Download Complete Service Repair Manual for BT Prime Mover RMX, HMX Electrical Tow Lift Pallet Truck.

This Factory Service Repair Manual offers all the service and repair information about BT Prime Mover RMX, HMX Electrical Tow Lift Pallet Truck. The information on this manual covered everything you need to know when you want to repair or service BT Prime Mover RMX, HMX Electrical Tow Lift Pallet Truck.

Models Covered:

RMX, HMX

Manuals Covered:

Service manuals
Parts manuals
Master Parts Manuals
Electrical Schematics
Operators manuals

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Service Manual 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 RMX and HMX. ………………………………………………………. 17
Intended Application of the Trucks ………………………………………………… 17
Forbidden Application of the Trucks ………………………………………………. 18
Truck Data …………………………………………………………………………………. 18
RMX Dimensions ………………………………………………………………………… 19
HMX Dimensions ………………………………………………………………………… 20
RMX Data plate ………………………………………………………………………….. 21
HMX Data plate ………………………………………………………………………….. 22
Main Components ………………………………………………………………………………. 23
Inch (SAE) and Metric Fasteners …………………………………………………………… 27
Introduction ……………………………………………………………………………………….. 27
Nomenclature, Threads ………………………………………………………………………. 28
Strength Identification …………………………………………………………………………. 29
Conversion of Metric and English Units …………………………………………………. 35
Technical Service Data ………………………………………………………………………….. 37
Ordering Spare Parts …………………………………………………………………………….. 41
Contents, Section P ………………………………………………………………………………. 43
Planned Maintenance …………………………………………………………………………. 43
Introduction, Maintenance …………………………………………………………………….. 45
Safe Jacking Procedure ………………………………………………………………………. 45
Service Schedule ………………………………………………………………………………….. 47
Planned Maintenance Schedule …………………………………………………………… 47
Planned Maintenance Procedures ………………………………………………………… 50
Services to be Performed Daily …………………………………………………….. 50
Services to be Performed Monthly …………………………………………………. 52
Services to be Performed Annually ……………………………………………….. 55
Lubrication Chart ………………………………………………………………………………….. 57
Oil and Grease Specifications ……………………………………………………………….. 59
Approved Oils and Grease ………………………………………………………………….. 59
Contents, Section S ………………………………………………………………………………. 61
Service Instructions ……………………………………………………………………………. 61
Lift Frame ……………………………………………………………………………………………… 63
Pull rod ……………………………………………………………………………………………… 64
Removal …………………………………………………………………………………….. 64
Inspection ………………………………………………………………………………….. 66
Installation ………………………………………………………………………………….. 67
Carrier Frame Bushings ………………………………………………………………………. 69
Inspection Covers …………………………………………………………………………………. 71
General Information ……………………………………………………………………………. 71
Drive Motor Mounting Points …………………………………………………………………. 73
Drive Motor Brush ………………………………………………………………………………. 74
Removal and Installation ……………………………………………………………… 74
Drive Motor Assembly …………………………………………………………………………. 74
Remove …………………………………………………………………………………….. 74
Installation ………………………………………………………………………………….. 75
Drive Motor …………………………………………………………………………………………… 77
General Information ……………………………………………………………………………. 77
Operating Conditions ………………………………………………………………………….. 77
Troubleshooting …………………………………………………………………………………. 77
Drive Motor Service ………………………………………………………………………………. 83
Motor Repair ……………………………………………………………………………………… 84
Disassembly ………………………………………………………………………………. 84
Inspection and Troubleshooting ……………………………………………………………. 87
Drive End Head ………………………………………………………………………….. 87
Commutator End Head ………………………………………………………………… 87
Bearings …………………………………………………………………………………….. 87
Brush and Commutator ………………………………………………………………… 88
Armature ……………………………………………………………………………………. 88
Frame and Field Assembly …………………………………………………………… 89
Assembly …………………………………………………………………………………… 91
Changing Brushes ……………………………………………………………………………… 92
Transmission ………………………………………………………………………………………… 93
System Description …………………………………………………………………………….. 93
Troubleshooting …………………………………………………………………………………. 93
Removal ……………………………………………………………………………………………. 95
Installation …………………………………………………………………………………………. 97
Transmission Axle Seal …………………………………………………………………………. 99
General Information ……………………………………………………………………………. 99
Removal …………………………………………………………………………………….. 99
Installation ………………………………………………………………………………….. 99
Transmission Disassembly / Assembly …………………………………………………. 101
Disassembly …………………………………………………………………………………….. 102
Assembly …………………………………………………………………………………………. 102
Parking Brake System ………………………………………………………………………….. 105
Brake Theory of Operation …………………………………………………………………. 106
Brake Adjustment ……………………………………………………………………………… 107
Brake Shoe Removal / Installation ……………………………………………………….. 108
Parking Brake Interlock Switch ……………………………………………………………. 109
Drive Wheel ………………………………………………………………………………………….. 111
Removal ……………………………………………………………………………………. 111
Installation …………………………………………………………………………………. 112
Load Wheels ………………………………………………………………………………………… 113
Support / Swivel Wheels ……………………………………………………………………….. 115
Stabilizing Caster ………………………………………………………………………………. 115
Removal ……………………………………………………………………………………. 116
Inspection …………………………………………………………………………………. 118
Installation …………………………………………………………………………………. 119
Maintenance ……………………………………………………………………………… 120
Stabilizing Caster …………………………………………………………………………………. 121
Stabilizing Caster ………………………………………………………………………………. 121
Disassembly ……………………………………………………………………………… 122
Inspection …………………………………………………………………………………. 123
Assembly ………………………………………………………………………………….. 124
Stabilizing Caster Spring Loaded ………………………………………………………….. 125
Removal …………………………………………………………………………………………… 126
Disassembly …………………………………………………………………………………….. 127
Inspection ………………………………………………………………………………………… 128
Assemble …………………………………………………………………………………………. 129
Installation ………………………………………………………………………………………… 129
Steering Arm / Handle ………………………………………………………………………….. 131
Control Handle Stem …………………………………………………………………………. 132
Removal ……………………………………………………………………………………. 132
Inspection …………………………………………………………………………………. 132
Installation …………………………………………………………………………………. 133
Steering Handle Head …………………………………………………………………………… 135
Control Handle Head …………………………………………………………………………. 137
Removal ……………………………………………………………………………………. 137
Installation …………………………………………………………………………………. 137
Direction Control Switches ………………………………………………………………….. 138
Horn, Raise, and Lower Switches ………………………………………………………… 139
Potentiometer …………………………………………………………………………………… 141
300/400 Amp Contactor ………………………………………………………………………… 143
Maintenance …………………………………………………………………………………….. 144
Removal/Replacement of Contact Tips …………………………………………. 144
“EE” Contactor …………………………………………………………………………………….. 147
Maintenance …………………………………………………………………………………….. 148
Removal/Replacement of Contact Tips …………………………………………. 148
Battery Controller / Hourmeter / Lift Interrupt ………………………………………… 151
General Information …………………………………………………………………………… 151
Electrical ………………………………………………………………………………………….. 151
Voltage ……………………………………………………………………………………… 151
Battery Controller (BC) ………………………………………………………………………. 152
General Information ……………………………………………………………………. 152
Reset ……………………………………………………………………………………….. 154
Key Switch ………………………………………………………………………………… 154
Hourmeter …………………………………………………………………………………. 155
Troubleshooting ………………………………………………………………………………… 155
Battery Discharge Indicator (BDI) …………………………………………………. 155
Hourmeter …………………………………………………………………………………. 157
Battery Discharge Indicator / Hourmeter ……………………………………………….. 159
General Information …………………………………………………………………………… 159
Electrical ………………………………………………………………………………………….. 159
Voltage ……………………………………………………………………………………… 159
Battery Discharge Indicator (BDI) ………………………………………………………… 160
General Information ……………………………………………………………………. 160
Key Switch ………………………………………………………………………………… 160
Hourmeter …………………………………………………………………………………. 160
Troubleshooting ………………………………………………………………………………… 161
Battery Discharge Indicator (BDI) …………………………………………………. 161
Hourmeter …………………………………………………………………………………. 162
12 Volt Electrical System ………………………………………………………………………. 165
Electrical Panel Components ………………………………………………………………. 165
RMX Circuit Diagram ………………………………………………………………….. 166
Electrical Schematic Symbols ………………………………………………………. 167
Direction Contactor ………………………………………………………………………………. 169
General Information …………………………………………………………………………… 170
Remove / replace contact tips …………………………………………………………….. 170
12 Volt Transistor Controller …………………………………………………………………. 175
Maintenance …………………………………………………………………………………….. 175
Safety ……………………………………………………………………………………….. 175
Cleaning ……………………………………………………………………………………. 175
Troubleshooting …………………………………………………………………………. 176
Basics Of Circuit Operation ………………………………………………………………… 178
Battery connected and emergency disconnect switch in “RUN” position. 178
Key switch turned “ON” ……………………………………………………………….. 178
Control handle pulled down; brakes released and brake interlock switch
closed. ……………………………………………………………………………………… 179
Reverse travel (fork direction) switch is closed. ………………………………. 179
Forward travel (control handle direction) switch is closed. ……………….. 180
Curtis® PMC controller power circuits. …………………………………………… 180
Accelerator Potentiometer Circuits ……………………………………………….. 181
Emergency Reverser Switch ……………………………………………………….. 182
Lift Pallet Forks ………………………………………………………………………….. 182
Lower pallet forks ……………………………………………………………………….. 183
Controller Adjustments ……………………………………………………………….. 184
12 Volt Transistor Controller Troubleshooting ………………………………………. 185
Troubleshooting Chart Index ………………………………………………………………. 185
Troubleshooting Charts ……………………………………………………………………… 186
24 Volt 300 Amp Electrical System ………………………………………………………… 203
Electrical Panel Components ………………………………………………………………. 203
List of Symbols …………………………………………………………………………………. 204
RMX Circuit Diagram 1(3) ……………………………………………………………. 206
RMX Circuit Diagram 2(3) ……………………………………………………………. 207
RMX Circuit Diagram 3(3) ……………………………………………………………. 208
Description of Function ………………………………………………………………………. 209
General Information ……………………………………………………………………. 209
References Information ………………………………………………………………. 209
Key Switch S17 in the ON Position ……………………………………………….. 209
The Operating Arm in Drive Position, S10, Brake Switch Closed ………. 209
Driving, Fork Direction ………………………………………………………………… 209
Driving, Steer Wheel Direction ……………………………………………………… 210
Reversing/Motor Brake Fork Direction to Steer Wheel Direction ……….. 210
Reversing/Motor Brake Steer Wheel Direction to Fork Direction ……….. 210
Reverser switch …………………………………………………………………………. 210
Lifting the Forks …………………………………………………………………………. 211
Lowering the Forks …………………………………………………………………….. 211
Horn …………………………………………………………………………………………. 211
Lift Interrupt ……………………………………………………………………………….. 211
24 Volt, 300 Amp Transistor Controller ………………………………………………….. 213
Maintenance …………………………………………………………………………………….. 213
Safety ……………………………………………………………………………………….. 213
Cleaning ……………………………………………………………………………………. 213
Diagnostics and Troubleshooting …………………………………………………. 214
Basics Of Circuit Operation ………………………………………………………………… 216
Control Features ………………………………………………………………………… 218
Motor Circuit …………………………………………………………………………………….. 220
Control Circuit …………………………………………………………………………………… 220
Diagnostics and Troubleshooting ………………………………………………………… 222
1307 Programmer Diagnostics …………………………………………………….. 222
Troubleshooting Chart ………………………………………………………………… 223
Technical Specification ……………………………………………………………….. 227
Troubleshooting Chart Using the Handset ……………………………………… 228
24 Volt, 300 Amp Transistor Controller Troubleshooting ……………………….. 231
Troubleshooting Chart Index ………………………………………………………………. 231
Troubleshooting Charts ……………………………………………………………………… 232
24 Volt 400 Amp Electrical System ………………………………………………………… 243
Electrical Panel Components ………………………………………………………………. 243
List of Symbols …………………………………………………………………………………. 244
HMX Circuit Diagram 1(3) ……………………………………………………………. 246
HMX Circuit Diagram 2(3) ……………………………………………………………. 247
HMX Circuit Diagram 3(3) ……………………………………………………………. 248
Description of Function ………………………………………………………………………. 249
General Information ……………………………………………………………………. 249
References Information ………………………………………………………………. 249
Key Switch S17 in the ON Position ……………………………………………….. 249
The Operating Arm in Drive Position, S10, Brake Switch Closed ………. 249
Driving, Fork Direction ………………………………………………………………… 249
Driving, Steer Wheel Direction ……………………………………………………… 250
Reversing/Motor Brake Fork Direction to Steer Wheel Direction ……….. 250
Reversing/Motor Brake Steer Wheel Direction to Fork Direction ……….. 250
Reverser switch …………………………………………………………………………. 250
Lifting the Forks …………………………………………………………………………. 251
Lowering the Forks …………………………………………………………………….. 251
Horn …………………………………………………………………………………………. 251
High Speed Switch …………………………………………………………………….. 251
Lift Interrupt ……………………………………………………………………………….. 252
24 Volt, 400 Amp Transistor Controller ………………………………………………….. 253
Maintenance …………………………………………………………………………………….. 253
Safety ……………………………………………………………………………………….. 253
Cleaning ……………………………………………………………………………………. 253
Diagnostics and Troubleshooting …………………………………………………. 254
Basics Of Circuit Operation ………………………………………………………………… 256
Control Features ………………………………………………………………………… 258
Motor Circuit …………………………………………………………………………………….. 260
Control Circuit …………………………………………………………………………………… 260
Diagnostics and Troubleshooting ………………………………………………………… 263
1307 Programmer Diagnostics …………………………………………………….. 263
Troubleshooting Chart ………………………………………………………………… 264
Technical Specification ……………………………………………………………….. 268
Troubleshooting Chart Using the Handset ……………………………………… 269
24 Volt, 400 Amp Transistor Controller Troubleshooting ……………………….. 271
Troubleshooting Chart Index ………………………………………………………………. 271
Troubleshooting Charts ……………………………………………………………………… 272
Handset Operation ……………………………………………………………………………….. 285
Operating Modes ………………………………………………………………………………. 287
Revert to Previous Settings ………………………………………………………………… 291
Handset Self Test ……………………………………………………………………………… 291
Pump Motor ………………………………………………………………………………………… 293
Component Repair …………………………………………………………………………….. 294
Motor Disassembly …………………………………………………………………….. 294
Inspection and Troubleshooting …………………………………………………………… 296
Drive End Head …………………………………………………………………………. 296
Commutator End Head ……………………………………………………………….. 296
Bearings ……………………………………………………………………………………. 296
Brush and Commutator ……………………………………………………………….. 297
Armature …………………………………………………………………………………… 297
Frame and Field Assembly ………………………………………………………….. 298
Assembly ………………………………………………………………………………….. 300
Changing Brushes …………………………………………………………………………….. 301
Hydraulic System …………………………………………………………………………………. 303
Hydraulic Schematic ………………………………………………………………………….. 303
General Information …………………………………………………………………………… 303
Description ……………………………………………………………………………………….. 304
Lift ……………………………………………………………………………………………. 304
Lower ……………………………………………………………………………………….. 304
Relief Pressure ………………………………………………………………………….. 304
Maintenance …………………………………………………………………………………….. 305
Adjustments ……………………………………………………………………………………… 305
Lift Limit Switch …………………………………………………………………………………. 305
Troubleshooting ………………………………………………………………………………… 307
Lift Pump Assembly ……………………………………………………………………………… 309
Removal …………………………………………………………………………………………… 311
Disassembly …………………………………………………………………………………….. 312
Inspection ………………………………………………………………………………………… 313
Assembly …………………………………………………………………………………………. 314
Installation ………………………………………………………………………………………… 316
Adjustments ……………………………………………………………………………………… 318
Relief valve ……………………………………………………………………………….. 318
Solenoid Operated Valve …………………………………………………………….. 319
Lift Cylinder ………………………………………………………………………………………… 321
Removal …………………………………………………………………………………………… 322
Disassembly …………………………………………………………………………………….. 323
Inspection ………………………………………………………………………………………… 324
Assembly …………………………………………………………………………………………. 325
Installation ………………………………………………………………………………………… 326

Other manuals all cover full contents.

This manual can be used by anyone from a first time owner/amateur to a professional technician.Even the most novice mechanic can also easily follow the step-by-step guides which are made simple by the illustrations and drawings.Keep this manual handy and use it often. Performing routine, preventive maintenance will save you time & money by helping to prevent premature failure and unnecessary repairs.

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