description
  • 20.1.2. Selector Solenoid Valve Troubleshooting
  • 20.1.3. Selector Solenoid Valve Removal
  • 20.1.4. Selector Solenoid Valve Repair
  • 20.1.5. Selector Solenoid Valve Installation
  • 20.1.6. Device Selector Solenoid Valve
  • 21. Group 34 – Uprights
  • 21.1. Section 1 – Upright
  • 21.1.1. Upright Maintenance
  • 21.1.2. Triple Stage Upright
  • 21.1.3. Standard (Two Stage) Upright
  • 21.2. Section 2 – Chain Inspection, Adjustment, and Replacement
  • 21.2.1. Periodic Inspection
  • 21.2.2. Chain Length Adjustments
  • 21.2.3. Chain Lubrication
  • 21.2.4. Chain Removal and Replacement
  • 21.2.5. Other Chain Service Notes
  • 22. Group 40 – Specifications
  • 22.1. Section 1 – Specifications
  • 22.1.1. Group 12 – Battery
  • 22.1.2. Group 16 – Motors
  • 22.1.3. Group 19 – Electrical Controls
  • 22.1.4. Group 20 – Drive Axle
  • 22.1.5. Group 22 – Wheels and Tires
  • 22.1.6. Group 23 – Brakes
  • 22.1.7. Group 25/26 – Steering System
  • 22.1.8. Group 29/30 – Hydraulic System
  • 22.1.9. Group 32 – Tilt Cylinder
  • 22.1.10. Group 34 – Uprights
  • 22.1.11. Group 40 – Specifications
  • 22.2. Section 2 – Data Plate
  • 22.2.1. How to Read Data Plate
  • 22.2.2. Battery Weight Chart
  • 22.3. Section 3 – Lubricants and Shop Supplies
  • 22.3.1. Lubricants and Shop Supplies
  • 23. Back Cover
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