BT Prime-Mover PMX Electric Low Lift Pallet Truck Repair Manual PDF

Description

BT Prime-Mover PMX Electric Low Lift Pallet Truck Repair Manual – PDF DOWNLOAD

FILE DETAILS:

BT Prime-Mover PMX Electric Low Lift Pallet Truck Repair Manual – PDF DOWNLOAD 

Language : English
Pages : 1153
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

BT Prime-Mover PMX Electric Low Lift Pallet Truck Repair Manual – PDF DOWNLOAD 

Front Cover 2
Table of Contents 4
0 0 Maintenance 6
0 1 Truck Identification 6
0 2 System Operation 7
0 3 Specifications 8
Inch (SAE) and Metric Fasteners 10
Introduction 11
Nomenclature, Threads 11
Figure 1 – Thread Design 11
Strength Identification 12
Table 1 – Bolts and Screws 12
Table 2 – Studs and Nuts 13
Table 3 – Torque Nuts 14
Table 4 – Torque Nuts with Nylon Insert 15
Table 5 – Conversion Table for Metric and English Units 16
Table 6 – Torque Values for Coarse Threaded Metric Fasteners 18
0 4 Maintenance and Adjustments 20
Planned Maintenance Schedule 21
Services to be Performed Daily or at Each 8 Hour Operating Shift 23
Services to be Performed Monthly or Every 200 Operating Hours 24
Services to be Performed Annually or Every 2000 Operating Hours 25
0 5 Troubleshooting 27
0 6 Component Removal and Installation 27
0 7 Component Repair 27
1 0 Transmission 28
Transmission Assembly 29
1 2 System Operation 31
1 3 Specifications 31
1 4 Maintenance and Adjustments 31
1 5 Troubleshooting 32
1 6 Component Removal and Installation 32
Transmission Removal and Installation 32
Drive Wheel Removal and Installation 33
Axle Seal Removal and Installation 34
Brake Linkage Removal and Installation 35
Brake Shoe Removal and Installation 35
1 7 Component Repair 36
2 0 Electrical 40
2 1 Component Identification 41
12 Volt PMX 42
12 Volt Electrical Assembly 43
12 Volt Panel Assembly 45
24 Volt PMX 48
24 Volt Electrical Assembly 49
24 Volt Panel Assembly 51
2 2 System Operation 54
12 Volt PMX 54
24 Volt PMX 59
Basics of Circuit Operation 61
Control Features 62
2 3 Specifications 67
2 4 Maintenance and Adjustments 68
Lift Limit Switch 68
Accelerator Potentiometer 68
Brake Interlock Switch 69
Controller Adjustments – 12 Volt 72
Controller Adjustments – 24 Volt 73
2 5 Troubleshooting 75
Troubleshooting Chart Index – 12 Volt Trucks 77
Troubleshooting Chart Index – 24 Volt Trucks 78
Troubleshooting Charts 79
Troubleshooting Charts – 24 Volt Trucks 94
Battery Pack Schematic 105
Troubleshooting the Charger Used in the PMX Battery Pack 106
2 6 Component Removal and Installation 111
Drive Motor Removal and Installation 111
Drive Motor Brush Removal and Installation 112
Pump and Motor Removal and Installation 113
Pump Motor Brush Removal and Installation 113
Switch, Control 113
Contactor Tip Removal and Installation 114
Contactor Tip/Bar Replacement 114
2 7 Component Repair 115
Table # 1 – Indications, Causes and Correction of Unsatisfactory Brush Performance 116
Table # 2 – Primary Sources of Unsatisfactory Brush Performance 119
3 0 Hydraulics 126
3 1 Component Identification 127
Hydraulic Schematic 129
Hydraulic Schematic Symbols 130
3 2 System Operation 131
3 3 Specifications 131
3 4 Maintenance and Adjustments 131
3 5 Troubleshooting 132
3 6 Component Removal and Installation 134
Pump and Motor Removal and Installation 134
Reservoir and Pump Removal and Installation 134
Cylinder Removal and Installation 135
3 7 Component Repair 136
4 0 Frame 138
4 1 Component Identification 139
4 2 System Operation 140
4 3 Specifications 140
4 4 Maintenance and Adjustments 140
4 5 Troubleshooting 140
4 6 Component Removal and Installation 141
Control Handle Head 141
Load Wheels 141
Pull Rod Bushings 142
Carrier Frame Bushings 142
Back Cover 145
Front Cover 146
Table of Contents 148
Section 0 – Maintenance 150
0 1 Truck Identification 150
0 2 System Operation 151
0 3 Specifications 152
Inch (SAE) and Metric Fasteners 154
Introduction 155
Nomenclature, Threads 155
Figure 1 – Thread Design 155
Strength Identification 156
Table 1 – Bolts and Screws 156
Table 2 – Studs and Nuts 157
Table 3 – Torque Nuts 158
Table 4 – Torque Nuts with Nylon Insert 159
Table 5 – Conversion Table for Metric and English Units 160
Table 6 – Torque Values for Coarse Threaded Metric Fasteners 162
0 4 Maintenance and Adjustments 164
Planned Maintenance Schedule 165
Services to be Performed Monthly or Every 200 Operating Hours 168
Services to be Performed Annually or Every 2000 Operating Hours 169
0 5 Troubleshooting 171
0 6 Component Removal and Installation 171
0 7 Component Repair 171
Section 1 0 – Transmission 172
Transmission Assembly 173
Description 174
1 2 System Operation 175
1 3 Specifications 175
1 4 Maintenance and Adjustments 175
Brake Theory of Operation 175
Brake Adjustment 175
Transmission Pivot Bearing Adjustment 176
1 5 Troubleshooting 176
1 6 Component Removal and Installation 176
Transmission Removal and Installation 176
Drive Wheel Removal and Installation 177
Axle Seal Removal and Installation 178
Brake Linkage Removal and Installation 179
Brake Shoe Removal and Installation 179
1 7 Component Repair 180
Transmission Disassembly and Assembly 180
Section 2 0 – Electrical 184
2 1 Component Identification 185
12 Volt Electrical Assembly 187
12 Volt Panel Assembly 189
24 Volt Electrical Assembly 193
24 Volt Panel Assembly 195
2 2 System Operation – 12 volt PMX 198
Battery Connected and Emergency Disconnect Push Button Switch Pulled Out to “Run” Position 198
Key Switch Turned “On” 198
Control Handle Pulled Down; Brakes Released and Brake Interlock Switch Closed 199
Reverse Travel (Fork Direction) Switch is Closed 199
Forward Travel (Control Handle Direction) Switch is Closed 199
Curtis PMC Controller Power Circuits 200
Accelerator Potentiometer Circuits 200
Emergency Reverser Switch 201
Lift Pallet Forks 201
Lower Pallet Forks 202
System Operation – 24 volt PMX 203
Battery Connected and Emergency Disconnect Push Button Switch Pulled Out to “Run” Position 203
Key Switch Turned “On” 203
Control Handle Pulled Down; Brakes Released and Brake Interlock Switch Closed 204
Reverse Travel (Fork Direction) Switch is Closed 204
Forward Travel (Control Handle Direction) Switch is Closed 205
“Prime-Drive 200” Controller Power Circuits 205
Basics of Circuit Operation 205
Control Features 206
Accelerator Potentiometer Circuit 208
Emergency Reverser Switch 209
Lift Pallet Forks 209
Lower Pallet Forks 210
2 3 Specifications 211
2 4 Maintenance and Adjustments 212
2 4 1 Maintenance 212
2 4 2 Adjustments 212
Lift Limit Switch 212
Accelerator Potentiometer 212
Brake Interlock Switch 213
Table of Pot Settings and Associated Voltages Per Cell 215
Controller Adjustments – 12 Volt 216
Controller Adjustments – 24 Volt 217
2 5 Troubleshooting 219
Troubleshooting Chart Index 221
Troubleshooting Charts 237
Battery Pack Schematic 248
Troubleshooting the Charger Used in the PMX Battery Pack 249
2 6 Component Removal and Installation 254
Drive Motor Removal and Installation 254
Drive Motor Brush Removal and Installation 255
Pump and Motor Removal and Installation 256
Pump Motor Brush Removal and Installation 256
Switch, Control 256
Contactor Tips 257
2 7 Component Repair 258
Table # 1 259
Table # 2 262
Section 3 0 – Hydraulics 270
3 1 Component Identification 271
Hydraulic Schematic 273
Hydraulic Schematic Symbols 274
3 2 System Operation 275
3 3 Specifications 275
3 4 Maintenance and Adjustments 275
3 5 Troubleshooting 276
Hydraulic Pump Assembly 276
Relief Valve 277
Removing Solenoid Operated Release Valve 277
Install Solenoid Operated Release Valve 278
3 6 Component Removal and Installation 278
Pump and Motor Removal and Installation 278
Reservoir and Pump Removal and Installation 278
Cylinder Removal and Installation 279
3 7 Component Repair 280
Cylinder Disassembly 280
Inspection 281
Assembly 281
Section 4 0 – Frame 282
4 1 Component Identification 283
4 2 System Operation 284
4 3 Specifications 284
4 4 Maintenance and Adjustments 284
4 5 Troubleshooting 284
4 6 Component Removal and Installation 285
Control Handle Head 285
Load Wheels 285
Pull Rod Bushings 286
Carrier Frame Bushings 286
Back Cover 289
Front Cover 290
Table of Contents 292
0 0 Maintenance 294
0 1 Truck Identification 295
0 2 System Operation 296
0 3 Specifications 297
Inch (SAE) and Metric Fasteners 298
Introduction 299
Nomenclature, Threads 299
Figure 1 – Thread Design 299
Strength Identification 300
Table 2 – Studs and Nuts 301
Table 3 – Torque Nuts 302
Table 4 – Torque Nuts with Nylon Insert 303
Table 5 – Conversion Table for Metric and English Units 304
Table 6 – Torque Values for Coarse Threaded Metric Fasteners 306
0 4 Maintenance and Adjustments 307
Planned Maintenance Schedule 308
Services to be Performed Monthly or Every 200 Operating Hours 311
Services to be Performed Annually or Every 2000 Operating Hours 312
0 5 Troubleshooting 314
0 6 Component Removal and Installation 314
0 7 Component Repair 314
1 0 Transmission 316
Figure # 1 1 Handle Stem Assembly 317
Figure # 1 2 Transmission Assembly 319
1 2 System Operation 321
1 3 Specifications 321
1 4 Maintenance and Adjustments 321
1 5 Troubleshooting 322
1 6 Component Removal and Installation 322
1 7 Component Repair 327
2 0 Electrical 330
2 1 Component Identification 332
PMX 12 Volt Electrical Schematic 333
Electrical Schematic Symbols 334
PMX 12 Volt Electrical Assembly 335
PMX 12 Volt Panel Assembly 337
PMX 24 Volt Electric Schematic 339
Electrical Schematic Symbols 340
PMX 24 Volt Electrical Assembly 341
PMX 24 Volt Panel Assembly 343
QMX 24 Volt Electric Schematic 345
Electrical Schematic Symbols 346
QMX 24 Volt Electrical Assembly 347
QMX 24 Volt Panel Assembly 349
2 2 System Operation 351
12 Volt PMX 351
24 Volt PMX 357
2 3 Specifications 366
2 4 Maintenance and Adjustments 367
Lift Limit Switch 367
Accelerator Potentiometer 367
Brake Interlock Switch 368
Hourmeter with BDI and Lift Interrupt 369
Table of Pot Settings 370
Controller Adjustments – 12 Volt 371
Controller Adjustments – 24 Volt 372
2 5 Troubleshooting 374
Troubleshooting Chart Index 376
Troubleshooting Charts 378
Battery Pack Charger Schematic 404
Battery Wiring Diagram 405
Troubleshooting the Charger Used in the PMX Battery Pack 406
2 6 Component Removal and Installation 411
Drive Motor Removal and Installation 411
Drive Motor Brush Removal and Installation 412
Pump and Motor Removal and Installation 413
Pump Motor Brush Removal and Installation 413
Brake Interlock Switch 413
Contactor Tip Removal and Installation 414
Direction Control Switches 414
Potentiometer 415
Raise, Lower and Horn Switches 415
Raise, Lower and Horn Switches (QMX Hand Rail) 416
2 7 Component Repair 417
Table # 1 418
Table # 2 422
3 0 Hydraulics 430
Hydraulic Schematic 431
Hydraulic Schematic Symbols 432
Figure # 3 1 Component Identification 433
Figure # 3 2 Hydraulic Pump and Motor Assembly 435
3 2 System Operation 437
3 3 Specifications 437
3 4 Maintenance and Adjustments 437
3 5 Troubleshooting 438
3 6 Component Removal and Installation 440
Pump and Motor Removal and Installation 440
Reservoir and Pump Removal and Installation 441
Cylinder Removal and Installation 442
3 7 Component Repair 442
4 0 Frame 446
Figure # 4 1 Control Handle Head Assembly 447
Figure # 4 2 Lift Frame and Carrier Frame Assembly 449
Figure # 4 3 QMX Hand Rail Assembly 451
Figure # 4 4 QMX Rider Platform 453
4 2 System Operation 455
4 3 Specifications 455
4 4 Maintenance and Adjustments 455
4 5 Troubleshooting 456
4 6 Component Removal and Installation 456
Control Handle Head 456
Load Wheels 456
Pull Rod Bushings 457
Carrier Frame Bushings 457
Bumper Bushing (QMX only) 458
Rider Platform Caster (QMX only) 458
Caster Wheel and Bearings (QMX only) 458
Back Cover 461
Front Cover 462
Table of Contents 464
Important Safety Regulations 466
Warning Symbols 466
Warning Levels 466
Prohibitory Symbols 466
Ordinance Symbols 467
0 0 – Maintenance 468
0 1 Truck Identification 469
0 2 System Operation 470
0 3 Specifications 471
Inch (SAE) and Metric Fasteners 472
Introduction 473
Nomenclature, Threads 474
Figure # 1 – Thread Design 474
Strength Identification 475
Table # 1 – Bolts and Screws 475
Table # 2 – Studs and Nuts 476
Table # 3 – Torque Nuts 477
Table # 4 – Torque Nuts with Nylon Insert 478
Table # 5 – Conversion Table for Metric and English Units 479
Table # 6 – Conversion Table for Metric and English Units 481
0 4 Maintenance and Adjustments 482
Planned Maintenance Schedule 483
Battery 485
Hydraulic System 485
Frame/Sheet Metal 485
Wheels/Tires 485
Functions/Operations 485
Services to be Performed Monthly or Every 200 Operating Hours 486
Services to be Performed Annually or Every 2000 Operating Hours 488
0 5 Troubleshooting 489
0 6 Component Removal and Installation 490
0 7 Component Repair 490
1 0 – Transmission 492
Handle Stem Assembly 493
Transmission Assembly Part # I 494
Transmission Assembly Part # II 495
1 2 System Operation 496
1 3 Specifications 496
1 4 Maintenance and Adjustments 496
1 5 Troubleshooting 497
1 6 Component Removal and Installation 498
1 7 Component Repair 503
2 0 – Electrical 506
2 1 Component Identification 507
Electrical Schematic Symbols 507
Electrical Schematic, 12 Volt PMX 508
Electrical Assembly, 12 Volt PMX 509
Panel Assembly, 12 Volt PMX 511
Forward & Rearward Contactor Assembly, 12 Volt PMX 512
2 2 System Operation 513
Electrical Schematic, 24 Volt “E” & “EE” PMX 519
Electrical Schematic Symbols 520
Electrical Assembly, 24 Volt PMX 521
Panel Assembly, 24 Volt “E” PMX and QMX 523
Panel Assembly, 24 Volt “EE” PMX 524
Electrical Schematic, 24 Volt QMX 525
Electrical Schematic Symbols 526
Electrical Assembly, QMX 527
2 3 Specifications 539
2 4 Maintenance and Adjustments 540
2 5 Troubleshooting 547
Troubleshooting Chart Index 549
Troubleshooting Charts 569
Battery Pack 584
Battery Pack Charger Diagram, Swing Out 585
Battery Pack Charger Diagram, NDC Battery Pack 586
Battery Pack Cable Assembly, Swing Out 587
Troubleshooting the Charger Used in the PMX Battery Pack 588
2 6 Component Removal and Installation 594
2 7 Component Repair 601
Table # 1 602
Table # 2 605
3 0 – Hydraulics 610
Hydraulic Schematic 611
Hydraulic Schematic Symbols 612
Component Identification 613
Hydraulic Pump and Motor Assembly 615
3 2 System Operation 617
3 3 Specifications 617
3 4 Maintenance and Adjustments 618
3 5 Troubleshooting 619
3 6 Component Removal and Installation 621
3 7 Component Repair 624
4 0 – Frame 626
Control Handle Head Assembly 627
Lift Frame and Carrier Frame 629
Hand Rail Assembly, QMX 631
Rider Platform, QMX 632
4 2 System Operation 633
4 3 Specifications 633
4 4 Maintenance and Adjustments 633
4 5 Troubleshooting 634
4 6 Component Removal and Installation 634
Back Cover 637
Front Cover 638
Warning Symbols 642
Prohibitory Symbols 643
Introduction, Service Manual 644
Contents, Section M 646
General Product Information 648
Technical Service Data 666
Ordering Spare Parts 670
Contents, Section P 672
Introduction, Maintenance 674
Service Schedule 880
Lubrication Chart 680
Oil and Grease Specifications 682
Contents, Section S 684
Chassis 686
Drive Motor 688
Drive Motor 12 Volt 694
Drive Motor 24 Volt 704
Transmission 712
Parking Brake System 720
Wheels 724
Load Wheels 726
Steering 728
Electrical System, 12 Volt 730
Electrical System, PMX 24 Volt 740
Electrical System, QMX 24 Volt 752
Battery Pack, Swing Out 764
Battery Pack, GNB 772
Contactor, direction 780
Battery Controller/Hourmeter 978
Transistor Controller 792
Handset Operation 802
Pump Motor 810
Hydraulic System 820
Lift Cylinder 830
Back Cover 835
Front Cover 836
BT Standard Codes 838
Warning Symbols 848
1 Warning Levels 848
Prohibitory Symbols 849
1 Ordinance Symbols 849
Introduction, Service Manual 850
Contents, Section M 852
1 Machine Information 852
General Product Information 854
1 Presentation of the PMX and QMX 854
1 1 Intended Application of the Trucks 854
1 2 Forbidden Application of the Trucks 855
1 3 Truck Data 855
1 4 PMX Dimensions 856
1 5 QMX Dimensions 857
1 6 Data Plate 858
2 Main Components 859
Inch (SAE) and Metric Fasteners 862
1 Introduction 862
2 Nomenclature, Threads 863
3 Strength Identification 864
4 Conversion of Metric and English Units 870
Technical Service Data 872
Ordering Spare Parts 876
Contents, Section P 878
1 Planned Maintenance 878
Introduction, Maintenance 880
1 Safe Jacking Procedure 880
Service Schedule 882
1 Planned Maintenance Schedule 882
2 Planned Maintenance Procedures 886
2 1 Services to be Performed Daily 886
2 1 1 Battery Discharge Indicator with slow down 886
2 1 2 Hydraulic System 886
2 1 3 Frame/Sheet Metal 887
2 1 4 Wheels/Tires 887
2 1 5 Functions/Operations 887
2 2 Services to be Performed Monthly 888
2 2 1 Inspection 888
2 2 2 Transmission 888
2 2 3 Brakes 888
2 2 4 Battery 888
2 2 5 Electrical Connections 888
2 2 6 Contactor Tips (NOT Sealed) 889
2 2 7 Motor Brushes 889
2 2 8 Drive Motor 889
2 2 9 Hydraulic Reservoir 889
2 2 10 Frame Lube (“Lubrication Chart” on page57) 889
2 2 11 Pivot Points 890
2 3 Services to be Performed Annually 891
2 3 1 Inspection 891
2 3 2 Transmission 891
2 3 3 Battery 891
2 3 4 Hydraulic System 891
2 3 5 Brakes 892
Lubrication Chart 894
Oil and Grease Specifications 896
1 Approved Oils and Grease 896
Contents, Section S 898
1 Service Instructions 898
Lift Frame 900
1 Pull rod 901
1 1 Removal 901
1 2 Inspection 902
1 3 Installation 903
2 Carrier Frame Bushings 905
Chassis 906
1 General Information 906
Drive Motor Mounting Points 908
1 Drive Motor Brush 909
1 1 Removal and Installation 909
2 Drive Motor Assembly 909
2 1 Remove 909
2 2 Installation 911
Drive Motor 914
1 General Information 914
2 Operating Conditions 914
3 Troubleshooting 914
12 Volt Drive Motor 920
1 Component Repair 921
1 1 Disassembly 921
2 Inspection and Troubleshooting 923
2 1 Drive End Head 923
2 2 Commutator End Head 923
2 3 Bearings 923
2 4 Brush and Commutator 924
2 5 Armature 924
2 6 Frame and Field Assembly 925
2 6 1 Testing 925
2 6 2 Frame and Field Service Notes 926
2 7 Assembly 927
2 7 1 Field Coil Installation 927
2 7 2 Bearing Installation 927
2 7 3 After Assembly 928
3 Changing Brushes 928
24 Volt Drive Motor 930
1 Component Repair 931
1 1 Disassembly 931
2 Inspection and Troubleshooting 932
2 1 Drive End Head 932
2 2 Commutator End Head 932
2 3 Bearings 932
2 4 Brush and Commutator 933
2 5 Armature 933
2 6 Frame and Field Assembly 934
2 6 1 Testing 934
2 6 2 Frame and Field Service Notes 935
2 7 Assembly 936
2 7 1 Field Coil Installation 936
2 7 2 Bearing Installation 936
2 7 3 After Assembly 937
3 Changing Brushes 937
Transmission 938
1 System Description 938
2 Troubleshooting 938
3 Axle Seal Removal and Installation 939
3 1 Removal 939
3 2 Installation 939
4 Transmission Removal/Installation 940
4 1 Removal 940
4 2 Installation 941
5 Transmission Assembly 942
5 1 Disassembly 943
5 2 Assembly 944
Parking Brake System 946
1 Brake Theory of Operation 947
2 Brake Adjustment 948
3 Brake Shoe Removal / Installation 949
Drive Wheel 950
3 1 Removal 950
3 2 Installation 951
Load Wheels 952
1 Removal/Installation 952
Steering 954
1 Control Handle Head 954
1 1 Removal 954
1 2 Installation 955
Steering Handle Head 956
1 Control Handle Head 958
1 1 Removal 958
1 2 Installation 958
2 Direction Control Switches 959
3 Horn, Raise, and Lower Switches 960
4 Potentiometer 962
Swing Out Battery Pack 964
1 Charger Diagram 964
2 Battery Cable routing diagram 965
3 Troubleshooting 966
3 1 Electrical testing 966
3 1 1 Equipment required: 966
3 1 2 Instructions 966
GNB Battery Pack 972
1 General Information 972
2 Troubleshooting 974
2 1 Troubleshooting Symptoms 975
Battery Controller / Hourmeter / Lift Interrupt 978
1 General Information 978
2 Electrical 978
2 1 Voltage 978
2 1 1 The Contact Voltage and Current Ratings for Switching Resistive Loads 979
2 1 2 Memory Retention 979
3 Battery Controller (BC) 979
3 1 General Information 979
3 1 1 Discharge Adjustment 979
3 2 Reset 981
3 3 Key Switch 981
3 4 Hourmeter 982
4 Troubleshooting 982
4 1 Battery Discharge Indicator (BDI) 982
4 1 1 No Reset 982
4 1 2 Reset After Break in Power 982
4 1 3 No Discharge, Gauge Does Not Run Down 983
4 1 4 No Lockout 983
4 1 5 No Lift 983
4 1 6 Early Lockout 984
4 1 7 LEDs Do Not Light 984
4 2 Hourmeter 984
4 2 1 No Display 984
4 2 2 Hourmeter Glass Icon Does Not Flash 984
4 2 3 Hourmeter Glass Icon Always Flashes 985
Battery Discharge Indicator / Hourmeter 986
1 General Information 986
2 Electrical 986
2 1 Voltage 986
3 Battery Discharge Indicator (BDI) 987
3 1 General Information 987
3 2 Key Switch 987
3 3 Hourmeter 987
4 Troubleshooting 988
4 1 Battery Discharge Indicator (BDI) 988
4 1 1 No Reset 988
4 1 2 Reset After Break in Power 988
4 1 3 No Discharge, Gauge Does Not Run Down 989
4 1 4 LEDs Do Not Light 989
4 2 Hourmeter 989
4 2 1 No Display 989
4 2 2 Hourmeter Glass Icon Does Not Flash 989
4 2 3 Hourmeter Glass Icon Always Flashes 990
PMX 12 Volt Electrical System 992
1 Electrical Panel Components 992
1 1 Electrical Schematic 993
1 2 Electrical Schematic Symbols 994
PMX 12 Volt Transistor Controller 996
1 Maintenance 996
1 1 Safety 996
1 2 Cleaning 996
1 3 Troubleshooting 997
2 Basics Of Circuit Operation 999
2 1 Battery connected and emergency disconnect switch in the “RUN” position 999
2 2 Key switch turned “ON” 999
2 3 Control handle pulled down; brakes released and brake interlock switch closed 1000
2 4 Reverse travel (fork direction) switch is closed 1000
2 5 Forward travel (control handle direction) switch is closed 1001
2 6 Curtis® PMC controller power circuits 1001
2 7 Accelerator Potentiometer Circuits 1002
2 8 Emergency Reverser Switch 1003
2 9 Lift Pallet Forks 1003
2 10 Lower pallet forks 1004
2 11 Controller Adjustments 1005
PMX 12 Volt Transistor Controller Troubleshooting 1006
1 Troubleshooting Chart Index 1006
2 Troubleshooting Charts 1007
Contactor, Direction 1026
1 Maintenance 1027
1 1 Removal/Replacement of Contact Tips 1027
PMX 24 Volt Electrical System 1030
1 Electrical Panel Components 1030
2 List of Symbols 1031
2 1 Circuit Diagram 1(3) 1033
2 2 Circuit Diagram 2(3) 1034
2 3 Circuit Diagram 3(3) 1035
3 Description of Function 1036
3 1 General Information 1036
3 2 References Information 1036
3 3 Key Switch S17 in the ON Position 1036
3 4 The Operating Arm in Drive Position, S10, Brake Switch Closed 1036
3 5 Driving, Fork Direction 1036
3 6 Driving, Steer Wheel Direction 1037
3 7 Reversing/Motor Brake Fork Direction to Steer Wheel Direction 1037
3 8 Reversing/Motor Brake Steer Wheel Direction to Fork Direction 1037
3 9 Reverser switch 1037
3 10 Lifting the Forks 1038
3 11 Lowering the Forks 1038
3 12 Horn 1038
3 13 Lift Interrupt 1038
PMX 24 Volt, Transistor Controller 1040
1 Maintenance 1040
1 1 Safety 1040
1 2 Cleaning 1040
1 3 Diagnostics and Troubleshooting 1041
1 3 1 Handset Diagnostics 1041
1 3 2 Troubleshooting 1041
2 Basics Of Circuit Operation 1043
2 1 Control Features 1045
3 Motor Circuit 1047
4 Control Circuit 1047
5 Diagnostics and Troubleshooting 1049
5 1 1307 Programmer Diagnostics 1049
5 2 Troubleshooting Chart 1050
5 3 Technical Specification 1054
5 4 Troubleshooting Chart Using the Handset 1055
PMX 24 Volt, Transistor Controller Troubleshooting 1058
1 Troubleshooting Chart Index 1058
2 Troubleshooting Charts 1059
QMX 24 Volt Electrical System 1070
1 Electrical Panel Components 1070
2 List of Symbols 1071
2 1 Circuit Diagram 1(3) 1073
2 2 Circuit Diagram 2(3) 1074
2 3 Circuit Diagram 3(3) 1075
3 Description of Function 1076
3 1 General Information 1076
3 2 References Information 1076
3 3 Key Switch S17 in the ON Position 1076
3 4 The Operating Arm in Drive Position, S10, Brake Switch Closed 1076
3 5 Driving, Fork Direction 1076
3 6 Driving, Steer Wheel Direction 1077
3 7 Reversing/Motor Brake Fork Direction to Steer Wheel Direction 1077
3 8 Reversing/Motor Brake Steer Wheel Direction to Fork Direction 1077
3 9 Reverser switch 1077
3 10 Lifting the Forks 1078
3 11 Lowering the Forks 1078
3 12 Horn 1078
3 13 High Speed Switch 1078
3 14 Lift Interrupt 1079
QMX 24 Volt,Transistor Controller 1080
1 Maintenance 1080
1 1 Safety 1080
1 2 Cleaning 1080
1 3 Diagnostics and Troubleshooting 1081
1 3 1 Handset Diagnostics 1081
1 3 2 Troubleshooting 1081
2 Basics Of Circuit Operation 1083
2 1 Control Features 1085
3 Motor Circuit 1087
4 Control Circuit 1087
5 Diagnostics and Troubleshooting 1089
5 1 1307 Programmer Diagnostics 1089
5 2 Troubleshooting Chart 1090
5 3 Technical Specification 1094
5 4 Troubleshooting Chart Using the Handset 1095
QMX 24 Volt, Transistor Controller Troubleshooting 1098
1 Troubleshooting Chart Index 1098
2 Troubleshooting Charts 1099
Handset Operation 1113
1 Operating Modes 1115
2 Revert to Previous Settings 1119
3 Handset Self Test 1119
Pump Motor 1120
1 Component Repair 1121
1 1 Motor Disassembly 1121
2 Inspection and Troubleshooting 1123
2 1 Drive End Head 1123
2 2 Commutator End Head 1123
2 3 Bearings 1123
2 4 Brush and Commutator 1124
2 5 Armature 1124
2 6 Frame and Field Assembly 1125
2 6 1 Testing 1125
2 6 2 Frame and Field Service Notes 1126
2 7 Assembly 1127
2 7 1 Field Coil Installation 1127
2 7 2 Bearing Installation 1127
2 7 3 After Assembly 1128
3 Changing Brushes 1128
Hydraulic System 1130
1 Hydraulic Schematic 1130
2 General Information 1130
3 Description 1131
3 1 Lift 1131
3 2 Lower 1131
3 3 Relief Pressure 1131
4 Maintenance 1132
5 Adjustments 1132
6 Lift Limit Switch 1132
7 Troubleshooting 1134
Lift Pump Assembly 1136
1 Removal 1138
2 Disassembly 1139
3 Inspection 1140
4 Assembly 1141
5 Installation 1143
6 Adjustments 1145
6 1 Relief valve 1145
6 2 Solenoid Operated Valve 1146
Lift Cylinder 1148
1 Cylinder Repair 1149
1 1 Removal 1149
1 2 Disassembly 1149
1 3 Inspection 1150
1 4 Assembly 1150
1 5 Installation 1150
Back Cover 1153

DESCRIPTION:

BT Prime-Mover PMX Electric Low Lift Pallet Truck Repair Manual – PDF DOWNLOAD 

302266-000 1994_January
302266-000 1995_January
302266-001 1995_June
302266-001 1996_March
302266-001 1997_July
302266-001 1998_March

Manual Number 9402
Manual Part Number 302266-000
Effective Serial Number PMX00230773

INTRODUCTION:

• Threaded fasteners like bolts, nuts, capscrews and studs are made to specifications
  that describe the mechanical strength and hardness of the fastener. A fastener used
  in a design application is selected according to its specifications. The Prime-Mover
  Company buys parts from many countries. There are several standards used by
  these countries in the manufacture of threaded fasteners. Many of these fasteners are
  similar, but cannot be used as direct replacement.
• Service persons must use replacement fasteners that have the same specifications.
  Fasteners made to each specification have identification marks for that specification.
• This specification is commonly called “Grade” for SAE standards and “property” for
  metric standards. This section describes the identification of some common fasteners.
  The metric system used by BT Prime-Mover is described as SI (International System
  of Units, also called SI in all languages). The SI system of measurement is described
  in ISO Standard 1000, 1973.

S.V 02/02/2025