BT PRIME MOVER CMX60/80 SERVICE MANUAL 302825-000 – PDF DOWNLOAD

Description

BT PRIME MOVER CMX60/80 SERVICE MANUAL 302825-000 – PDF DOWNLOAD

FILE DETAILS:

BT PRIME MOVER CMX60/80 SERVICE MANUAL 302825-000 – PDF DOWNLOAD

Language : English
Pages : 356
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

BT PRIME MOVER CMX60/80 SERVICE MANUAL 302825-000 – PDF DOWNLOAD

Front Cove r...........................................................................................  1
Ordering Spare Parts...................................................................................  3
Standard Codes.........................................................................................  5
Table of Contents......................................................................................  7
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
Contents, Section P.................................................................................... 59
	1. Planned Maintenance............................................................................. 59
Introduction, Maintenance.............................................................................. 61
	1. Jacking Truck Off The Floor..................................................................... 62
		1.1. Elevate Rear of Truck..................................................................... 62
		1.1. Elevate Either Side of Truck.............................................................. 62
	2. Lubricants...................................................................................... 62
		2.1. Standard Conditioning..................................................................... 62
		2.2. Corrosion Conditioning.................................................................... 62
		2.3. Cold Storage Conditioning................................................................. 64
Service Schedule....................................................................................... 65
	1. Planned Maintenance Schedule.................................................................... 65
	2. Planned Maintenance Procedures.................................................................. 69
		2.1. Services Performed Daily or Every 8 Operating Hours....................................... 69
			2.1.1. Frame............................................................................... 69
			2.1.2. Brake............................................................................... 69
			2.1.3. Wheels/Tires........................................................................ 69
			2.1.4. Steering Control Handle............................................................. 69
			2.1.5. Functions/Operations................................................................ 70
			2.1.6. Battery Discharge Indicator with Lift Cut Out (Optional Equipment) and Hourmeter.... 70
			2.1.7. Hydraulic System (Prime-Trak Optional).............................................. 70
		2.2. Services Performed Weekly or Every 30 Operating Hours..................................... 71
			2.2.1. Battery............................................................................. 71
		2.3. Services Performed Monthly or Every 120 Operating Hours................................... 71
			2.3.1. Inspection.......................................................................... 71
			2.3.2. Motors.............................................................................. 71
			2.3.3. Transmission........................................................................ 72
			2.3.4. Brakes.............................................................................. 72
			2.3.5. Control Handle Pivot Points......................................................... 72
			2.3.6. Battery............................................................................. 72
			2.3.7. Lift Cylinder Pivot Points.......................................................... 72
		2.4. Services Performed Quarterly or Every 360 Operating Hours................................. 73
			2.4.1. Frame Lube.......................................................................... 73
			2.4.2. Wheels/Tires........................................................................ 73
			2.4.3. Hydraulic System (Prime-Trak Optional).............................................. 73
		2.5. Services Performed Semi-Annually or Every 720 Operating Hours............................. 74
			2.5.1. Frame............................................................................... 74
			2.5.2. Drive Gear.......................................................................... 74
			2.5.3. Brakes.............................................................................. 74
			2.5.4. Steering Control Handle............................................................. 74
			2.5.5. Electrical Control System........................................................... 74
			2.5.6. Instrument Panel.................................................................... 74
			2.5.7. Electrical Panel.................................................................... 75
			2.5.8. Electrical Connections.............................................................. 75
			2.5.9. Contactor Tips (NOT Sealed)......................................................... 75
			2.5.10. Hydraulic System (Prime-Trak Optional)............................................. 75
			2.5.11. Hydraulic Reservoir................................................................ 75
		2.6. Services Performed Annually or Every 1440 Operating Hours................................. 76
			2.6.1. Inspection.......................................................................... 76
			2.6.2. Transmission........................................................................ 76
			2.6.3. Brakes.............................................................................. 76
			2.6.4. Steer Bearings...................................................................... 77
			2.6.5. Battery............................................................................. 77
			2.6.6. Hydraulic System (Prime-Trak Optional).............................................. 77
Lubrication Chart...................................................................................... 79
Oil and Grease Specifications.......................................................................... 80
	1. Approved Oils and Grease........................................................................ 80
	2. Grease Location Points.......................................................................... 81
Contents, Section S.................................................................................... 83
	1. Service Instructions............................................................................ 83
Frame.................................................................................................. 85
	1. Theory of Operation............................................................................. 85
	2. Maintenance..................................................................................... 85
		2.1. Inspection................................................................................ 85
	3. Troubleshooting................................................................................. 86
	4. Repair and Rebuild.............................................................................. 86
Inspection Covers...................................................................................... 93
	1. Theory of Operation............................................................................. 93
	2. Maintenance..................................................................................... 93
	3. Troubleshooting................................................................................. 93
	4. Repair and Rebuild.............................................................................. 93
Battery Compartment.................................................................................... 95
	1. Theory of Operation............................................................................. 95
	2. Maintenance..................................................................................... 95
	3. Troubleshooting................................................................................. 95
	4. Repair and Rebuild.............................................................................. 96
		4.1. Battery Door.............................................................................. 97
		4.2. Battery Rollers........................................................................... 98
Operator Controls...................................................................................... 99
	1. Theory of Operation............................................................................. 99
	2. Maintenance..................................................................................... 99
	3. Troubleshooting................................................................................. 99
	4. Repair and Rebuild.............................................................................. 99
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
	3. Troubleshooting.................................................................................106
	4. Repair and Rebuild..............................................................................107
		4.1. Pump Motor................................................................................107
		4.2. Drive Motor...............................................................................113
		4.3. Brush Replacement.........................................................................115
			4.3.1. Inspection and Replacement..........................................................115
			4.3.2. Brush Inspection....................................................................115
Transmission...........................................................................................117
	1. Theory of Operation.............................................................................117
	2. Maintenance.....................................................................................117
		2.1. Fluid Changing............................................................................117
	3. Troubleshooting.................................................................................118
	4. Repair and Rebuild..............................................................................118
		4.1. Transmission Disassembly..................................................................122
		4.1. Axle Seal.................................................................................127
Parking Brake System...................................................................................129
	1. Theory of Operation.............................................................................129
	2. Maintenance.....................................................................................130
		2.1. Brake Adjustment..........................................................................130
	3. Troubleshooting.................................................................................131
	4. Repair and Rebuild..............................................................................131
		4.1. Brake Shoe................................................................................132
Drive Wheel............................................................................................135
	1. Theory of Operation.............................................................................135
	2. Maintenance.....................................................................................135
	3. Troubleshooting.................................................................................135
	4. Repair and Rebuild..............................................................................136
Support / Swivel Wheels................................................................................139
	1. Theory of Operation.............................................................................139
	2. Maintenance.....................................................................................139
		2.1. Inspection................................................................................139
	3. Troubleshooting.................................................................................140
	4. Repair and Rebuild..............................................................................141
Load Wheels............................................................................................145
	1. Theory of Operation.............................................................................145
	2. Maintenance.....................................................................................145
	3. Troubleshooting.................................................................................145
	4. Repair and Rebuild..............................................................................146
Stabilizing Caster.....................................................................................151
	1. Theory of Operation.............................................................................151
	2. Maintenance.....................................................................................151
		2.1. Inspection................................................................................151
	3. Troubleshooting.................................................................................152
	4. Repair and Rebuild..............................................................................152
Steering Arm / Wheel (Handle Stem and Brake Levers)....................................................155
	1. Theory of Operation.............................................................................155
	2. Maintenance.....................................................................................155
		2.1. Inspection................................................................................155
	3. Troubleshooting.................................................................................155
	4. Repair and Rebuild..............................................................................156
		4.1. Control Handle Stem.......................................................................158
		4.2. Hand Brake Levers.........................................................................160
Steering Arm / Wheel (Control Head Assembly)...........................................................163
	1. Theory of Operation.............................................................................163
	2. Maintenance.....................................................................................163
	3. Troubleshooting.................................................................................163
	4. Repair and Rebuild..............................................................................164
Steering Bearing.......................................................................................169
	1. Theory of Operation.............................................................................169
	2. Maintenance.....................................................................................169
	3. Troubleshooting.................................................................................169
	4. Repair and Rebuild..............................................................................170
Electrical Functions...................................................................................173
	1. Theory of Operation.............................................................................173
		1.1. Start-up A................................................................................174
		1.2. Start-up B................................................................................176
		1.3. Travel, Tractor-first Direction...........................................................178
		1.4. Travel, Forks-first Direction.............................................................179
		1.5. High Speed................................................................................180
		1.6. Prime-Trak® with Operator Off Truck.......................................................181
		1.7. Prime-Trak® with Operator On Truck........................................................182
	2. Maintenance.....................................................................................199
		2.1. Wiring....................................................................................199
			2.1.1. Definitions.........................................................................200
			2.1.2. Shorts to Frame Test................................................................201
	3. Troubleshooting.................................................................................205
		3.1. Troubleshooting Chart Index...............................................................206
		3.2. Troubleshooting Charts....................................................................207
Battery................................................................................................223
	1. Theory of Operation.............................................................................223
	2. Maintenance.....................................................................................223
		2.1. Inspection and Care.......................................................................223
		2.2. Exterior Cleaning.........................................................................224
		2.3. Charging..................................................................................224
		2.4. Storage...................................................................................225
		2.5. History Record............................................................................226
	3. Troubleshooting.................................................................................226
	4. Repair and Rebuild..............................................................................227
Battery Connector......................................................................................229
	1. Theory of Operation.............................................................................229
	2. Maintenance.....................................................................................229
		2.1. Inspection................................................................................229
	3. Troubleshooting.................................................................................229
	4. Repair and Rebuild..............................................................................230
Horn...................................................................................................233
	1. Theory of Operation.............................................................................233
	2. Maintenance.....................................................................................233
	3. Troubleshooting.................................................................................233
	4. Repair and Rebuild..............................................................................233
		4.1. Horn......................................................................................234
		4.2. Horn Switch...............................................................................235
Line Contactor.........................................................................................237
	1. Theory of Operation.............................................................................237
	2. Maintenance.....................................................................................237
		2.1. Contact Tip Inspection....................................................................237
	3. Troubleshooting.................................................................................238
	4. Repair and Rebuild..............................................................................238
Battery Controller/Hourmeter/Lift Interrupt............................................................243
	1. Theory of Operation.............................................................................243
	2. Maintenance.....................................................................................245
		2.1. Discharge Adjustment......................................................................245
	3. Troubleshooting.................................................................................247
		3.1. Battery Discharge Indicator (BDI).........................................................247
		3.2. Hourmeter.................................................................................249
Battery Discharge Indicator / Hourmeter................................................................251
	1. Theory of Operation.............................................................................251
	2. Maintenance.....................................................................................252
	3. Troubleshooting.................................................................................253
		3.1. Battery Discharge Indicator (BDI).........................................................253
		3.2. Hourmeter.................................................................................254
Switches...............................................................................................255
	1. Theory of Operation.............................................................................255
	2. Maintenance.....................................................................................255
		2.1. Key Switch Inspection.....................................................................255
		2.2. Master Control On/Off Switch Inspection...................................................255
		2.3. Prime-Trak® ON/OFF Switch Adjustment......................................................256
		2.4. Lift Limit Switch Adjustment..............................................................256
		2.5. Lift and Lower Switches...................................................................256
		2.6. Brake Interlock Switch Adjustment.........................................................257
	3. Troubleshooting.................................................................................258
	4. Repair and Rebuild..............................................................................258
		4.1. Key Switch................................................................................259
		4.2. Master Control On/Off Switch..............................................................260
		4.3. Prime-Trak® On/Off Switch.................................................................260
		4.4. Lift Limit Switch.........................................................................261
		4.5. Lift and Lower Switches...................................................................262
		4.6. Brake Interlock Switch....................................................................263
Speed Controls.........................................................................................265
	1. Theory of Operation.............................................................................265
	2. Maintenance.....................................................................................265
		2.1. Potentiometer Adjustment..................................................................265
	3. Troubleshooting.................................................................................267
	4. Repair and Rebuild..............................................................................267
		4.1. Potentiometer Assembly....................................................................269
		4.2. Rearward and Forward Switches.............................................................271
		4.3. Prime-Trak® Limit Switch..................................................................272
Transistor Controller..................................................................................273
	1. Theory of Operation.............................................................................273
		1.1. Basics Of Circuit Operation...............................................................273
		1.2. Control Features..........................................................................274
		1.3. Motor Circuit.............................................................................276
		1.4. Control Circuit...........................................................................277
	2. Maintenance.....................................................................................278
		2.1. Safety....................................................................................278
		2.2. Cleaning..................................................................................279
		2.3. Transistor Adjustable Settings............................................................279
		2.4. Definitions...............................................................................280
	3. Troubleshooting.................................................................................281
		3.1. Diagnostics and Troubleshooting...........................................................281
		3.2. Handset Diagnostics.......................................................................281
		3.3. Troubleshooting Chart.....................................................................283
		3.4. Troubleshooting Chart Using Handset.......................................................286
	4. Repair and Rebuild..............................................................................287
Hydraulic System.......................................................................................289
	1. Theory of Operation.............................................................................289
		1.1. Electric Lift.............................................................................290
		1.2. Lower.....................................................................................291
		1.3. Hydraulic Lift............................................................................292
		1.4. Hydraulic Relief..........................................................................293
		1.5. Hydraulic Hold............................................................................294
		1.6. Hydraulic Lower...........................................................................295
		1.7. Relief Pressure...........................................................................296
	2. Maintenance.....................................................................................296
		2.1. Hydraulic Fluid Check.....................................................................296
		2.2. Adjustments...............................................................................296
	3. Troubleshooting.................................................................................298
	4. Repair and Rebuild..............................................................................304
Prime-Trak® Hydraulic System...........................................................................309
	1. Theory of Operation.............................................................................309
	2. Maintenance.....................................................................................311
		2.1. Hydraulic Fluid Check.....................................................................311
		2.2. Adjustments...............................................................................311
	3. Troubleshooting.................................................................................312
	4. Repair and Rebuild..............................................................................314
Lift Cylinder..........................................................................................319
	1. Theory of Operation.............................................................................319
	2. Maintenance.....................................................................................319
		2.1. Inspection................................................................................319
	3. Troubleshooting.................................................................................319
	4. Repair and Rebuild..............................................................................320
Prime-Trak® Cylinders..................................................................................325
	1. Theory of Operation.............................................................................325
	2. Maintenance.....................................................................................325
		2.1. Inspection................................................................................325
	3. Troubleshooting.................................................................................325
	4. Repair and Rebuild..............................................................................326
Battery Top Tray (Optional)............................................................................331
	1. Theory of Operation.............................................................................331
	2. Maintenance.....................................................................................331
	3. Troubleshooting.................................................................................331
	4. Repair and Rebuild..............................................................................331
Electrical Heater (Optional)...........................................................................333
	1. Theory of Operation.............................................................................333
	2. Maintenance.....................................................................................333
	3. Troubleshooting.................................................................................333
	4. Repair and Rebuild..............................................................................333
Version One Handset....................................................................................337
	1. Theory of Operation.............................................................................337
Version Two Handset....................................................................................345
	1. Theory of Operation.............................................................................345
Index..................................................................................................353
	A..................................................................................................353
	B..................................................................................................353
	C..................................................................................................353
	D..................................................................................................353
	E..................................................................................................353
	F..................................................................................................353
	G..................................................................................................353
	H..................................................................................................353
	J..................................................................................................353
	L..................................................................................................353
	M..................................................................................................353
	O..................................................................................................353
	P..................................................................................................354
	S..................................................................................................354
	T..................................................................................................354
	W..................................................................................................354
Back Cover.............................................................................................356

DESCRIPTION:

BT PRIME MOVER CMX60/80 SERVICE MANUAL 302825-000 – PDF DOWNLOAD

• The information in this service manual covers models CMXGO 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.

S.S 05/01/2025