BT RMX HMX ELECTRIC LOW LIFT PALLET TRUCK SERVICE, PARTS, OPERATOR, SCHEMATICS MANUAL

BT RMX HMX ELECTRIC LOW LIFT PALLET TRUCK SERVICE, PARTS, OPERATOR, SCHEMATICS MANUAL
LANGUAGE: ENGLISH
FORMAT: PDF
PAGES: 4,125
FILE SIZE: 127MB

MODEL COVERED:

BT RMX HMX ELECTRIC LOW LIFT PALLET TRUCK

ISSUED:

PART NO: 302065-000 - JANUARY, 1995 - SERIAL: 241341

PART NO: 302065-000 - MARCH, 1998 - SERIAL: _MX__27091001

PART NO: 313701-000 - DECEMBER, 2006 - SERIAL: _MX_27328000-UP
 

CONTENTS:

BT Standard Codes 3

Warning Symbols 13

1 Warning Levels 13

Prohibitory Symbols 14

1 Ordinance Symbols 14

Introduction, Service Manual 15

Contents, Section M 17

1 Machine Information 17

General Product Information 19

1 Presentation of the RMX and HMX 19

1 1 Intended Application of the Trucks 19

1 2 Forbidden Application of the Trucks 20

1 3 Truck Data 20

1 4 RMX Dimensions 21

1 5 HMX Dimensions 22

1 6 RMX Data plate 23

1 7 HMX Data plate 24

2 Main Components 25

Inch (SAE) and Metric Fasteners 29

1 Introduction 29

2 Nomenclature, Threads 30

3 Strength Identification 31

4 Conversion of Metric and English Units 37

Technical Service Data 39

Ordering Spare Parts 43

Contents, Section P 45

1 Planned Maintenance 45

Introduction, Maintenance 47

1 Safe Jacking Procedure 47

Service Schedule 49

1 Planned Maintenance Schedule 49

2 Planned Maintenance Procedures 52

2 1 Services to be Performed Daily 52

2 1 1 Battery Discharge Indicator with slow down 52

2 1 2 Hydraulic System 52

2 1 3 Frame/Sheet Metal 53

2 1 4 Wheels/Tires 53

2 1 5 Functions/Operations 53

2 2 Services to be Performed Monthly 54

2 2 1 Inspection 54

2 2 2 Transmission 54

2 2 3 Brakes 54

2 2 4 Battery 54

2 2 5 Electrical Connections 54

2 2 6 Contactor Tips (NOT Sealed) 55

2 2 7 Motor Brushes 55

2 2 8 Drive Motor 55

2 2 9 Hydraulic Reservoir 55

2 2 10 Frame Lube (“Lubrication Chart” on page 57) 55

2 2 11 Pivot Points 56

2 3 Services to be Performed Annually 57

2 3 1 Inspection 57

2 3 2 Transmission 57

2 3 3 Battery 57

2 3 4 Hydraulic System 57

2 3 5 Brakes 58

Lubrication Chart 59

Oil and Grease Specifications 61

1 Approved Oils and Grease 61

Contents, Section S 63

1 Service Instructions 63

Lift Frame 65

1 Pull rod 66

1 1 Removal 66

1 2 Inspection 68

1 3 Installation 69

2 Carrier Frame Bushings 71

Inspection Covers 73

1 General Information 73

Drive Motor Mounting Points 75

1 Drive Motor Brush 76

1 1 Removal and Installation 76

2 Drive Motor Assembly 76

2 1 Remove 76

2 2 Installation 77

Drive Motor 79

1 General Information 79

2 Operating Conditions 79

3 Troubleshooting 79

Drive Motor Service 85

1 Motor Repair 86

1 1 Disassembly 86

2 Inspection and Troubleshooting 89

2 1 Drive End Head 89

2 2 Commutator End Head 89

2 3 Bearings 89

2 4 Brush and Commutator 90

2 5 Armature 90

2 6 Frame and Field Assembly 91

2 6 1 Testing 91

2 6 2 Frame and Field Service Notes 92

2 7 Assembly 93

2 7 1 Field Coil Installation 93

2 7 2 Bearing Installation 93

2 7 3 After Assembly 94

3 Changing Brushes 94

Transmission 95

1 System Description 95

2 Troubleshooting 95

3 Removal 97

4 Installation 99

Transmission Axle Seal 101

1 General Information 101

1 1 Removal 101

1 2 Installation 101

Transmission Disassembly / Assembly 103

1 Disassembly 104

2 Assembly 104

Parking Brake System 107

1 Brake Theory of Operation 108

2 Brake Adjustment 109

3 Brake Shoe Removal / Installation 110

4 Parking Brake Interlock Switch 111

Drive Wheel 113

4 1 Removal 113

4 2 Installation 114

Load Wheels 115

Support / Swivel Wheels 117

1 Stabilizing Caster 117

1 1 Removal 118

1 2 Inspection 120

1 3 Installation 121

1 4 Maintenance 122

Stabilizing Caster 123

1 Stabilizing Caster 123

1 1 Disassembly 124

1 2 Inspection 125

1 3 Assembly 126

Stabilizing Caster Spring Loaded 127

1 Removal 128

2 Disassembly 129

3 Inspection 130

4 Assemble 131

5 Installation 131

Steering Arm / Handle 133

1 Control Handle Stem 134

1 1 Removal 134

1 2 Inspection 134

1 3 Installation 135

Steering Handle Head 137

1 Control Handle Head 139

1 1 Removal 139

1 2 Installation 139

2 Direction Control Switches 140

3 Horn, Raise, and Lower Switches 141

4 Potentiometer 143

300/400 Amp Contactor 145

1 Maintenance 146

1 1 Removal/Replacement of Contact Tips 146

“EE” Contactor 149

1 Maintenance 150

1 1 Removal/Replacement of Contact Tips 150

Battery Controller / Hourmeter / Lift Interrupt 153

1 General Information 153

2 Electrical 153

2 1 Voltage 153

2 1 1 The Contact Voltage and Current Ratings for Switching Resistive Loads 154

2 1 2 Memory Retention 154

3 Battery Controller (BC) 154

3 1 General Information 154

3 1 1 Discharge Adjustment 154

3 2 Reset 156

3 3 Key Switch 156

3 4 Hourmeter 157

4 Troubleshooting 157

4 1 Battery Discharge Indicator (BDI) 157

4 1 1 No Reset 157

4 1 2 Reset After Break in Power 157

4 1 3 No Discharge, Gauge Does Not Run Down 158

4 1 4 No Lockout 158

4 1 5 No Lift 158

4 1 6 Early Lockout 159

4 1 7 LEDs Do Not Light 159

4 2 Hourmeter 159

4 2 1 No Display 159

4 2 2 Hourmeter Glass Icon Does Not Flash 159

4 2 3 Hourmeter Glass Icon Always Flashes 160

Battery Discharge Indicator / Hourmeter 161

1 General Information 161

2 Electrical 161

2 1 Voltage 161

3 Battery Discharge Indicator (BDI) 162

3 1 General Information 162

3 2 Key Switch 162

3 3 Hourmeter 162

4 Troubleshooting 163

4 1 Battery Discharge Indicator (BDI) 163

4 1 1 No Reset 163

4 1 2 Reset After Break in Power 163

4 1 3 No Discharge, Gauge Does Not Run Down 164

4 1 4 LEDs Do Not Light 164

4 2 Hourmeter 164

4 2 1 No Display 164

4 2 2 Hourmeter Glass Icon Does Not Flash 164

4 2 3 Hourmeter Glass Icon Always Flashes 165

12 Volt Electrical System 167

1 Electrical Panel Components 167

1 1 RMX Circuit Diagram 168

1 2 Electrical Schematic Symbols 169

Direction Contactor 171

1 General Information 172

2 Remove / replace contact tips 172

12 Volt Transistor Controller 177

1 Maintenance 177

1 1 Safety 177

1 2 Cleaning 177

1 3 Troubleshooting 178

2 Basics Of Circuit Operation 180

2 1 Battery connected and emergency disconnect switch in “RUN” position 180

2 2 Key switch turned “ON” 180

2 3 Control handle pulled down; brakes released and brake interlock switch closed 181

2 4 Reverse travel (fork direction) switch is closed 181

2 5 Forward travel (control handle direction) switch is closed 182

2 6 Curtis® PMC controller power circuits 182

2 7 Accelerator Potentiometer Circuits 183

2 8 Emergency Reverser Switch 184

2 9 Lift Pallet Forks 184

2 10 Lower pallet forks 185

2 11 Controller Adjustments 186

12 Volt Transistor Controller Troubleshooting 187

1 Troubleshooting Chart Index 187

2 Troubleshooting Charts 188

24 Volt 300 Amp Electrical System 205

1 Electrical Panel Components 205

2 List of Symbols 206

2 1 RMX Circuit Diagram 1(3) 208

2 2 RMX Circuit Diagram 2(3) 209

2 3 RMX Circuit Diagram 3(3) 210

3 Description of Function 211

3 1 General Information 211

3 2 References Information 211

3 3 Key Switch S17 in the ON Position 211

3 4 The Operating Arm in Drive Position, S10, Brake Switch Closed 211

3 5 Driving, Fork Direction 211

3 6 Driving, Steer Wheel Direction 212

3 7 Reversing/Motor Brake Fork Direction to Steer Wheel Direction 212

3 8 Reversing/Motor Brake Steer Wheel Direction to Fork Direction 212

3 9 Reverser switch 212

3 10 Lifting the Forks 213

3 11 Lowering the Forks 213

3 12 Horn 213

3 13 Lift Interrupt 213

24 Volt, 300 Amp Transistor Controller 215

1 Maintenance 215

1 1 Safety 215

1 2 Cleaning 215

1 3 Diagnostics and Troubleshooting 216

1 3 1 Handset Diagnostics 216

1 3 2 Troubleshooting 216

2 Basics Of Circuit Operation 218

2 1 Control Features 220

3 Motor Circuit 222

4 Control Circuit 222

5 Diagnostics and Troubleshooting 224

5 1 1307 Programmer Diagnostics 224

5 2 Troubleshooting Chart 225

5 3 Technical Specification 229

5 4 Troubleshooting Chart Using the Handset 230

24 Volt, 300 Amp Transistor Controller Troubleshooting 233

1 Troubleshooting Chart Index 233

2 Troubleshooting Charts 234

24 Volt 400 Amp Electrical System 245

1 Electrical Panel Components 245

2 List of Symbols 246

2 1 HMX Circuit Diagram 1(3) 248

2 2 HMX Circuit Diagram 2(3) 249

2 3 HMX Circuit Diagram 3(3) 250

3 Description of Function 251

3 1 General Information 251

3 2 References Information 251

3 3 Key Switch S17 in the ON Position 251

3 4 The Operating Arm in Drive Position, S10, Brake Switch Closed 251

3 5 Driving, Fork Direction 251

3 6 Driving, Steer Wheel Direction 252

3 7 Reversing/Motor Brake Fork Direction to Steer Wheel Direction 252

3 8 Reversing/Motor Brake Steer Wheel Direction to Fork Direction 252

3 9 Reverser switch 252

3 10 Lifting the Forks 253

3 11 Lowering the Forks 253

3 12 Horn 253

3 13 High Speed Switch 253

3 14 Lift Interrupt 254

24 Volt, 400 Amp Transistor Controller 255

1 Maintenance 255

1 1 Safety 255

1 2 Cleaning 255

1 3 Diagnostics and Troubleshooting 256

1 3 1 Handset Diagnostics 256

1 3 2 Troubleshooting 256

2 Basics Of Circuit Operation 258

2 1 Control Features 260

3 Motor Circuit 262

4 Control Circuit 262

5 Diagnostics and Troubleshooting 265

5 1 1307 Programmer Diagnostics 265

5 2 Troubleshooting Chart 266

5 3 Technical Specification 270

5 4 Troubleshooting Chart Using the Handset 271

24 Volt, 400 Amp Transistor Controller Troubleshooting 273

1 Troubleshooting Chart Index 273

2 Troubleshooting Charts 274

Handset Operation 287

1 Operating Modes 289

2 Revert to Previous Settings 293

3 Handset Self Test 293

Pump Motor 295

1 Component Repair 296

1 1 Motor Disassembly 296

2 Inspection and Troubleshooting 298

2 1 Drive End Head 298

2 2 Commutator End Head 298

2 3 Bearings 298

2 4 Brush and Commutator 299

2 5 Armature 299

2 6 Frame and Field Assembly 300

2 6 1 Testing 300

2 6 2 Frame and Field Service Notes 301

2 7 Assembly 302

2 7 1 Field Coil Installation 302

2 7 2 Bearing Installation 302

2 7 3 After Assembly 303

3 Changing Brushes 303

Hydraulic System 305

1 Hydraulic Schematic 305

2 General Information 305

3 Description 306

3 1 Lift 306

3 2 Lower 306

3 3 Relief Pressure 306

4 Maintenance 307

5 Adjustments 307

6 Lift Limit Switch 307

7 Troubleshooting 309

Lift Pump Assembly 311

1 Removal 313

2 Disassembly 314

3 Inspection 315

4 Assembly 316

5 Installation 318

6 Adjustments 320

6 1 Relief valve 320

6 2 Solenoid Operated Valve 321

Lift Cylinder 323

1 Removal 324

2 Disassembly 325

3 Inspection 326

4 Assembly 327

5 Installation 328

OPERATOR’S MANUAL:

302063-000 1994_FEBRUARY

302063-001 1994_JULY

302063-002 1995_MAY

302063-002 1997_APRIL

302063-002 1997_OCTOBER

302063-002 1998_JUNE

302063-002 1998_OCTOBER
 

PARTS MANUAL:

302064-000 1994_FEBRUARY

302064-001 1994_APRIL

302064-002 1994_SEPTEMBER

302064-003 1994_NOVEMBER

302064-004 1995_JANUARY

302064-005 1995_JUNE

302064-006 1995_SEPTEMBER

302064-007 1995_DECEMBER

302064-008 1996_DECEMBER

302064-008 1997_MAY

302064-008 1997_DECEMBER

302064-008 1998_SEPTEMBER

302064-008 1999_OCTOBER

302064-009 2001_AUGUST

302064-010 2002_FEBRUARY
 

MASTER PARTS MANUAL:

308493-000 1998_NOVEMBER

308493-000 1999_OCTOBER

308493-000 2001_AUGUST

308493-000 2002_FEBRUARY
 

ELECTRICAL SCHEMATICS:

RMX-50 - 12 VOLT

308587-000 1998_AUGUST
 

RMX - 24 VOLT

308588-000 1998_AUGUST

308588-001 2002_AUGUST
 

HMX - 24 VOLT

308589-000 A998_AUGUST

308589-000 2000_JUNE

308589-000 2000_NOVEMBER

308589-002 2001_MAY

308589-003 2002_JUNE

308589-004 2002_AUGUST