BT Prime Mover CMX60/80 Electric Center Riding Pallet Truck Service Manual PDF

Description

BT Prime Mover CMX60/80 Electric Center Riding Pallet Truck Service Manual – PDF DOWNLOAD

FILE DETAILS:

BT Prime Mover CMX60/80 Electric Center Riding Pallet Truck Service Manual – PDF DOWNLOAD

Language : English
Pages : 360
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

BT Prime Mover CMX60/80 Electric Center Riding Pallet Truck Service Manual – PDF DOWNLOAD

Manual Part Number 302825-000
Effective Serial Number CMX__25268001

Front Cover 1
Standard Codes 3
Table of Contents 5
Warning Symbols 15
1 Warning Levels 15
Prohibitory Symbols 16
1 Ordinance Symbols 16
Safety 17
1 General Safety 17
Battery Safety 21
Static Discharge Precautions 26
Welding Safety 28
Introduction, Service Manual 31
Contents, Section M 33
1 Machine Information 33
General Product Information 35
1 Truck Presentation 35
1 1 Truck Side Views 35
1 2 Intended Truck Application 35
1 3 Prohibited Truck Application 36
1 4 Truck Data 36
1 5 CMX Dimensions 37
1 6 Data Plate 38
2 Main Components 41
Inch (SAE) and Metric Fasteners 43
1 Introduction 43
2 Nomenclature, Threads 44
3 Strength Identification 45
4 Conversion of Metric and English Units 52
Technical Service Data 55
Ordering Spare Parts 59
Contents, Section P 61
1 Planned Maintenance 61
Introduction, Maintenance 63
1 Jacking Truck Off The Floor 64
1 1 Elevate Rear of Truck 64
1 1 Elevate Either Side of Truck 64
2 Lubricants 64
2 1 Standard 64
2 2 Cold Storage 65
Service Schedule 67
1 Planned Maintenance Schedule 67
2 Planned Maintenance Procedures 71
2 1 Services Performed Daily or Every 8 Operating Hours 71
2 1 1 Battery Discharge Indicator with Lift Cut Out (Optional) 71
2 1 2 Functions/Operations 71
2 1 3 Hourmeter 72
2 1 4 Hydraulic System 72
2 1 5 Frame/Sheet Metal 72
2 1 6 Wheels/Tires 72
2 1 7 Brakes 72
2 2 Services Performed Weekly or Every 30 Operating Hours 73
2 2 1 Battery 73
2 2 2 Prime-Trak® System 73
2 3 Services Performed Monthly or Every 120 Operating Hours 73
2 3 1 Inspection 73
2 3 2 Transmission 73
2 3 3 Brakes 74
2 3 4 Battery 74
2 3 5 Motors 74
2 3 6 Hydraulic Reservoir 75
2 3 7 Frame Lube 75
2 3 8 Pivot Points 75
2 4 Services Performed Quarterly or Every 360 Operating Hours 75
2 4 1 Wheels/Tires 75
2 4 2 Hydraulic System 75
2 4 3 Pivot Points 75
2 5 Services Performed Semi-Annually or Every 720 Operating Hours 76
2 5 1 Frame 76
2 5 2 Drive Gear 76
2 5 3 Brakes 76
2 5 4 Steering Control Handle 76
2 5 5 Instrument Panel 76
2 5 6 Electrical Control System 76
2 5 7 Electrical Panel 76
2 5 8 Electrical Connections 77
2 5 9 Contactor Tips (NOT Sealed) 77
2 5 10 Hydraulic System 77
2 6 Services Performed Annually or Every 1440 Operating Hours 77
2 6 1 Inspection 77
2 6 2 Transmission 77
2 6 3 Battery 78
2 6 4 Hydraulic System 78
2 6 5 Brakes 79
Lubrication Chart 81
Oil and Grease Specifications 82
1 Approved Oils and Grease 82
2 Grease Location Points 83
Contents, Section S 85
1 Service Instructions 85
Frame 87
1 Theory of Operation 88
2 Maintenance 88
2 1 Inspection 88
3 Troubleshooting 89
4 Repair and Rebuild 89
Inspection Covers 93
1 Theory of Operation 94
2 Maintenance 94
3 Troubleshooting 94
4 Repair and Rebuild 94
Battery Compartment 95
1 Theory of Operation 96
2 Maintenance 96
3 Troubleshooting 96
4 Repair and Rebuild 97
4 1 Battery Door 97
4 2 Battery Rollers 98
Operator Controls 99
1 Theory of Operation 100
2 Maintenance 100
3 Troubleshooting 100
4 Repair and Rebuild 100
Decals 103
1 Decal with Protective Sheet 103
2 Decal without Protective Sheet 103
Electric Motors 105
1 Theory of Operation 105
2 Maintenance 105
2 1 Commutator 106
2 2 Motor Brush Inspection 107
3 Troubleshooting 109
4 Repair 116
4 1 Brush Replacement 116
4 2 Pump Motor 117
4 3 Drive Motor 121
5 Rebuild 123
5 1 Pump Motor and Drive Motor Component Disassembly 123
5 2 Inspection 125
5 2 1 Drive End Head 125
5 2 2 Commutator End Head 125
5 2 3 Bearings 125
5 2 4 Armature 125
5 2 5 Frame and Field Assembly 126
5 3 Assembly/Testing 127
5 3 1 Bearing Installation 127
5 3 2 Testing 128
Transmission 129
1 Theory of Operation 131
2 Maintenance 131
2 1 Fluid Changing 131
3 Troubleshooting 132
4 Repair and Rebuild 133
4 1 Transmission Disassembly 133
4 1 Axle Seal 138
Parking Brake System 141
1 Theory of Operation 142
2 Maintenance 143
2 1 Brake Adjustment 143
3 Troubleshooting 144
4 Repair and Rebuild 144
4 1 Brake Shoe 144
Drive Wheel 147
1 Theory of Operation 147
2 Maintenance 147
3 Troubleshooting 147
4 Repair and Rebuild 148
Support / Swivel Wheels 151
1 Theory of Operation 152
2 Maintenance 152
2 1 Inspection 152
3 Troubleshooting 153
4 Repair and Rebuild 153
Load Wheels 155
1 Theory of Operation 157
2 Maintenance 157
3 Troubleshooting 157
4 Repair and Rebuild 157
Stabilizing Caster 159
1 Theory of Operation 160
2 Maintenance 160
2 1 Inspection 160
3 Troubleshooting 160
4 Repair and Rebuild 161
Steering Arm / Wheel (Handle Stem and Brake Levers) 163
1 Theory of Operation 165
2 Maintenance 165
2 1 Inspection 165
3 Troubleshooting 165
4 Repair and Rebuilt 166
4 1 Control Handle Stem 166
4 2 Hand Brake Levers 168
Steering Arm / Wheel (Control Head Assembly) 171
1 Theory of Operation 172
2 Maintenance 172
3 Troubleshooting 172
4 Repair and Rebuild 172
Steering Bearing 175
1 Theory of Operation 176
2 Maintenance 176
3 Troubleshooting 176
4 Repair and Rebuild 177
Electrical Functions 179
1 Theory of Operation 180
1 1 Start-up, A 180
1 2 Start-up B 182
1 3 Travel, Forks-trailing Direction 184
1 4 Travel, Forks-first Direction 185
1 5 High Speed 186
1 6 Prime-Trak® with Operator Off Truck 187
1 7 Prime-Trak® with Operator On Truck 188
2 Maintenance 204
2 1 Wiring 204
2 1 1 Definitions 205
2 1 2 Shorts to Frame Test 206
3 Troubleshooting 210
Battery 229
1 Theory of Operation 229
2 Maintenance 229
2 1 Inspection and Care 229
2 2 Exterior Cleaning 230
2 3 Charging 230
2 4 Storage 231
2 5 History Record 231
3 Troubleshooting 232
4 Repair and Rebuild 233
Battery Connector 235
1 Theory of Operation 235
2 Maintenance 235
2 1 Inspection 235
3 Troubleshooting 235
4 Repair and Rebuild 235
Horn 239
1 Theory of Operation 240
2 Maintenance 240
3 Troubleshooting 240
4 Repair and Rebuild 240
Line Contactor 243
1 Theory of Operation 245
2 Maintenance 245
2 1 Contact Tip Inspection 245
3 Troubleshooting 245
4 Repair and Rebuild 246
Battery Controller/Hourmeter/Lift Interrupt 249
1 Theory of Operation 249
2 Maintenance 251
2 1 Discharge Adjustment 251
3 Troubleshooting 253
3 1 Battery Discharge Indicator (BDI) 253
3 2 Hourmeter 255
Battery Discharge Indicator / Hourmeter 257
1 Theory of Operation 257
2 Maintenance 258
3 Troubleshooting 259
3 1 Battery Discharge Indicator (BDI) 259
3 2 Hourmeter 260
Switches 261
1 Theory of Operation 262
2 Maintenance 262
3 Troubleshooting 265
4 Repair and Rebuild 265
4 1 Key Switch 265
4 2 Master Control On/Off Switch 266
4 3 Lift Limit Switch 267
4 4 Lift and Lower Switches 268
4 5 Prime-Trak® Switch 269
4 6 Brake Interlock Switch 270
Speed Controls 271
1 Theory of Operation 273
2 Maintenance 273
2 1 Potentiometer Adjustment 273
3 Troubleshooting 274
4 Repair and Rebuild 275
4 1 Potentiometer Assembly 275
4 2 Rearward and Forward Switches 277
4 3 Prime-Trak® Switch 278
Transistor Controller 279
1 Theory of Operation 279
1 1 Basics Of Circuit Operation 279
1 2 Control Features 280
1 3 Motor Circuit 282
1 4 Control Circuit 283
2 Maintenance 284
2 1 Safety 284
2 2 Cleaning 285
2 3 Transistor Adjustable Settings 285
2 4 Definitions 286
3 Troubleshooting 287
3 1 Diagnostics and Troubleshooting 287
3 2 Handset Diagnostics 287
3 3 Troubleshooting Chart 289
3 4 Troubleshooting Chart Using Handset 292
4 Repair and Rebuild 293
Hydraulic System 295
1 Theory of Operation 295
1 1 Electric Lift 295
1 2 Lower 296
1 3 Hydraulic Lift 298
1 4 Hydraulic Relief 299
1 5 Hydraulic Hold 300
1 6 Hydraulic Lower 301
1 7 Relief Pressure 302
2 Maintenance 302
2 1 Hydraulic Fluid Check 302
2 2 Adjustments 302
3 Troubleshooting 304
4 Repair and Rebuild 309
Prime-Trak® Hydraulic System 315
1 Theory of Operation 315
2 Maintenance 317
2 1 Hydraulic Fluid Check 317
2 2 Adjustments 317
3 Troubleshooting 318
4 Repair and Rebuild 321
Lift Cylinder 327
1 Theory of Operation 329
2 Maintenance 329
2 1 Inspection 329
3 Troubleshooting 329
4 Repair and Rebuild 330
Prime-Trak® Cylinders 335
1 Theory of Operation 335
2 Maintenance 336
2 1 Inspection 336
3 Troubleshooting 336
4 Repair and Rebuild 337
Handset, Old 341
1 Theory of Operation 341
Handset, New 349
1 Theory of Operation 349
Index 357
A 357
B 357
C 357
D 357
E 357
F 357
G 357
H 357
I 357
J 357
L 357
M 357
O 358
P 358
S 358
T 358
W 358
Back Cover 360

DESCRIPTION:

BT Prime Mover CMX60/80 Electric Center Riding Pallet Truck Service Manual – PDF DOWNLOAD

Manual Part Number 302825-000
Effective Serial Number CMX__25268001

Introduction, Service Manual:

• The information in this service manual covers models CMX60 and CMX80.
• Federal and State laws require that operators be completely trained in the safe operation of lift trucks in accordance with OHSA regulation 1910.178.
• An operator’s manual is sent with every Prime-Mover lift truck when it is manufactured.
• The information contained in this service manual is intended as a guide to help trained, qualified, and authorized technicians safely service the truck.
• The service manual is divided into four separate sections which cover needed information for servicing the truck types.

S.V 10/01/2025