Download Complete Service Repair Manual for BT Prime Mover CMX60, CMX80 Electric Center Riding Pallet Truck.

This Factory Service Repair Manual offers all the service and repair information about BT Prime Mover CMX60, CMX80 Electric Center Riding Pallet Truck. The information on this manual covered everything you need to know when you want to repair or service BT Prime Mover CMX60, CMX80 Electric Center Riding Pallet Truck.

Models Covered:

CMX60, CMX80

Manuals Covered:

Service manuals
Parts manuals
Master Parts Manuals
Electrical Schematics
Operators manuals

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Service Manual Contents:

BT Standard Codes …………………………………………………………………………… 1
Warning Symbols …………………………………………………………………………….. 11
Warning Levels …………………………………………………………………………….. 11
Prohibitory Symbols ………………………………………………………………………… 12
Ordinance Symbols ………………………………………………………………………. 12
Introduction, Service Manual ……………………………………………………………. 13
Contents, Section M …………………………………………………………………………. 15
Machine Information ……………………………………………………………………… 15
General Product Information ……………………………………………………………. 17
Presentation of the Rider Trucks CMX60 and CMX80. ………………………. 17
Intended Application of the Trucks …………………………………………… 17
Forbidden Application of the Trucks …………………………………………. 18
Truck Data ……………………………………………………………………………. 18
CMX Dimensions …………………………………………………………………… 19
Data Plate …………………………………………………………………………….. 20
Main Components …………………………………………………………………………. 21
Inch (SAE) and Metric Fasteners ……………………………………………………… 23
Introduction ………………………………………………………………………………….. 23
Nomenclature, Threads …………………………………………………………………. 24
Strength Identification ……………………………………………………………………. 25
Conversion of Metric and English Units ……………………………………………. 31
Technical Service Data …………………………………………………………………….. 33
Ordering Spare Parts ……………………………………………………………………….. 37
Contents, Section P …………………………………………………………………………. 39
Planned Maintenance ……………………………………………………………………. 39
Introduction, Maintenance ……………………………………………………………….. 41
Safe Jacking Procedure …………………………………………………………………. 41
Service Schedule …………………………………………………………………………….. 43
Planned Maintenance Schedule ……………………………………………………… 43
Planned Maintenance Procedures …………………………………………………… 47
Services to be Performed Daily ……………………………………………….. 47
Services to be Performed Monthly ……………………………………………. 49
Services to be Performed Annually ………………………………………….. 52
Lubrication Chart …………………………………………………………………………….. 55
Oil and Grease Specifications ………………………………………………………….. 57
Approved Oils and Grease …………………………………………………………….. 57
Contents, Section S …………………………………………………………………………. 59
Service Instructions ………………………………………………………………………. 59
Chassis …………………………………………………………………………………………… 61
General Information ………………………………………………………………………. 61
Door ……………………………………………………………………………………………. 62
Removal ……………………………………………………………………………….. 62
Lift Frame ………………………………………………………………………………………… 63
Pull rod ………………………………………………………………………………………… 64
Removal ……………………………………………………………………………….. 64
Inspection …………………………………………………………………………….. 66
Installation …………………………………………………………………………….. 67
Drive Motor Mounting Points ……………………………………………………………. 69
Drive Motor Brush …………………………………………………………………………. 70
Removal and Installation ………………………………………………………… 70
Drive Motor Assembly ……………………………………………………………………. 70
Remove ……………………………………………………………………………….. 70
Installation …………………………………………………………………………….. 71
Drive Motor ……………………………………………………………………………………… 73
General Information ………………………………………………………………………. 73
Operating Conditions …………………………………………………………………….. 73
Troubleshooting ……………………………………………………………………………. 73
Drive Motor Service …………………………………………………………………………. 79
Motor Repair ………………………………………………………………………………… 80
Disassembly …………………………………………………………………………. 80
Inspection and Troubleshooting ………………………………………………………. 83
Drive End Head …………………………………………………………………….. 83
Commutator End Head …………………………………………………………… 83
Bearings ……………………………………………………………………………….. 83
Brush and Commutator …………………………………………………………… 84
Armature ………………………………………………………………………………. 84
Frame and Field Assembly ……………………………………………………… 85
Assembly ……………………………………………………………………………… 87
Changing Brushes ………………………………………………………………………… 88
Transmission …………………………………………………………………………………… 89
System Description ……………………………………………………………………….. 89
Troubleshooting ……………………………………………………………………………. 89
Removal ………………………………………………………………………………………. 90
Installation ……………………………………………………………………………………. 91
Transmission Axle Seal ……………………………………………………………………. 93
General Information ………………………………………………………………………. 93
Removal ……………………………………………………………………………….. 93
Installation …………………………………………………………………………….. 93
Transmission Disassembly / Assembly …………………………………………….. 95
Disassembly ………………………………………………………………………………… 96
Assembly …………………………………………………………………………………….. 96
Parking Brake System ……………………………………………………………………… 99
Brake Theory of Operation ……………………………………………………………. 100
Brake Adjustment ………………………………………………………………………… 101
Brake Shoe Removal / Installation ………………………………………………….. 102
Brake Interlock Switch ………………………………………………………………….. 103
Drive Wheel …………………………………………………………………………………….. 105
Removal ………………………………………………………………………………. 105
Installation ……………………………………………………………………………. 106
Load Wheels …………………………………………………………………………………… 107
Support / Swivel Wheel ……………………………………………………………………. 109
Stabilizing Caster …………………………………………………………………………. 109
Removal ………………………………………………………………………………. 110
Inspection ……………………………………………………………………………. 112
Installation ……………………………………………………………………………. 113
Maintenance ………………………………………………………………………… 114
Stabilizing Caster ……………………………………………………………………………. 115
Stabilizing Caster …………………………………………………………………………. 115
Disassembly ………………………………………………………………………… 116
Inspection ……………………………………………………………………………. 117
Assembly …………………………………………………………………………….. 118
Steering Control Arm ………………………………………………………………………. 119
Control Handle Stem ……………………………………………………………………. 120
Removal ………………………………………………………………………………. 120
Installation ……………………………………………………………………………. 121
Hand Brake Levers ………………………………………………………………………. 122
Removal ………………………………………………………………………………. 122
Disassembly ………………………………………………………………………… 122
Assembly …………………………………………………………………………….. 122
Installation ……………………………………………………………………………. 123
Steering Handle Head ……………………………………………………………………… 125
Control Handle Head ……………………………………………………………………. 127
Removal ………………………………………………………………………………. 127
Installation ……………………………………………………………………………. 127
Direction Control Switches …………………………………………………………….. 128
Horn, Raise, and Lower Switches …………………………………………………… 129
Potentiometer ……………………………………………………………………………… 131
300/400 Amp Contactor …………………………………………………………………… 133
Maintenance ……………………………………………………………………………….. 134
Removal/Replacement of Contact Tips ……………………………………. 134
“EE” Contactor ……………………………………………………………………………….. 137
Maintenance ……………………………………………………………………………….. 138
Removal/Replacement of Contact Tips ……………………………………. 138
Battery Controller / Hourmeter / Lift Interrupt …………………………………… 141
General Information ……………………………………………………………………… 141
Electrical …………………………………………………………………………………….. 141
Voltage ………………………………………………………………………………… 141
Battery Controller (BC) …………………………………………………………………. 142
General Information ………………………………………………………………. 142
Reset ………………………………………………………………………………….. 144
Key Switch …………………………………………………………………………… 144
Hourmeter ……………………………………………………………………………. 144
Troubleshooting …………………………………………………………………………… 145
Battery Discharge Indicator (BDI) ……………………………………………. 145
Hourmeter ……………………………………………………………………………. 147
Battery Discharge Indicator / Hourmeter ………………………………………….. 149
General Information ……………………………………………………………………… 149
Electrical …………………………………………………………………………………….. 149
Voltage ………………………………………………………………………………… 149
Battery Discharge Indicator (BDI) …………………………………………………… 150
General Information ………………………………………………………………. 150
Key Switch …………………………………………………………………………… 150
Hourmeter ……………………………………………………………………………. 150
Troubleshooting …………………………………………………………………………… 151
Battery Discharge Indicator (BDI) ……………………………………………. 151
Hourmeter ……………………………………………………………………………. 152
24 Volt 400 Amp Electrical System …………………………………………………… 155
Electrical Panel Components …………………………………………………………. 155
List of Symbols ……………………………………………………………………………. 156
Circuit Diagram 1(5) ………………………………………………………………. 158
Circuit Diagram 2(5) ………………………………………………………………. 159
Circuit Diagram 3(5) ………………………………………………………………. 160
Circuit Diagram 4(5) ………………………………………………………………. 161
Circuit Diagram 5(5) ………………………………………………………………. 162
Description of Function …………………………………………………………………. 163
General Information ………………………………………………………………. 163
References Information …………………………………………………………. 163
Key Switch S17 in the ON Position ………………………………………….. 163
Brake released, S10 Brake Switch Closed ……………………………….. 163
Driving, Fork Direction …………………………………………………………… 163
Driving, Steer Wheel Direction ………………………………………………… 164
Reversing/Motor Brake Fork Direction to Steer Wheel Direction ….. 164
Reversing/Motor Brake Steer Wheel Direction to Fork Direction ….. 164
Lifting the Forks ……………………………………………………………………. 164
Lowering the Forks ……………………………………………………………….. 164
Horn ……………………………………………………………………………………. 165
Prime-Trak; operator off of the truck ………………………………………… 165
Prime-Trak; operator on the truck ……………………………………………. 165
Lift Interrupt ………………………………………………………………………….. 166
24 Volt, 400 Amp Transistor Controller …………………………………………….. 167
Maintenance ……………………………………………………………………………….. 167
Safety ………………………………………………………………………………….. 167
Cleaning ………………………………………………………………………………. 167
Diagnostics and Troubleshooting ……………………………………………. 168
Basics Of Circuit Operation …………………………………………………………… 170
Control Features …………………………………………………………………… 171
Motor Circuit ……………………………………………………………………………….. 174
Control Circuit ……………………………………………………………………………… 174
Diagnostics and Troubleshooting …………………………………………………… 177
1307 Programmer Diagnostics ……………………………………………….. 177
Troubleshooting Chart …………………………………………………………… 178
Technical Specification ………………………………………………………….. 182
Troubleshooting Chart Using the Handset ………………………………… 183
24 Volt, 400 Amp Transistor Controller Troubleshooting ………………….. 185
Troubleshooting Chart Index …………………………………………………………. 185
Troubleshooting Charts ………………………………………………………………… 186
………………………………………………………………………………………………………. 203
Handset Operation ………………………………………………………………………….. 204
Operating Modes …………………………………………………………………………. 206
Revert to Previous Settings …………………………………………………………… 210
Handset Self Test ………………………………………………………………………… 210
Pump Motor …………………………………………………………………………………… 211
Component Repair ……………………………………………………………………….. 212
Motor Disassembly ……………………………………………………………….. 212
Inspection and Troubleshooting ……………………………………………………… 214
Drive End Head ……………………………………………………………………. 214
Commutator End Head ………………………………………………………….. 214
Bearings ………………………………………………………………………………. 214
Brush and Commutator ………………………………………………………….. 215
Armature ……………………………………………………………………………… 215
Frame and Field Assembly …………………………………………………….. 216
Assembly …………………………………………………………………………….. 218
Changing Brushes ……………………………………………………………………….. 219
Hydraulic System ……………………………………………………………………………. 221
Hydraulic Schematic …………………………………………………………………….. 221
General Information ……………………………………………………………………… 221
Description ………………………………………………………………………………….. 222
Lift ………………………………………………………………………………………. 222
Lower ………………………………………………………………………………….. 222
Relief Pressure …………………………………………………………………….. 222
Maintenance ……………………………………………………………………………….. 223
Adjustments ………………………………………………………………………………… 223
Lift Limit Switch ……………………………………………………………………………. 223
Troubleshooting …………………………………………………………………………… 225
Prime-Trak Hydraulic System ………………………………………………………….. 227
Prime-Trak Hydraulic Schematic ……………………………………………………. 227
General Information ……………………………………………………………………… 228
Maintenance ……………………………………………………………………………….. 229
Adjustments ………………………………………………………………………………… 229
Prime-Trak Lift Limit Switch …………………………………………………………… 230
Troubleshooting …………………………………………………………………………… 231
Lift Pump Assembly ………………………………………………………………………… 233
Removal ……………………………………………………………………………………… 235
Disassembly ……………………………………………………………………………….. 236
Inspection …………………………………………………………………………………… 237
Assembly ……………………………………………………………………………………. 238
Installation …………………………………………………………………………………… 240
Adjustments ………………………………………………………………………………… 242
Relief valve ………………………………………………………………………….. 242
Solenoid Operated Valve ……………………………………………………….. 243
Prime-Trak Hydraulic Pump …………………………………………………………….. 245
Removal ……………………………………………………………………………………… 246
Disassembly ……………………………………………………………………………….. 247
Inspection …………………………………………………………………………………… 248
Assembly ……………………………………………………………………………………. 249
Installation …………………………………………………………………………………… 251
Lift Cylinder …………………………………………………………………………………… 253
Removal ……………………………………………………………………………………… 254
Disassembly ……………………………………………………………………………….. 255
Inspection …………………………………………………………………………………… 256
Assembly ……………………………………………………………………………………. 257
Installation …………………………………………………………………………………… 258
Prime-Trak Cylinders ……………………………………………………………………… 259
Removal ……………………………………………………………………………………… 260
Disassembly ……………………………………………………………………………….. 261
Inspection …………………………………………………………………………………… 262
Assembly ……………………………………………………………………………………. 263
Installation …………………………………………………………………………………… 264

Other manuals all cover full contents

This manual can be used by anyone from a first time owner/amateur to a professional technician.Even the most novice mechanic can also easily follow the step-by-step guides which are made simple by the illustrations and drawings.Keep this manual handy and use it often. Performing routine, preventive maintenance will save you time & money by helping to prevent premature failure and unnecessary repairs.

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