BT Forklift WSX20/25 ELECTRIC WALKIE ADJUSTABLE STRADDLE STACKER SERVICE MANUAL

BT Forklift WSX20/25 ELECTRIC WALKIE ADJUSTABLE STRADDLE STACKER SERVICE MANUAL – PDF DOWNLOAD

FILE DETAILS:

BT Forklift WSX20/25 ELECTRIC WALKIE ADJUSTABLE STRADDLE STACKER SERVICE MANUAL – PDF DOWNLOAD

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

Effective Serial Number 272581AA000

TABLE OF CONTENTS:

BT Forklift WSX20/25 ELECTRIC WALKIE ADJUSTABLE STRADDLE STACKER 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
11 Intended Application of the Truck 10
12 Forbidden Application of the Truck 10
13 Truck Data 11
14 Truck Dimensions 12
15 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
11 Technical Data 46
12 Gear Components 48
13 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
21 Circuit Diagram 1(3) 63
22 Circuit Diagram 2(3) 64
23 Circuit Diagram 3(3) 65
3 Description of Function 66
31 General 66
32 Adjustable Settings 66
33 References 66
34 Key Switch S17 in the ON position 67
35 The Operating Arm in Drive Position, S10, Brake Switch Closed 67
36 Driving, Fork Direction 67
37 Driving, Steer Wheel Direction 68
38 Reversing/Motor Brake Fork Direction to Steer Wheel Direction 68
39 Reversing/Motor Brake Steer Wheel Direction to Fork Direction 69
310 Reverser Switch 69
311 Lifting the Forks 70
312 Horn 70
4 Options 70
41 Electrical Lowering of the Forks 70
Battery Controller/Hourmeter 72
1 General 72
2 Electrical 72
21 Voltage 72
3 Battery Controller 73
31 General 73
32 Reset 76
33 Keyswitch 76
34 Hourmeter 76
4 Troubleshooting 77
41 Battery Discharge Indicator 77
42 Hourmeter 79
Transistor Controller 80
1 Motor Circuit 80
2 Control Circuit 81
3 Technical Specification 82
4 Adjustment Panel 84
41 Adjustable Potentiometers 84
42 Connection of Handheld Terminal 84
43 Status LED 85
5 Maintenance 85
51 Safety 85
52 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
21 Hydraulic Diagram and Components 92
22 Main Components 93
23 Description 93
Hydraulic System Version 002 94
1 General 94
2 Description of Function 94
21 Hydraulic Diagram and Components 94
22 Main Components 95
23 Description 95
Back Cover 98
Front Cover 99
BT Standard Codes101
Worksheet standard101
C-Code List101
Warning Symbols105
1 Warning Levels105
DANGER105
WARNING105
CAUTION105
NOTE!105
Prohibitory Symbols106
NO SMOKING106
OPEN FLAMES PROHIBITED106
GENERAL PROHIBITION106
1 Ordinance Symbols106
SAFETY SHOES106
PROTECTIVE GLASSES106
Introduction, service manual107
Contents, Section M109
1 Machine Information109
General product information111
Valid from machine number: 270001-111
2 Presentation of the WSX20/25111
21 Intended application of the truck111
22 Forbidden application of the truck112
23 Truck data112
Truck type112
WSX20/25112
24 Truck dimensions113
25 Truck data plate114
3 Main components115
1 Tiller arm: The truck is to be controlled by th115
2 Type plate: With type designation, manufacturin115
3 Hoods: Removable which provides good accessibil115
4 Instrument: (accessory) Combined hour meter/bat115
5 Hydraulic control: For controlling lifting and 115
6 Hydraulic unit: Pump motor, pump, valves, and o115
7 Hydraulic valves: The valves are located to pro115
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 good115
11 Battery: 24V with different Ah values The tru115
12 Battery isolator/Recharging connector: The bat115
13 Mast: Covered by a finger protection which cov116
4 Warning and information signs117
1 Hydraulic control: Lifting117
2 Signal/Horn117
3 Direction: Forward/Rearward117
4 General warning /informations sign117
5 Hydraulic control: Lowering117
6 Hydraulic oil level117
7 Machine data plate117
8 No Riding decal117
9 Machine signs117
10 Do not stand on the forks/Do not walk under li117
11 Lifting points117
12 Pinch point117
Inch (SAE) and Metric Fasteners119
1 Introduction119
2 Nomenclature, Threads120
3 Strength Identification121
4 Conversion of Metric and English Units127
Technical service data129
Valid from machine number: 270001 -129
Ordering Spare Parts133
1 Locate the fault on the truck133
2 Find out the machine model and serial number133
3 Locate the page with the exploded diagram and f133
4 Locate the position number in the table Select133
5 Note the part number133
6 Call the local BT dealer and state the part num133
Contents, Section P135
5 Planned Maintenance135
Introduction, Maintenance137
1 Safe Jacking Procedure137
Service schedule139
Valid from machine number: 270001 -139
1 Preventive maintenance schedule139
ITEM139
WORK REQUIRED139
Interval in hours139
Interval in Days/Weeks/Months139
Lubrication chart145
Valid from machine number: 270001-145
Pos no145
Service point145
Interval/Running hours145
Lubricant145
Oil and grease specification147
Valid from machine number: 270001-147
2 Approved oils and grease147
Lubricant147
Specification147
Application area147
> – 15C147
< – 15C147
Contents, Section S149
1 Service Instructions149
Support arm chassis151
Valid from machine number: 270001-151
2 General151
3 Main components152
Pos no152
Description152
4 Maintenance152
5 Adjustment of the support arm width153
Warning!153
6 Exchange of support arms154
Transmission157
Valid from machine number: 270001-157
1 General technical description157
11 Technical data158
Data158
Description158
12 Gear components159
Pos No159
Component159
13 Special tools161
Pos No161
Tool161
2 Removing the gear from the truck161
3 Change of seal on the drive shaft163
4 Reconditioning of the gear166
Electrical System173
Valid from machine number: 270001-173
1 Electrical panel, components173
2 List of symbols174
Symbol174
Description174
Function174
Remark174
21 Circuit diagram 1(3)176
22 Circuit diagram 2(3)177
23 Circuit diagram 3(3)178
3 DESCRIPTION OF FUNCTION179
31 General179
32 Adjustable settings:179
33 References:179
34 Key switch S17 in the ON position180
35 The operating arm in drive position, S10, bra180
36 Driving, fork direction180
37 Driving, steer wheel direction181
38 Reversing/motor brake fork direction to steer181
39 Reversing/motor brake steer wheel direction t181
310 Reverser switch182
311 Lifting the forks182
312 Horn183
4 Options183
41 Electrical lowering of the forks183
5 Wire Coupler183
51 Electrical wire coupler183
Battery Controller / Hourmeter / Lift Interrupt185
1 General Information185
2 Electrical185
21 Voltage185
211 The Contact Voltage and Current Ratings for186
212 Memory Retention186
3 Battery Controller (BC)186
31 General Information186
311 Discharge Adjustment186
Battery Ah187
SETTING187
VPC187
SETTING187
VPC187
PIN NO:187
FUNCTION187
32 Reset188
33 Key Switch188
34 Hourmeter189
4 Troubleshooting189
41 Battery Discharge Indicator (BDI)189
411 No Reset189
412 Reset After Break in Power189
413 No Discharge, Gauge Does Not Run Down190
414 No Lockout190
415 No Lift190
416 Early Lockout191
417 LEDs Do Not Light191
42 Hourmeter191
421 No Display191
422 Hourmeter Glass Icon Does Not Flash191
423 Hourmeter Glass Icon Always Flashes192
Transistor Controller193
Valid from machine number: 270001-193
1 Motor circuit193
Terminal193
Connecting193
2 Control circuit194
Pin No194
Connecting194
3 Technical specification195
PARAMETER195
RANGE195
STD SETTING195
UNITS195
DESCRIPTION195
4 Adjustment panel196
41 Adjustable Potentiometers:197
42 Connection of hand held terminal:197
43 Status LED:197
5 Maintenance197
51 Safety197
52 Cleaning198
1 Remove power by disconnecting the battery198
2 Discharge the capacitors in the controller, by 198
3 Remove all dirt or corrosion from the bus bar a198
4 Make sure the connections to the bus bars are t198
6 Diagnostics and troubleshooting198
LED CODE199
TERMINAL LCD DISPLAY199
EXPLANATION199
POSSIBLE CAUSE199
PCB Card201
Valid from machine number: 270001-201
7 The PCB201
8 Connectors and adjustments202
Position202
Connection/Adjustment202
9 Terminals and LED’s203
Terminal No203
LED No203
Connection203
Function203
Hydraulic system, mechanical lowering207
Valid from machine number: 270001-207
1 General207
2 Description of function207
21 Hydraulic diagram and components207
22 Main components208
Pos No208
Description208
Remark208
23 Description208
231 Lift208
232 Lower208
233 Operating pressure208
1 WSX20: 2090 psi208
2 WSX25: 2610 psi208
234 Relief valve208
1 WSX20: 2300 psi208
2 WSX25: 2870 psi208
Hydraulic system, electrical lowering209
Valid from machine number: 270001-209
1 General209
2 Description of function209
21 Hydraulic diagram and components209
22 Main components210
Pos No210
Description210
Remark210
23 Description210
231 Lift210
232 Lower210
233 Lower, electrical210
234 Operating pressure210
1 WSX20: 2090 psi210
2 WSX25: 2610 psi210
235 Relief valve210
1 WSX20: 2300 psi210
2 WSX25: 2870 psi210
Back Cover212

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