BT PRIME MOVER CMX60/80 SERVICE MANUALS – PDF DOWNLOAD

Description

BT PRIME MOVER CMX60/80 SERVICE MANUALS – PDF DOWNLOAD

FILE DETAILS:

BT PRIME MOVER CMX60/80 SERVICE MANUALS – PDF DOWNLOAD

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

302825-000 1995_April
302825-000 1995_August
302825-000 1998_March

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

BT PRIME MOVER CMX60/80 SERVICE MANUALS – PDF DOWNLOAD

Front Cover..................................................................................  2
Table of Contents............................................................................  4
0.0 Maintenance..............................................................................  7
	0.1 Truck Identification.................................................................  8
	0.2 System Operation.....................................................................  9
	0.3 Specifications....................................................................... 10
	0.4 Maintenance and Adjustments.......................................................... 22
	0.5 Troubleshooting...................................................................... 29
	0.6 Component Removal and Installation................................................... 29
	0.7 Component Repair..................................................................... 29
1.0 Transmission............................................................................. 31
	1.1 Component Identification............................................................. 32
	1.2 System Operation..................................................................... 36
	1.3 Specifications....................................................................... 36
	1.4 Maintenance and Adjustments.......................................................... 36
	1.5 Troubleshooting...................................................................... 37
	1.6 Component Removal and Installation................................................... 37
	1.7 Component Repair..................................................................... 43
2.0 Electrical............................................................................... 45
	2.1 Component Identification............................................................. 47
	2.2 System Operation..................................................................... 54
	2.3 Specifications....................................................................... 60
	2.4 Maintenance and Adjustments.......................................................... 60
	2.5 Troubleshooting...................................................................... 66
	2.6 Component Removal and Installation................................................... 87
	2.7 Component Repair..................................................................... 92
3.0 Hydraulics...............................................................................105
	3.1 Component Identification.............................................................106
	3.2 System Operation.....................................................................116
	3.3 Specifications.......................................................................117
	3.4 Maintenance and Adjustments..........................................................117
	3.5 Troubleshooting......................................................................118
	3.6 Component Removal and Installation...................................................121
	3.7 Component Repair.....................................................................125
4.0 Frame....................................................................................127
	4.1 Component Identification.............................................................128
	4.2 System Operation.....................................................................134
	4.3 Specifications.......................................................................134
	4.4 Maintenance and Adjustments..........................................................134
	4.5 Troubleshooting......................................................................134
	4.6 Component Removal and Installation...................................................135
Back Cover...................................................................................139
Front Cover..................................................................................140
Table of Contents............................................................................142
0.0 Maintenance..............................................................................145
	0.1 Truck Identification.................................................................146
	0.2 System Operation.....................................................................147
	0.3 Specifications.......................................................................148
	0.4 Maintenance and Adjustments..........................................................160
	0.5 Troubleshooting......................................................................167
	0.6 Component Removal and Installation...................................................167
	0.7 Component Repair.....................................................................167
1.0 Transmission.............................................................................169
	1.1 Component Identification.............................................................170
	1.2 System Operation.....................................................................174
	1.3 Specifications.......................................................................174
	1.4 Maintenance and Adjustments..........................................................174
	1.5 Troubleshooting......................................................................175
	1.6 Component Removal and Installation...................................................175
	1.7 Component Repair.....................................................................181
2.0 Electrical...............................................................................184
	2.1 Component Identification.............................................................186
	2.2 System Operation.....................................................................193
	2.3 Specifications.......................................................................199
	2.4 Maintenance and Adjustments..........................................................199
	2.5 Troubleshooting......................................................................205
	2.6 Component Removal and Installation...................................................226
	2.7 Component Repair.....................................................................232
3.0 Hydraulics...............................................................................244
	3.1 Component Identification.............................................................245
	3.2 System Operation.....................................................................255
	3.3 Specifications.......................................................................255
	3.4 Maintenance and Adjustments..........................................................256
	3.5 Troubleshooting......................................................................257
	3.6 Component Removal and Installation...................................................259
	3.7 Component Repair.....................................................................262
4.0 Frame....................................................................................264
	4.1 Component Identification.............................................................265
	4.2 System Operation.....................................................................271
	4.3 Specifications.......................................................................271
	4.4 Maintenance and Adjustments..........................................................271
	4.5 Troubleshooting......................................................................271
	4.6 Component Removal and Installation...................................................272
Back Cover...................................................................................275
Front Cover..................................................................................276
BT Standard Codes............................................................................  0
Warning Symbols..............................................................................  0
	1. Warning Levels........................................................................  0
Prohibitory Symbols..........................................................................  0
	1. Ordinance Symbols.....................................................................  0
Introduction, Service Manual.................................................................  0
Contents, Section M..........................................................................  0
	1. Machine Information...................................................................  0
General Product Information..................................................................  0
	1. Presentation of the Rider Trucks CMX60 and CMX80......................................  0
		1.1. Intended Application of the Trucks..............................................  0
		1.2. Forbidden Application of the Trucks.............................................  0
		1.3. Truck Data......................................................................  0
		1.4. CMX Dimensions..................................................................  0
		1.5. Data Plate......................................................................  0
Inch (SAE) and Metric Fasteners..............................................................  0
	1. Introduction..........................................................................  0
Technical Service Data.......................................................................  0
Ordering Spare Parts.........................................................................  0
Contents, Section P..........................................................................  0
	1. Planned Maintenance...................................................................  0
Introduction, Maintenance....................................................................  0
	1. Safe Jacking Procedure................................................................  0
Service Schedule.............................................................................  0
	1. Planned Maintenance Schedule..........................................................  0
		2.1. Services to be Performed Daily..................................................  0
			2.1.1. Battery Discharge Indicator with slow down................................  0
			2.1.2. Hydraulic System..........................................................  0
			2.1.3. Frame/Sheet Metal.........................................................  0
			2.1.4. Wheels/Tires..............................................................  0
			2.1.5. Functions/Operations......................................................  0
		2.2. Services to be Performed Monthly................................................  0
			2.2.1. Inspection................................................................  0
			2.2.2. Transmission..............................................................  0
			2.2.3. Brakes....................................................................  0
			2.2.4. Battery...................................................................  0
			2.2.5. Electrical Connections....................................................  0
			2.2.6. Contactor Tips (NOT Sealed)...............................................  0
			2.2.7. Motor Brushes.............................................................  0
			2.2.8. Drive Motor...............................................................  0
			2.2.9. Hydraulic Reservoir.......................................................  0
			2.2.10. Frame Lube (“Lubrication Chart” on page57)..............................  0
			2.2.11. Pivot Points.............................................................  0
		2.3. Services to be Performed Annually...............................................  0
			2.3.1. Inspection................................................................  0
			2.3.2. Transmission..............................................................  0
			2.3.3. Battery...................................................................  0
			2.3.4. Hydraulic System..........................................................  0
			2.3.5. Brakes....................................................................  0
Lubrication Chart............................................................................  0
Oil and Grease Specifications................................................................  0
	1. Approved Oils and Grease..............................................................  0
Contents, Section S..........................................................................  0
	1. Service Instructions..................................................................  0
Chassis......................................................................................  0
	1. General Information...................................................................  0
		2.1. Removal.........................................................................  0
Lift Frame...................................................................................  0
	1. Pull rod..............................................................................  0
		1.1. Removal.........................................................................  0
		1.2. Inspection......................................................................  0
		1.3. Installation....................................................................  0
Drive Motor Mounting Points..................................................................  0
	1. Drive Motor Brush.....................................................................  0
		1.1. Removal and Installation........................................................  0
		2.1. Remove..........................................................................  0
		2.2. Installation....................................................................  0
Drive Motor..................................................................................  0
	1. General Information...................................................................  0
Drive Motor Service..........................................................................  0
	1. Motor Repair..........................................................................  0
		1.1. Disassembly.....................................................................  0
		2.1. Drive End Head..................................................................  0
		2.2. Commutator End Head.............................................................  0
		2.3. Bearings........................................................................  0
		2.4. Brush and Commutator............................................................  0
		2.5. Armature........................................................................  0
		2.6. Frame and Field Assembly........................................................  0
			2.6.1. Testing...................................................................  0
			2.6.2. Frame and Field Service Notes.............................................  0
		2.7. Assembly........................................................................  0
			2.7.1. Field Coil Installation...................................................  0
			2.7.2. Bearing Installation......................................................  0
			2.7.3. After Assembly............................................................  0
Transmission.................................................................................  0
	1. System Description....................................................................  0
Transmission Axle Seal.......................................................................  0
	1. General Information...................................................................  0
		1.1. Removal.........................................................................  0
		1.2. Installation....................................................................  0
Transmission Disassembly / Assembly..........................................................  0
	1. Disassembly...........................................................................  0
Parking Brake System.........................................................................  0
	1. Brake Theory of Operation.............................................................  0
Drive Wheel..................................................................................  0
	4.1. Removal.............................................................................  0
	4.2. Installation........................................................................  0
Load Wheels..................................................................................  0
Support / Swivel Wheel.......................................................................  0
	1. Stabilizing Caster....................................................................  0
		1.1. Removal.........................................................................  0
		1.2. Inspection......................................................................  0
		1.3. Installation....................................................................  0
		1.4. Maintenance.....................................................................  0
Stabilizing Caster...........................................................................  0
	1. Stabilizing Caster....................................................................  0
		1.1. Disassembly.....................................................................  0
		1.2. Inspection......................................................................  0
		1.3. Assembly........................................................................  0
Steering Control Arm.........................................................................  0
	1. Control Handle Stem...................................................................  0
		1.1. Removal.........................................................................  0
		1.2. Installation....................................................................  0
		2.1. Removal.........................................................................  0
		2.2. Disassembly.....................................................................  0
		2.3. Assembly........................................................................  0
		2.4. Installation....................................................................  0
Steering Handle Head.........................................................................  0
	1. Control Handle Head...................................................................  0
		1.1. Removal.........................................................................  0
		1.2. Installation....................................................................  0
300/400 Amp Contactor........................................................................  0
	1. Maintenance...........................................................................  0
		1.1. Removal/Replacement of Contact Tips.............................................  0
“EE” Contactor...............................................................................  0
	1. Maintenance...........................................................................  0
		1.1. Removal/Replacement of Contact Tips.............................................  0
Battery Controller / Hourmeter / Lift Interrupt..............................................  0
	1. General Information...................................................................  0
		2.1. Voltage.........................................................................  0
			2.1.1. The Contact Voltage and Current Ratings for Switching Resistive Loads.....  0
			2.1.2. Memory Retention..........................................................  0
		3.1. General Information.............................................................  0
			3.1.1. Discharge Adjustment......................................................  0
		3.2. Reset...........................................................................  0
		3.3. Key Switch......................................................................  0
		3.4. Hourmeter.......................................................................  0
		4.1. Battery Discharge Indicator (BDI)...............................................  0
			4.1.1. No Reset..................................................................  0
			4.1.2. Reset After Break in Power................................................  0
			4.1.3. No Discharge, Gauge Does Not Run Down.....................................  0
			4.1.4. No Lockout................................................................  0
			4.1.5. No Lift...................................................................  0
			4.1.6. Early Lockout.............................................................  0
			4.1.7. LEDs Do Not Light.........................................................  0
		4.2. Hourmeter.......................................................................  0
			4.2.1. No Display................................................................  0
			4.2.2. Hourmeter Glass Icon Does Not Flash.......................................  0
			4.2.3. Hourmeter Glass Icon Always Flashes.......................................  0
Battery Discharge Indicator / Hourmeter......................................................  0
	1. General Information...................................................................  0
		2.1. Voltage.........................................................................  0
		3.1. General Information.............................................................  0
		3.2. Key Switch......................................................................  0
		3.3. Hourmeter.......................................................................  0
		4.1. Battery Discharge Indicator (BDI)...............................................  0
			4.1.1. No Reset..................................................................  0
			4.1.2. Reset After Break in Power................................................  0
			4.1.3. No Discharge, Gauge Does Not Run Down.....................................  0
			4.1.4. LEDs Do Not Light.........................................................  0
		4.2. Hourmeter.......................................................................  0
			4.2.1. No Display................................................................  0
			4.2.2. Hourmeter Glass Icon Does Not Flash.......................................  0
			4.2.3. Hourmeter Glass Icon Always Flashes.......................................  0
24 Volt 400 Amp Electrical System............................................................  0
	1. Electrical Panel Components...........................................................  0
		2.1. Circuit Diagram 1(5)............................................................  0
		2.2. Circuit Diagram 2(5)............................................................  0
		2.3. Circuit Diagram 3(5)............................................................  0
		2.4. Circuit Diagram 4(5)............................................................  0
		2.5. Circuit Diagram 5(5)............................................................  0
		3.1. General Information.............................................................  0
		3.2. References Information..........................................................  0
		3.3. Key Switch S17 in the ON Position...............................................  0
		3.4. Brake released, S10 Brake Switch Closed.........................................  0
		3.5. Driving, Fork Direction.........................................................  0
		3.6. Driving, Steer Wheel Direction..................................................  0
		3.7. Reversing/Motor Brake Fork Direction to Steer Wheel Direction...................  0
		3.8. Reversing/Motor Brake Steer Wheel Direction to Fork Direction...................  0
		3.9. Lifting the Forks...............................................................  0
		3.10. Lowering the Forks.............................................................  0
		3.11. Horn...........................................................................  0
		3.12. Prime-Trak; operator off of the truck..........................................  0
		3.13. Prime-Trak; operator on the truck..............................................  0
		3.14. Lift Interrupt.................................................................  0
24 Volt, 400 Amp Transistor Controller.......................................................  0
	1. Maintenance...........................................................................  0
		1.1. Safety..........................................................................  0
		1.2. Cleaning........................................................................  0
		1.3. Diagnostics and Troubleshooting.................................................  0
			1.3.1. Handset Diagnostics.......................................................  0
			1.3.2. Troubleshooting...........................................................  0
		2.1. Control Features................................................................  0
		5.1. 1307 Programmer Diagnostics.....................................................  0
		5.2. Troubleshooting Chart...........................................................  0
		5.3. Technical Specification.........................................................  0
		5.4. Troubleshooting Chart Using the Handset.........................................  0
24 Volt, 400 Amp Transistor Controller Troubleshooting.......................................  0
	1. Troubleshooting Chart Index...........................................................  0
Handset Operation............................................................................  0
	1. Operating Modes.......................................................................  0
Pump Motor...................................................................................  0
	1. Component Repair......................................................................  0
		1.1. Motor Disassembly...............................................................  0
		2.1. Drive End Head..................................................................  0
		2.2. Commutator End Head.............................................................  0
		2.3. Bearings........................................................................  0
		2.4. Brush and Commutator............................................................  0
		2.5. Armature........................................................................  0
		2.6. Frame and Field Assembly........................................................  0
			2.6.1. Testing...................................................................  0
			2.6.2. Frame and Field Service Notes.............................................  0
		2.7. Assembly........................................................................  0
			2.7.1. Field Coil Installation...................................................  0
			2.7.2. Bearing Installation......................................................  0
			2.7.3. After Assembly............................................................  0
Hydraulic System.............................................................................  0
	1. Hydraulic Schematic...................................................................  0
		3.1. Lift............................................................................  0
		3.2. Lower...........................................................................  0
		3.3. Relief Pressure.................................................................  0
Prime-Trak Hydraulic System..................................................................  0
	1. Prime-Trak Hydraulic Schematic........................................................  0
Lift Pump Assembly...........................................................................  0
	1. Removal...............................................................................  0
		6.1. Relief valve....................................................................  0
		6.2. Solenoid Operated Valve.........................................................  0
Prime-Trak Hydraulic Pump....................................................................  0
	1. Removal...............................................................................  0
Lift Cylinder................................................................................  0
	1. Removal...............................................................................  0
Prime-Trak Cylinders.........................................................................  0
	1. Removal...............................................................................  0
Back Cover...................................................................................543

DESCRIPTION:

BT PRIME MOVER CMX60/80 SERVICE MANUALS – PDF DOWNLOAD

• 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 Prime-Mover lift truck when it is manufactured. If the Operator’s Manual is missing from the truck a new manual may be obtained by contacting The Prime-Mover Company, 3000 North Highway 61, Muscatine, Iowa, 52761-5810, (319) 262-7700.
• This service manual is not a training manual. The information contained in this manual is intended as a guide to help the authorized technician safely service the truck.

S.S 08/01/2025