BT Prime-Mover CMX60/80 Service Manual – PDF DOWNLOAD

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BT Prime-Mover CMX60/80 Service Manual – PDF DOWNLOAD

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BT Prime-Mover CMX60/80 Service Manual – PDF DOWNLOAD

Language : English
Pages : 543
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

BT Prime-Mover CMX60/80 Service Manual – PDF DOWNLOAD

Front Cover..................................................................................  2
Table of Contents............................................................................  4
0.0 Maintenance..............................................................................  7
	0.1 Truck Identification.................................................................  8
	0.2 System Operation.....................................................................  9
	0.3 Specifications....................................................................... 10
	0.4 Maintenance and Adjustments.......................................................... 22
	0.5 Troubleshooting...................................................................... 29
	0.6 Component Removal and Installation................................................... 29
	0.7 Component Repair..................................................................... 29
1.0 Transmission............................................................................. 31
	1.1 Component Identification............................................................. 32
	1.2 System Operation..................................................................... 36
	1.3 Specifications....................................................................... 36
	1.4 Maintenance and Adjustments.......................................................... 36
	1.5 Troubleshooting...................................................................... 37
	1.6 Component Removal and Installation................................................... 37
	1.7 Component Repair..................................................................... 43
2.0 Electrical............................................................................... 45
	2.1 Component Identification............................................................. 47
	2.2 System Operation..................................................................... 54
	2.3 Specifications....................................................................... 60
	2.4 Maintenance and Adjustments.......................................................... 60
	2.5 Troubleshooting...................................................................... 66
	2.6 Component Removal and Installation................................................... 87
	2.7 Component Repair..................................................................... 92
3.0 Hydraulics...............................................................................105
	3.1 Component Identification.............................................................106
	3.2 System Operation.....................................................................116
	3.3 Specifications.......................................................................117
	3.4 Maintenance and Adjustments..........................................................117
	3.5 Troubleshooting......................................................................118
	3.6 Component Removal and Installation...................................................121
	3.7 Component Repair.....................................................................125
4.0 Frame....................................................................................127
	4.1 Component Identification.............................................................128
	4.2 System Operation.....................................................................134
	4.3 Specifications.......................................................................134
	4.4 Maintenance and Adjustments..........................................................134
	4.5 Troubleshooting......................................................................134
	4.6 Component Removal and Installation...................................................135
Back Cover...................................................................................139
Front Cover..................................................................................140
Table of Contents............................................................................142
0.0 Maintenance..............................................................................145
	0.1 Truck Identification.................................................................146
	0.2 System Operation.....................................................................147
	0.3 Specifications.......................................................................148
	0.4 Maintenance and Adjustments..........................................................160
	0.5 Troubleshooting......................................................................167
	0.6 Component Removal and Installation...................................................167
	0.7 Component Repair.....................................................................167
1.0 Transmission.............................................................................169
	1.1 Component Identification.............................................................170
	1.2 System Operation.....................................................................174
	1.3 Specifications.......................................................................174
	1.4 Maintenance and Adjustments..........................................................174
	1.5 Troubleshooting......................................................................175
	1.6 Component Removal and Installation...................................................175
	1.7 Component Repair.....................................................................181
2.0 Electrical...............................................................................184
	2.1 Component Identification.............................................................186
	2.2 System Operation.....................................................................193
	2.3 Specifications.......................................................................199
	2.4 Maintenance and Adjustments..........................................................199
	2.5 Troubleshooting......................................................................205
	2.6 Component Removal and Installation...................................................226
	2.7 Component Repair.....................................................................232
3.0 Hydraulics...............................................................................244
	3.1 Component Identification.............................................................245
	3.2 System Operation.....................................................................255
	3.3 Specifications.......................................................................255
	3.4 Maintenance and Adjustments..........................................................256
	3.5 Troubleshooting......................................................................257
	3.6 Component Removal and Installation...................................................259
	3.7 Component Repair.....................................................................262
4.0 Frame....................................................................................264
	4.1 Component Identification.............................................................265
	4.2 System Operation.....................................................................271
	4.3 Specifications.......................................................................271
	4.4 Maintenance and Adjustments..........................................................271
	4.5 Troubleshooting......................................................................271
	4.6 Component Removal and Installation...................................................272
Back Cover...................................................................................275
Front Cover..................................................................................276
BT Standard Codes............................................................................278
Warning Symbols..............................................................................288
	1. Warning Levels........................................................................288
Prohibitory Symbols..........................................................................289
	1. Ordinance Symbols.....................................................................289
Introduction, Service Manual.................................................................290
Contents, Section M..........................................................................292
	1. Machine Information...................................................................292
General Product Information..................................................................294
	1. Presentation of the Rider Trucks CMX60 and CMX80......................................294
		1.1. Intended Application of the Trucks..............................................294
		1.2. Forbidden Application of the Trucks.............................................295
		1.3. Truck Data......................................................................295
		1.4. CMX Dimensions..................................................................296
		1.5. Data Plate......................................................................297
Inch (SAE) and Metric Fasteners..............................................................300
	1. Introduction..........................................................................300
Technical Service Data.......................................................................310
Ordering Spare Parts.........................................................................314
Contents, Section P..........................................................................316
	1. Planned Maintenance...................................................................316
Introduction, Maintenance....................................................................318
	1. Safe Jacking Procedure................................................................318
Service Schedule.............................................................................320
	1. Planned Maintenance Schedule..........................................................320
		2.1. Services to be Performed Daily..................................................324
			2.1.1. Battery Discharge Indicator with slow down................................324
			2.1.2. Hydraulic System..........................................................324
			2.1.3. Frame/Sheet Metal.........................................................325
			2.1.4. Wheels/Tires..............................................................325
			2.1.5. Functions/Operations......................................................325
		2.2. Services to be Performed Monthly................................................326
			2.2.1. Inspection................................................................326
			2.2.2. Transmission..............................................................326
			2.2.3. Brakes....................................................................326
			2.2.4. Battery...................................................................326
			2.2.5. Electrical Connections....................................................326
			2.2.6. Contactor Tips (NOT Sealed)...............................................327
			2.2.7. Motor Brushes.............................................................327
			2.2.8. Drive Motor...............................................................327
			2.2.9. Hydraulic Reservoir.......................................................327
			2.2.10. Frame Lube (“Lubrication Chart” on page57)..............................327
			2.2.11. Pivot Points.............................................................328
		2.3. Services to be Performed Annually...............................................329
			2.3.1. Inspection................................................................329
			2.3.2. Transmission..............................................................329
			2.3.3. Battery...................................................................329
			2.3.4. Hydraulic System..........................................................329
			2.3.5. Brakes....................................................................330
Lubrication Chart............................................................................332
Oil and Grease Specifications................................................................334
	1. Approved Oils and Grease..............................................................334
Contents, Section S..........................................................................336
	1. Service Instructions..................................................................336
Chassis......................................................................................338
	1. General Information...................................................................338
		2.1. Removal.........................................................................339
Lift Frame...................................................................................340
	1. Pull rod..............................................................................341
		1.1. Removal.........................................................................341
		1.2. Inspection......................................................................343
		1.3. Installation....................................................................344
Drive Motor Mounting Points..................................................................346
	1. Drive Motor Brush.....................................................................347
		1.1. Removal and Installation........................................................347
		2.1. Remove..........................................................................347
		2.2. Installation....................................................................348
Drive Motor..................................................................................350
	1. General Information...................................................................350
Drive Motor Service..........................................................................356
	1. Motor Repair..........................................................................357
		1.1. Disassembly.....................................................................357
		2.1. Drive End Head..................................................................360
		2.2. Commutator End Head.............................................................360
		2.3. Bearings........................................................................360
		2.4. Brush and Commutator............................................................361
		2.5. Armature........................................................................361
		2.6. Frame and Field Assembly........................................................362
			2.6.1. Testing...................................................................362
			2.6.2. Frame and Field Service Notes.............................................363
		2.7. Assembly........................................................................364
			2.7.1. Field Coil Installation...................................................364
			2.7.2. Bearing Installation......................................................364
			2.7.3. After Assembly............................................................365
Transmission.................................................................................366
	1. System Description....................................................................366
Transmission Axle Seal.......................................................................370
	1. General Information...................................................................370
		1.1. Removal.........................................................................370
		1.2. Installation....................................................................370
Transmission Disassembly / Assembly..........................................................372
	1. Disassembly...........................................................................373
Parking Brake System.........................................................................376
	1. Brake Theory of Operation.............................................................377
Drive Wheel..................................................................................382
	4.1. Removal.............................................................................382
	4.2. Installation........................................................................383
Load Wheels..................................................................................384
Support / Swivel Wheel.......................................................................386
	1. Stabilizing Caster....................................................................386
		1.1. Removal.........................................................................387
		1.2. Inspection......................................................................389
		1.3. Installation....................................................................390
		1.4. Maintenance.....................................................................391
Stabilizing Caster...........................................................................392
	1. Stabilizing Caster....................................................................392
		1.1. Disassembly.....................................................................393
		1.2. Inspection......................................................................394
		1.3. Assembly........................................................................395
Steering Control Arm.........................................................................396
	1. Control Handle Stem...................................................................397
		1.1. Removal.........................................................................397
		1.2. Installation....................................................................398
		2.1. Removal.........................................................................399
		2.2. Disassembly.....................................................................399
		2.3. Assembly........................................................................399
		2.4. Installation....................................................................400
Steering Handle Head.........................................................................402
	1. Control Handle Head...................................................................404
		1.1. Removal.........................................................................404
		1.2. Installation....................................................................404
300/400 Amp Contactor........................................................................410
	1. Maintenance...........................................................................411
		1.1. Removal/Replacement of Contact Tips.............................................411
“EE” Contactor...............................................................................414
	1. Maintenance...........................................................................415
		1.1. Removal/Replacement of Contact Tips.............................................415
Battery Controller / Hourmeter / Lift Interrupt..............................................418
	1. General Information...................................................................418
		2.1. Voltage.........................................................................418
			2.1.1. The Contact Voltage and Current Ratings for Switching Resistive Loads.....419
			2.1.2. Memory Retention..........................................................419
		3.1. General Information.............................................................419
			3.1.1. Discharge Adjustment......................................................419
		3.2. Reset...........................................................................421
		3.3. Key Switch......................................................................421
		3.4. Hourmeter.......................................................................421
		4.1. Battery Discharge Indicator (BDI)...............................................422
			4.1.1. No Reset..................................................................422
			4.1.2. Reset After Break in Power................................................422
			4.1.3. No Discharge, Gauge Does Not Run Down.....................................423
			4.1.4. No Lockout................................................................423
			4.1.5. No Lift...................................................................423
			4.1.6. Early Lockout.............................................................424
			4.1.7. LEDs Do Not Light.........................................................424
		4.2. Hourmeter.......................................................................424
			4.2.1. No Display................................................................424
			4.2.2. Hourmeter Glass Icon Does Not Flash.......................................424
			4.2.3. Hourmeter Glass Icon Always Flashes.......................................425
Battery Discharge Indicator / Hourmeter......................................................426
	1. General Information...................................................................426
		2.1. Voltage.........................................................................426
		3.1. General Information.............................................................427
		3.2. Key Switch......................................................................427
		3.3. Hourmeter.......................................................................427
		4.1. Battery Discharge Indicator (BDI)...............................................428
			4.1.1. No Reset..................................................................428
			4.1.2. Reset After Break in Power................................................428
			4.1.3. No Discharge, Gauge Does Not Run Down.....................................429
			4.1.4. LEDs Do Not Light.........................................................429
		4.2. Hourmeter.......................................................................429
			4.2.1. No Display................................................................429
			4.2.2. Hourmeter Glass Icon Does Not Flash.......................................429
			4.2.3. Hourmeter Glass Icon Always Flashes.......................................430
24 Volt 400 Amp Electrical System............................................................432
	1. Electrical Panel Components...........................................................432
		2.1. Circuit Diagram 1(5)............................................................435
		2.2. Circuit Diagram 2(5)............................................................436
		2.3. Circuit Diagram 3(5)............................................................437
		2.4. Circuit Diagram 4(5)............................................................438
		2.5. Circuit Diagram 5(5)............................................................439
		3.1. General Information.............................................................440
		3.2. References Information..........................................................440
		3.3. Key Switch S17 in the ON Position...............................................440
		3.4. Brake released, S10 Brake Switch Closed.........................................440
		3.5. Driving, Fork Direction.........................................................440
		3.6. Driving, Steer Wheel Direction..................................................441
		3.7. Reversing/Motor Brake Fork Direction to Steer Wheel Direction...................441
		3.8. Reversing/Motor Brake Steer Wheel Direction to Fork Direction...................441
		3.9. Lifting the Forks...............................................................441
		3.10. Lowering the Forks.............................................................441
		3.11. Horn...........................................................................442
		3.12. Prime-Trak; operator off of the truck..........................................442
		3.13. Prime-Trak; operator on the truck..............................................442
		3.14. Lift Interrupt.................................................................443
24 Volt, 400 Amp Transistor Controller.......................................................444
	1. Maintenance...........................................................................444
		1.1. Safety..........................................................................444
		1.2. Cleaning........................................................................444
		1.3. Diagnostics and Troubleshooting.................................................445
			1.3.1. Handset Diagnostics.......................................................445
			1.3.2. Troubleshooting...........................................................445
		2.1. Control Features................................................................448
		5.1. 1307 Programmer Diagnostics.....................................................454
		5.2. Troubleshooting Chart...........................................................455
		5.3. Technical Specification.........................................................459
		5.4. Troubleshooting Chart Using the Handset.........................................460
24 Volt, 400 Amp Transistor Controller Troubleshooting.......................................462
	1. Troubleshooting Chart Index...........................................................462
Handset Operation............................................................................481
	1. Operating Modes.......................................................................483
Pump Motor...................................................................................488
	1. Component Repair......................................................................489
		1.1. Motor Disassembly...............................................................489
		2.1. Drive End Head..................................................................491
		2.2. Commutator End Head.............................................................491
		2.3. Bearings........................................................................491
		2.4. Brush and Commutator............................................................492
		2.5. Armature........................................................................492
		2.6. Frame and Field Assembly........................................................493
			2.6.1. Testing...................................................................493
			2.6.2. Frame and Field Service Notes.............................................494
		2.7. Assembly........................................................................495
			2.7.1. Field Coil Installation...................................................495
			2.7.2. Bearing Installation......................................................495
			2.7.3. After Assembly............................................................496
Hydraulic System.............................................................................498
	1. Hydraulic Schematic...................................................................498
		3.1. Lift............................................................................499
		3.2. Lower...........................................................................499
		3.3. Relief Pressure.................................................................499
Prime-Trak Hydraulic System..................................................................504
	1. Prime-Trak Hydraulic Schematic........................................................504
Lift Pump Assembly...........................................................................510
	1. Removal...............................................................................512
		6.1. Relief valve....................................................................519
		6.2. Solenoid Operated Valve.........................................................520
Prime-Trak Hydraulic Pump....................................................................522
	1. Removal...............................................................................523
Lift Cylinder................................................................................530
	1. Removal...............................................................................531
Prime-Trak Cylinders.........................................................................536
	1. Removal...............................................................................537
Back Cover...................................................................................543

S.S 06/24