BT Prime-Mover RMX/HMX Electric Low Lift Pallet Truck Service Manual – PDF DOWNLOAD

BT Prime-Mover RMX/HMX Electric Low Lift Pallet Truck Service Manual – PDF DOWNLOAD

FILE DETAILS:

BT Prime-Mover RMX/HMX Electric Low Lift Pallet Truck Service Manual – PDF DOWNLOAD

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

TABLE OF CONTENTS:

BT Prime-Mover RMX/HMX Electric Low Lift Pallet Truck Service Manual – PDF DOWNLOAD

Front Cover 2
Table of Contents 4
Section 0 – Maintenance 7
01 Truck Identification 7
02 System Operation 8
03 Specifications 9
04 Maintenance and Adjustments 22
05 Troubleshooting 29
06 Component Removal and Installation 29
07 Component Repair 29
Section 1 – Transmission 30
Figure # 11 Handle and Transmission Installation 31
12 System Operation 33
13 Specifications 33
14 Maintenance and Adjustments 33
15 Troubleshooting 34
16 Component Removal and Installation 34
Figure # 12 Transmission Assembly 41
17 Component Repair 43
Section 2 – Electrical 46
21 Component Identification 48
22 System Operation 69
23 Specifications 77
24 Maintenance and Adjustments 78
25 Troubleshooting 84
26 Component Removal and Installation104
27 Component Repair109
Section 3 – Hydraulics120
31 Component Identification121
32 System Operation125
33 Specifications125
34 Maintenance and Adjustments126
35 Troubleshooting126
36 Component Removal and Installation129
37 Component Repair131
Section 4 – Frame134
41 Component Identification135
Figure # 42 HMX Caster Torsion Rod Assembly137
42 System Operation139
43 Specifications139
44 Maintenance and Adjustments139
45 Troubleshooting140
Figure # 43 Handle and Transmission Installation141
46 Component Removal and Installation143
Back Cover147
Front Cover148
BT Standard Codes150
Warning Symbols160
1 Warning Levels160
Prohibitory Symbols161
1 Ordinance Symbols161
Introduction, Service Manual162
Contents, Section M164
1 Machine Information164
General Product Information166
1 Presentation of the RMX and HMX166
11 Intended Application of the Trucks166
12 Forbidden Application of the Trucks167
13 Truck Data167
14 RMX Dimensions168
15 HMX Dimensions169
16 RMX Data plate170
17 HMX Data plate171
2 Main Components172
Inch (SAE) and Metric Fasteners176
1 Introduction176
2 Nomenclature, Threads177
3 Strength Identification178
4 Conversion of Metric and English Units184
Technical Service Data186
Ordering Spare Parts190
Contents, Section P192
1 Planned Maintenance192
Introduction, Maintenance194
1 Safe Jacking Procedure194
Service Schedule196
1 Planned Maintenance Schedule196
2 Planned Maintenance Procedures199
21 Services to be Performed Daily199
211 Battery Discharge Indicator with slow down199
212 Hydraulic System199
213 Frame/Sheet Metal200
214 Wheels/Tires200
215 Functions/Operations200
22 Services to be Performed Monthly201
221 Inspection201
222 Transmission201
223 Brakes201
224 Battery201
225 Electrical Connections201
226 Contactor Tips (NOT Sealed)202
227 Motor Brushes202
228 Drive Motor202
229 Hydraulic Reservoir202
2210 Frame Lube (“Lubrication Chart” on page57)202
2211 Pivot Points203
23 Services to be Performed Annually204
231 Inspection204
232 Transmission204
233 Battery204
234 Hydraulic System204
235 Brakes205
Lubrication Chart206
Oil and Grease Specifications208
1 Approved Oils and Grease208
Contents, Section S210
1 Service Instructions210
Lift Frame212
1 Pull rod213
11 Removal213
12 Inspection215
13 Installation216
2 Carrier Frame Bushings218
Inspection Covers220
1 General Information220
Drive Motor Mounting Points222
1 Drive Motor Brush223
11 Removal and Installation223
2 Drive Motor Assembly223
21 Remove223
22 Installation224
Drive Motor226
1 General Information226
2 Operating Conditions226
3 Troubleshooting226
Drive Motor Service232
1 Motor Repair233
11 Disassembly233
2 Inspection and Troubleshooting236
21 Drive End Head236
22 Commutator End Head236
23 Bearings236
24 Brush and Commutator237
25 Armature237
26 Frame and Field Assembly238
261 Testing238
262 Frame and Field Service Notes239
27 Assembly240
271 Field Coil Installation240
272 Bearing Installation240
273 After Assembly241
3 Changing Brushes241
Transmission242
1 System Description242
2 Troubleshooting242
3 Removal244
4 Installation246
Transmission Axle Seal248
1 General Information248
11 Removal248
12 Installation248
Transmission Disassembly / Assembly250
1 Disassembly251
2 Assembly251
Parking Brake System254
1 Brake Theory of Operation255
2 Brake Adjustment256
3 Brake Shoe Removal / Installation257
4 Parking Brake Interlock Switch258
Drive Wheel260
41 Removal260
42 Installation261
Load Wheels262
Support / Swivel Wheels264
1 Stabilizing Caster264
11 Removal265
12 Inspection267
13 Installation268
14 Maintenance269
Stabilizing Caster270
1 Stabilizing Caster270
11 Disassembly271
12 Inspection272
13 Assembly273
Stabilizing Caster Spring Loaded274
1 Removal275
2 Disassembly276
3 Inspection277
4 Assemble278
5 Installation278
Steering Arm / Handle280
1 Control Handle Stem281
11 Removal281
12 Inspection281
13 Installation282
Steering Handle Head284
1 Control Handle Head286
11 Removal286
12 Installation286
2 Direction Control Switches287
3 Horn, Raise, and Lower Switches288
4 Potentiometer290
300/400 Amp Contactor292
1 Maintenance293
11 Removal/Replacement of Contact Tips293
“EE” Contactor296
1 Maintenance297
11 Removal/Replacement of Contact Tips297
Battery Controller / Hourmeter / Lift Interrupt300
1 General Information300
2 Electrical300
21 Voltage300
211 The Contact Voltage and Current Ratings for Switching Resistive Loads301
212 Memory Retention301
3 Battery Controller (BC)301
31 General Information301
311 Discharge Adjustment301
32 Reset303
33 Key Switch303
34 Hourmeter304
4 Troubleshooting304
41 Battery Discharge Indicator (BDI)304
411 No Reset304
412 Reset After Break in Power304
413 No Discharge, Gauge Does Not Run Down305
414 No Lockout305
415 No Lift305
416 Early Lockout306
417 LEDs Do Not Light306
42 Hourmeter306
421 No Display306
422 Hourmeter Glass Icon Does Not Flash306
423 Hourmeter Glass Icon Always Flashes307
Battery Discharge Indicator / Hourmeter308
1 General Information308
2 Electrical308
21 Voltage308
3 Battery Discharge Indicator (BDI)309
31 General Information309
32 Key Switch309
33 Hourmeter309
4 Troubleshooting310
41 Battery Discharge Indicator (BDI)310
411 No Reset310
412 Reset After Break in Power310
413 No Discharge, Gauge Does Not Run Down311
414 LEDs Do Not Light311
42 Hourmeter311
421 No Display311
422 Hourmeter Glass Icon Does Not Flash311
423 Hourmeter Glass Icon Always Flashes312
12 Volt Electrical System314
1 Electrical Panel Components314
11 RMX Circuit Diagram315
12 Electrical Schematic Symbols316
Direction Contactor318
1 General Information319
2 Remove / replace contact tips319
12 Volt Transistor Controller324
1 Maintenance324
11 Safety324
12 Cleaning324
13 Troubleshooting325
2 Basics Of Circuit Operation327
21 Battery connected and emergency disconnect switch in “RUN” position327
22 Key switch turned “ON”327
23 Control handle pulled down; brakes released and brake interlock switch closed328
24 Reverse travel (fork direction) switch is closed328
25 Forward travel (control handle direction) switch is closed329
26 Curtis® PMC controller power circuits329
27 Accelerator Potentiometer Circuits330
28 Emergency Reverser Switch331
29 Lift Pallet Forks331
210 Lower pallet forks332
211 Controller Adjustments333
12 Volt Transistor Controller Troubleshooting334
1 Troubleshooting Chart Index334
2 Troubleshooting Charts335
24 Volt 300 Amp Electrical System352
1 Electrical Panel Components352
2 List of Symbols353
21 RMX Circuit Diagram 1(3)355
22 RMX Circuit Diagram 2(3)356
23 RMX Circuit Diagram 3(3)357
3 Description of Function358
31 General Information358
32 References Information358
33 Key Switch S17 in the ON Position358
34 The Operating Arm in Drive Position, S10, Brake Switch Closed358
35 Driving, Fork Direction358
36 Driving, Steer Wheel Direction359
37 Reversing/Motor Brake Fork Direction to Steer Wheel Direction359
38 Reversing/Motor Brake Steer Wheel Direction to Fork Direction359
39 Reverser switch359
310 Lifting the Forks360
311 Lowering the Forks360
312 Horn360
313 Lift Interrupt360
24 Volt, 300 Amp Transistor Controller362
1 Maintenance362
11 Safety362
12 Cleaning362
13 Diagnostics and Troubleshooting363
131 Handset Diagnostics363
132 Troubleshooting363
2 Basics Of Circuit Operation365
21 Control Features367
3 Motor Circuit369
4 Control Circuit369
5 Diagnostics and Troubleshooting371
51 1307 Programmer Diagnostics371
52 Troubleshooting Chart372
53 Technical Specification376
54 Troubleshooting Chart Using the Handset377
24 Volt, 300 Amp Transistor Controller Troubleshooting380
1 Troubleshooting Chart Index380
2 Troubleshooting Charts381
24 Volt 400 Amp Electrical System392
1 Electrical Panel Components392
2 List of Symbols393
21 HMX Circuit Diagram 1(3)395
22 HMX Circuit Diagram 2(3)396
23 HMX Circuit Diagram 3(3)397
3 Description of Function398
31 General Information398
32 References Information398
33 Key Switch S17 in the ON Position398
34 The Operating Arm in Drive Position, S10, Brake Switch Closed398
35 Driving, Fork Direction398
36 Driving, Steer Wheel Direction399
37 Reversing/Motor Brake Fork Direction to Steer Wheel Direction399
38 Reversing/Motor Brake Steer Wheel Direction to Fork Direction399
39 Reverser switch399
310 Lifting the Forks400
311 Lowering the Forks400
312 Horn400
313 High Speed Switch400
314 Lift Interrupt401
24 Volt, 400 Amp Transistor Controller402
1 Maintenance402
11 Safety402
12 Cleaning402
13 Diagnostics and Troubleshooting403
131 Handset Diagnostics403
132 Troubleshooting403
2 Basics Of Circuit Operation405
21 Control Features407
3 Motor Circuit409
4 Control Circuit409
5 Diagnostics and Troubleshooting412
51 1307 Programmer Diagnostics412
52 Troubleshooting Chart413
53 Technical Specification417
54 Troubleshooting Chart Using the Handset418
24 Volt, 400 Amp Transistor Controller Troubleshooting420
1 Troubleshooting Chart Index420
2 Troubleshooting Charts421
Handset Operation434
1 Operating Modes436
2 Revert to Previous Settings440
3 Handset Self Test440
Pump Motor442
1 Component Repair443
11 Motor Disassembly443
2 Inspection and Troubleshooting445
21 Drive End Head445
22 Commutator End Head445
23 Bearings445
24 Brush and Commutator446
25 Armature446
26 Frame and Field Assembly447
261 Testing447
262 Frame and Field Service Notes448
27 Assembly449
271 Field Coil Installation449
272 Bearing Installation449
273 After Assembly450
3 Changing Brushes450
Hydraulic System452
1 Hydraulic Schematic452
2 General Information452
3 Description453
31 Lift453
32 Lower453
33 Relief Pressure453
4 Maintenance454
5 Adjustments454
6 Lift Limit Switch454
7 Troubleshooting456
Lift Pump Assembly458
1 Removal460
2 Disassembly461
3 Inspection462
4 Assembly463
5 Installation465
6 Adjustments467
61 Relief valve467
62 Solenoid Operated Valve468
Lift Cylinder470
1 Removal471
2 Disassembly472
3 Inspection473
4 Assembly474
5 Installation475
Back Cover477

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