BT PRIME MOVER RMX/HMX SERVICE MANUAL 313701-000 – PDF DOWNLOAD

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BT PRIME MOVER RMX/HMX SERVICE MANUAL 313701-000 – PDF DOWNLOAD

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BT PRIME MOVER RMX/HMX SERVICE MANUAL 313701-000 – PDF DOWNLOAD

Language : English
Pages : 482
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

BT PRIME MOVER RMX/HMX SERVICE MANUAL 313701-000 – PDF DOWNLOAD

Front Cover.......................................................................  1
Ordering Spare Parts..............................................................  3
Table of Contents.................................................................  5
Standard Codes.................................................................... 15
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..................................................... 38
		1.2. Intended Truck Application........................................... 38
		1.3. Prohibited Truck Application......................................... 38
		1.4. Truck Data........................................................... 39
		1.5. Truck Dimensions..................................................... 40
		1.6. Data Plate........................................................... 43
	2. Main Components............................................................ 46
Inch (SAE) and Metric Fasteners................................................... 49
	1. Introduction............................................................... 49
	2. Nomenclature, Threads...................................................... 50
	3. Strength Identification.................................................... 51
	4. Conversion of Metric and English Units..................................... 58
Technical Service Data............................................................ 61
Contents, Section P............................................................... 65
	1. Planned Maintenance........................................................ 65
Introduction, Maintenance......................................................... 67
	1. Jacking Truck Off The Floor................................................ 68
		1.1. Elevate Rear of Truck................................................ 68
		1.1. Elevate Either Side of Truck......................................... 68
	2. Lubricants................................................................. 69
		2.1. Standard Conditioning................................................ 69
		2.2. Corrosion Conditioning............................................... 69
		2.3. Cold Storage Conditioning............................................ 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. Frame.......................................................... 75
			2.1.2. Battery Discharge Indicator With Lift Cut Out (Optional)....... 75
			2.1.3. Functions/Operations........................................... 75
			2.1.4. Hourmeter...................................................... 76
			2.1.5. Hydraulic System............................................... 76
			2.1.6. Frame/Sheet Metal.............................................. 76
			2.1.7. Wheels/Tires................................................... 76
			2.1.8. Brakes......................................................... 76
		2.2. Services Performed Weekly or Every 30 Operating Hours................ 77
			2.2.1. Battery........................................................ 77
		2.3. Services Performed Monthly or Every 120 Operating Hours.............. 77
			2.3.1. Inspection..................................................... 77
			2.3.2. Transmission................................................... 77
			2.3.3. Brake.......................................................... 77
			2.3.4. Battery........................................................ 78
			2.3.5. Motors......................................................... 78
			2.3.6. Hydraulic Reservoir............................................ 78
			2.3.7. Frame Lube..................................................... 78
			2.3.8. Pivot Points................................................... 79
		2.4. Services Performed Quarterly or Every 360 Operating Hours............ 79
			2.4.1. Wheels/Tires................................................... 79
			2.4.2. Hydraulic System............................................... 79
			2.4.3. Pivot Points................................................... 79
		2.5. Services Performed Semi-Annually or Every 720 Operating Hours........ 79
			2.5.1. Frame.......................................................... 79
			2.5.2. Drive Gear..................................................... 80
			2.5.3. Brakes......................................................... 80
			2.5.4. Steering Control Handle........................................ 80
			2.5.5. Instrument Panel............................................... 80
			2.5.6. Electrical Control System...................................... 80
			2.5.7. Electrical Panel............................................... 80
			2.5.8. Electrical Connections......................................... 80
			2.5.9. Contactor Tips (NOT Sealed).................................... 80
			2.5.10. Hydraulic System.............................................. 81
		2.6. Services Performed Annually or Every 1440 Operating Hours............ 81
			2.6.1. Inspection..................................................... 81
			2.6.2. Transmission................................................... 81
			2.6.3. Battery........................................................ 81
			2.6.4. Hydraulic System............................................... 82
			2.6.5. Brakes......................................................... 82
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
Frame............................................................................. 89
	1. Theory of Operation........................................................ 89
	2. Maintenance................................................................ 89
		2.1. Inspection........................................................... 89
	3. Troubleshooting............................................................ 90
	4. Repair and Rebuild......................................................... 90
Inspection Covers................................................................. 99
	1. Theory of Operation........................................................ 99
	2. Maintenance................................................................ 99
	3. Troubleshooting............................................................ 99
	4. Repair and Rebuild......................................................... 99
Battery Compartment...............................................................101
	1. Theory of Operation........................................................101
	2. Maintenance................................................................101
	3. Troubleshooting............................................................101
	4. Repair and Rebuild.........................................................101
		4.1. Battery Door.........................................................103
		4.2. Battery Rollers......................................................104
Operator Controls.................................................................105
	1. Theory of Operation........................................................105
	2. Maintenance................................................................105
	3. Troubleshooting............................................................105
	4. Repair and Rebuild.........................................................105
		4.1. Control Handle.......................................................105
		4.2. Handle Rail..........................................................108
Decals............................................................................111
	1. Decal with Protective Sheet................................................111
	2. Decal without Protective Sheet.............................................111
Electric Motors...................................................................113
	1. Theory of Operation........................................................113
	2. Maintenance................................................................113
	3. Troubleshooting............................................................114
	4. Repair and Rebuild.........................................................115
		4.1. Pump Motor...........................................................115
		4.2. Drive Motor..........................................................120
		4.3. Brushes..............................................................127
			4.3.1. Inspection and Replacement.....................................127
			4.3.2. Brush Inspection...............................................127
Transmission......................................................................129
	1. Theory of Operation........................................................129
	2. Maintenance................................................................129
		2.1. Fluid Changing.......................................................129
	3. Troubleshooting............................................................130
	4. Repair and Rebuild.........................................................130
		4.1. Transmission.........................................................131
		4.2. Axle Seal............................................................138
Parking Brake System..............................................................141
	1. Theory of Operation........................................................141
	2. Maintenance................................................................141
		2.1. Brake Adjustment.....................................................141
	3. Troubleshooting............................................................142
	4. Repair and Rebuild.........................................................142
		4.1. Brake Shoe...........................................................143
Drive Wheel.......................................................................145
	1. Theory of Operation........................................................145
	2. Maintenance................................................................145
	3. Troubleshooting............................................................145
	4. Repair and Rebuild.........................................................146
Support / Swivel Wheels...........................................................149
	1. Theory of Operation........................................................149
	2. Maintenance................................................................149
		2.1. Inspection...........................................................149
	3. Troubleshooting............................................................150
	4. Repair and Rebuild.........................................................150
Load Wheels.......................................................................153
	1. Theory of Operation........................................................153
	2. Maintenance................................................................153
	3. Troubleshooting............................................................153
	4. Repair and Rebuild.........................................................154
Stabilizing Caster................................................................157
	1. Theory of Operation........................................................157
	2. Maintenance................................................................157
		2.1. Inspection...........................................................157
	3. Troubleshooting............................................................157
	4. Repair and Rebuild.........................................................158
Stabilizing Caster Spring Loaded..................................................161
	1. Theory of Operation........................................................161
	2. Maintenance................................................................161
		2.1. Inspection...........................................................161
	3. Troubleshooting............................................................162
	4. Repair and Rebuild.........................................................162
Steering Arm / Wheel (Tiller Arm).................................................167
	1. Theory of Operation........................................................167
	2. Maintenance................................................................167
		2.1. Inspection...........................................................167
	3. Troubleshooting............................................................167
	4. Repair and Rebuild.........................................................168
Steering Arm/Wheel (Head).........................................................175
	1. Theory of Operation........................................................175
	2. Maintenance................................................................175
	3. Troubleshooting............................................................175
	4. Repair and Rebuild.........................................................176
Steering Bearing..................................................................179
	1. Theory of Operation........................................................179
	2. Maintenance................................................................179
	3. Troubleshooting............................................................179
	4. Repair and Rebuild.........................................................180
Electrical Functions, 12 Volt.....................................................183
	1. Theory of Operation........................................................183
		1.1. Battery Connected/Master Control On/ Off Switch in “On” Position.....183
		1.2. Key Switch in “ON” Position..........................................183
		1.3. Control Handle Down/Brakes Released/Brake Interlock Switch Closed....184
		1.4. Travel, Forks-first Direction........................................184
		1.5. Travel, Tractor-first Direction......................................185
		1.6. Transistor Controller Power Circuits.................................185
		1.7. Accelerator Potentiometer Circuits...................................186
		1.8. Reverser Switch......................................................186
		1.9. Forks Lifting........................................................187
		1.10. Forks Lowering......................................................188
	2. Maintenance................................................................188
		2.1. Wiring...............................................................188
			2.1.1. Definitions....................................................189
	3. Troubleshooting............................................................189
		3.1. Troubleshooting Chart Index..........................................191
		3.2. Troubleshooting Charts...............................................192
Electrical Functions, 24 Volt 300 Amp.............................................213
	1. Theory of Operation........................................................213
		1.1. Start-up A...........................................................214
		1.2. Start-up B...........................................................216
		1.3. Travel, Tractor-first Direction......................................218
		1.4. Travel, Forks-first Direction........................................220
		1.5. Reverse..............................................................222
	2. Maintenance................................................................224
		2.1. Wiring...............................................................224
			2.1.1. Definitions....................................................225
			2.1.2. Shorts to Frame Test...........................................226
	3. Troubleshooting............................................................230
		3.1. Troubleshooting Chart Index..........................................231
		3.2. Troubleshooting Charts...............................................232
Electrical Functions, 24 Volt 400 Amp.............................................257
	1. Theory of Operation........................................................257
		1.1. Start-up, A..........................................................258
		1.2. Start-up B...........................................................260
		1.3. Travel, Tractor-first Direction......................................262
		1.4. Travel, Forks-first Direction........................................264
		1.5. High Speed...........................................................266
		1.6. Reverse..............................................................268
	2. Maintenance................................................................270
		2.1. Wiring...............................................................270
			2.1.1. Definitions....................................................270
			2.1.2. Shorts to Frame Test...........................................270
	3. Troubleshooting............................................................271
		3.1. Troubleshooting Chart Index..........................................273
		3.2. Troubleshooting Charts...............................................274
Battery...........................................................................307
	1. Theory of Operation........................................................307
	2. Maintenance................................................................307
		2.1. Inspection and Care..................................................307
		2.2. Exterior Cleaning....................................................308
		2.3. Charging.............................................................308
		2.4. Storage..............................................................309
		2.5. History Record.......................................................310
	3. Troubleshooting............................................................310
	4. Repair and Rebuild.........................................................311
Battery Connector.................................................................313
	1. Theory of Operation........................................................313
	2. Maintenance................................................................313
		2.1. Inspection...........................................................313
	3. Troubleshooting............................................................314
	4. Repair and Rebuild.........................................................315
Horn..............................................................................317
	1. Theory of Operation........................................................317
	2. Maintenance................................................................317
	3. Troubleshooting............................................................317
	4. Repair and Rebuild.........................................................317
		4.1. Horn.................................................................318
		4.2. Horn Switch..........................................................319
Line Contactor....................................................................321
	1. Theory of Operation........................................................321
	2. Maintenance................................................................321
	3. Troubleshooting............................................................321
	4. Repair and Rebuild.........................................................322
Battery Controller/Hourmeter/Lift Interrupt.......................................327
	1. Theory of Operation........................................................327
	2. Maintenance................................................................329
		2.1. Discharge Adjustment.................................................329
	3. Troubleshooting............................................................331
		3.1. Battery Discharge Indicator (BDI)....................................331
		3.2. Hourmeter............................................................333
Battery Discharge Indicator/ Hourmeter............................................335
	1. Theory of Operation........................................................335
	2. Maintenance................................................................337
	3. Troubleshooting............................................................337
		3.1. Battery Discharge Indicator (BDI)....................................337
		3.2. Hourmeter............................................................339
Switches..........................................................................341
	1. Theory of Operation........................................................341
	2. Maintenance................................................................341
		2.1. Key Switch Inspection................................................341
		2.2. Master Control On/Off Switch Inspection..............................341
		2.3. Lift Limit Switch Adjustment.........................................342
		2.4. Magnetic (Reed) Switch Adjustment....................................343
		2.5. Brake Interlock Switch Adjustment....................................344
	3. Troubleshooting............................................................344
	4. Repair and Rebuild.........................................................345
		4.1. Key Switch...........................................................347
		4.2. Master Control On/Off Switch.........................................348
		4.3. Lift Limit Switch....................................................349
		4.4. Magnetic (Reed) Switch...............................................350
		4.5. Brake Interlock Switch...............................................351
Speed Controls....................................................................353
	1. Theory of Operation........................................................353
	2. Maintenance................................................................353
		2.1. Potentiometer Adjustment.............................................353
	3. Troubleshooting............................................................354
	4. Repair and Rebuild.........................................................355
		4.1. Potentiometer Assembly...............................................356
		4.2. Rearward and Forward Switches........................................358
Direction Contactors..............................................................361
	1. Theory of Operation........................................................361
	2. Maintenance................................................................361
		2.1. Resistance Testing...................................................361
		2.2. Contact Tip Inspection...............................................362
		2.3. Parts Inspection.....................................................362
	3. Troubleshooting............................................................362
	4. Repair and Rebuild.........................................................363
1A Speed Contactor................................................................371
	1. Theory of Operation........................................................371
	2. Maintenance................................................................371
		2.1. Resistance Testing...................................................371
		2.2. Contact Tip Inspection...............................................371
		2.3. Parts Inspection.....................................................371
	3. Troubleshooting............................................................371
	4. Repair and Rebuild.........................................................372
12 Volt Transistor Controller.....................................................377
	1. Theory of Operation........................................................377
		1.1. Basics Of Circuit Operation..........................................377
	2. Maintenance................................................................378
		2.1. Safety...............................................................378
		2.2. Cleaning.............................................................378
		2.3. Controller Adjustments...............................................379
		2.4. Definitions..........................................................379
	3. Troubleshooting............................................................380
	4. Repair and Rebuild.........................................................382
24 Volt, 300 Amp Transistor Controller............................................383
	1. Theory of Operation........................................................383
		1.1. Basics Of Circuit Operation..........................................383
		1.2. Control Features.....................................................385
		1.3. Motor Circuit........................................................386
		1.4. Control Circuit......................................................387
	2. Maintenance................................................................388
		2.1. Safety...............................................................388
		2.2. Cleaning.............................................................388
		2.3. Transistor Adjustable Settings.......................................389
		2.4. Definitions..........................................................390
	3. Troubleshooting............................................................390
		3.1. Diagnostics and Troubleshooting......................................390
		3.2. Handset Diagnostics..................................................391
		3.3. Troubleshooting Chart................................................393
		3.4. Troubleshooting Chart Using Handset..................................395
	4. Repair and Rebuild.........................................................396
24 Volt, 400 Amp Transistor Controller............................................397
	1. Theory of Operation........................................................397
		1.1. Basics Of Circuit Operation..........................................397
		1.2. Control Features.....................................................399
		1.3. Motor Circuit........................................................400
		1.4. Control Circuit......................................................401
	2. Maintenance................................................................403
		2.1. Safety...............................................................403
		2.2. Cleaning.............................................................403
		2.3. Transistor Adjustable Settings.......................................404
		2.4. Definitions..........................................................405
	3. Troubleshooting............................................................406
		3.1. Diagnostics and Troubleshooting......................................406
		3.2. Handset Diagnostics..................................................406
		3.3. Troubleshooting Chart................................................409
		3.4. Troubleshooting Chart Using Handset..................................412
	4. Repair and Rebuild.........................................................413
Hydraulic System..................................................................415
	1. Theory of Operation........................................................415
		1.1. Electric Lift........................................................416
		1.2. Electric Lower.......................................................417
		1.3. Hydraulic Lift.......................................................418
		1.4. Hydraulic Relief.....................................................419
		1.5. Hydraulic Hold.......................................................420
		1.6. Hydraulic Lower......................................................421
		1.7. Relief Pressure......................................................422
	2. Maintenance................................................................422
		2.1. Hydraulic Fluid Check................................................422
		2.2. Adjustments..........................................................422
	3. Troubleshooting............................................................424
	4. Repair and Rebuild.........................................................426
Lift Cylinder.....................................................................439
	1. Theory of Operation........................................................439
	2. Maintenance................................................................439
		2.1. Inspection...........................................................439
	3. Troubleshooting............................................................439
	4. Repair and Rebuild.........................................................440
Battery Top Tray (Optional).......................................................445
	1. Theory of Operation........................................................445
	2. Maintenance................................................................445
	3. Troubleshooting............................................................445
	4. Repair and Rebuild.........................................................445
Electrical Heater (Optional)......................................................447
	1. Theory of Operation........................................................447
	2. Maintenance................................................................447
	3. Troubleshooting............................................................447
	4. Repair and Rebuild.........................................................447
Tilting Package Guard (Optional)..................................................459
	1. Theory of Operation........................................................459
	2. Maintenance................................................................459
	3. Troubleshooting............................................................459
	4. Repair and Rebuild.........................................................459
Removable Load Backrest (Optional)................................................461
	1. Theory of Operation........................................................461
	2. Maintenance................................................................461
	3. Troubleshooting............................................................461
	4. Repair and Rebuild.........................................................461
Version One Handset...............................................................463
	1. Theory of Operation........................................................463
Version Two Handset...............................................................471
	1. Theory of Operation........................................................471
Index.............................................................................479
	A.............................................................................479
	B.............................................................................479
	C.............................................................................479
	D.............................................................................479
	E.............................................................................479
	F.............................................................................479
	G.............................................................................479
	H.............................................................................479
	J.............................................................................479
	L.............................................................................479
	M.............................................................................479
	O.............................................................................480
	P.............................................................................480
	S.............................................................................480
	T.............................................................................480
	W.............................................................................480
Back Cover........................................................................482

DESCRIPTION:

BT PRIME MOVER RMX/HMX SERVICE MANUAL 313701-000 – PDF DOWNLOAD

S.S 05/01/2025