BT Prime-Mover TMX Master Service Manual – PDF DOWNLOAD

BT Prime-Mover TMX Master Service Manual – PDF DOWNLOAD

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BT Prime-Mover TMX Master Service Manual – PDF DOWNLOAD

Language : English
Pages : 374
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

BT Prime-Mover TMX Master Service Manual – PDF DOWNLOAD

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
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
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