BT Prime-Mover WSX20/25 Service Manual – PDF DOWNLOAD

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BT Prime-Mover WSX20/25 Service Manual – PDF DOWNLOAD

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BT Prime-Mover WSX20/25 Service Manual – PDF DOWNLOAD

Language : English
Pages : 212
Downloadable : Yes
File Type : PDF

304944-000 1995_December
304944-000 1997_July

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TABLE OF CONTENTS:

BT Prime-Mover WSX20/25 Service Manual – PDF DOWNLOAD

Front Cover...................................................................  2
Table of Contents.............................................................  4
Introduction..................................................................  6
Contents, Section M...........................................................  8
General Product Information................................................... 10
1.  Presentation of the Pedestrian Truck BT WSX20/25.......................... 10
	1.1  Intended Application of the Truck.................................... 10
	1.2  Forbidden Application of the Truck................................... 10
	1.3  Truck Data........................................................... 11
	1.4  Truck Dimensions..................................................... 12
	1.5  Type Plate........................................................... 13
2.  Main Components........................................................... 14
3.  Warning and Information Signs............................................. 16
Technical Service Data........................................................ 18
	Drive Motor............................................................... 18
	Transmission/Gear......................................................... 18
	Wheels.................................................................... 18
	Hydraulic Unit............................................................ 19
	Fuses..................................................................... 19
	Batteries................................................................. 19
	Driving Speeds............................................................ 20
	Lifting/Lowering Time..................................................... 20
	Current Consumption....................................................... 20
Ordering Spare Parts.......................................................... 22
Contents, Section P........................................................... 24
Introduction, Maintenance..................................................... 26
1.  Safe Jacking Procedure.................................................... 26
Service Schedule.............................................................. 28
	1.  Preventive Maintenance Schedule....................................... 28
Lubrication Chart............................................................. 34
Oil and Grease Specification.................................................. 36
	1.  Approved Oils and Grease for WSX20/25................................. 36
Contents, Section S........................................................... 38
Support Arm Chassis........................................................... 40
	1.  General............................................................... 40
	2.  Main Components....................................................... 41
	3.  Maintenance........................................................... 41
	4.  Adjustment of the Support Arm Width................................... 42
	5.  Exchange of Support Arms.............................................. 43
Transmission.................................................................. 46
	1.  General Technical Description......................................... 46
		1.1  Technical Data................................................... 46
		1.2  Gear Components.................................................. 48
		1.3  Special Tools.................................................... 50
	2.  Removing the Gear from the Truck...................................... 50
	3.  Change of Seal on the Drive Shaft..................................... 51
	4.  Reconditioning of the Gear............................................ 54
Electrical System............................................................. 60
	1.  Electrical Panel, Components.......................................... 60
	2.  List of Symbols....................................................... 61
		2.1  Circuit Diagram 1(3)............................................. 63
		2.2  Circuit Diagram 2(3)............................................. 64
		2.3  Circuit Diagram 3(3)............................................. 65
	3.  Description of Function............................................... 66
		3.1  General.......................................................... 66
		3.2  Adjustable Settings.............................................. 66
		3.3  References....................................................... 66
		3.4  Key Switch S17 in the ON position................................ 67
		3.5  The Operating Arm in Drive Position, S10, Brake Switch Closed.... 67
		3.6  Driving, Fork Direction.......................................... 67
		3.7 Driving, Steer Wheel Direction.................................... 68
		3.8  Reversing/Motor Brake Fork Direction to Steer Wheel Direction.... 68
		3.9  Reversing/Motor Brake Steer Wheel Direction to Fork Direction.... 69
		3.10  Reverser Switch................................................. 69
		3.11  Lifting the Forks............................................... 70
		3.12  Horn............................................................ 70
	4.  Options............................................................... 70
		4.1  Electrical Lowering of the Forks................................. 70
Battery Controller/Hourmeter.................................................. 72
	1.  General............................................................... 72
	2.  Electrical............................................................ 72
		2.1  Voltage.......................................................... 72
	3.  Battery Controller.................................................... 73
		3.1  General.......................................................... 73
		3.2  Reset............................................................ 76
		3.3  Keyswitch........................................................ 76
		3.4  Hourmeter........................................................ 76
	4.  Troubleshooting....................................................... 77
		4.1  Battery Discharge Indicator...................................... 77
		4.2  Hourmeter........................................................ 79
Transistor Controller......................................................... 80
	1.  Motor Circuit......................................................... 80
	2.  Control Circuit....................................................... 81
	3.  Technical Specification............................................... 82
	4.  Adjustment Panel...................................................... 84
		4.1  Adjustable Potentiometers........................................ 84
		4.2  Connection of Handheld Terminal.................................. 84
		4.3  Status LED....................................................... 85
	5.  Maintenance........................................................... 85
		5.1  Safety........................................................... 85
		5.2  Cleaning......................................................... 85
	6.  Diagnostics and Troubleshooting....................................... 86
PCB Card...................................................................... 88
	1.  The PCB............................................................... 88
	2.  Connectors and Adjustments............................................ 89
	3.  Terminals and LED's................................................... 90
Hydraulic System Version 001.................................................. 92
	1.  General............................................................... 92
	2.  Description of Function............................................... 92
		2.1  Hydraulic Diagram and Components................................. 92
		2.2  Main Components.................................................. 93
		2.3  Description...................................................... 93
Hydraulic System Version 002.................................................. 94
	1.  General............................................................... 94
	2.  Description of Function............................................... 94
		2.1  Hydraulic Diagram and Components................................. 94
		2.2  Main Components.................................................. 95
		2.3  Description...................................................... 95
Back Cover.................................................................... 98
Front Cover................................................................... 99
BT Standard Codes.............................................................101
	Worksheet standard........................................................101
	C-Code List...............................................................101
Warning Symbols...............................................................105
	1. Warning Levels.........................................................105
		DANGER................................................................105
		WARNING...............................................................105
		CAUTION...............................................................105
		NOTE!.................................................................105
Prohibitory Symbols...........................................................106
	NO SMOKING................................................................106
	OPEN FLAMES PROHIBITED....................................................106
	GENERAL PROHIBITION.......................................................106
	1. Ordinance Symbols......................................................106
		SAFETY SHOES..........................................................106
		PROTECTIVE GLASSES....................................................106
Introduction, service manual..................................................107
Contents, Section M...........................................................109
	1. Machine Information....................................................109
General product information...................................................111
	Valid from machine number: 270001-........................................111
	2. Presentation of the WSX20/25...........................................111
		2.1. Intended application of the truck................................111
		2.2. Forbidden application of the truck...............................112
		2.3. Truck data.......................................................112
			Truck type........................................................112
			WSX20/25..........................................................112
		2.4. Truck dimensions.................................................113
		2.5. Truck data plate.................................................114
	3. Main components........................................................115
		1. Tiller arm: The truck is to be controlled by th....................115
		2. Type plate: With type designation, manufacturin....................115
		3. Hoods: Removable which provides good accessibil....................115
		4. Instrument: (accessory) Combined hour meter/bat....................115
		5. Hydraulic control: For controlling lifting and ....................115
		6. Hydraulic unit: Pump motor, pump, valves, and o....................115
		7. Hydraulic valves: The valves are located to pro....................115
		8. Drive unit with brake: Fixed drive unit with a ....................115
		9. Machine number: The manufacturing number plate ....................115
		10. Electric panel: Removable, which provides good....................115
		11. Battery: 24V with different Ah values. The tru....................115
		12. Battery isolator/Recharging connector: The bat....................115
		13. Mast: Covered by a finger protection which cov....................116
	4. Warning and information signs..........................................117
		1. Hydraulic control: Lifting.........................................117
		2. Signal/Horn........................................................117
		3. Direction: Forward/Rearward........................................117
		4. General warning /informations sign.................................117
		5. Hydraulic control: Lowering........................................117
		6. Hydraulic oil level................................................117
		7. Machine data plate.................................................117
		8. No Riding decal....................................................117
		9. Machine signs......................................................117
		10. Do not stand on the forks/Do not walk under li....................117
		11. Lifting points....................................................117
		12. Pinch point.......................................................117
Inch (SAE) and Metric Fasteners...............................................119
	1. Introduction...........................................................119
	2. Nomenclature, Threads..................................................120
	3. Strength Identification................................................121
	4. Conversion of Metric and English Units.................................127
Technical service data........................................................129
	Valid from machine number: 270001 -.......................................129
Ordering Spare Parts..........................................................133
	1. Locate the fault on the truck..........................................133
	2. Find out the machine model and serial number...........................133
	3. Locate the page with the exploded diagram and f........................133
	4. Locate the position number in the table. Select........................133
	5. Note the part number...................................................133
	6. Call the local BT dealer and state the part num........................133
Contents, Section P...........................................................135
	5. Planned Maintenance....................................................135
Introduction, Maintenance.....................................................137
	1. Safe Jacking Procedure.................................................137
Service schedule..............................................................139
	Valid from machine number: 270001 -.......................................139
	1. Preventive maintenance schedule........................................139
		ITEM..................................................................139
		WORK REQUIRED.........................................................139
			Interval in hours.................................................139
			5.................................................................139
			20................................................................139
			80................................................................139
			250...............................................................139
			500...............................................................139
			1000..............................................................139
			3000..............................................................139
			Interval in Days/Weeks/Months.....................................139
			1 d...............................................................139
			1 w...............................................................139
			1 m...............................................................139
			3 m...............................................................139
			6 m...............................................................139
			12 m..............................................................139
			36 m..............................................................139
Lubrication chart.............................................................145
	Valid from machine number: 270001-........................................145
		Pos no................................................................145
		Service point.........................................................145
		Interval/Running hours................................................145
		Lubricant.............................................................145
		500h..................................................................145
		1000h.................................................................145
		3000h.................................................................145
Oil and grease specification..................................................147
	Valid from machine number: 270001-........................................147
	2. Approved oils and grease...............................................147
		Lubricant.............................................................147
		Specification.........................................................147
		Application area......................................................147
		> - 15C..............................................................147
		< - 15C..............................................................147
Contents, Section S...........................................................149
	1. Service Instructions...................................................149
Support arm chassis...........................................................151
	Valid from machine number: 270001-........................................151
	2. General................................................................151
	3. Main components........................................................152
		Pos no................................................................152
		Description...........................................................152
	4. Maintenance............................................................152
	5. Adjustment of the support arm width....................................153
		Warning!..............................................................153
	6. Exchange of support arms...............................................154
	Transmission..............................................................157
		Valid from machine number: 270001-....................................157
		1. General technical description......................................157
			1.1. Technical data...............................................158
				Data..........................................................158
				Description...................................................158
			1.2. Gear components..............................................159
				Pos No........................................................159
				Component.....................................................159
			1.3. Special tools................................................161
				Pos No........................................................161
				Tool..........................................................161
		2. Removing the gear from the truck...................................161
		3. Change of seal on the drive shaft..................................163
		4. Reconditioning of the gear.........................................166
Electrical System.............................................................173
	Valid from machine number: 270001-........................................173
	1. Electrical panel, components...........................................173
	2. List of symbols........................................................174
		Symbol................................................................174
		Description...........................................................174
		Function..............................................................174
		Remark................................................................174
		2.1. Circuit diagram 1(3).............................................176
		2.2. Circuit diagram 2(3).............................................177
		2.3. Circuit diagram 3(3).............................................178
	3. DESCRIPTION OF FUNCTION................................................179
		3.1. General..........................................................179
		3.2. Adjustable settings:.............................................179
		3.3. References:......................................................179
		3.4. Key switch S17 in the ON position................................180
		3.5. The operating arm in drive position, S10, bra....................180
		3.6. Driving, fork direction..........................................180
		3.7. Driving, steer wheel direction...................................181
		3.8. Reversing/motor brake fork direction to steer....................181
		3.9. Reversing/motor brake steer wheel direction t....................181
		3.10. Reverser switch.................................................182
		3.11. Lifting the forks...............................................182
		3.12. Horn............................................................183
	4. Options................................................................183
		4.1. Electrical lowering of the forks.................................183
	5. Wire Coupler...........................................................183
		5.1. Electrical wire coupler..........................................183
Battery Controller / Hourmeter / Lift Interrupt...............................185
	1. General Information....................................................185
	2. Electrical.............................................................185
		2.1. Voltage..........................................................185
			2.1.1. The Contact Voltage and Current Ratings for................186
			2.1.2. Memory Retention...........................................186
	3. Battery Controller (BC)................................................186
		3.1. General Information..............................................186
			3.1.1. Discharge Adjustment.......................................186
				Battery Ah....................................................187
				SETTING.......................................................187
				VPC...........................................................187
				SETTING.......................................................187
				VPC...........................................................187
				PIN NO:.......................................................187
				FUNCTION......................................................187
		3.2. Reset............................................................188
		3.3. Key Switch.......................................................188
		3.4. Hourmeter........................................................189
	4. Troubleshooting........................................................189
		4.1. Battery Discharge Indicator (BDI)................................189
			4.1.1. No Reset...................................................189
			4.1.2. Reset After Break in Power.................................189
			4.1.3. No Discharge, Gauge Does Not Run Down......................190
			4.1.4. No Lockout.................................................190
			4.1.5. No Lift....................................................190
			4.1.6. Early Lockout..............................................191
			4.1.7. LEDs Do Not Light..........................................191
		4.2. Hourmeter........................................................191
			4.2.1. No Display.................................................191
			4.2.2. Hourmeter Glass Icon Does Not Flash........................191
			4.2.3. Hourmeter Glass Icon Always Flashes........................192
Transistor Controller.........................................................193
	Valid from machine number: 270001-........................................193
	1. Motor circuit..........................................................193
		Terminal..............................................................193
		Connecting............................................................193
	2. Control circuit........................................................194
		Pin No................................................................194
		Connecting............................................................194
	3. Technical specification................................................195
		PARAMETER.............................................................195
		RANGE.................................................................195
		STD SETTING...........................................................195
		UNITS.................................................................195
		DESCRIPTION...........................................................195
	4. Adjustment panel.......................................................196
		4.1. Adjustable Potentiometers:.......................................197
		4.2. Connection of hand held terminal:................................197
		4.3. Status LED:......................................................197
	5. Maintenance............................................................197
		5.1. Safety...........................................................197
		5.2. Cleaning.........................................................198
			1. Remove power by disconnecting the battery......................198
			2. Discharge the capacitors in the controller, by ................198
			3. Remove all dirt or corrosion from the bus bar a................198
			4. Make sure the connections to the bus bars are t................198
	6. Diagnostics and troubleshooting........................................198
		LED CODE..............................................................199
		TERMINAL LCD DISPLAY..................................................199
		EXPLANATION...........................................................199
		POSSIBLE CAUSE........................................................199
PCB Card......................................................................201
	Valid from machine number: 270001-........................................201
	7. The PCB................................................................201
	8. Connectors and adjustments.............................................202
		Position..............................................................202
		Connection/Adjustment.................................................202
	9. Terminals and LED’s....................................................203
		Terminal No...........................................................203
		LED No................................................................203
		Connection............................................................203
		Function..............................................................203
Hydraulic system, mechanical lowering.........................................207
	Valid from machine number: 270001-........................................207
	1. General................................................................207
	2. Description of function................................................207
		2.1. Hydraulic diagram and components.................................207
		2.2. Main components..................................................208
			Pos No............................................................208
			Description.......................................................208
			Remark............................................................208
		2.3. Description......................................................208
			2.3.1. Lift.......................................................208
			2.3.2. Lower......................................................208
			2.3.3. Operating pressure.........................................208
				1. WSX20: 2090 psi............................................208
				2. WSX25: 2610 psi............................................208
			2.3.4. Relief valve...............................................208
				1. WSX20: 2300 psi............................................208
				2. WSX25: 2870 psi............................................208
Hydraulic system, electrical lowering.........................................209
	Valid from machine number: 270001-........................................209
	1. General................................................................209
	2. Description of function................................................209
		2.1. Hydraulic diagram and components.................................209
		2.2. Main components..................................................210
			Pos No............................................................210
			Description.......................................................210
			Remark............................................................210
		2.3. Description......................................................210
			2.3.1. Lift.......................................................210
			2.3.2. Lower......................................................210
			2.3.3. Lower, electrical..........................................210
			2.3.4. Operating pressure.........................................210
				1. WSX20: 2090 psi............................................210
				2. WSX25: 2610 psi............................................210
			2.3.5. Relief valve...............................................210
				1. WSX20: 2300 psi............................................210
				2. WSX25: 2870 psi............................................210
Back Cover....................................................................212

S.S 06/24