BT Prime Mover PMX45 Electric Low Lift Pallet Truck Parts Manual PDF

Description

BT Prime Mover PMX45 Electric Low Lift Pallet Truck Parts Manual – PDF DOWNLOAD

FILE DETAILS:

BT Prime Mover PMX45 Electric Low Lift Pallet Truck Parts Manual – PDF DOWNLOAD

Language : English
Pages : 310
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

BT Prime Mover PMX45 Electric Low Lift Pallet Truck Parts Manual – PDF DOWNLOAD

Front Cover 1
Ordering Spare Parts 3
Table of Contents 5
Standard Codes 13
Warning Symbols 15
1 Warning Levels 15
Prohibitory Symbols 16
1 Ordinance Symbols 16
Safety 17
1 General Safety 17
Battery Safety 21
Static Safety 26
Welding Safety 27
Introduction, Service Manual 29
Contents, Section M 31
1 Machine Information 31
General Product Information 33
1 Truck Presentation 33
1 1 Truck Side Views 33
1 2 Intended Truck Application 33
1 3 Prohibited Truck Application 34
1 4 Truck Data 34
1 5 Truck Dimensions 35
1 6 Data Plate 36
2 Main Components 37
Inch and Metric (SAE) Fasteners 39
1 Introduction 39
2 Nomenclature, Threads 40
3 Strength Identification 41
4 Truck Torque Specifications 47
5 Conversion of English and Metric Units 48
Technical Service Data 51
Contents, Section P 53
1 Planned Maintenance 53
Introduction, Maintenance 55
1 Jacking Truck Off The Floor 56
1 1 Elevate Rear of Truck 56
1 1 Elevate Either Side of Truck 56
2 Lubricants 57
2 1 Standard Conditioning 57
2 2 Corrosion Conditioning 57
2 3 Cold Storage Conditioning 58
Service Schedule 59
1 Planned Maintenance Schedule 59
2 Planned Maintenance Procedures 62
2 1 General 62
2 1 1 Hardware 62
2 1 2 Noise 62
2 1 3 Leaks 62
2 1 4 Cables and Connections 63
2 1 5 Grease Location Points 63
2 2 Services Performed Daily or Every 8 Operating Hours 63
2 2 1 Chassis 63
2 2 2 Brakes 64
2 2 3 Wheels/Tires 64
2 2 4 Steering Control Handle 64
2 2 5 Functions/Operations 64
2 2 6 Battery 64
2 2 7 Battery Connector 65
2 3 Services Performed Every Two Months or Every 250 Operating Hours 65
2 3 1 Chassis 66
2 3 2 Motors 66
2 3 3 Drive Unit 66
2 3 4 Wheels/Tires 66
2 3 5 Brakes 66
2 3 6 Wheels/Tires 67
2 3 7 Instrument Panel 67
2 3 8 Hydraulic System 67
2 4 Services Performed Annually or Every 1500 Operating Hours 67
2 4 1 Drive Unit 67
2 4 2 Hydraulic System 68
Lubrication Chart 69
Oil and Grease Specifications 70
1 Lubricants 70
2 Grease Location Points 70
Contents, Section S 71
1 Service Instructions 71
Frame / Chassis 73
1 Theory of Operation 73
2 Maintenance 73
2 1 Inspection 73
3 Troubleshooting 74
4 Repair and Rebuild 74
4 1 Pull Rod Replacement for Truck S/N 31141001 – 36132000 77
4 2 Pull Rod Replacement for Truck S/N 36132001 – UP 81
Inspection Covers 85
1 Theory of Operation 85
2 Maintenance 85
3 Troubleshooting 85
4 Repair and Rebuild 85
Operator Controls 89
1 Theory of Operation 89
2 Maintenance 89
3 Troubleshooting 89
4 Repair and Rebuild 90
Decals 93
1 Decal with Protective Sheet 93
2 Decal without Protective Sheet 93
Electric Motors 95
1 Theory of Operation 95
2 Maintenance 95
3 Troubleshooting 96
4 Repair and Rebuild 97
4 1 Pump Motor 97
4 2 Drive Motor 100
4 3 Brushes 106
4 3 1 Inspection and Replacement 106
4 3 2 Brush Inspection 107
4 3 3 Assembly 109
Transmission 111
1 Theory of Operation 111
2 Maintenance 111
2 1 Fluid Changing 111
3 Troubleshooting 111
4 Repair and Rebuild 112
4 1 Transmission 114
4 2 Axle Seal 118
Parking Brake System 121
1 Theory of Operation 121
2 Maintenance 121
2 1 Brake Adjustment 121
3 Troubleshooting 122
4 Repair and Rebuild 123
Drive Wheel 127
1 Theory of Operation 127
2 Maintenance 127
3 Troubleshooting 127
4 Repair and Rebuild 127
Support/Swivel Wheel (Optional) 131
1 Theory of Operation 131
2 Maintenance and Adjustments 131
2 1 Inspection 131
2 2 Caster Adjustment 132
3 Troubleshooting 132
4 Repair and Rebuild 133
Load Wheels 135
1 Theory of Operation 135
2 Maintenance 135
3 Troubleshooting 135
4 Rebuild and Repair 135
Steering Arm / Wheel (Stem) 137
1 Theory of Operation 137
2 Maintenance 137
2 1 Inspection 137
3 Troubleshooting 137
4 Repair and Rebuild 138
Steering Arm / Wheel (Head) 141
1 Theory of Operation 141
2 Maintenance 141
3 Troubleshooting 141
4 Repair and Rebuild 142
Steering Bearing 145
1 Theory of Operation 145
2 Maintenance 145
3 Troubleshooting 145
4 Repair and Rebuild 146
Electrical Functions 149
1 Theory of Operation 149
1 1 Master Control ON/OFF Switch in the ON Position 149
1 2 Key Switch in the ON Position 149
1 3 Operating Arm in Drive Position, Brake Switch Closed 150
1 4 Travel Request, Forks-first 150
1 5 Travel Request, Tractor-first 150
1 6 Reversing/Motor Brake Forks-first Direction to Tractor-first Direction 150
1 7 Reversing/Motor Brake Tractor-first Direction to Forks-first Direction 150
1 8 Reverser Switch 150
1 9 Lifting 151
1 10 Lowering 151
1 11 Horn 151
1 12 Lift Interrupt 151
2 Maintenance 152
2 1 Wiring 152
2 1 1 Definitions 152
2 1 2 Shorts to Frame Test 153
3 Troubleshooting 156
3 1 Troubleshooting Chart Index 158
3 2 Troubleshooting Charts 158
Battery 185
1 Theory of Operation 185
2 Maintenance 185
2 1 Inspection and Care 185
2 2 Exterior Cleaning 186
2 3 Charging 186
2 4 Storage 187
2 5 History Record 188
3 Troubleshooting 188
4 Repair and Rebuild 189
Swing Out Battery Pack 191
1 Theory of Operation 191
2 Maintenance 191
2 1 Electrical Testing 191
2 1 1 Equipment required 191
2 1 2 Instructions 191
3 Troubleshooting 196
4 Repair and Rebuild 197
Battery Connector 207
1 Theory of Operation 207
2 Maintenance 207
2 1 Inspection 207
3 Troubleshooting 207
4 Repair and Rebuild 208
Line Contactor 211
1 Theory of Operation 211
2 Maintenance 211
2 1 Resistance Testing 211
3 Troubleshooting 211
4 Repair and Rebuild 212
Battery Controller/Hourmeter/ Lift Interrupt (Optional) 213
1 Theory of Operation 213
1 1 Battery Controller (BC) 214
1 1 Hourmeter 214
2 Maintenance 215
3 Troubleshooting 217
3 1 Battery Discharge Indicator (BDI) 217
3 2 Hourmeter 220
Battery Discharge Indicator / Hourmeter 221
1 Theory of Operation 221
1 1 Hourmeter 222
1 2 Battery Discharge Indicator (BDI) 222
2 Maintenance 222
3 Troubleshooting 223
3 1 Battery Discharge Indicator (BDI) 223
3 2 Hourmeter 224
Switches 227
1 Theory of Operation 227
2 Maintenance 227
2 1 General 227
2 2 Master Control ON/OFF Switch (S21) 227
2 3 Key Switch (S17) 228
2 4 Lift Limit Switch (S36) Adjustment 228
2 5 Brake Interlock Switch (S10) Adjustment 229
3 Troubleshooting 230
4 Repair and Rebuild 231
4 1 Master ON/OFF Switch (S21) 232
4 2 Key Switch (S17) 232
4 3 Lift/Limit Switch (S36) 233
4 4 Brake Interlock Switch (S10) 233
Speed Controls 235
1 Theory of Operation 235
2 Maintenance 235
2 1 Potentiometer Adjustment 235
3 Troubleshooting 237
4 Repair and Rebuild 237
4 1 Potentiometer Assembly 237
4 2 Rearward and Forward Switches 240
4 3 Direction Control Switches 242
4 4 Raise, Lower, and Horn Switches 244
4 5 Driver Protection (Reverser) Assembly Replacement 247
Fuses/Circuit Breakers 249
1 Theory of Operation 249
2 Maintenance 249
2 1 Wiring Harness 250
2 2 Power Cables 251
2 3 Circuit Breaker 252
3 Troubleshooting 253
4 Repair and Rebuild 253
Transistor Controller 255
1 Theory of Operation 255
1 1 Basics Of Circuit Operation 255
1 2 Control Features 257
1 3 Motor Circuit 258
1 4 Control Circuit 259
2 Maintenance 260
2 1 Safety 260
2 2 Cleaning 260
2 3 Transistor Adjustable Settings 261
2 4 Definitions 262
3 Troubleshooting 262
3 1 Diagnostics and Troubleshooting 262
3 2 Handset Diagnostics 263
3 3 Troubleshooting Chart 265
3 4 Troubleshooting Chart Using Handset 267
4 Repair and Rebuild 268
Hydraulic System 269
1 Theory of Operation 269
1 1 Lift 269
1 2 Lower 269
1 3 Relief Pressure 269
2 Maintenance 269
2 1 Fluid Check 269
2 1 Relief valve Adjustment 270
2 2 Solenoid Operated Valve 271
3 Troubleshooting 272
3 1 Preliminary Checks 272
3 2 Pressure Checks 272
4 Repair and Rebuild 275
Lift Cylinder 283
1 Theory of Operation 283
2 Maintenance 283
2 1 Inspection 283
3 Troubleshooting 283
4 Repair and Rebuild 284
Battery Charger, Optima Pack 289
Version One Handset 291
1 Theory of Operation 291
Version Two Handset 299
1 Theory of Operation 299
A 307
B 307
C 307
D 307
E 307
F 307
G 307
H 307
I 307
L 307
O 307
P 307
S 308
T 308
W 308
Index 307
Back Cover 310

DESCRIPTION:

BT Prime Mover PMX45 Electric Low Lift Pallet Truck Parts Manual – PDF DOWNLOAD

General Product Information:
1. Truck Presentation:

• The PMX45 is a battery powered low-lift pallet truck. The truck is intended solely to be operated indoors carrying pallets or similar load carriers. The truck is equipped with a steering arm with all the controls for operating within easy access. The truck’s lifting capacities can be found on the truck’s data plate.
• The truck is equipped with a 24 volt electrical system. Speed is regulated by means of a transistor controller to provide infinite control of acceleration and speed while driving.
• The chassis/lift frame is raised by means of a hydraulic unit. The control of the lift/lower is done electrically with the push button on the steering arm. The truck can be fitted with a battery pack and can be specially equipped to work in cold conditions.

S.V 10/01/2025