BT PRIME MOVER TMX ELECTRIC TOW TRACTOR SERVICE, OPERATOR, PARTS, WIRING MANUAL

BT PRIME MOVER TMX ELECTRIC TOW TRACTOR SERVICE, OPERATOR, PARTS, WIRING MANUAL
LANGUAGE: ENGLISH
FORMAT: PDF
PAGES: 1,988
FILE SIZE: 44.1MB

MODEL COVERED:

TMX ELECTRIC TOW TRACTOR

PART NO: 303047-000

SERIAL NO: 255600, TMX0026288001

ISSUED:

APRIL, 1995

AUGUST, 1995

MARCH, 1998
                  

CONTENTS:

BT Standard Codes ................................................................................................ 3

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 TMX. ................................................................................... 17

Intended Application of the Trucks ............................................................ 17

Forbidden Application of the Trucks .......................................................... 18

Truck Data ................................................................................................. 18

TMX 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 ............................................................................................ 35

Contents, Section P .............................................................................................. 37

Planned Maintenance ........................................................................................ 37

Introduction, Maintenance ................................................................................... 39

Safe Jacking Procedure ..................................................................................... 39

Service Schedule .................................................................................................. 41

Planned Maintenance Schedule ........................................................................ 41

Planned Maintenance Procedures ..................................................................... 44

Services to be Performed Daily ................................................................. 44

Services to be Performed Monthly ............................................................. 46

Services to be Performed Annually ........................................................... 49

Lubrication Chart .................................................................................................. 51

Oil and Grease Specifications ............................................................................. 53

Approved Oils and Grease ................................................................................ 53

Contents, Section S .............................................................................................. 55

Service Instructions ........................................................................................... 55

Chassis .................................................................................................................. 57

General Information ........................................................................................... 57

Drive Motor Mounting Points ............................................................................... 59

Drive Motor Brush .............................................................................................. 60

Removal and Installation ........................................................................... 60

Drive Motor Assembly ........................................................................................ 60

Remove ..................................................................................................... 60

Installation .................................................................................................. 61

Drive Motor ............................................................................................................ 63

General Information ........................................................................................... 63

Operating Conditions ......................................................................................... 63

Troubleshooting ................................................................................................. 63

Drive Motor Service .............................................................................................. 69

Motor Repair ...................................................................................................... 70

Disassembly .............................................................................................. 70

Inspection and Troubleshooting ......................................................................... 73

Drive End Head ......................................................................................... 73

Commutator End Head .............................................................................. 73

Bearings ..................................................................................................... 73

Brush and Commutator .............................................................................. 74

Armature .................................................................................................... 74

Frame and Field Assembly ........................................................................ 75

Assembly ................................................................................................... 77

Changing Brushes ............................................................................................. 78

Transmission ......................................................................................................... 79

System Description ............................................................................................ 79

Troubleshooting ................................................................................................. 79

Removal ............................................................................................................. 80

Installation .......................................................................................................... 81

Transmission Axle Seal ........................................................................................ 83

General Information ........................................................................................... 83

Removal ..................................................................................................... 83

Installation .................................................................................................. 83

Transmission Disassembly / Assembly .............................................................. 85

Disassembly ...................................................................................................... 86

Assembly ........................................................................................................... 86

Parking Brake System .......................................................................................... 89

Brake Theory of Operation ................................................................................ 90

Brake Adjustment .............................................................................................. 91

Brake Shoe Removal / Installation ..................................................................... 92

Brake Interlock Switch ....................................................................................... 93

Drive Wheel ............................................................................................................ 95

Removal ..................................................................................................... 95

Installation .................................................................................................. 96

Load Wheels .......................................................................................................... 97

Steering Control Arm ............................................................................................ 99

Control Handle Stem ........................................................................................ 100

Removal .................................................................................................... 100

Installation ................................................................................................. 101

Hand Brake Levers ........................................................................................... 102

Removal .................................................................................................... 102

Disassembly ............................................................................................. 102

Assembly .................................................................................................. 102

Installation ................................................................................................. 103

Steering Handle head .......................................................................................... 105

Control Handle Head ........................................................................................ 107

Removal .................................................................................................... 107

Installation ................................................................................................. 107

Direction Control Switches ................................................................................ 108

Horn Switch ...................................................................................................... 109

Potentiometer ................................................................................................... 111

300/400 Amp Contactor ....................................................................................... 113

Maintenance ..................................................................................................... 114

Removal/Replacement of Contact Tips .................................................... 114

“EE” Contactor ..................................................................................................... 117

Maintenance ..................................................................................................... 118

Removal/Replacement of Contact Tips .................................................... 118

Battery Controller / Hourmeter / Speed Dropout ............................................... 121

General Information .......................................................................................... 121

Electrical ........................................................................................................... 121

Voltage ...................................................................................................... 121

Battery Controller (BC) ..................................................................................... 122

General Information .................................................................................. 122

Reset ........................................................................................................ 124

Key Switch ................................................................................................ 124

Hourmeter ................................................................................................. 124

Troubleshooting ................................................................................................ 125

Battery Discharge Indicator (BDI) ............................................................. 125

Hourmeter ................................................................................................. 127

Battery Discharge Indicator / Hourmeter ........................................................... 129

General Information .......................................................................................... 129

Electrical ........................................................................................................... 129

Voltage ...................................................................................................... 129

Battery Discharge Indicator (BDI) ..................................................................... 130

General Information .................................................................................. 130

Key Switch ................................................................................................ 130

Hourmeter ................................................................................................. 130

Troubleshooting ................................................................................................ 131

Battery Discharge Indicator (BDI) ............................................................. 131

Hourmeter ................................................................................................. 132

24 Volt 400 Amp Electrical System ..................................................................... 135

Electrical Panel Components ............................................................................ 135

List of Symbols ................................................................................................. 136

Circuit Diagram 1(3) .................................................................................. 138

Circuit Diagram 2(3) .................................................................................. 139

Circuit Diagram 3(3) .................................................................................. 140

Description of Function ..................................................................................... 141

General Information .................................................................................. 141

References Information ............................................................................ 141

Key Switch S17 in the ON Position ........................................................... 141

The Operating Arm in Drive Position, S10, Brake Switch Closed ............. 141

Driving, Load Wheels Direction ................................................................ 142

Driving, Steer Wheel Direction .................................................................. 142

Reversing/Motor Brake Load Wheels Direction to Steer Wheel Direction 142

Reversing/Motor Brake Steer Wheel Direction to Load Wheels Direction 142

Horn .......................................................................................................... 142

24 Volt, 400 Amp Transistor Controller .............................................................. 143

Maintenance ..................................................................................................... 143

Safety ........................................................................................................ 143

Cleaning .................................................................................................... 143

Diagnostics and Troubleshooting ............................................................. 144

Basics Of Circuit Operation .............................................................................. 146

Control Features ....................................................................................... 148

Motor Circuit ..................................................................................................... 150

Control Circuit ................................................................................................... 150

Diagnostics and Troubleshooting ..................................................................... 153

1307 Programmer Diagnostics ................................................................. 153

Troubleshooting Chart .............................................................................. 154

Technical Specification ............................................................................. 158

Troubleshooting Chart Using the Handset ................................................ 159

24 Volt, 400 Amp Transistor Controller Troubleshooting ................................ 161

Troubleshooting Chart Index ............................................................................ 161

Troubleshooting Charts .................................................................................... 162

Handset Operation ............................................................................................... 171

Operating Modes .............................................................................................. 173

Revert to Previous Settings .............................................................................. 177

Handset Self Test ............................................................................................. 177

EXTRAS INCLUDED:

ELECTRICAL DIAGRAMS

OPERATOR’S MANUAL

MASTER PARTS MANUALS

PARTS MANUAL