BT Prime-Mover HMX/RMX Service Manual Digital PDF Download

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BT Prime-Mover HMX/RMX Service Manual – PDF DOWNLOAD

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BT Prime-Mover HMX/RMX Service Manual – PDF DOWNLOAD

Language : English
Pages : 477
Downloadable : Yes
File Type : PDF

302065-000 1995_January
302065-000 1998_March

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

BT Prime-Mover HMX/RMX Service Manual – PDF DOWNLOAD

Front Cover....................................................................................  2
Table of Contents..............................................................................  4
Section 0 - Maintenance........................................................................  7
	0.1 Truck Identification...................................................................  7
	0.2 System Operation.......................................................................  8
	0.3 Specifications.........................................................................  9
	0.4 Maintenance and Adjustments............................................................ 22
	0.5 Troubleshooting........................................................................ 29
	0.6 Component Removal and Installation..................................................... 29
	0.7 Component Repair....................................................................... 29
Section 1 - Transmission....................................................................... 30
	Figure # 1.1 Handle and Transmission Installation.......................................... 31
	1.2 System Operation....................................................................... 33
	1.3 Specifications......................................................................... 33
	1.4 Maintenance and Adjustments............................................................ 33
	1.5 Troubleshooting........................................................................ 34
	1.6 Component Removal and Installation..................................................... 34
	Figure # 1.2 Transmission Assembly......................................................... 41
	1.7 Component Repair....................................................................... 43
Section 2 - Electrical......................................................................... 46
	2.1 Component Identification............................................................... 48
	2.2 System Operation....................................................................... 69
	2.3 Specifications......................................................................... 77
	2.4 Maintenance and Adjustments............................................................ 78
	2.5 Troubleshooting........................................................................ 84
	2.6 Component Removal and Installation.....................................................104
	2.7 Component Repair.......................................................................109
Section 3 - Hydraulics.........................................................................120
	3.1 Component Identification...............................................................121
	3.2 System Operation.......................................................................125
	3.3 Specifications.........................................................................125
	3.4 Maintenance and Adjustments............................................................126
	3.5 Troubleshooting........................................................................126
	3.6 Component Removal and Installation.....................................................129
	3.7 Component Repair.......................................................................131
Section 4 - Frame..............................................................................134
	4.1 Component Identification...............................................................135
	Figure # 4.2 HMX Caster Torsion Rod Assembly...............................................137
	4.2 System Operation.......................................................................139
	4.3 Specifications.........................................................................139
	4.4 Maintenance and Adjustments............................................................139
	4.5 Troubleshooting........................................................................140
	Figure # 4.3 Handle and Transmission Installation..........................................141
	4.6 Component Removal and Installation.....................................................143
Back Cover.....................................................................................147
Front Cover....................................................................................148
BT Standard Codes..............................................................................150
Warning Symbols................................................................................160
	1. Warning Levels..........................................................................160
Prohibitory Symbols............................................................................161
	1. Ordinance Symbols.......................................................................161
Introduction, Service Manual...................................................................162
Contents, Section M............................................................................164
	1. Machine Information.....................................................................164
General Product Information....................................................................166
	1. Presentation of the RMX and HMX.........................................................166
		1.1. Intended Application of the Trucks................................................166
		1.2. Forbidden Application of the Trucks...............................................167
		1.3. Truck Data........................................................................167
		1.4. RMX Dimensions....................................................................168
		1.5. HMX Dimensions....................................................................169
		1.6. RMX Data plate....................................................................170
		1.7. HMX Data plate....................................................................171
	2. Main Components.........................................................................172
Inch (SAE) and Metric Fasteners................................................................176
	1. Introduction............................................................................176
	2. Nomenclature, Threads...................................................................177
	3. Strength Identification.................................................................178
	4. Conversion of Metric and English Units..................................................184
Technical Service Data.........................................................................186
Ordering Spare Parts...........................................................................190
Contents, Section P............................................................................192
	1. Planned Maintenance.....................................................................192
Introduction, Maintenance......................................................................194
	1. Safe Jacking Procedure..................................................................194
Service Schedule...............................................................................196
	1. Planned Maintenance Schedule............................................................196
	2. Planned Maintenance Procedures..........................................................199
		2.1. Services to be Performed Daily....................................................199
			2.1.1. Battery Discharge Indicator with slow down..................................199
			2.1.2. Hydraulic System............................................................199
			2.1.3. Frame/Sheet Metal...........................................................200
			2.1.4. Wheels/Tires................................................................200
			2.1.5. Functions/Operations........................................................200
		2.2. Services to be Performed Monthly..................................................201
			2.2.1. Inspection..................................................................201
			2.2.2. Transmission................................................................201
			2.2.3. Brakes......................................................................201
			2.2.4. Battery.....................................................................201
			2.2.5. Electrical Connections......................................................201
			2.2.6. Contactor Tips (NOT Sealed).................................................202
			2.2.7. Motor Brushes...............................................................202
			2.2.8. Drive Motor.................................................................202
			2.2.9. Hydraulic Reservoir.........................................................202
			2.2.10. Frame Lube (“Lubrication Chart” on page57)................................202
			2.2.11. Pivot Points...............................................................203
		2.3. Services to be Performed Annually.................................................204
			2.3.1. Inspection..................................................................204
			2.3.2. Transmission................................................................204
			2.3.3. Battery.....................................................................204
			2.3.4. Hydraulic System............................................................204
			2.3.5. Brakes......................................................................205
Lubrication Chart..............................................................................206
Oil and Grease Specifications..................................................................208
	1. Approved Oils and Grease................................................................208
Contents, Section S............................................................................210
	1. Service Instructions....................................................................210
Lift Frame.....................................................................................212
	1. Pull rod................................................................................213
		1.1. Removal...........................................................................213
		1.2. Inspection........................................................................215
		1.3. Installation......................................................................216
	2. Carrier Frame Bushings..................................................................218
Inspection Covers..............................................................................220
	1. General Information.....................................................................220
Drive Motor Mounting Points....................................................................222
	1. Drive Motor Brush.......................................................................223
		1.1. Removal and Installation..........................................................223
	2. Drive Motor Assembly....................................................................223
		2.1. Remove............................................................................223
		2.2. Installation......................................................................224
Drive Motor....................................................................................226
	1. General Information.....................................................................226
	2. Operating Conditions....................................................................226
	3. Troubleshooting.........................................................................226
Drive Motor Service............................................................................232
	1. Motor Repair............................................................................233
		1.1. Disassembly.......................................................................233
	2. Inspection and Troubleshooting..........................................................236
		2.1. Drive End Head....................................................................236
		2.2. Commutator End Head...............................................................236
		2.3. Bearings..........................................................................236
		2.4. Brush and Commutator..............................................................237
		2.5. Armature..........................................................................237
		2.6. Frame and Field Assembly..........................................................238
			2.6.1. Testing.....................................................................238
			2.6.2. Frame and Field Service Notes...............................................239
		2.7. Assembly..........................................................................240
			2.7.1. Field Coil Installation.....................................................240
			2.7.2. Bearing Installation........................................................240
			2.7.3. After Assembly..............................................................241
	3. Changing Brushes........................................................................241
Transmission...................................................................................242
	1. System Description......................................................................242
	2. Troubleshooting.........................................................................242
	3. Removal.................................................................................244
	4. Installation............................................................................246
Transmission Axle Seal.........................................................................248
	1. General Information.....................................................................248
		1.1. Removal...........................................................................248
		1.2. Installation......................................................................248
Transmission Disassembly / Assembly............................................................250
	1. Disassembly.............................................................................251
	2. Assembly................................................................................251
Parking Brake System...........................................................................254
	1. Brake Theory of Operation...............................................................255
	2. Brake Adjustment........................................................................256
	3. Brake Shoe Removal / Installation.......................................................257
	4. Parking Brake Interlock Switch..........................................................258
Drive Wheel....................................................................................260
	4.1. Removal...............................................................................260
	4.2. Installation..........................................................................261
Load Wheels....................................................................................262
Support / Swivel Wheels........................................................................264
	1. Stabilizing Caster......................................................................264
		1.1. Removal...........................................................................265
		1.2. Inspection........................................................................267
		1.3. Installation......................................................................268
		1.4. Maintenance.......................................................................269
Stabilizing Caster.............................................................................270
	1. Stabilizing Caster......................................................................270
		1.1. Disassembly.......................................................................271
		1.2. Inspection........................................................................272
		1.3. Assembly..........................................................................273
Stabilizing Caster Spring Loaded...............................................................274
	1. Removal.................................................................................275
	2. Disassembly.............................................................................276
	3. Inspection..............................................................................277
	4. Assemble................................................................................278
	5. Installation............................................................................278
Steering Arm / Handle..........................................................................280
	1. Control Handle Stem.....................................................................281
		1.1. Removal...........................................................................281
		1.2. Inspection........................................................................281
		1.3. Installation......................................................................282
Steering Handle Head...........................................................................284
	1. Control Handle Head.....................................................................286
		1.1. Removal...........................................................................286
		1.2. Installation......................................................................286
	2. Direction Control Switches..............................................................287
	3. Horn, Raise, and Lower Switches.........................................................288
	4. Potentiometer...........................................................................290
300/400 Amp Contactor..........................................................................292
	1. Maintenance.............................................................................293
		1.1. Removal/Replacement of Contact Tips...............................................293
“EE” Contactor.................................................................................296
	1. Maintenance.............................................................................297
		1.1. Removal/Replacement of Contact Tips...............................................297
Battery Controller / Hourmeter / Lift Interrupt................................................300
	1. General Information.....................................................................300
	2. Electrical..............................................................................300
		2.1. Voltage...........................................................................300
			2.1.1. The Contact Voltage and Current Ratings for Switching Resistive Loads.......301
			2.1.2. Memory Retention............................................................301
	3. Battery Controller (BC).................................................................301
		3.1. General Information...............................................................301
			3.1.1. Discharge Adjustment........................................................301
		3.2. Reset.............................................................................303
		3.3. Key Switch........................................................................303
		3.4. Hourmeter.........................................................................304
	4. Troubleshooting.........................................................................304
		4.1. Battery Discharge Indicator (BDI).................................................304
			4.1.1. No Reset....................................................................304
			4.1.2. Reset After Break in Power..................................................304
			4.1.3. No Discharge, Gauge Does Not Run Down.......................................305
			4.1.4. No Lockout..................................................................305
			4.1.5. No Lift.....................................................................305
			4.1.6. Early Lockout...............................................................306
			4.1.7. LEDs Do Not Light...........................................................306
		4.2. Hourmeter.........................................................................306
			4.2.1. No Display..................................................................306
			4.2.2. Hourmeter Glass Icon Does Not Flash.........................................306
			4.2.3. Hourmeter Glass Icon Always Flashes.........................................307
Battery Discharge Indicator / Hourmeter........................................................308
	1. General Information.....................................................................308
	2. Electrical..............................................................................308
		2.1. Voltage...........................................................................308
	3. Battery Discharge Indicator (BDI).......................................................309
		3.1. General Information...............................................................309
		3.2. Key Switch........................................................................309
		3.3. Hourmeter.........................................................................309
	4. Troubleshooting.........................................................................310
		4.1. Battery Discharge Indicator (BDI).................................................310
			4.1.1. No Reset....................................................................310
			4.1.2. Reset After Break in Power..................................................310
			4.1.3. No Discharge, Gauge Does Not Run Down.......................................311
			4.1.4. LEDs Do Not Light...........................................................311
		4.2. Hourmeter.........................................................................311
			4.2.1. No Display..................................................................311
			4.2.2. Hourmeter Glass Icon Does Not Flash.........................................311
			4.2.3. Hourmeter Glass Icon Always Flashes.........................................312
12 Volt Electrical System......................................................................314
	1. Electrical Panel Components.............................................................314
		1.1. RMX Circuit Diagram...............................................................315
		1.2. Electrical Schematic Symbols......................................................316
Direction Contactor............................................................................318
	1. General Information.....................................................................319
	2. Remove / replace contact tips...........................................................319
12 Volt Transistor Controller..................................................................324
	1. Maintenance.............................................................................324
		1.1. Safety............................................................................324
		1.2. Cleaning..........................................................................324
		1.3. Troubleshooting...................................................................325
	2. Basics Of Circuit Operation.............................................................327
		2.1. Battery connected and emergency disconnect switch in “RUN” position...............327
		2.2. Key switch turned “ON”............................................................327
		2.3. Control handle pulled down; brakes released and brake interlock switch closed.....328
		2.4. Reverse travel (fork direction) switch is closed..................................328
		2.5. Forward travel (control handle direction) switch is closed........................329
		2.6. Curtis® PMC controller power circuits.............................................329
		2.7. Accelerator Potentiometer Circuits................................................330
		2.8. Emergency Reverser Switch.........................................................331
		2.9. Lift Pallet Forks.................................................................331
		2.10. Lower pallet forks...............................................................332
		2.11. Controller Adjustments...........................................................333
12 Volt Transistor Controller Troubleshooting..................................................334
	1. Troubleshooting Chart Index.............................................................334
	2. Troubleshooting Charts..................................................................335
24 Volt 300 Amp Electrical System..............................................................352
	1. Electrical Panel Components.............................................................352
	2. List of Symbols.........................................................................353
		2.1. RMX Circuit Diagram 1(3)..........................................................355
		2.2. RMX Circuit Diagram 2(3)..........................................................356
		2.3. RMX Circuit Diagram 3(3)..........................................................357
	3. Description of Function.................................................................358
		3.1. General Information...............................................................358
		3.2. References Information............................................................358
		3.3. Key Switch S17 in the ON Position.................................................358
		3.4. The Operating Arm in Drive Position, S10, Brake Switch Closed.....................358
		3.5. Driving, Fork Direction...........................................................358
		3.6. Driving, Steer Wheel Direction....................................................359
		3.7. Reversing/Motor Brake Fork Direction to Steer Wheel Direction.....................359
		3.8. Reversing/Motor Brake Steer Wheel Direction to Fork Direction.....................359
		3.9. Reverser switch...................................................................359
		3.10. Lifting the Forks................................................................360
		3.11. Lowering the Forks...............................................................360
		3.12. Horn.............................................................................360
		3.13. Lift Interrupt...................................................................360
24 Volt, 300 Amp Transistor Controller.........................................................362
	1. Maintenance.............................................................................362
		1.1. Safety............................................................................362
		1.2. Cleaning..........................................................................362
		1.3. Diagnostics and Troubleshooting...................................................363
			1.3.1. Handset Diagnostics.........................................................363
			1.3.2. Troubleshooting.............................................................363
	2. Basics Of Circuit Operation.............................................................365
		2.1. Control Features..................................................................367
	3. Motor Circuit...........................................................................369
	4. Control Circuit.........................................................................369
	5. Diagnostics and Troubleshooting.........................................................371
		5.1. 1307 Programmer Diagnostics.......................................................371
		5.2. Troubleshooting Chart.............................................................372
		5.3. Technical Specification...........................................................376
		5.4. Troubleshooting Chart Using the Handset...........................................377
24 Volt, 300 Amp Transistor Controller Troubleshooting.........................................380
	1. Troubleshooting Chart Index.............................................................380
	2. Troubleshooting Charts..................................................................381
24 Volt 400 Amp Electrical System..............................................................392
	1. Electrical Panel Components.............................................................392
	2. List of Symbols.........................................................................393
		2.1. HMX Circuit Diagram 1(3)..........................................................395
		2.2. HMX Circuit Diagram 2(3)..........................................................396
		2.3. HMX Circuit Diagram 3(3)..........................................................397
	3. Description of Function.................................................................398
		3.1. General Information...............................................................398
		3.2. References Information............................................................398
		3.3. Key Switch S17 in the ON Position.................................................398
		3.4. The Operating Arm in Drive Position, S10, Brake Switch Closed.....................398
		3.5. Driving, Fork Direction...........................................................398
		3.6. Driving, Steer Wheel Direction....................................................399
		3.7. Reversing/Motor Brake Fork Direction to Steer Wheel Direction.....................399
		3.8. Reversing/Motor Brake Steer Wheel Direction to Fork Direction.....................399
		3.9. Reverser switch...................................................................399
		3.10. Lifting the Forks................................................................400
		3.11. Lowering the Forks...............................................................400
		3.12. Horn.............................................................................400
		3.13. High Speed Switch................................................................400
		3.14. Lift Interrupt...................................................................401
24 Volt, 400 Amp Transistor Controller.........................................................402
	1. Maintenance.............................................................................402
		1.1. Safety............................................................................402
		1.2. Cleaning..........................................................................402
		1.3. Diagnostics and Troubleshooting...................................................403
			1.3.1. Handset Diagnostics.........................................................403
			1.3.2. Troubleshooting.............................................................403
	2. Basics Of Circuit Operation.............................................................405
		2.1. Control Features..................................................................407
	3. Motor Circuit...........................................................................409
	4. Control Circuit.........................................................................409
	5. Diagnostics and Troubleshooting.........................................................412
		5.1. 1307 Programmer Diagnostics.......................................................412
		5.2. Troubleshooting Chart.............................................................413
		5.3. Technical Specification...........................................................417
		5.4. Troubleshooting Chart Using the Handset...........................................418
24 Volt, 400 Amp Transistor Controller Troubleshooting.........................................420
	1. Troubleshooting Chart Index.............................................................420
	2. Troubleshooting Charts..................................................................421
Handset Operation..............................................................................434
	1. Operating Modes.........................................................................436
	2. Revert to Previous Settings.............................................................440
	3. Handset Self Test.......................................................................440
Pump Motor.....................................................................................442
	1. Component Repair........................................................................443
		1.1. Motor Disassembly.................................................................443
	2. Inspection and Troubleshooting..........................................................445
		2.1. Drive End Head....................................................................445
		2.2. Commutator End Head...............................................................445
		2.3. Bearings..........................................................................445
		2.4. Brush and Commutator..............................................................446
		2.5. Armature..........................................................................446
		2.6. Frame and Field Assembly..........................................................447
			2.6.1. Testing.....................................................................447
			2.6.2. Frame and Field Service Notes...............................................448
		2.7. Assembly..........................................................................449
			2.7.1. Field Coil Installation.....................................................449
			2.7.2. Bearing Installation........................................................449
			2.7.3. After Assembly..............................................................450
	3. Changing Brushes........................................................................450
Hydraulic System...............................................................................452
	1. Hydraulic Schematic.....................................................................452
	2. General Information.....................................................................452
	3. Description.............................................................................453
		3.1. Lift..............................................................................453
		3.2. Lower.............................................................................453
		3.3. Relief Pressure...................................................................453
	4. Maintenance.............................................................................454
	5. Adjustments.............................................................................454
	6. Lift Limit Switch.......................................................................454
	7. Troubleshooting.........................................................................456
Lift Pump Assembly.............................................................................458
	1. Removal.................................................................................460
	2. Disassembly.............................................................................461
	3. Inspection..............................................................................462
	4. Assembly................................................................................463
	5. Installation............................................................................465
	6. Adjustments.............................................................................467
		6.1. Relief valve......................................................................467
		6.2. Solenoid Operated Valve...........................................................468
Lift Cylinder..................................................................................470
	1. Removal.................................................................................471
	2. Disassembly.............................................................................472
	3. Inspection..............................................................................473
	4. Assembly................................................................................474
	5. Installation............................................................................475
Back Cover.....................................................................................477

S.S 06/24