BT PRIME MOVER PMX45 ELECTRIC LOW LIFT PALLET TRUCK SERVICE, OPERATOR, PARTS, WIRING MANUAL

BT PRIME MOVER PMX45 ELECTRIC LOW LIFT PALLET TRUCK SERVICE, OPERATOR, PARTS, WIRING MANUAL
LANGUAGE: ENGLISH
FORMAT: PDF
PAGES: 1,104
FILE SIZE: 44.2MB

MODEL COVERED:

BT PRIME MOVER PMX45 ELECTRIC LOW LIFT PALLET TRUCK

PART NO: 311230-000

SERIAL NO: PMX4531141001 - UP

ISSUED:

MAY, 2001

MARCH, 2002
                  

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

EXTRAS INCLUDED:

ELECTRICAL SCHEMATICS

MASTER PARTS MANUALS

OPERATOR MANUALS

PARTS MANUALS