BT Prime Mover PMX45 Electrical Tow Lift Pallet Truck Service Repair Manual

Download Complete Service Repair Manual for BT Prime Mover PMX45 Electrical Tow Lift Pallet Truck.

This Factory Service Repair Manual offers all the service and repair information about BT Prime Mover PMX45 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 PMX45 Electrical Tow Lift Pallet Truck.

Models Covered:

PMX45

Manuals Covered:

Service manuals
Parts manuals
Master Parts Manuals
Electrical Schematics
Operators manuals

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Service Manual Contents:

Standard Codes ………………………………………………………………………………… 1
Warning Symbols …………………………………………………………………………….. 11
Warning Levels …………………………………………………………………………….. 11
Prohibitory Symbols ………………………………………………………………………… 12
Ordinance Symbols ………………………………………………………………………. 12
Safety ……………………………………………………………………………………………… 13
General Safety ……………………………………………………………………………… 13
Battery Safety ………………………………………………………………………………….. 17
Static Safety …………………………………………………………………………………….. 22
Welding Safety ………………………………………………………………………………… 23
Introduction, Service Manual ……………………………………………………………. 25
Contents, Section M …………………………………………………………………………. 27
Machine Information ……………………………………………………………………… 27
General Product Information ……………………………………………………………. 29
Truck Presentation. ……………………………………………………………………….. 29
Truck Side Views ……………………………………………………………………….. 29
Intended Truck Application ………………………………………………………….. 30
Prohibited Truck Application ………………………………………………………… 30
Truck Data ………………………………………………………………………………… 30
Truck Dimensions ………………………………………………………………………. 31
Data Plate …………………………………………………………………………………. 32
Main Components …………………………………………………………………………. 33
Inch and Metric (SAE) Fasteners ……………………………………………………… 35
Introduction ………………………………………………………………………………….. 35
Nomenclature, Threads …………………………………………………………………. 36
Strength Identification ……………………………………………………………………. 37
Conversion of English and Metric Units ……………………………………………. 44
Technical Service Data …………………………………………………………………….. 47
Ordering Spare Parts ……………………………………………………………………….. 49
Contents, Section P …………………………………………………………………………. 51
Planned Maintenance ……………………………………………………………………. 51
Introduction, Maintenance ……………………………………………………………….. 53
Jacking Truck Off The Floor …………………………………………………………… 54
Elevate Rear of Truck …………………………………………………………………. 54
Elevate Either Side of Truck ………………………………………………………… 54
Lubricants ……………………………………………………………………………………. 55
Standard …………………………………………………………………………………… 55
Corrosion ………………………………………………………………………………….. 55
Cold Storage ……………………………………………………………………………… 56
Service Schedule …………………………………………………………………………….. 59
Planned Maintenance Schedule ……………………………………………………… 59
Planned Maintenance Procedures …………………………………………………… 63
Services Performed Daily or Every 8 Operating Hours …………………….. 63
Battery Discharge Indicator with lift interrupt (optional) ………….. 63
Hydraulic System …………………………………………………………….. 63
Frame/Sheet Metal …………………………………………………………… 64
Wheels/Tires …………………………………………………………………… 64
Functions/Operations ……………………………………………………….. 64
Services Performed Monthly or Every 120 Operating Hours …………….. 65
Inspection ……………………………………………………………………….. 65
Transmission …………………………………………………………………… 65
Brakes ……………………………………………………………………………. 65
Battery ……………………………………………………………………………. 65
Electrical Connections ………………………………………………………. 66
Main Contactor ………………………………………………………………… 66
Motor Brushes …………………………………………………………………. 66
Drive Motor ……………………………………………………………………… 66
Hydraulic Reservoir ………………………………………………………….. 66
Frame Lube …………………………………………………………………….. 67
Pivot Points …………………………………………………………………….. 67
Services Performed Every 480 or 960 Operating Hours …………………… 68
Drive Motor ……………………………………………………………………… 68
Services Performed Annually or Every 1440 Operating Hours ………….. 69
Inspection ……………………………………………………………………….. 69
Transmission …………………………………………………………………… 69
Battery ……………………………………………………………………………. 69
Hydraulic System …………………………………………………………….. 70
Brakes ……………………………………………………………………………. 70
Lubrication Chart …………………………………………………………………………….. 71
Oil and Grease Specifications ………………………………………………………….. 72
Approved Oils and Grease …………………………………………………………….. 72
Grease Location Points …………………………………………………………………. 72
Contents, Section S …………………………………………………………………………. 73
Service Instructions ………………………………………………………………………. 73
Chassis/Lift Frame …………………………………………………………………………… 75
Pull rod ………………………………………………………………………………………… 76
Removal ……………………………………………………………………………………. 76
Inspection ………………………………………………………………………………….. 77
Installation …………………………………………………………………………………. 78
Carrier Frame Bushings …………………………………………………………………. 80
Inspection Covers ……………………………………………………………………………. 81
General Information ………………………………………………………………………. 81
Driver Controls ………………………………………………………………………………… 85
Decals ……………………………………………………………………………………………… 87
Decal with Protective Sheet ……………………………………………………………. 87
Decal without Protective Sheet ……………………………………………………….. 87
Motor Maintenance Schedule/Troubleshooting …………………………………. 89
General Information ………………………………………………………………………. 89
Operating Conditions …………………………………………………………………….. 89
Troubleshooting ……………………………………………………………………………. 90
Pump Motor …………………………………………………………………………………….. 97
Mounting Points ……………………………………………………………………………. 97
Removal ……………………………………………………………………………………. 97
Installation …………………………………………………………………………………. 97
Pump Repair ………………………………………………………………………………… 98
Disassembly ………………………………………………………………………………. 99
Inspection and Troubleshooting ……………………………………………………… 100
Drive End Head …………………………………………………………………………. 100
Commutator End Head ………………………………………………………………. 100
Bearings …………………………………………………………………………………… 100
Brush Inspection ………………………………………………………………………….. 101
Brush Replacement Determination ………………………………………………. 101
Replacement Procedures …………………………………………………………… 102
Drive Motor …………………………………………………………………………………….. 105
Mounting Points …………………………………………………………………………… 105
Drive Motor Brush ……………………………………………………………………… 106
Drive Motor Removal …………………………………………………………………. 106
Drive Motor Installation ………………………………………………………………. 108
Component Repair ………………………………………………………………………. 110
Motor Disassembly ……………………………………………………………………. 112
Motor Inspection …………………………………………………………………………. 113
External Motor …………………………………………………………………………… 113
Brush and Commutator ………………………………………………………………. 113
Bearings …………………………………………………………………………………… 116
Armature Electrical Check ………………………………………………………….. 116
Frame and Field Service Recommendation …………………………………… 116
Assembly/Testing ………………………………………………………………………. 117
Transmission ………………………………………………………………………………….. 119
System Description ………………………………………………………………………. 119
Troubleshooting …………………………………………………………………………… 119
Transmission Mounting …………………………………………………………………. 120
Wrap Around Bumper ………………………………………………………………… 121
Guards …………………………………………………………………………………….. 122
Removal …………………………………………………………………………………… 123
Installation ………………………………………………………………………………… 124
Transmission Repair …………………………………………………………………….. 125
Disassembly ……………………………………………………………………………… 126
Reassembly ……………………………………………………………………………… 127
Axle Seal …………………………………………………………………………………….. 129
Removal …………………………………………………………………………………… 129
Installation ………………………………………………………………………………… 129
Parking Brake System …………………………………………………………………….. 131
Brake Theory of Operation ……………………………………………………………. 132
Brake Adjustment ………………………………………………………………………… 133
Brake Shoe Removal / Installation ………………………………………………….. 134
Drive Wheel …………………………………………………………………………………….. 135
Removal ……………………………………………………………………………………… 135
Installation …………………………………………………………………………………… 136
Tire Pressing Procedure ……………………………………………………………….. 137
Support/Swivel Wheel (Optional) ……………………………………………………… 139
Maintenance and Adjustments ………………………………………………………. 141
Caster Adjustment …………………………………………………………………….. 141
Troubleshooting …………………………………………………………………………… 141
Stabilizing Caster ………………………………………………………………………. 141
Caster Replacement ……………………………………………………….. 141
Fork Wheels ……………………………………………………………………………………. 143
Removal/Installation …………………………………………………………………….. 143
Steering ………………………………………………………………………………………….. 145
Control Handle Head ……………………………………………………………………. 146
Removal …………………………………………………………………………………… 146
Installation ………………………………………………………………………………… 146
Driver Protection (Reverser) Assembly Replacement ……………………….. 147
Direction Control Switches …………………………………………………………….. 149
Removal …………………………………………………………………………………… 149
Installation ………………………………………………………………………………… 149
Raise, Lower, and Horn Switches …………………………………………………… 151
Removal …………………………………………………………………………………… 151
Installation ………………………………………………………………………………… 152
Potentiometer ……………………………………………………………………………… 153
Removal …………………………………………………………………………………… 153
Installation ………………………………………………………………………………… 154
Steering Stem ……………………………………………………………………………… 158
Removal …………………………………………………………………………………… 158
Installation ………………………………………………………………………………… 158
Electrical Functions ………………………………………………………………………… 159
General ………………………………………………………………………………………. 159
Adjustable Settings: …………………………………………………………………… 159
References ……………………………………………………………………………….. 159
Key Switch S17 in the ON Position ………………………………………………. 159
Operating Arm in Drive Position, S10, Brake Switch Closed ……………. 160
Travel Request, Fork First ………………………………………………………….. 160
Travel Request, Forks Trailing …………………………………………………….. 160
Reversing/Motor Brake Forks First Direction to Forks Trailing Direction 160
Reversing/Motor Brake Forks Trailing Direction to Forks First Direction 161
Reverser switch ………………………………………………………………………… 161
Lifting Forks ……………………………………………………………………………… 161
Lowering Forks …………………………………………………………………………. 161
Horn ………………………………………………………………………………………… 162
Lift Interrupt ………………………………………………………………………………. 162
Electrical Symbols ………………………………………………………………………….. 165
Electrical Schematics ……………………………………………………………………… 169
Battery ……………………………………………………………………………………………. 173
Removal ……………………………………………………………………………………… 173
Installation …………………………………………………………………………………… 173
Battery Maintenance …………………………………………………………………….. 174
Battery Inspection and Care ……………………………………………………….. 174
Battery Exterior Cleaning ……………………………………………………………. 175
Charging ………………………………………………………………………………….. 175
Storage ………………………………………………………………………………………. 176
Battery History Record ………………………………………………………………….. 176
Swing Out Battery Pack …………………………………………………………………… 177
Battery Cable Routing Diagram ……………………………………………………… 179
Charger Diagram …………………………………………………………………………. 181
Troubleshooting …………………………………………………………………………… 182
Electrical Testing ……………………………………………………………………….. 182
Equipment required: ………………………………………………………… 182
Instructions …………………………………………………………………….. 182
Battery Connector …………………………………………………………………………… 189
Location ……………………………………………………………………………………… 189
Inspection …………………………………………………………………………………… 189
Installation …………………………………………………………………………………… 190
Battery Controller/Hourmeter/ Lift Interrupt (Optional) ……………………… 191
General Information ……………………………………………………………………… 191
Electrical …………………………………………………………………………………….. 192
Voltage …………………………………………………………………………………….. 192
Battery Controller (BC) …………………………………………………………………. 193
General Information …………………………………………………………………… 193
Discharge Adjustment ……………………………………………………… 193
Reset ……………………………………………………………………………………….. 195
Key Switch ……………………………………………………………………………….. 195
Hourmeter ………………………………………………………………………………… 196
Troubleshooting …………………………………………………………………………… 196
Battery Discharge Indicator (BDI) ………………………………………………… 196
No Reset ……………………………………………………………………….. 196
Reset After Break in Power ………………………………………………. 196
No Discharge, Gauge Does Not Run Down ………………………… 197
No Lockout …………………………………………………………………….. 197
No Lift ……………………………………………………………………………. 198
Early Lockout …………………………………………………………………. 198
LEDs Do Not Light ………………………………………………………….. 198
Hourmeter ………………………………………………………………………………… 199
No Display ……………………………………………………………………… 199
Hourmeter Glass Icon Does Not Flash ………………………………. 199
Hourmeter Glass Icon Always Flashes ………………………………. 199
Battery Discharge Indicator / Hourmeter ………………………………………….. 201
General Information ……………………………………………………………………… 201
Electrical …………………………………………………………………………………….. 202
Voltage …………………………………………………………………………………….. 202
Battery Discharge Indicator (BDI) …………………………………………………… 202
General Information …………………………………………………………………… 202
Key Switch ……………………………………………………………………………….. 202
Hourmeter ………………………………………………………………………………… 203
Troubleshooting …………………………………………………………………………… 203
Battery Discharge Indicator (BDI) ………………………………………………… 203
No Reset ……………………………………………………………………….. 203
Reset After Break in Power ………………………………………………. 204
No Discharge, Gauge Does Not Run Down ………………………… 204
LEDs Do Not Light ………………………………………………………….. 204
Hourmeter ………………………………………………………………………………… 205
No Display ……………………………………………………………………… 205
Hourmeter Glass Icon Does Not Flash ………………………………. 205
Hourmeter Glass Icon Always Flashes ………………………………. 205
Start/Stop Switches ………………………………………………………………………… 207
General ………………………………………………………………………………………. 207
Test/Inspection ………………………………………………………………………….. 207
Master Control On/Off Switch (S21) ……………………………………………….. 209
Inspection …………………………………………………………………………………. 209
Removal …………………………………………………………………………………… 209
Installation ………………………………………………………………………………… 209
Transistor Controller ………………………………………………………………………. 211
Basics Of Circuit Operation …………………………………………………………… 211
Control Features ……………………………………………………………………….. 213
Maintenance ……………………………………………………………………………….. 214
Safety ………………………………………………………………………………………. 214
Cleaning …………………………………………………………………………………… 214
Motor Circuit ……………………………………………………………………………….. 215
Control Circuit ……………………………………………………………………………… 216
Troubleshooting Guidelines …………………………………………………………… 217
General ……………………………………………………………………………………. 219
Shorts to Frame Test ……………………………………………………………………. 220
Definitions …………………………………………………………………………………… 224
Diagnostics and Troubleshooting …………………………………………………… 225
Handset Diagnostics ………………………………………………………………….. 225
Troubleshooting ………………………………………………………………………… 225
Troubleshooting Chart ……………………………………………………………….. 227
Technical Specification ………………………………………………………………. 232
Troubleshooting Chart Using Handset ………………………………………….. 233
Transistor Controller Troubleshooting …………………………………………….. 235
Troubleshooting Chart Index …………………………………………………………. 235
Troubleshooting Charts ………………………………………………………………… 236
Hydraulic System ……………………………………………………………………………. 247
General ………………………………………………………………………………………. 247
Troubleshooting …………………………………………………………………………… 247
Schematic …………………………………………………………………………………… 249
Description ………………………………………………………………………………….. 250
Lift …………………………………………………………………………………………… 250
Lower ………………………………………………………………………………………. 250
Relief Pressure …………………………………………………………………………. 250
Maintenance ……………………………………………………………………………….. 251
Lift Limit Switch ……………………………………………………………………………. 251
Hydraulic Pump …………………………………………………………………………….. 253
Removal ……………………………………………………………………………………… 255
Disassembly ……………………………………………………………………………….. 256
Inspection …………………………………………………………………………………… 257
Reassembly ………………………………………………………………………………… 258
Installation …………………………………………………………………………………… 260
Adjustments ………………………………………………………………………………… 261
Relief valve ………………………………………………………………………………. 262
Solenoid Operated Valve ……………………………………………………………. 262
Lift Cylinder …………………………………………………………………………………… 263
Cylinder Repair …………………………………………………………………………… 264
Removal …………………………………………………………………………………… 264
Disassembly ……………………………………………………………………………… 265
Inspection …………………………………………………………………………………. 265
Assembly …………………………………………………………………………………. 265
Installation ………………………………………………………………………………… 266
Battery Charger, Optima Pack …………………………………………………………. 267
Handset Operation ………………………………………………………………………….. 269
Operating Modes …………………………………………………………………………. 272
Revert to Previous Settings …………………………………………………………… 275
Handset Self Test ………………………………………………………………………… 275

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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