BT Prime Mover OPX30 Electric Order Picker Parts Manual 311348-000 PDF

Description

BT Prime Mover OPX30 Electric Order Picker Parts Manual 311348-000 – PDF DOWNLOAD

FILE DETAILS:

BT Prime Mover OPX30 Electric Order Picker Parts Manual 311348-000 – PDF DOWNLOAD

Language : English
Pages : 570
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

BT Prime Mover OPX30 Electric Order Picker Parts Manual 311348-000 – PDF DOWNLOAD

Manual Part Number 311348-000
Effective Serial Number OPX3031253001-up

Front Cover 1
Standard Codes 3
Table of Contents 5
Warning Symbols 17
1 Warning Levels 17
Prohibitory Symbols 18
1 Ordinance Symbols 18
Safety 19
1 General Safety 19
Battery Safety 23
Static Discharge Precautions 28
Welding Safety 30
Introduction, Service Manual 33
Contents, Section M 35
1 Machine Information 35
General Product Information 37
1 Truck Presentation 37
1 1 Truck Side Views 37
1 2 Intended Truck Application 37
1 3 Prohibited Truck Application 38
1 4 Truck Data 38
1 5 Dimensions 39
1 6 Data Plate 40
2 Main Components 41
Inch (SAE) and Metric Fasteners 45
1 Introduction 45
2 Nomenclature, Threads 46
3 Strength Identification 47
4 Conversion of Metric and English Units 54
Technical Service Data 57
Ordering Spare Parts 61
Contents, Section P 63
1 Planned Maintenance 63
Introduction, Maintenance 65
1 Jacking Truck Off The Floor 66
1 1 Operator Platform 66
1 2 Truck Frame 66
1 3 Baseleg 67
2 Lubricants 68
2 1 Standard 68
2 2 Cold Storage 68
2 3 Freezer 70
Service Schedule 71
1 Planned Maintenance Schedule 71
2 Planned Maintenance Procedures 75
2 1 Services Performed Daily or Every 8 Operating Hours 75
2 1 1 Battery Level (BL) 75
2 1 2 Drive Wheel Indicator 76
2 1 3 Hourmeter 76
2 1 4 Hydraulic System 76
2 1 5 Frame/Sheet Metal 77
2 1 6 Wheels/Tires 77
2 1 7 Functions/Operations 77
2 1 8 Safety Belt, Tether, and Body Harness 77
2 2 Services Performed Monthly or Every 120 Operating Hours 77
2 2 1 Inspection 77
2 2 2 Transmission 77
2 2 3 Battery 78
2 2 4 Electrical Connections 78
2 2 5 Contactor Tips (NOT Sealed) 78
2 2 6 Motor Brushes 78
2 2 7 Drive Motor 78
2 2 8 Hydraulic Reservoir 79
2 2 9 Frame Lube 79
2 2 10 Pivot Points 79
2 3 Services Performed Semi-Annually or Every 720 Operating Hours 79
2 3 1 Inspection 79
2 3 2 Transmission 79
2 3 3 Hydraulic System 80
2 3 4 Brakes 80
2 3 5 Lift and Platform Chains 80
2 4 Services Performed Annually or Every 1440 Operating Hours 81
2 4 1 Battery 81
2 4 2 Brake 81
2 4 3 Hydraulic Fluid 81
Lubrication Chart 83
Oil and Grease Specifications 84
1 Approved Oils and Grease 84
2 Grease Location Points 85
Contents, Section S 87
1 Service Instructions 87
Chassis 89
1 Theory of Operation 90
2 Maintenance 90
3 Troubleshooting 90
4 Repair and Rebuild 90
4 1 Front Cover 90
4 2 Front Panel 91
4 3 Left-hand Cover 91
4 4 Right-hand Cover 92
Operator Platform 93
1 Theory of Operation 94
2 Maintenance 94
3 Troubleshooting 94
4 Repair and Rebuild 95
4 1 Console Cover 95
4 2 Floor Mat 96
Battery Compartment 97
1 Theory of Operation 98
2 Maintenance 98
3 Troubleshooting 98
4 Repair and Rebuild 99
4 1 Battery Stop Plate 99
4 2 Battery 100
4 3 Battery Rollers 101
Operator Controls 103
1 Theory of Operation 103
2 Maintenance 103
3 Troubleshooting 103
3 1 Throttle Potentiometer Test 103
4 Repair and Rebuild 104
4 1 Multi-Function Control Handle 104
4 2 Steer Wheel 106
4 3 Deadman Pedal 107
4 4 Pallet Clamp 110
4 5 Tether 112
Decals 113
1 Decal with Protective Sheet 113
2 Decal without Protective Sheet 113
Electric Motors 117
1 Theory of Operation 117
2 Maintenance 117
3 Troubleshooting 118
4 Repair 129
4 1 Brush Replacement 129
4 2 Pump Motor 129
4 3 Drive Motor 134
4 4 Fan Motor Assembly 136
5 Rebuild 137
5 1 Pump Motor and Drive Motor Component Disassembly 137
5 2 Inspection 139
5 2 1 Drive End Head 139
5 2 2 Commutator End Head 139
5 2 3 Bearings 139
5 2 4 Brush and Commutator 139
5 2 5 Armature 142
5 2 6 Frame and Field Assembly 143
5 3 Assembly/Testing 144
5 3 1 Bearing Installation 144
5 3 2 Testing 145
5 4 Fan Motor Rebuild 145
Transmission 147
1 Theory of Operation 148
2 Maintenance 148
2 1 Fluid Changing 148
3 Troubleshooting 148
4 Repair and Rebuild 152
4 1 Transmission Disassembly 152
4 1 1 Pivot Ring 154
4 1 2 Drive Unit Gear Case 158
4 1 3 Radial Ring 158
4 1 4 Axle Shaft and Bevel Gear 159
4 1 5 Spiral Gear and Helical Gear 161
4 1 6 Bearing Cup and Shim 163
4 1 7 Spur Gear 165
4 2 Transmission Reassembly 166
4 2 1 Gear Case 166
4 2 2 Axle Shaft 166
4 2 3 Bevel Gear 168
4 2 4 Spiral Gear 169
4 2 1 Gear Set 170
4 2 2 Calculating Shim Formulas 171
4 2 3 Gear Case Bearing Cup and Shim 174
4 2 4 Helical Gear/Spiral Pinion Gear 176
4 2 5 Axle 179
4 2 6 Measuring Backlash 183
4 2 7 Pivot Ring 185
4 2 8 Drive Unit 187
4 2 9 Gear Case Cover 190
Electric Brake 191
1 Theory of Operation 191
2 Maintenance 191
2 1 Brake Air Gap Adjustment 191
3 Troubleshooting 192
4 Repair and Rebuild 193
4 1 Brake Assembly 194
4 2 Brake Friction Plate (Rotor) 195
Drive Wheel 197
1 Theory of Operation 197
2 Maintenance 197
3 Troubleshooting 197
4 Repair and Rebuild 198
Load Wheels 201
1 Theory of Operation 204
2 Maintenance 204
3 Troubleshooting 204
4 Repair and Rebuild 204
4 1 Single Load Wheel 205
4 2 Tandem Articulated Load Wheel 206
4 3 Guide Wheel (Optional) 208
Steering Unit 209
1 Theory of Operation 212
2 Maintenance 212
3 Troubleshooting 212
4 Repair and Rebuild 213
Steering Arm / Wheel / Lever 215
1 Theory of Operation 216
2 Maintenance 216
3 Troubleshooting 216
3 1 Steer Encoder Test 216
4 Repair and Rebuild 218
4 1 Steering Wheel 218
4 2 Steering Encoder 219
Steering Bearing 221
1 Theory of Operation 222
2 Maintenance 222
3 Troubleshooting 222
4 Repair and Rebuild 222
Electrical Functions 225
1 Theory of Operation 225
1 1 Battery Plugged In 226
1 3 Deadman 232
1 3 2 Closing Deadman Switches (S2 and S23) 232
1 4 Steering 238
1 5 Travel 240
1 6 Lift/Lower 246
1 6 2 Lower (S4) 250
1 Maintenance 273
1 1 Horn Button Pass Codes 273
1 2 Wiring 279
1 2 1 Definitions 280
1 2 2 Shorts to Frame Test 281
2 Troubleshooting 285
2 1 Maintenance (Chirp) Mode 287
2 1 1 Entering Maintenance Mode Using Deadman Pedal 287
2 1 2 General Testing 287
2 2 Platform Manager Fault Codes 289
Electronic Components 331
1 Theory of Operation 333
2 Maintenance 334
3 Troubleshooting 334
4 Repair and Rebuild 334
Battery 337
1 Theory of Operation 337
2 Maintenance 337
2 1 Inspection and Care 337
2 2 Exterior Cleaning 338
2 3 Charging 338
2 4 Storage 339
2 5 History Record 339
3 Troubleshooting 340
4 Repair and Rebuild 341
Battery Connector 343
1 Theory of Operation 343
2 Maintenance 343
2 1 Inspection 343
3 Troubleshooting 344
4 Repair and Rebuild 344
Lights (Optional) 347
1 Theory of Operation 347
2 Maintenance 347
3 Troubleshooting 347
4 Repair and Rebuild 347
4 1 Overhead Guard Light 347
4 2 Adjustable Lights (Optional) 350
4 3 Warning Light 351
Horn and Travel Alarm 353
1 Theory of Operation 353
2 Maintenance 353
3 Troubleshooting 353
4 Repair and Rebuild 354
4 1 Horn 354
4 2 Travel Alarm 355
Instrument Panel and Displays 357
1 Theory of Operation 357
1 1 Start Up 357
1 2 Battery Level Display LED Messages 359
1 3 Steering Indicator Messages 362
1 4 Display Messages 363
1 5 Hourmeter 363
1 6 Sounder 364
2 Maintenance 365
3 Troubleshooting 365
3 1 Display 365
3 2 Hourmeter 366
3 2 1 No Display 366
3 2 2 Hourmeter Glass Icon Does Not Flash 366
3 2 3 Hourmeter Glass Icon Always Flashes 366
Start/Stop Switches 367
1 Theory of Operation 368
2 Maintenance 368
3 Troubleshooting 368
4 Repair and Rebuild 369
4 1 Key Switch 369
4 2 Emergency Power Off (EPO) 370
4 2 1 Contact Block 370
4 2 2 EPO Actuator 372
4 3 Deadman Switches 372
Mast Switches 373
1 Theory of Operation 374
2 Maintenance 375
2 1 Adjustment 375
3 Troubleshooting 378
4 Repair and Rebuild 378
Steer Switches 379
1 Theory of Operation 380
2 Maintenance 380
3 Troubleshooting 381
4 Repair and Rebuild 382
Fuses 383
1 Theory of Operation 384
2 Maintenance 384
2 1 Wiring Harness 384
2 2 Power Cables 385
3 Troubleshooting 385
4 Repair and Rebuild 385
Contactor Panel 387
1 Theory of Operation 388
2 Maintenance 388
2 1 Contact Tip Inspection 389
2 2 Resistance Testing 389
3 Troubleshooting 389
4 Repair and Rebuild 390
4 1 Contact Assembly 390
Traction Power Amplifier (TPA) [Transistor Controller] 393
1 Theory of Operation 393
1 1 Basics Of Circuit Operation 393
1 2 Interface 395
1 3 Control Features 395
1 4 Motor Circuit 397
1 5 Control Circuit 398
1 6 Definitions 399
2 Maintenance 400
2 1 Safety 400
2 2 Cleaning 400
2 1 TPA Adjustable Settings 401
3 Troubleshooting 402
3 1 Diagnostics and Troubleshooting 402
3 2 Handset Diagnostics 402
3 3 Fault Codes 405
3 4 Troubleshooting Chart 406
4 Repair and Rebuild 408
Hydraulic System 409
1 Theory of Operation 410
1 1 Lift 410
1 2 Lower 412
2 Maintenance 413
2 1 Changing Hydraulic System Fluid 413
2 2 System Draining 414
2 3 Refilling System 414
2 4 Bleeding Hydraulic System 415
3 Troubleshooting 416
4 Repair and Rebuild 416
4 1 Lift Manifold 419
4 2 Hydraulic Reservoir 422
4 3 Manual Release Valve 423
4 4 Lift Pump 426
Two Stage Mast Staging Cylinder 429
1 Theory of Operation 430
2 Maintenance 430
3 Troubleshooting 430
4 Repair and Rebuild 430
4 1 Bearing and Seals 431
Three Stage Mast Staging Cylinder 439
1 Theory of Operation 440
2 Maintenance 440
3 Troubleshooting 440
4 Repair and Rebuild 440
4 1 Bearing and Seals 441
Three Stage Mast Freelift Cylinder 449
1 Theory of Operation 450
2 Maintenance 450
3 Troubleshooting 450
4 Repair and Rebuild 451
Mast 459
1 Theory of Operation 459
2 Maintenance 460
2 1 Visual Inspection 460
2 2 Chain Inspection 460
2 3 Lubrication 464
2 4 Adjustment 466
3 Troubleshooting 467
4 Repair and Rebuild 467
Platform 495
1 Theory of Operation 497
2 Maintenance 498
2 1 Platform Shimming 498
3 Troubleshooting 500
4 Repair and Rebuild 500
Lifting Gear (Crosshead), Three Stage Mast 507
1 Theory of Operation 509
2 Maintenance 509
3 Troubleshooting 509
4 Repair and Rebuild 509
Fork Assembly 511
1 Theory of Operation 512
2 Maintenance 512
3 Troubleshooting 512
4 Repair and Rebuild 512
4 1 Forks 512
4 2 Pallet Clamp 514
Wire Guidance (Optional) 517
1 Theory of Operation 517
2 Maintenance 520
3 Troubleshooting 527
3 1 Fault Codes 529
Handset Operation 549
1 Operating Modes 552
2 Revert to Previous Settings 555
3 Handset Self Test 555
Electrical Controllers (Handset) 557
1 Display Screen 558
1 1 Menu Navigation Key 558
1 2 Data Inc/Dec Key 558
1 3 Bookmark Keys 558
2 Operation 559
2 1 Menu Structure 559
2 2 Main Menu 560
2 3 Interface Protocols and Backward Compatibility 561
2 4 Parameter Changing 561
2 5 Real-Time Monitoring 562
2 6 Reading Faults and Diagnostic History File 562
2 7 Cloning and Restoring the Previous Programming 563
2 8 Information Displays 563
2 9 Programmer SetUp 564
A 565
B 565
C 565
D 565
E 565
F 565
G 565
H 566
I 566
J 566
K 566
L 566
M 566
O 566
P 566
S 566
T 567
U 567
W 567
Index 565
Back Cover 570

DESCRIPTION:

BT Prime Mover OPX30 Electric Order Picker Parts Manual 311348-000 – PDF DOWNLOAD

Manual Part Number 311348-000
Effective Serial Number OPX3031253001-up

Introduction, Service Manual:

• The information in this service manual covers model OPX30. Federal and State laws require that operators be completely trained in the safe operation of the truck in accordance with OSHA 1910.178.
• An operator’s manual is sent with every Prime-Mover truck when it is manufactured. If the operator’s manual is missing from the truck, a new manual may be obtained by contacting:
• This service manual is not a training manual. The information contained in this service manual is intended as a guide to help trained, qualified, and authorized technicians safely service this truck.
  The service manual is divided into four separate sections, which cover needed information for servicing the truck types.

S.V 10/01/2025