BT Forklift RMX/HMX Electric Low Lift Pallet Truck Service Manual – PDF

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BT Forklift RMX/HMX Electric Low Lift Pallet Truck Service Manual 302065-000 – PDF DOWNLOAD

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BT Forklift RMX/HMX Electric Low Lift Pallet Truck Service Manual 302065-000 – PDF DOWNLOAD

Language : English
Pages : 330
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

BT Forklift RMX/HMX Electric Low Lift Pallet Truck Service Manual 302065-000 – PDF DOWNLOAD

Front Cover....................................................................................  1
BT Standard Codes..............................................................................  3
Warning Symbols................................................................................ 13
	1. Warning Levels.......................................................................... 13
Prohibitory Symbols............................................................................ 14
	1. Ordinance Symbols....................................................................... 14
Introduction, Service Manual................................................................... 15
Contents, Section M............................................................................ 17
	1. Machine Information..................................................................... 17
General Product Information.................................................................... 19
	1. Presentation of the RMX and HMX......................................................... 19
		1.1. Intended Application of the Trucks................................................ 19
		1.2. Forbidden Application of the Trucks............................................... 20
		1.3. Truck Data........................................................................ 20
		1.4. RMX Dimensions.................................................................... 21
		1.5. HMX Dimensions.................................................................... 22
		1.6. RMX Data plate.................................................................... 23
		1.7. HMX Data plate.................................................................... 24
	2. Main Components......................................................................... 25
Inch (SAE) and Metric Fasteners................................................................ 29
	1. Introduction............................................................................ 29
	2. Nomenclature, Threads................................................................... 30
	3. Strength Identification................................................................. 31
	4. Conversion of Metric and English Units.................................................. 37
Technical Service Data......................................................................... 39
Ordering Spare Parts........................................................................... 43
Contents, Section P............................................................................ 45
	1. Planned Maintenance..................................................................... 45
Introduction, Maintenance...................................................................... 47
	1. Safe Jacking Procedure.................................................................. 47
Service Schedule............................................................................... 49
	1. Planned Maintenance Schedule............................................................ 49
	2. Planned Maintenance Procedures.......................................................... 52
		2.1. Services to be Performed Daily.................................................... 52
			2.1.1. Battery Discharge Indicator with slow down.................................. 52
			2.1.2. Hydraulic System............................................................ 52
			2.1.3. Frame/Sheet Metal........................................................... 53
			2.1.4. Wheels/Tires................................................................ 53
			2.1.5. Functions/Operations........................................................ 53
		2.2. Services to be Performed Monthly.................................................. 54
			2.2.1. Inspection.................................................................. 54
			2.2.2. Transmission................................................................ 54
			2.2.3. Brakes...................................................................... 54
			2.2.4. Battery..................................................................... 54
			2.2.5. Electrical Connections...................................................... 54
			2.2.6. Contactor Tips (NOT Sealed)................................................. 55
			2.2.7. Motor Brushes............................................................... 55
			2.2.8. Drive Motor................................................................. 55
			2.2.9. Hydraulic Reservoir......................................................... 55
			2.2.10. Frame Lube (“Lubrication Chart” on page57)................................ 55
			2.2.11. Pivot Points............................................................... 56
		2.3. Services to be Performed Annually................................................. 57
			2.3.1. Inspection.................................................................. 57
			2.3.2. Transmission................................................................ 57
			2.3.3. Battery..................................................................... 57
			2.3.4. Hydraulic System............................................................ 57
			2.3.5. Brakes...................................................................... 58
Lubrication Chart.............................................................................. 59
Oil and Grease Specifications.................................................................. 61
	1. Approved Oils and Grease................................................................ 61
Contents, Section S............................................................................ 63
	1. Service Instructions.................................................................... 63
Lift Frame..................................................................................... 65
	1. Pull rod................................................................................ 66
		1.1. Removal........................................................................... 66
		1.2. Inspection........................................................................ 68
		1.3. Installation...................................................................... 69
	2. Carrier Frame Bushings.................................................................. 71
Inspection Covers.............................................................................. 73
	1. General Information..................................................................... 73
Drive Motor Mounting Points.................................................................... 75
	1. Drive Motor Brush....................................................................... 76
		1.1. Removal and Installation.......................................................... 76
	2. Drive Motor Assembly.................................................................... 76
		2.1. Remove............................................................................ 76
		2.2. Installation...................................................................... 77
Drive Motor.................................................................................... 79
	1. General Information..................................................................... 79
	2. Operating Conditions.................................................................... 79
	3. Troubleshooting......................................................................... 79
Drive Motor Service............................................................................ 85
	1. Motor Repair............................................................................ 86
		1.1. Disassembly....................................................................... 86
	2. Inspection and Troubleshooting.......................................................... 89
		2.1. Drive End Head.................................................................... 89
		2.2. Commutator End Head............................................................... 89
		2.3. Bearings.......................................................................... 89
		2.4. Brush and Commutator.............................................................. 90
		2.5. Armature.......................................................................... 90
		2.6. Frame and Field Assembly.......................................................... 91
			2.6.1. Testing..................................................................... 91
			2.6.2. Frame and Field Service Notes............................................... 92
		2.7. Assembly.......................................................................... 93
			2.7.1. Field Coil Installation..................................................... 93
			2.7.2. Bearing Installation........................................................ 93
			2.7.3. After Assembly.............................................................. 94
	3. Changing Brushes........................................................................ 94
Transmission................................................................................... 95
	1. System Description...................................................................... 95
	2. Troubleshooting......................................................................... 95
	3. Removal................................................................................. 97
	4. Installation............................................................................ 99
Transmission Axle Seal.........................................................................101
	1. General Information.....................................................................101
		1.1. Removal...........................................................................101
		1.2. Installation......................................................................101
Transmission Disassembly / Assembly............................................................103
	1. Disassembly.............................................................................104
	2. Assembly................................................................................104
Parking Brake System...........................................................................107
	1. Brake Theory of Operation...............................................................108
	2. Brake Adjustment........................................................................109
	3. Brake Shoe Removal / Installation.......................................................110
	4. Parking Brake Interlock Switch..........................................................111
Drive Wheel....................................................................................113
	4.1. Removal...............................................................................113
	4.2. Installation..........................................................................114
Load Wheels....................................................................................115
Support / Swivel Wheels........................................................................117
	1. Stabilizing Caster......................................................................117
		1.1. Removal...........................................................................118
		1.2. Inspection........................................................................120
		1.3. Installation......................................................................121
		1.4. Maintenance.......................................................................122
Stabilizing Caster.............................................................................123
	1. Stabilizing Caster......................................................................123
		1.1. Disassembly.......................................................................124
		1.2. Inspection........................................................................125
		1.3. Assembly..........................................................................126
Stabilizing Caster Spring Loaded...............................................................127
	1. Removal.................................................................................128
	2. Disassembly.............................................................................129
	3. Inspection..............................................................................130
	4. Assemble................................................................................131
	5. Installation............................................................................131
Steering Arm / Handle..........................................................................133
	1. Control Handle Stem.....................................................................134
		1.1. Removal...........................................................................134
		1.2. Inspection........................................................................134
		1.3. Installation......................................................................135
Steering Handle Head...........................................................................137
	1. Control Handle Head.....................................................................139
		1.1. Removal...........................................................................139
		1.2. Installation......................................................................139
	2. Direction Control Switches..............................................................140
	3. Horn, Raise, and Lower Switches.........................................................141
	4. Potentiometer...........................................................................143
300/400 Amp Contactor..........................................................................145
	1. Maintenance.............................................................................146
		1.1. Removal/Replacement of Contact Tips...............................................146
“EE” Contactor.................................................................................149
	1. Maintenance.............................................................................150
		1.1. Removal/Replacement of Contact Tips...............................................150
Battery Controller / Hourmeter / Lift Interrupt................................................153
	1. General Information.....................................................................153
	2. Electrical..............................................................................153
		2.1. Voltage...........................................................................153
			2.1.1. The Contact Voltage and Current Ratings for Switching Resistive Loads.......154
			2.1.2. Memory Retention............................................................154
	3. Battery Controller (BC).................................................................154
		3.1. General Information...............................................................154
			3.1.1. Discharge Adjustment........................................................154
		3.2. Reset.............................................................................156
		3.3. Key Switch........................................................................156
		3.4. Hourmeter.........................................................................157
	4. Troubleshooting.........................................................................157
		4.1. Battery Discharge Indicator (BDI).................................................157
			4.1.1. No Reset....................................................................157
			4.1.2. Reset After Break in Power..................................................157
			4.1.3. No Discharge, Gauge Does Not Run Down.......................................158
			4.1.4. No Lockout..................................................................158
			4.1.5. No Lift.....................................................................158
			4.1.6. Early Lockout...............................................................159
			4.1.7. LEDs Do Not Light...........................................................159
		4.2. Hourmeter.........................................................................159
			4.2.1. No Display..................................................................159
			4.2.2. Hourmeter Glass Icon Does Not Flash.........................................159
			4.2.3. Hourmeter Glass Icon Always Flashes.........................................160
Battery Discharge Indicator / Hourmeter........................................................161
	1. General Information.....................................................................161
	2. Electrical..............................................................................161
		2.1. Voltage...........................................................................161
	3. Battery Discharge Indicator (BDI).......................................................162
		3.1. General Information...............................................................162
		3.2. Key Switch........................................................................162
		3.3. Hourmeter.........................................................................162
	4. Troubleshooting.........................................................................163
		4.1. Battery Discharge Indicator (BDI).................................................163
			4.1.1. No Reset....................................................................163
			4.1.2. Reset After Break in Power..................................................163
			4.1.3. No Discharge, Gauge Does Not Run Down.......................................164
			4.1.4. LEDs Do Not Light...........................................................164
		4.2. Hourmeter.........................................................................164
			4.2.1. No Display..................................................................164
			4.2.2. Hourmeter Glass Icon Does Not Flash.........................................164
			4.2.3. Hourmeter Glass Icon Always Flashes.........................................165
12 Volt Electrical System......................................................................167
	1. Electrical Panel Components.............................................................167
		1.1. RMX Circuit Diagram...............................................................168
		1.2. Electrical Schematic Symbols......................................................169
Direction Contactor............................................................................171
	1. General Information.....................................................................172
	2. Remove / replace contact tips...........................................................172
12 Volt Transistor Controller..................................................................177
	1. Maintenance.............................................................................177
		1.1. Safety............................................................................177
		1.2. Cleaning..........................................................................177
		1.3. Troubleshooting...................................................................178
	2. Basics Of Circuit Operation.............................................................180
		2.1. Battery connected and emergency disconnect switch in “RUN” position...............180
		2.2. Key switch turned “ON”............................................................180
		2.3. Control handle pulled down; brakes released and brake interlock switch closed.....181
		2.4. Reverse travel (fork direction) switch is closed..................................181
		2.5. Forward travel (control handle direction) switch is closed........................182
		2.6. Curtis® PMC controller power circuits.............................................182
		2.7. Accelerator Potentiometer Circuits................................................183
		2.8. Emergency Reverser Switch.........................................................184
		2.9. Lift Pallet Forks.................................................................184
		2.10. Lower pallet forks...............................................................185
		2.11. Controller Adjustments...........................................................186
12 Volt Transistor Controller Troubleshooting..................................................187
	1. Troubleshooting Chart Index.............................................................187
	2. Troubleshooting Charts..................................................................188
24 Volt 300 Amp Electrical System..............................................................205
	1. Electrical Panel Components.............................................................205
	2. List of Symbols.........................................................................206
		2.1. RMX Circuit Diagram 1(3)..........................................................208
		2.2. RMX Circuit Diagram 2(3)..........................................................209
		2.3. RMX Circuit Diagram 3(3)..........................................................210
	3. Description of Function.................................................................211
		3.1. General Information...............................................................211
		3.2. References Information............................................................211
		3.3. Key Switch S17 in the ON Position.................................................211
		3.4. The Operating Arm in Drive Position, S10, Brake Switch Closed.....................211
		3.5. Driving, Fork Direction...........................................................211
		3.6. Driving, Steer Wheel Direction....................................................212
		3.7. Reversing/Motor Brake Fork Direction to Steer Wheel Direction.....................212
		3.8. Reversing/Motor Brake Steer Wheel Direction to Fork Direction.....................212
		3.9. Reverser switch...................................................................212
		3.10. Lifting the Forks................................................................213
		3.11. Lowering the Forks...............................................................213
		3.12. Horn.............................................................................213
		3.13. Lift Interrupt...................................................................213
24 Volt, 300 Amp Transistor Controller.........................................................215
	1. Maintenance.............................................................................215
		1.1. Safety............................................................................215
		1.2. Cleaning..........................................................................215
		1.3. Diagnostics and Troubleshooting...................................................216
			1.3.1. Handset Diagnostics.........................................................216
			1.3.2. Troubleshooting.............................................................216
	2. Basics Of Circuit Operation.............................................................218
		2.1. Control Features..................................................................220
	3. Motor Circuit...........................................................................222
	4. Control Circuit.........................................................................222
	5. Diagnostics and Troubleshooting.........................................................224
		5.1. 1307 Programmer Diagnostics.......................................................224
		5.2. Troubleshooting Chart.............................................................225
		5.3. Technical Specification...........................................................229
		5.4. Troubleshooting Chart Using the Handset...........................................230
24 Volt, 300 Amp Transistor Controller Troubleshooting.........................................233
	1. Troubleshooting Chart Index.............................................................233
	2. Troubleshooting Charts..................................................................234
24 Volt 400 Amp Electrical System..............................................................245
	1. Electrical Panel Components.............................................................245
	2. List of Symbols.........................................................................246
		2.1. HMX Circuit Diagram 1(3)..........................................................248
		2.2. HMX Circuit Diagram 2(3)..........................................................249
		2.3. HMX Circuit Diagram 3(3)..........................................................250
	3. Description of Function.................................................................251
		3.1. General Information...............................................................251
		3.2. References Information............................................................251
		3.3. Key Switch S17 in the ON Position.................................................251
		3.4. The Operating Arm in Drive Position, S10, Brake Switch Closed.....................251
		3.5. Driving, Fork Direction...........................................................251
		3.6. Driving, Steer Wheel Direction....................................................252
		3.7. Reversing/Motor Brake Fork Direction to Steer Wheel Direction.....................252
		3.8. Reversing/Motor Brake Steer Wheel Direction to Fork Direction.....................252
		3.9. Reverser switch...................................................................252
		3.10. Lifting the Forks................................................................253
		3.11. Lowering the Forks...............................................................253
		3.12. Horn.............................................................................253
		3.13. High Speed Switch................................................................253
		3.14. Lift Interrupt...................................................................254
24 Volt, 400 Amp Transistor Controller.........................................................255
	1. Maintenance.............................................................................255
		1.1. Safety............................................................................255
		1.2. Cleaning..........................................................................255
		1.3. Diagnostics and Troubleshooting...................................................256
			1.3.1. Handset Diagnostics.........................................................256
			1.3.2. Troubleshooting.............................................................256
	2. Basics Of Circuit Operation.............................................................258
		2.1. Control Features..................................................................260
	3. Motor Circuit...........................................................................262
	4. Control Circuit.........................................................................262
	5. Diagnostics and Troubleshooting.........................................................265
		5.1. 1307 Programmer Diagnostics.......................................................265
		5.2. Troubleshooting Chart.............................................................266
		5.3. Technical Specification...........................................................270
		5.4. Troubleshooting Chart Using the Handset...........................................271
24 Volt, 400 Amp Transistor Controller Troubleshooting.........................................273
	1. Troubleshooting Chart Index.............................................................273
	2. Troubleshooting Charts..................................................................274
Handset Operation..............................................................................287
	1. Operating Modes.........................................................................289
	2. Revert to Previous Settings.............................................................293
	3. Handset Self Test.......................................................................293
Pump Motor.....................................................................................295
	1. Component Repair........................................................................296
		1.1. Motor Disassembly.................................................................296
	2. Inspection and Troubleshooting..........................................................298
		2.1. Drive End Head....................................................................298
		2.2. Commutator End Head...............................................................298
		2.3. Bearings..........................................................................298
		2.4. Brush and Commutator..............................................................299
		2.5. Armature..........................................................................299
		2.6. Frame and Field Assembly..........................................................300
			2.6.1. Testing.....................................................................300
			2.6.2. Frame and Field Service Notes...............................................301
		2.7. Assembly..........................................................................302
			2.7.1. Field Coil Installation.....................................................302
			2.7.2. Bearing Installation........................................................302
			2.7.3. After Assembly..............................................................303
	3. Changing Brushes........................................................................303
Hydraulic System...............................................................................305
	1. Hydraulic Schematic.....................................................................305
	2. General Information.....................................................................305
	3. Description.............................................................................306
		3.1. Lift..............................................................................306
		3.2. Lower.............................................................................306
		3.3. Relief Pressure...................................................................306
	4. Maintenance.............................................................................307
	5. Adjustments.............................................................................307
	6. Lift Limit Switch.......................................................................307
	7. Troubleshooting.........................................................................309
Lift Pump Assembly.............................................................................311
	1. Removal.................................................................................313
	2. Disassembly.............................................................................314
	3. Inspection..............................................................................315
	4. Assembly................................................................................316
	5. Installation............................................................................318
	6. Adjustments.............................................................................320
		6.1. Relief valve......................................................................320
		6.2. Solenoid Operated Valve...........................................................321
Lift Cylinder..................................................................................323
	1. Removal.................................................................................324
	2. Disassembly.............................................................................325
	3. Inspection..............................................................................326
	4. Assembly................................................................................327
	5. Installation............................................................................328
Back Cover.....................................................................................330

S.S 06/24