BT PRIME MOVER WSX20/25 SERVICE MANUALS – PDF DOWNLOAD

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BT PRIME MOVER WSX20/25 SERVICE MANUALS – PDF DOWNLOAD

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BT PRIME MOVER WSX20/25 SERVICE MANUALS – PDF DOWNLOAD

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

304944-000 1995_December
304944-000 1997_July

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

BT PRIME MOVER WSX20/25 SERVICE MANUALS – PDF DOWNLOAD

WSX20_25 Service Welcome..........................................................  1
304944-000 1995_December..........................................................  2
	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
304944-000 1997_July.............................................................. 99
	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

DESCRIPTION:

BT PRIME MOVER WSX20/25 SERVICE MANUALS – PDF DOWNLOAD

• The information in this Service Manual covers the truck types BT WSX20 and WSX25.
• The Service Manual is divided into four separate sections, which covers different kinds of information needed for servicing these truck types. The main subject for each of the sections are as described below.

S.S 08/01/2025