BT PRIME MOVER TMX MASTER SERVICE MANUALS – PDF DOWNLOAD

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BT PRIME MOVER TMX MASTER SERVICE MANUALS – PDF DOWNLOAD

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BT PRIME MOVER TMX MASTER SERVICE MANUALS – PDF DOWNLOAD

Language : English
Pages : 374
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TABLE OF CONTENTS:

BT PRIME MOVER TMX MASTER SERVICE MANUALS – PDF DOWNLOAD

303047-000 1995_April (4)........................................................................  1
303047-000 1995_April............................................................................  2
	Front Cover..................................................................................  2
	Table of Contents............................................................................  4
	0.0 Maintenance..............................................................................  5
		0.1 Tow Tractor Identification...........................................................  6
		0.2 System Operation.....................................................................  7
		0.3 Specifications.......................................................................  8
		0.4 Maintenance and Adjustments.......................................................... 19
		0.5 Troubleshooting...................................................................... 25
		0.6 Component Removal and Installation................................................... 25
		0.7 Component Repair..................................................................... 25
	1.0 Transmission............................................................................. 27
		Figure # 1.1 Transmission Assembly....................................................... 28
		Figure # 1.2 Steering Stem Assembly...................................................... 30
		1.2 System Operation..................................................................... 32
		1.3 Specifications....................................................................... 32
		1.4 Maintenance and Adjustments.......................................................... 32
		1.5 Troubleshooting...................................................................... 33
		1.6 Component Removal and Installation................................................... 33
		1.7 Component Repair..................................................................... 39
	2.0 Electrical............................................................................... 41
		2.1 Component Identification............................................................. 43
		Figure # 2.1 Electrical Schematic........................................................ 44
		Figure # 2.2 Electrical Schematic Symbols................................................ 45
		Figure # 2.3 Electrical Assembly......................................................... 46
		Figure # 2.4 Electrical Panel Assembly................................................... 48
		2.2 System Operation..................................................................... 50
		2.3 Specifications....................................................................... 53
		2.4 Maintenance and Adjustments.......................................................... 53
		2.5 Troubleshooting...................................................................... 59
		2.6 Component Removal and Installation................................................... 72
		2.7 Component Repair..................................................................... 76
	4.0 Frame.................................................................................... 89
		Figure # 4.1 Shields and Guards.......................................................... 90
		Figure # 4.2 Control Head Assembly with Picking Knob..................................... 92
		4.3 Specifications....................................................................... 94
		4.4 Maintenance and Adjustments.......................................................... 94
		4.5 Troubleshooting...................................................................... 94
		4.6 Component Removal and Installation................................................... 94
	Back Cover................................................................................... 97
303047-000 1995_August........................................................................... 98
	Front Cover.................................................................................. 98
	Table of Contents............................................................................100
	0.0 Maintenance..............................................................................102
		0.1 Tow Tractor Identification...........................................................103
		0.2 System Operation.....................................................................104
		0.3 Specifications.......................................................................105
			Inch (SAE) and Metric Fasteners......................................................106
			Introduction.........................................................................107
			Figure 1 - Thread Design.............................................................108
			Strength Identification..............................................................108
			Table 1 - Bolts and Screws...........................................................109
			Table 2 - Studs and Nuts.............................................................110
			Table 3 - Torque Nuts................................................................111
			Table 4 - Torque Nuts with Nylon Insert..............................................112
			Table 5 - Conversion Table for Metric and English Units..............................113
			Table 6 - Torque Values for Coarse Threaded Metric Fasteners.........................115
		0.4 Maintenance and Adjustments..........................................................116
			Planned Maintenance Schedule.........................................................117
			Services to be Performed Daily or at Each 8 Hour Operating Shift.....................119
			Services to be Performed Monthly or Every 200 Operating Hours........................119
			Services to be Performed Annually or Every 2000 Operating Hours......................121
		0.5 Troubleshooting......................................................................122
		0.6 Component Removal and Installation...................................................122
		0.7 Component Repair.....................................................................122
	1.0 Transmission.............................................................................124
		Figure # 1.1 Transmission Assembly.......................................................125
		Figure # 1.2 Steering Stem Assembly......................................................127
		1.2 System Operation.....................................................................129
		1.3 Specifications.......................................................................129
		1.4 Maintenance and Adjustments..........................................................129
		1.5 Troubleshooting......................................................................130
		1.6 Component Removal and Installation...................................................130
			Transmission.........................................................................130
			Drive Wheel..........................................................................132
			Axle Seal............................................................................133
			Brake Shoe...........................................................................134
			Hand Brake Assembly..................................................................135
			Brake Lever Assembly.................................................................136
		1.7 Component Repair.....................................................................137
	2.0 Electrical...............................................................................140
		2.1 Component Identification.............................................................142
		Figure # 2.1 Electrical Schematic........................................................143
		Figure # 2.2 Electrical Schematic Symbols................................................144
		Figure # 2.3 Electrical Assembly.........................................................145
		Figure # 2.4 Electrical Panel Assembly...................................................147
		2.2 System Operation.....................................................................149
		2.3 Specifications.......................................................................152
		2.4 Maintenance and Adjustments..........................................................152
		2.5 Troubleshooting......................................................................158
			Troubleshooting Chart Index..........................................................160
			Troubleshooting Charts...............................................................161
		2.6 Component Removal and Installation...................................................171
			Drive Motor..........................................................................171
			Drive Motor Brush....................................................................172
			Contactor Tips.......................................................................173
			Direction Control Switches...........................................................173
		2.7 Component Repair.....................................................................175
			Table # 1............................................................................176
			Table # 2............................................................................180
	4.0 Frame....................................................................................186
		Figure # 4.1 Shields and Guards..........................................................187
		Figure # 4.2 Control Head Assembly with Picking Knob.....................................189
		4.3 Specifications.......................................................................191
		4.4 Maintenance and Adjustments..........................................................191
		4.5 Troubleshooting......................................................................191
		4.6 Component Removal and Installation...................................................191
			Control Handle Head..................................................................191
			Load Wheels..........................................................................191
	Back Cover...................................................................................195
303047-000 1998_March............................................................................196
	Front Cover..................................................................................196
	BT Standard Codes............................................................................198
	Warning Symbols..............................................................................206
		1. Warning Levels........................................................................206
	Prohibitory Symbols..........................................................................207
		1. Ordinance Symbols.....................................................................207
	Introduction, Service Manual.................................................................208
	Contents, Section M..........................................................................210
		1. Machine Information...................................................................210
	General Product Information..................................................................212
		1. Presentation of the TMX...............................................................212
			1.1. Intended Application of the Trucks..............................................212
			1.2. Forbidden Application of the Trucks.............................................213
			1.3. Truck Data......................................................................213
			1.4. TMX Dimensions..................................................................214
			1.5. Data Plate......................................................................215
		2. Main Components.......................................................................216
	Inch (SAE) and Metric Fasteners..............................................................218
		1. Introduction..........................................................................218
		2. Nomenclature, Threads.................................................................219
		3. Strength Identification...............................................................220
		4. Conversion of Metric and English Units................................................226
	Technical Service Data.......................................................................228
	Ordering Spare Parts.........................................................................230
	Contents, Section P..........................................................................232
		1. Planned Maintenance...................................................................232
	Introduction, Maintenance....................................................................234
		1. Safe Jacking Procedure................................................................234
	Service Schedule.............................................................................236
		1. Planned Maintenance Schedule..........................................................236
		2. Planned Maintenance Procedures........................................................239
			2.1. Services to be Performed Daily..................................................239
				2.1.1. Battery Discharge Indicator with slow down................................239
				2.1.2. Frame/Sheet Metal.........................................................239
				2.1.3. Wheels/Tires..............................................................240
				2.1.4. Functions/Operations......................................................240
			2.2. Services to be Performed Monthly................................................241
				2.2.1. Inspection................................................................241
				2.2.2. Transmission..............................................................241
				2.2.3. Brakes....................................................................241
				2.2.4. Battery...................................................................241
				2.2.5. Electrical Connections....................................................241
				2.2.6. Contactor Tips (NOT Sealed)...............................................242
				2.2.7. Motor Brushes.............................................................242
				2.2.8. Drive Motor...............................................................242
				2.2.9. Frame Lube (“Lubrication Chart” on page51)...............................242
				2.2.10. Pivot Points.............................................................243
			2.3. Services to be Performed Annually...............................................244
				2.3.1. Inspection................................................................244
				2.3.2. Transmission..............................................................244
				2.3.3. Battery...................................................................244
				2.3.4. Brakes....................................................................244
	Lubrication Chart............................................................................246
	Oil and Grease Specifications................................................................248
		3. Approved Oils and Grease..............................................................248
	Contents, Section S..........................................................................250
		1. Service Instructions..................................................................250
	Chassis......................................................................................252
		1. General Information...................................................................252
	Drive Motor Mounting Points..................................................................254
		1. Drive Motor Brush.....................................................................255
			1.1. Removal and Installation........................................................255
		2. Drive Motor Assembly..................................................................255
			2.1. Remove..........................................................................255
			2.2. Installation....................................................................256
	Drive Motor..................................................................................258
		1. General Information...................................................................258
		2. Operating Conditions..................................................................258
		3. Troubleshooting.......................................................................258
	Drive Motor Service..........................................................................264
		1. Motor Repair..........................................................................265
			1.1. Disassembly.....................................................................265
		2. Inspection and Troubleshooting........................................................268
			2.1. Drive End Head..................................................................268
			2.2. Commutator End Head.............................................................268
			2.3. Bearings........................................................................268
			2.4. Brush and Commutator............................................................269
			2.5. Armature........................................................................269
			2.6. Frame and Field Assembly........................................................270
				2.6.1. Testing...................................................................270
				2.6.2. Frame and Field Service Notes.............................................271
			2.7. Assembly........................................................................272
				2.7.1. Field Coil Installation...................................................272
				2.7.2. Bearing Installation......................................................272
				2.7.3. After Assembly............................................................273
		3. Changing Brushes......................................................................273
	Transmission.................................................................................274
		1. System Description....................................................................274
		2. Troubleshooting.......................................................................274
		3. Removal...............................................................................275
		4. Installation..........................................................................276
	Transmission Axle Seal.......................................................................278
		1. General Information...................................................................278
			1.1. Removal.........................................................................278
			1.2. Installation....................................................................278
	Transmission Disassembly / Assembly..........................................................280
		1. Disassembly...........................................................................281
		2. Assembly..............................................................................281
	Parking Brake System.........................................................................284
		1. Brake Theory of Operation.............................................................285
		2. Brake Adjustment......................................................................286
		3. Brake Shoe Removal / Installation.....................................................287
		4. Brake Interlock Switch................................................................288
	Drive Wheel..................................................................................290
		3.1. Removal.............................................................................290
		3.2. Installation........................................................................291
	Load Wheels..................................................................................292
	Steering Control Arm.........................................................................294
		1. Control Handle Stem...................................................................295
			1.1. Removal.........................................................................295
			1.2. Installation....................................................................296
		2. Hand Brake Levers.....................................................................297
			2.1. Removal.........................................................................297
			2.2. Disassembly.....................................................................297
			2.3. Assembly........................................................................297
			2.4. Installation....................................................................298
	Steering Handle head.........................................................................300
		1. Control Handle Head...................................................................302
			1.1. Removal.........................................................................302
			1.2. Installation....................................................................302
		2. Direction Control Switches............................................................303
		3. Horn Switch...........................................................................304
		4. Potentiometer.........................................................................306
	300/400 Amp Contactor........................................................................308
		1. Maintenance...........................................................................309
			1.1. Removal/Replacement of Contact Tips.............................................309
	“EE” Contactor...............................................................................312
		1. Maintenance...........................................................................313
			1.1. Removal/Replacement of Contact Tips.............................................313
	Battery Controller / Hourmeter / Speed Dropout...............................................316
		1. General Information...................................................................316
		2. Electrical............................................................................316
			2.1. Voltage.........................................................................316
				2.1.1. The Contact Voltage and Current Ratings for Switching Resistive Loads.....317
				2.1.2. Memory Retention..........................................................317
		3. Battery Controller (BC)...............................................................317
			3.1. General Information.............................................................317
				3.1.1. Discharge Adjustment......................................................317
			3.2. Reset...........................................................................319
			3.3. Key Switch......................................................................319
			3.4. Hourmeter.......................................................................319
		4. Troubleshooting.......................................................................320
			4.1. Battery Discharge Indicator (BDI)...............................................320
				4.1.1. No Reset..................................................................320
				4.1.2. Reset After Break in Power................................................320
				4.1.3. No Discharge, Gauge Does Not Run Down.....................................321
				4.1.4. No Lockout................................................................321
				4.1.5. No Lift...................................................................321
				4.1.6. Early Lockout.............................................................322
				4.1.7. LEDs Do Not Light.........................................................322
			4.2. Hourmeter.......................................................................322
				4.2.1. No Display................................................................322
				4.2.2. Hourmeter Glass Icon Does Not Flash.......................................322
				4.2.3. Hourmeter Glass Icon Always Flashes.......................................323
	Battery Discharge Indicator / Hourmeter......................................................324
		1. General Information...................................................................324
		2. Electrical............................................................................324
			2.1. Voltage.........................................................................324
		3. Battery Discharge Indicator (BDI).....................................................325
			3.1. General Information.............................................................325
			3.2. Key Switch......................................................................325
			3.3. Hourmeter.......................................................................325
		4. Troubleshooting.......................................................................326
			4.1. Battery Discharge Indicator (BDI)...............................................326
				4.1.1. No Reset..................................................................326
				4.1.2. Reset After Break in Power................................................326
				4.1.3. No Discharge, Gauge Does Not Run Down.....................................327
				4.1.4. LEDs Do Not Light.........................................................327
			4.2. Hourmeter.......................................................................327
				4.2.1. No Display................................................................327
				4.2.2. Hourmeter Glass Icon Does Not Flash.......................................327
				4.2.3. Hourmeter Glass Icon Always Flashes.......................................328
	24 Volt 400 Amp Electrical System............................................................330
		1. Electrical Panel Components...........................................................330
		2. List of Symbols.......................................................................331
			2.1. Circuit Diagram 1(3)............................................................333
			2.2. Circuit Diagram 2(3)............................................................334
			2.3. Circuit Diagram 3(3)............................................................335
		3. Description of Function...............................................................336
			3.1. General Information.............................................................336
			3.2. References Information..........................................................336
			3.3. Key Switch S17 in the ON Position...............................................336
			3.4. The Operating Arm in Drive Position, S10, Brake Switch Closed...................336
			3.5. Driving, Load Wheels Direction..................................................337
			3.6. Driving, Steer Wheel Direction..................................................337
			3.7. Reversing/Motor Brake Load Wheels Direction to Steer Wheel Direction............337
			3.8. Reversing/Motor Brake Steer Wheel Direction to Load Wheels Direction............337
			3.9. Horn............................................................................337
	24 Volt, 400 Amp Transistor Controller.......................................................338
		1. Maintenance...........................................................................338
			1.1. Safety..........................................................................338
			1.2. Cleaning........................................................................338
			1.3. Diagnostics and Troubleshooting.................................................339
				1.3.1. Handset Diagnostics.......................................................339
				1.3.2. Troubleshooting...........................................................339
		2. Basics Of Circuit Operation...........................................................341
			2.1. Control Features................................................................343
		3. Motor Circuit.........................................................................345
		4. Control Circuit.......................................................................345
		5. Diagnostics and Troubleshooting.......................................................348
			5.1. 1307 Programmer Diagnostics.....................................................348
			5.2. Troubleshooting Chart...........................................................349
			5.3. Technical Specification.........................................................353
			5.4. Troubleshooting Chart Using the Handset.........................................354
	24 Volt, 400 Amp Transistor Controller Troubleshooting.......................................356
		1. Troubleshooting Chart Index...........................................................356
		2. Troubleshooting Charts................................................................357
	Handset Operation............................................................................366
		1. Operating Modes.......................................................................368
		2. Revert to Previous Settings...........................................................372
		3. Handset Self Test.....................................................................372
	Back Cover...................................................................................374

DESCRIPTION:

BT PRIME MOVER TMX MASTER SERVICE MANUALS – PDF DOWNLOAD

This service manual covers the following BT Prime-Mover products:
TMX ELECTRIC TOW TRACTOR from serial number 255600 and above.These tow tractors 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 08/01/2025