BT Prime-Mover CMX-60 CMX-80 Electric Center Riding Pallet Truck Service Manual PDF

Description

BT Prime-Mover CMX-60 CMX-80 Electric Center Riding Pallet Truck Service Manual – PDF DOWNLOAD

FILE DETAILS:

BT Prime-Mover CMX-60 CMX-80 Electric Center Riding Pallet Truck Service Manual – PDF DOWNLOAD

Language : English
Pages : 268
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

BT Prime-Mover CMX-60 CMX-80 Electric Center Riding Pallet Truck Service Manual – PDF DOWNLOAD

Effective Serial Number CMX__26288001

Front Cover 1
BT Standard Codes 3
Warning Symbols 13
1 Warning Levels 13
Prohibitory Symbols 14
1 Ordinance Symbols 14
Introduction, Service Manual 15
Contents, Section M 17
1 Machine Information 17
General Product Information 19
1 Presentation of the Rider Trucks CMX60 and CMX80 19
1 1 Intended Application of the Trucks 19
1 2 Forbidden Application of the Trucks 20
1 3 Truck Data 20
1 4 CMX Dimensions 21
1 5 Data Plate 22
Inch (SAE) and Metric Fasteners 25
1 Introduction 25
Technical Service Data 35
Ordering Spare Parts 39
Contents, Section P 41
1 Planned Maintenance 41
Introduction, Maintenance 43
1 Safe Jacking Procedure 43
Service Schedule 45
1 Planned Maintenance Schedule 45
2 1 Services to be Performed Daily 49
2 1 1 Battery Discharge Indicator with slow down 49
2 1 2 Hydraulic System 49
2 1 3 Frame/Sheet Metal 50
2 1 4 Wheels/Tires 50
2 1 5 Functions/Operations 50
2 2 Services to be Performed Monthly 51
2 2 1 Inspection 51
2 2 2 Transmission 51
2 2 3 Brakes 51
2 2 4 Battery 51
2 2 5 Electrical Connections 51
2 2 6 Contactor Tips (NOT Sealed) 52
2 2 7 Motor Brushes 52
2 2 8 Drive Motor 52
2 2 9 Hydraulic Reservoir 52
2 2 10 Frame Lube (“Lubrication Chart” on page57) 52
2 2 11 Pivot Points 53
2 3 Services to be Performed Annually 54
2 3 1 Inspection 54
2 3 2 Transmission 54
2 3 3 Battery 54
2 3 4 Hydraulic System 54
2 3 5 Brakes 55
Lubrication Chart 57
Oil and Grease Specifications 59
1 Approved Oils and Grease 59
Contents, Section S 61
1 Service Instructions 61
Chassis 63
1 General Information 63
2 1 Removal 64
Lift Frame 65
1 Pull rod 66
1 1 Removal 66
1 2 Inspection 68
1 3 Installation 69
Drive Motor Mounting Points 71
1 Drive Motor Brush 72
1 1 Removal and Installation 72
2 1 Remove 72
2 2 Installation 73
Drive Motor 75
1 General Information 75
Drive Motor Service 81
1 Motor Repair 82
1 1 Disassembly 82
2 1 Drive End Head 85
2 2 Commutator End Head 85
2 3 Bearings 85
2 4 Brush and Commutator 86
2 5 Armature 86
2 6 Frame and Field Assembly 87
2 6 1 Testing 87
2 6 2 Frame and Field Service Notes 88
2 7 Assembly 89
2 7 1 Field Coil Installation 89
2 7 2 Bearing Installation 89
2 7 3 After Assembly 90
Transmission 91
1 System Description 91
Transmission Axle Seal 95
1 General Information 95
1 1 Removal 95
1 2 Installation 95
Transmission Disassembly / Assembly 97
1 Disassembly 98
Parking Brake System 101
1 Brake Theory of Operation 102
Drive Wheel 107
4 1 Removal 107
4 2 Installation 108
Load Wheels 109
Support / Swivel Wheel 111
1 Stabilizing Caster 111
1 1 Removal 112
1 2 Inspection 114
1 3 Installation 115
1 4 Maintenance 116
Stabilizing Caster 117
1 Stabilizing Caster 117
1 1 Disassembly 118
1 2 Inspection 119
1 3 Assembly 120
Steering Control Arm 121
1 Control Handle Stem 122
1 1 Removal 122
1 2 Installation 123
2 1 Removal 124
2 2 Disassembly 124
2 3 Assembly 124
2 4 Installation 125
Steering Handle Head 127
1 Control Handle Head 129
1 1 Removal 129
1 2 Installation 129
300/400 Amp Contactor 135
1 Maintenance 136
1 1 Removal/Replacement of Contact Tips 136
“EE” Contactor 139
1 Maintenance 140
1 1 Removal/Replacement of Contact Tips 140
Battery Controller / Hourmeter / Lift Interrupt 143
1 General Information 143
2 1 Voltage 143
2 1 1 The Contact Voltage and Current Ratings for Switching Resistive Loads 144
2 1 2 Memory Retention 144
3 1 General Information 144
3 1 1 Discharge Adjustment 144
3 2 Reset 146
3 3 Key Switch 146
3 4 Hourmeter 146
4 1 Battery Discharge Indicator (BDI) 147
4 1 1 No Reset 147
4 1 2 Reset After Break in Power 147
4 1 3 No Discharge, Gauge Does Not Run Down 148
4 1 4 No Lockout 148
4 1 5 No Lift 148
4 1 6 Early Lockout 149
4 1 7 LEDs Do Not Light 149
4 2 Hourmeter 149
4 2 1 No Display 149
4 2 2 Hourmeter Glass Icon Does Not Flash 149
4 2 3 Hourmeter Glass Icon Always Flashes 150
Battery Discharge Indicator / Hourmeter 151
1 General Information 151
2 1 Voltage 151
3 1 General Information 152
3 2 Key Switch 152
3 3 Hourmeter 152
4 1 Battery Discharge Indicator (BDI) 153
4 1 1 No Reset 153
4 1 2 Reset After Break in Power 153
4 1 3 No Discharge, Gauge Does Not Run Down 154
4 1 4 LEDs Do Not Light 154
4 2 Hourmeter 154
4 2 1 No Display 154
4 2 2 Hourmeter Glass Icon Does Not Flash 154
4 2 3 Hourmeter Glass Icon Always Flashes 155
24 Volt 400 Amp Electrical System 157
1 Electrical Panel Components 157
2 1 Circuit Diagram 1(5) 160
2 2 Circuit Diagram 2(5) 161
2 3 Circuit Diagram 3(5) 162
2 4 Circuit Diagram 4(5) 163
2 5 Circuit Diagram 5(5) 164
3 1 General Information 165
3 2 References Information 165
3 3 Key Switch S17 in the ON Position 165
3 4 Brake released, S10 Brake Switch Closed 165
3 5 Driving, Fork Direction 165
3 6 Driving, Steer Wheel Direction 166
3 7 Reversing/Motor Brake Fork Direction to Steer Wheel Direction 166
3 8 Reversing/Motor Brake Steer Wheel Direction to Fork Direction 166
3 9 Lifting the Forks 166
3 10 Lowering the Forks 166
3 11 Horn 167
3 12 Prime-Trak; operator off of the truck 167
3 13 Prime-Trak; operator on the truck 167
3 14 Lift Interrupt 168
24 Volt, 400 Amp Transistor Controller 169
1 Maintenance 169
1 1 Safety 169
1 2 Cleaning 169
1 3 Diagnostics and Troubleshooting 170
1 3 1 Handset Diagnostics 170
1 3 2 Troubleshooting 170
2 1 Control Features 173
5 1 1307 Programmer Diagnostics 179
5 2 Troubleshooting Chart 180
5 3 Technical Specification 184
5 4 Troubleshooting Chart Using the Handset 185
24 Volt, 400 Amp Transistor Controller Troubleshooting 187
1 Troubleshooting Chart Index 187
Handset Operation 206
1 Operating Modes 208
Pump Motor 213
1 Component Repair 214
1 1 Motor Disassembly 214
2 1 Drive End Head 216
2 2 Commutator End Head 216
2 3 Bearings 216
2 4 Brush and Commutator 217
2 5 Armature 217
2 6 Frame and Field Assembly 218
2 6 1 Testing 218
2 6 2 Frame and Field Service Notes 219
2 7 Assembly 220
2 7 1 Field Coil Installation 220
2 7 2 Bearing Installation 220
2 7 3 After Assembly 221
Hydraulic System 223
1 Hydraulic Schematic 223
3 1 Lift 224
3 2 Lower 224
3 3 Relief Pressure 224
Prime-Trak Hydraulic System 229
1 Prime-Trak Hydraulic Schematic 229
Lift Pump Assembly 235
1 Removal 237
6 1 Relief valve 244
6 2 Solenoid Operated Valve 245
Prime-Trak Hydraulic Pump 247
1 Removal 248
Lift Cylinder 255
1 Removal 256
Prime-Trak Cylinders 261
1 Removal 262
Back Cover 268

DESCRIPTION:

BT Prime-Mover CMX-60 CMX-80 Electric Center Riding Pallet Truck Service Manual – PDF DOWNLOAD

Effective Serial Number CMX__26288001

Introduction, Service Manual:

• The information in this Service Manual covers models CMX-60 & CMX-80.
  Federal and State laws require that operators be completely trained in the safe operation of lift trucks.
• An Operator’s Manual is attached to every BT lift truck when it is manufactured.
• This service manual is not a training manual. The information contained in this service manual is intended as a guide to help authorized technicians safely service this truck.
• The Service Manual is divided into four separate sections which cover different kinds of information needed for servicing these truck types. The main subject for each of these sections are as described below.

S.V 21/01/2025