BT PRIME MOVER HMX/RMX Service Manual – PDF DOWNLOAD

Description

BT PRIME MOVER HMX/RMX Service Manual – PDF DOWNLOAD

FILE DETAILS:

BT PRIME MOVER HMX/RMX Service Manual – PDF DOWNLOAD

Language : English
Pages : 477
Downloadable : Yes
File Type : PDF

302065-000 1995_January
302065-000 1998_March

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

BT PRIME MOVER HMX/RMX Service Manual – PDF DOWNLOAD

Front Cover....................................................................................  2
Table of Contents..............................................................................  4
Section 0 - Maintenance........................................................................  7
	0.1 Truck Identification...................................................................  7
	0.2 System Operation.......................................................................  8
	0.3 Specifications.........................................................................  9
	0.4 Maintenance and Adjustments............................................................ 22
	0.5 Troubleshooting........................................................................ 29
	0.6 Component Removal and Installation..................................................... 29
	0.7 Component Repair....................................................................... 29
Section 1 - Transmission....................................................................... 30
	Figure # 1.1 Handle and Transmission Installation.......................................... 31
	1.2 System Operation....................................................................... 33
	1.3 Specifications......................................................................... 33
	1.4 Maintenance and Adjustments............................................................ 33
	1.5 Troubleshooting........................................................................ 34
	1.6 Component Removal and Installation..................................................... 34
	Figure # 1.2 Transmission Assembly......................................................... 41
	1.7 Component Repair....................................................................... 43
Section 2 - Electrical......................................................................... 46
	2.1 Component Identification............................................................... 48
	2.2 System Operation....................................................................... 69
	2.3 Specifications......................................................................... 77
	2.4 Maintenance and Adjustments............................................................ 78
	2.5 Troubleshooting........................................................................ 84
	2.6 Component Removal and Installation.....................................................104
	2.7 Component Repair.......................................................................109
Section 3 - Hydraulics.........................................................................120
	3.1 Component Identification...............................................................121
	3.2 System Operation.......................................................................125
	3.3 Specifications.........................................................................125
	3.4 Maintenance and Adjustments............................................................126
	3.5 Troubleshooting........................................................................126
	3.6 Component Removal and Installation.....................................................129
	3.7 Component Repair.......................................................................131
Section 4 - Frame..............................................................................134
	4.1 Component Identification...............................................................135
	Figure # 4.2 HMX Caster Torsion Rod Assembly...............................................137
	4.2 System Operation.......................................................................139
	4.3 Specifications.........................................................................139
	4.4 Maintenance and Adjustments............................................................139
	4.5 Troubleshooting........................................................................140
	Figure # 4.3 Handle and Transmission Installation..........................................141
	4.6 Component Removal and Installation.....................................................143
Back Cover.....................................................................................147
Front Cover....................................................................................148
BT Standard Codes..............................................................................150
Warning Symbols................................................................................160
	1. Warning Levels..........................................................................160
Prohibitory Symbols............................................................................161
	1. Ordinance Symbols.......................................................................161
Introduction, Service Manual...................................................................162
Contents, Section M............................................................................164
	1. Machine Information.....................................................................164
General Product Information....................................................................166
	1. Presentation of the RMX and HMX.........................................................166
		1.1. Intended Application of the Trucks................................................166
		1.2. Forbidden Application of the Trucks...............................................167
		1.3. Truck Data........................................................................167
		1.4. RMX Dimensions....................................................................168
		1.5. HMX Dimensions....................................................................169
		1.6. RMX Data plate....................................................................170
		1.7. HMX Data plate....................................................................171
	2. Main Components.........................................................................172
Inch (SAE) and Metric Fasteners................................................................176
	1. Introduction............................................................................176
	2. Nomenclature, Threads...................................................................177
	3. Strength Identification.................................................................178
	4. Conversion of Metric and English Units..................................................184
Technical Service Data.........................................................................186
Ordering Spare Parts...........................................................................190
Contents, Section P............................................................................192
	1. Planned Maintenance.....................................................................192
Introduction, Maintenance......................................................................194
	1. Safe Jacking Procedure..................................................................194
Service Schedule...............................................................................196
	1. Planned Maintenance Schedule............................................................196
	2. Planned Maintenance Procedures..........................................................199
		2.1. Services to be Performed Daily....................................................199
			2.1.1. Battery Discharge Indicator with slow down..................................199
			2.1.2. Hydraulic System............................................................199
			2.1.3. Frame/Sheet Metal...........................................................200
			2.1.4. Wheels/Tires................................................................200
			2.1.5. Functions/Operations........................................................200
		2.2. Services to be Performed Monthly..................................................201
			2.2.1. Inspection..................................................................201
			2.2.2. Transmission................................................................201
			2.2.3. Brakes......................................................................201
			2.2.4. Battery.....................................................................201
			2.2.5. Electrical Connections......................................................201
			2.2.6. Contactor Tips (NOT Sealed).................................................202
			2.2.7. Motor Brushes...............................................................202
			2.2.8. Drive Motor.................................................................202
			2.2.9. Hydraulic Reservoir.........................................................202
			2.2.10. Frame Lube (“Lubrication Chart” on page57)................................202
			2.2.11. Pivot Points...............................................................203
		2.3. Services to be Performed Annually.................................................204
			2.3.1. Inspection..................................................................204
			2.3.2. Transmission................................................................204
			2.3.3. Battery.....................................................................204
			2.3.4. Hydraulic System............................................................204
			2.3.5. Brakes......................................................................205
Lubrication Chart..............................................................................206
Oil and Grease Specifications..................................................................208
	1. Approved Oils and Grease................................................................208
Contents, Section S............................................................................210
	1. Service Instructions....................................................................210
Lift Frame.....................................................................................212
	1. Pull rod................................................................................213
		1.1. Removal...........................................................................213
		1.2. Inspection........................................................................215
		1.3. Installation......................................................................216
	2. Carrier Frame Bushings..................................................................218
Inspection Covers..............................................................................220
	1. General Information.....................................................................220
Drive Motor Mounting Points....................................................................222
	1. Drive Motor Brush.......................................................................223
		1.1. Removal and Installation..........................................................223
	2. Drive Motor Assembly....................................................................223
		2.1. Remove............................................................................223
		2.2. Installation......................................................................224
Drive Motor....................................................................................226
	1. General Information.....................................................................226
	2. Operating Conditions....................................................................226
	3. Troubleshooting.........................................................................226
Drive Motor Service............................................................................232
	1. Motor Repair............................................................................233
		1.1. Disassembly.......................................................................233
	2. Inspection and Troubleshooting..........................................................236
		2.1. Drive End Head....................................................................236
		2.2. Commutator End Head...............................................................236
		2.3. Bearings..........................................................................236
		2.4. Brush and Commutator..............................................................237
		2.5. Armature..........................................................................237
		2.6. Frame and Field Assembly..........................................................238
			2.6.1. Testing.....................................................................238
			2.6.2. Frame and Field Service Notes...............................................239
		2.7. Assembly..........................................................................240
			2.7.1. Field Coil Installation.....................................................240
			2.7.2. Bearing Installation........................................................240
			2.7.3. After Assembly..............................................................241
	3. Changing Brushes........................................................................241
Transmission...................................................................................242
	1. System Description......................................................................242
	2. Troubleshooting.........................................................................242
	3. Removal.................................................................................244
	4. Installation............................................................................246
Transmission Axle Seal.........................................................................248
	1. General Information.....................................................................248
		1.1. Removal...........................................................................248
		1.2. Installation......................................................................248
Transmission Disassembly / Assembly............................................................250
	1. Disassembly.............................................................................251
	2. Assembly................................................................................251
Parking Brake System...........................................................................254
	1. Brake Theory of Operation...............................................................255
	2. Brake Adjustment........................................................................256
	3. Brake Shoe Removal / Installation.......................................................257
	4. Parking Brake Interlock Switch..........................................................258
Drive Wheel....................................................................................260
	4.1. Removal...............................................................................260
	4.2. Installation..........................................................................261
Load Wheels....................................................................................262
Support / Swivel Wheels........................................................................264
	1. Stabilizing Caster......................................................................264
		1.1. Removal...........................................................................265
		1.2. Inspection........................................................................267
		1.3. Installation......................................................................268
		1.4. Maintenance.......................................................................269
Stabilizing Caster.............................................................................270
	1. Stabilizing Caster......................................................................270
		1.1. Disassembly.......................................................................271
		1.2. Inspection........................................................................272
		1.3. Assembly..........................................................................273
Stabilizing Caster Spring Loaded...............................................................274
	1. Removal.................................................................................275
	2. Disassembly.............................................................................276
	3. Inspection..............................................................................277
	4. Assemble................................................................................278
	5. Installation............................................................................278
Steering Arm / Handle..........................................................................280
	1. Control Handle Stem.....................................................................281
		1.1. Removal...........................................................................281
		1.2. Inspection........................................................................281
		1.3. Installation......................................................................282
Steering Handle Head...........................................................................284
	1. Control Handle Head.....................................................................286
		1.1. Removal...........................................................................286
		1.2. Installation......................................................................286
	2. Direction Control Switches..............................................................287
	3. Horn, Raise, and Lower Switches.........................................................288
	4. Potentiometer...........................................................................290
300/400 Amp Contactor..........................................................................292
	1. Maintenance.............................................................................293
		1.1. Removal/Replacement of Contact Tips...............................................293
“EE” Contactor.................................................................................296
	1. Maintenance.............................................................................297
		1.1. Removal/Replacement of Contact Tips...............................................297
Battery Controller / Hourmeter / Lift Interrupt................................................300
	1. General Information.....................................................................300
	2. Electrical..............................................................................300
		2.1. Voltage...........................................................................300
			2.1.1. The Contact Voltage and Current Ratings for Switching Resistive Loads.......301
			2.1.2. Memory Retention............................................................301
	3. Battery Controller (BC).................................................................301
		3.1. General Information...............................................................301
			3.1.1. Discharge Adjustment........................................................301
		3.2. Reset.............................................................................303
		3.3. Key Switch........................................................................303
		3.4. Hourmeter.........................................................................304
	4. Troubleshooting.........................................................................304
		4.1. Battery Discharge Indicator (BDI).................................................304
			4.1.1. No Reset....................................................................304
			4.1.2. Reset After Break in Power..................................................304
			4.1.3. No Discharge, Gauge Does Not Run Down.......................................305
			4.1.4. No Lockout..................................................................305
			4.1.5. No Lift.....................................................................305
			4.1.6. Early Lockout...............................................................306
			4.1.7. LEDs Do Not Light...........................................................306
		4.2. Hourmeter.........................................................................306
			4.2.1. No Display..................................................................306
			4.2.2. Hourmeter Glass Icon Does Not Flash.........................................306
			4.2.3. Hourmeter Glass Icon Always Flashes.........................................307
Battery Discharge Indicator / Hourmeter........................................................308
	1. General Information.....................................................................308
	2. Electrical..............................................................................308
		2.1. Voltage...........................................................................308
	3. Battery Discharge Indicator (BDI).......................................................309
		3.1. General Information...............................................................309
		3.2. Key Switch........................................................................309
		3.3. Hourmeter.........................................................................309
	4. Troubleshooting.........................................................................310
		4.1. Battery Discharge Indicator (BDI).................................................310
			4.1.1. No Reset....................................................................310
			4.1.2. Reset After Break in Power..................................................310
			4.1.3. No Discharge, Gauge Does Not Run Down.......................................311
			4.1.4. LEDs Do Not Light...........................................................311
		4.2. Hourmeter.........................................................................311
			4.2.1. No Display..................................................................311
			4.2.2. Hourmeter Glass Icon Does Not Flash.........................................311
			4.2.3. Hourmeter Glass Icon Always Flashes.........................................312
12 Volt Electrical System......................................................................314
	1. Electrical Panel Components.............................................................314
		1.1. RMX Circuit Diagram...............................................................315
		1.2. Electrical Schematic Symbols......................................................316
Direction Contactor............................................................................318
	1. General Information.....................................................................319
	2. Remove / replace contact tips...........................................................319
12 Volt Transistor Controller..................................................................324
	1. Maintenance.............................................................................324
		1.1. Safety............................................................................324
		1.2. Cleaning..........................................................................324
		1.3. Troubleshooting...................................................................325
	2. Basics Of Circuit Operation.............................................................327
		2.1. Battery connected and emergency disconnect switch in “RUN” position...............327
		2.2. Key switch turned “ON”............................................................327
		2.3. Control handle pulled down; brakes released and brake interlock switch closed.....328
		2.4. Reverse travel (fork direction) switch is closed..................................328
		2.5. Forward travel (control handle direction) switch is closed........................329
		2.6. Curtis® PMC controller power circuits.............................................329
		2.7. Accelerator Potentiometer Circuits................................................330
		2.8. Emergency Reverser Switch.........................................................331
		2.9. Lift Pallet Forks.................................................................331
		2.10. Lower pallet forks...............................................................332
		2.11. Controller Adjustments...........................................................333
12 Volt Transistor Controller Troubleshooting..................................................334
	1. Troubleshooting Chart Index.............................................................334
	2. Troubleshooting Charts..................................................................335
24 Volt 300 Amp Electrical System..............................................................352
	1. Electrical Panel Components.............................................................352
	2. List of Symbols.........................................................................353
		2.1. RMX Circuit Diagram 1(3)..........................................................355
		2.2. RMX Circuit Diagram 2(3)..........................................................356
		2.3. RMX Circuit Diagram 3(3)..........................................................357
	3. Description of Function.................................................................358
		3.1. General Information...............................................................358
		3.2. References Information............................................................358
		3.3. Key Switch S17 in the ON Position.................................................358
		3.4. The Operating Arm in Drive Position, S10, Brake Switch Closed.....................358
		3.5. Driving, Fork Direction...........................................................358
		3.6. Driving, Steer Wheel Direction....................................................359
		3.7. Reversing/Motor Brake Fork Direction to Steer Wheel Direction.....................359
		3.8. Reversing/Motor Brake Steer Wheel Direction to Fork Direction.....................359
		3.9. Reverser switch...................................................................359
		3.10. Lifting the Forks................................................................360
		3.11. Lowering the Forks...............................................................360
		3.12. Horn.............................................................................360
		3.13. Lift Interrupt...................................................................360
24 Volt, 300 Amp Transistor Controller.........................................................362
	1. Maintenance.............................................................................362
		1.1. Safety............................................................................362
		1.2. Cleaning..........................................................................362
		1.3. Diagnostics and Troubleshooting...................................................363
			1.3.1. Handset Diagnostics.........................................................363
			1.3.2. Troubleshooting.............................................................363
	2. Basics Of Circuit Operation.............................................................365
		2.1. Control Features..................................................................367
	3. Motor Circuit...........................................................................369
	4. Control Circuit.........................................................................369
	5. Diagnostics and Troubleshooting.........................................................371
		5.1. 1307 Programmer Diagnostics.......................................................371
		5.2. Troubleshooting Chart.............................................................372
		5.3. Technical Specification...........................................................376
		5.4. Troubleshooting Chart Using the Handset...........................................377
24 Volt, 300 Amp Transistor Controller Troubleshooting.........................................380
	1. Troubleshooting Chart Index.............................................................380
	2. Troubleshooting Charts..................................................................381
24 Volt 400 Amp Electrical System..............................................................392
	1. Electrical Panel Components.............................................................392
	2. List of Symbols.........................................................................393
		2.1. HMX Circuit Diagram 1(3)..........................................................395
		2.2. HMX Circuit Diagram 2(3)..........................................................396
		2.3. HMX Circuit Diagram 3(3)..........................................................397
	3. Description of Function.................................................................398
		3.1. General Information...............................................................398
		3.2. References Information............................................................398
		3.3. Key Switch S17 in the ON Position.................................................398
		3.4. The Operating Arm in Drive Position, S10, Brake Switch Closed.....................398
		3.5. Driving, Fork Direction...........................................................398
		3.6. Driving, Steer Wheel Direction....................................................399
		3.7. Reversing/Motor Brake Fork Direction to Steer Wheel Direction.....................399
		3.8. Reversing/Motor Brake Steer Wheel Direction to Fork Direction.....................399
		3.9. Reverser switch...................................................................399
		3.10. Lifting the Forks................................................................400
		3.11. Lowering the Forks...............................................................400
		3.12. Horn.............................................................................400
		3.13. High Speed Switch................................................................400
		3.14. Lift Interrupt...................................................................401
24 Volt, 400 Amp Transistor Controller.........................................................402
	1. Maintenance.............................................................................402
		1.1. Safety............................................................................402
		1.2. Cleaning..........................................................................402
		1.3. Diagnostics and Troubleshooting...................................................403
			1.3.1. Handset Diagnostics.........................................................403
			1.3.2. Troubleshooting.............................................................403
	2. Basics Of Circuit Operation.............................................................405
		2.1. Control Features..................................................................407
	3. Motor Circuit...........................................................................409
	4. Control Circuit.........................................................................409
	5. Diagnostics and Troubleshooting.........................................................412
		5.1. 1307 Programmer Diagnostics.......................................................412
		5.2. Troubleshooting Chart.............................................................413
		5.3. Technical Specification...........................................................417
		5.4. Troubleshooting Chart Using the Handset...........................................418
24 Volt, 400 Amp Transistor Controller Troubleshooting.........................................420
	1. Troubleshooting Chart Index.............................................................420
	2. Troubleshooting Charts..................................................................421
Handset Operation..............................................................................434
	1. Operating Modes.........................................................................436
	2. Revert to Previous Settings.............................................................440
	3. Handset Self Test.......................................................................440
Pump Motor.....................................................................................442
	1. Component Repair........................................................................443
		1.1. Motor Disassembly.................................................................443
	2. Inspection and Troubleshooting..........................................................445
		2.1. Drive End Head....................................................................445
		2.2. Commutator End Head...............................................................445
		2.3. Bearings..........................................................................445
		2.4. Brush and Commutator..............................................................446
		2.5. Armature..........................................................................446
		2.6. Frame and Field Assembly..........................................................447
			2.6.1. Testing.....................................................................447
			2.6.2. Frame and Field Service Notes...............................................448
		2.7. Assembly..........................................................................449
			2.7.1. Field Coil Installation.....................................................449
			2.7.2. Bearing Installation........................................................449
			2.7.3. After Assembly..............................................................450
	3. Changing Brushes........................................................................450
Hydraulic System...............................................................................452
	1. Hydraulic Schematic.....................................................................452
	2. General Information.....................................................................452
	3. Description.............................................................................453
		3.1. Lift..............................................................................453
		3.2. Lower.............................................................................453
		3.3. Relief Pressure...................................................................453
	4. Maintenance.............................................................................454
	5. Adjustments.............................................................................454
	6. Lift Limit Switch.......................................................................454
	7. Troubleshooting.........................................................................456
Lift Pump Assembly.............................................................................458
	1. Removal.................................................................................460
	2. Disassembly.............................................................................461
	3. Inspection..............................................................................462
	4. Assembly................................................................................463
	5. Installation............................................................................465
	6. Adjustments.............................................................................467
		6.1. Relief valve......................................................................467
		6.2. Solenoid Operated Valve...........................................................468
Lift Cylinder..................................................................................470
	1. Removal.................................................................................471
	2. Disassembly.............................................................................472
	3. Inspection..............................................................................473
	4. Assembly................................................................................474
	5. Installation............................................................................475
Back Cover.....................................................................................477

DESCRIPTION:

BT PRIME MOVER HMX/RMX Service Manual – PDF DOWNLOAD

• Threaded fasteners like bolts, nuts, cap screws and studs are made to specifications that describe the mechanical strength and hardness of the fastener. A fastener used in a design application is selected according to its specifications. The Prime-Mover Company buys parts from many countries. There are several standards used by these countries in the manufacture of threaded fasteners. Many of these fasteners are similar, but cannot be used as direct replacement.
• Service persons must use replacement fasteners that have the same specifications. Fasteners made to each specification have identification marks for that specification. This specification is commonly called “Grade” for SAE standards and “pr0perty” for metric standards. This section describes the identification of some common fasteners.
• The metric system used by BT Prime-Mover is described as SI (International System of Units, also called SI in a1 languages). The SI system of measurement is described in ISO Standard 1000, 1973.

S.S 08/01/2025