BT PRIME-MOVER CMX60/80 Service Manuals – PDF DOWNLOAD

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BT PRIME-MOVER CMX60/80 Service Manuals – PDF DOWNLOAD

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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

CMX Service Welcome..............................................................................  1
302825-000 1995_April............................................................................  2
	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
302825-000 1995_August...........................................................................140
	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
302825-000 1998_March............................................................................276
	Front Cover..................................................................................276
	BT Standard Codes............................................................................278
	Warning Symbols..............................................................................288
		1. Warning Levels........................................................................288
	Prohibitory Symbols..........................................................................289
		1. Ordinance Symbols.....................................................................289
	Introduction, Service Manual.................................................................290
	Contents, Section M..........................................................................292
		1. Machine Information...................................................................292
	General Product Information..................................................................294
		1. Presentation of the Rider Trucks CMX60 and CMX80......................................294
			1.1. Intended Application of the Trucks..............................................294
			1.2. Forbidden Application of the Trucks.............................................295
			1.3. Truck Data......................................................................295
			1.4. CMX Dimensions..................................................................296
			1.5. Data Plate......................................................................297
	Inch (SAE) and Metric Fasteners..............................................................300
		1. Introduction..........................................................................300
	Technical Service Data.......................................................................310
	Ordering Spare Parts.........................................................................314
	Contents, Section P..........................................................................316
		1. Planned Maintenance...................................................................316
	Introduction, Maintenance....................................................................318
		1. Safe Jacking Procedure................................................................318
	Service Schedule.............................................................................320
		1. Planned Maintenance Schedule..........................................................320
			2.1. Services to be Performed Daily..................................................324
				2.1.1. Battery Discharge Indicator with slow down................................324
				2.1.2. Hydraulic System..........................................................324
				2.1.3. Frame/Sheet Metal.........................................................325
				2.1.4. Wheels/Tires..............................................................325
				2.1.5. Functions/Operations......................................................325
			2.2. Services to be Performed Monthly................................................326
				2.2.1. Inspection................................................................326
				2.2.2. Transmission..............................................................326
				2.2.3. Brakes....................................................................326
				2.2.4. Battery...................................................................326
				2.2.5. Electrical Connections....................................................326
				2.2.6. Contactor Tips (NOT Sealed)...............................................327
				2.2.7. Motor Brushes.............................................................327
				2.2.8. Drive Motor...............................................................327
				2.2.9. Hydraulic Reservoir.......................................................327
				2.2.10. Frame Lube (“Lubrication Chart” on page57)..............................327
				2.2.11. Pivot Points.............................................................328
			2.3. Services to be Performed Annually...............................................329
				2.3.1. Inspection................................................................329
				2.3.2. Transmission..............................................................329
				2.3.3. Battery...................................................................329
				2.3.4. Hydraulic System..........................................................329
				2.3.5. Brakes....................................................................330
	Lubrication Chart............................................................................332
	Oil and Grease Specifications................................................................334
		1. Approved Oils and Grease..............................................................334
	Contents, Section S..........................................................................336
		1. Service Instructions..................................................................336
	Chassis......................................................................................338
		1. General Information...................................................................338
			2.1. Removal.........................................................................339
	Lift Frame...................................................................................340
		1. Pull rod..............................................................................341
			1.1. Removal.........................................................................341
			1.2. Inspection......................................................................343
			1.3. Installation....................................................................344
	Drive Motor Mounting Points..................................................................346
		1. Drive Motor Brush.....................................................................347
			1.1. Removal and Installation........................................................347
			2.1. Remove..........................................................................347
			2.2. Installation....................................................................348
	Drive Motor..................................................................................350
		1. General Information...................................................................350
	Drive Motor Service..........................................................................356
		1. Motor Repair..........................................................................357
			1.1. Disassembly.....................................................................357
			2.1. Drive End Head..................................................................360
			2.2. Commutator End Head.............................................................360
			2.3. Bearings........................................................................360
			2.4. Brush and Commutator............................................................361
			2.5. Armature........................................................................361
			2.6. Frame and Field Assembly........................................................362
				2.6.1. Testing...................................................................362
				2.6.2. Frame and Field Service Notes.............................................363
			2.7. Assembly........................................................................364
				2.7.1. Field Coil Installation...................................................364
				2.7.2. Bearing Installation......................................................364
				2.7.3. After Assembly............................................................365
	Transmission.................................................................................366
		1. System Description....................................................................366
	Transmission Axle Seal.......................................................................370
		1. General Information...................................................................370
			1.1. Removal.........................................................................370
			1.2. Installation....................................................................370
	Transmission Disassembly / Assembly..........................................................372
		1. Disassembly...........................................................................373
	Parking Brake System.........................................................................376
		1. Brake Theory of Operation.............................................................377
	Drive Wheel..................................................................................382
		4.1. Removal.............................................................................382
		4.2. Installation........................................................................383
	Load Wheels..................................................................................384
	Support / Swivel Wheel.......................................................................386
		1. Stabilizing Caster....................................................................386
			1.1. Removal.........................................................................387
			1.2. Inspection......................................................................389
			1.3. Installation....................................................................390
			1.4. Maintenance.....................................................................391
	Stabilizing Caster...........................................................................392
		1. Stabilizing Caster....................................................................392
			1.1. Disassembly.....................................................................393
			1.2. Inspection......................................................................394
			1.3. Assembly........................................................................395
	Steering Control Arm.........................................................................396
		1. Control Handle Stem...................................................................397
			1.1. Removal.........................................................................397
			1.2. Installation....................................................................398
			2.1. Removal.........................................................................399
			2.2. Disassembly.....................................................................399
			2.3. Assembly........................................................................399
			2.4. Installation....................................................................400
	Steering Handle Head.........................................................................402
		1. Control Handle Head...................................................................404
			1.1. Removal.........................................................................404
			1.2. Installation....................................................................404
	300/400 Amp Contactor........................................................................410
		1. Maintenance...........................................................................411
			1.1. Removal/Replacement of Contact Tips.............................................411
	“EE” Contactor...............................................................................414
		1. Maintenance...........................................................................415
			1.1. Removal/Replacement of Contact Tips.............................................415
	Battery Controller / Hourmeter / Lift Interrupt..............................................418
		1. General Information...................................................................418
			2.1. Voltage.........................................................................418
				2.1.1. The Contact Voltage and Current Ratings for Switching Resistive Loads.....419
				2.1.2. Memory Retention..........................................................419
			3.1. General Information.............................................................419
				3.1.1. Discharge Adjustment......................................................419
			3.2. Reset...........................................................................421
			3.3. Key Switch......................................................................421
			3.4. Hourmeter.......................................................................421
			4.1. Battery Discharge Indicator (BDI)...............................................422
				4.1.1. No Reset..................................................................422
				4.1.2. Reset After Break in Power................................................422
				4.1.3. No Discharge, Gauge Does Not Run Down.....................................423
				4.1.4. No Lockout................................................................423
				4.1.5. No Lift...................................................................423
				4.1.6. Early Lockout.............................................................424
				4.1.7. LEDs Do Not Light.........................................................424
			4.2. Hourmeter.......................................................................424
				4.2.1. No Display................................................................424
				4.2.2. Hourmeter Glass Icon Does Not Flash.......................................424
				4.2.3. Hourmeter Glass Icon Always Flashes.......................................425
	Battery Discharge Indicator / Hourmeter......................................................426
		1. General Information...................................................................426
			2.1. Voltage.........................................................................426
			3.1. General Information.............................................................427
			3.2. Key Switch......................................................................427
			3.3. Hourmeter.......................................................................427
			4.1. Battery Discharge Indicator (BDI)...............................................428
				4.1.1. No Reset..................................................................428
				4.1.2. Reset After Break in Power................................................428
				4.1.3. No Discharge, Gauge Does Not Run Down.....................................429
				4.1.4. LEDs Do Not Light.........................................................429
			4.2. Hourmeter.......................................................................429
				4.2.1. No Display................................................................429
				4.2.2. Hourmeter Glass Icon Does Not Flash.......................................429
				4.2.3. Hourmeter Glass Icon Always Flashes.......................................430
	24 Volt 400 Amp Electrical System............................................................432
		1. Electrical Panel Components...........................................................432
			2.1. Circuit Diagram 1(5)............................................................435
			2.2. Circuit Diagram 2(5)............................................................436
			2.3. Circuit Diagram 3(5)............................................................437
			2.4. Circuit Diagram 4(5)............................................................438
			2.5. Circuit Diagram 5(5)............................................................439
			3.1. General Information.............................................................440
			3.2. References Information..........................................................440
			3.3. Key Switch S17 in the ON Position...............................................440
			3.4. Brake released, S10 Brake Switch Closed.........................................440
			3.5. Driving, Fork Direction.........................................................440
			3.6. Driving, Steer Wheel Direction..................................................441
			3.7. Reversing/Motor Brake Fork Direction to Steer Wheel Direction...................441
			3.8. Reversing/Motor Brake Steer Wheel Direction to Fork Direction...................441
			3.9. Lifting the Forks...............................................................441
			3.10. Lowering the Forks.............................................................441
			3.11. Horn...........................................................................442
			3.12. Prime-Trak; operator off of the truck..........................................442
			3.13. Prime-Trak; operator on the truck..............................................442
			3.14. Lift Interrupt.................................................................443
	24 Volt, 400 Amp Transistor Controller.......................................................444
		1. Maintenance...........................................................................444
			1.1. Safety..........................................................................444
			1.2. Cleaning........................................................................444
			1.3. Diagnostics and Troubleshooting.................................................445
				1.3.1. Handset Diagnostics.......................................................445
				1.3.2. Troubleshooting...........................................................445
			2.1. Control Features................................................................448
			5.1. 1307 Programmer Diagnostics.....................................................454
			5.2. Troubleshooting Chart...........................................................455
			5.3. Technical Specification.........................................................459
			5.4. Troubleshooting Chart Using the Handset.........................................460
	24 Volt, 400 Amp Transistor Controller Troubleshooting.......................................462
		1. Troubleshooting Chart Index...........................................................462
	Handset Operation............................................................................481
		1. Operating Modes.......................................................................483
	Pump Motor...................................................................................488
		1. Component Repair......................................................................489
			1.1. Motor Disassembly...............................................................489
			2.1. Drive End Head..................................................................491
			2.2. Commutator End Head.............................................................491
			2.3. Bearings........................................................................491
			2.4. Brush and Commutator............................................................492
			2.5. Armature........................................................................492
			2.6. Frame and Field Assembly........................................................493
				2.6.1. Testing...................................................................493
				2.6.2. Frame and Field Service Notes.............................................494
			2.7. Assembly........................................................................495
				2.7.1. Field Coil Installation...................................................495
				2.7.2. Bearing Installation......................................................495
				2.7.3. After Assembly............................................................496
	Hydraulic System.............................................................................498
		1. Hydraulic Schematic...................................................................498
			3.1. Lift............................................................................499
			3.2. Lower...........................................................................499
			3.3. Relief Pressure.................................................................499
	Prime-Trak Hydraulic System..................................................................504
		1. Prime-Trak Hydraulic Schematic........................................................504
	Lift Pump Assembly...........................................................................510
		1. Removal...............................................................................512
			6.1. Relief valve....................................................................519
			6.2. Solenoid Operated Valve.........................................................520
	Prime-Trak Hydraulic Pump....................................................................522
		1. Removal...............................................................................523
	Lift Cylinder................................................................................530
		1. Removal...............................................................................531
	Prime-Trak Cylinders.........................................................................536
		1. Removal...............................................................................537
	Back Cover...................................................................................543

DESCRIPTION:

BT PRIME-MOVER CMX60/80 Service Manuals – PDF DOWNLOAD

• This repair manual covers the following BT Prime-Mover products: CMX60 AND CMX80 CENTER CONTROL RIDER PALLET TRUCKS from serial number 245334 and above.
• These trucks are manufactured by The Prime-Mover Company in Muscatine, Iowa, USA.
• The Prime-Mover Company reserves the right to change the information and specifications contained within this manual at any time without incurring any obligation relating to such changes.

S.S 07/01/2025