BT CMX60 CMX80 RIDING PALLET TRUCK SERVICE REPAIR, PARTS, OPERATOR, SCHEMATICS MANUAL

BT CMX60 CMX80 RIDING PALLET TRUCK SERVICE REPAIR, PARTS, OPERATOR, SCHEMATICS MANUAL
LANGUAGE: ENGLISH
FORMAT: PDF
PAGES: 3,837
FILE SIZE: 100MB

MODEL COVERED:

CMX60

CMX80

PART NO:

302825-000 1995_APRIL - SERIAL - 245334

302825-000 1995_AUGUST - SERIAL - 245334

302825-000 1998_MARCH - SERIAL - CMX__26288001

302825-000 2006_APRIL - SERIAL - 27179000-UP
 

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

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

OPERATOR'S MANUAL:

302823-000 1994_APRIL

302823-000 1994_OCTOBER

302823-001 1994_DECEMBER

302823-002 1995_APRIL

302823-003 1995_OCTOBER

302823-004 1996_JANUARY

302823-004 1997_SEPTEMBER

302823-004 1998_JUNE

302823-004 1998_OCTOBER

302823-005 2002_JUNE
 

PARTS MANUAL:

302824-000 1994_APRIL

302824-001 1994_DECEMBER

302824-002 1995_APRIL

302824-003 1995_SEPTEMBER

302824-004 1995_DECEMBER

302824-004 1997_JANUARY

302824-004 1997_JULY

302824-004 1998_AUGUST

302824-004 1999_OCTOBER

302824-005 2001_SEPTEMBER

302824-006 2002_MARCH

308563-000 2004_AUGUST
 

MASTER PARTS MANUAL:

308563-000 1998_AUGUST

308563-000 1998_NOVEMBER

308563-000 1999_OCTOBER

308563-000 2001_SEPTEMBER

308563-000 2002_MARCH
 

ELECTRICAL SCHEMATICS:

308590-000 1998_AUGUST

308590-001 2000_NOVEMBER

308590-002 2001_MAY