BT CSX10 20 30 40 WSX22 30 40 WRX30 Master Service Manual 304959-000 – PDF DOWNLOAD
DESCRIPTION:
BT CSX10 20 30 40 WSX22 30 40 WRX30 Master Service Manual 304959-000 – PDF DOWNLOAD
Introduction, Service Manual :
- The information in this Service Manual covers models CSX10/20/30/40, WSX22/30/40, and WRX30. Federal and State laws require that operators be completely trained in the safe operation of trucks in accordance with OSHA1910.178.
- An Operator’s Manual is sent with every BT Prime-Mover lift truck when it is manufactured. If the Operator’s Manual is missing from the truck.
- This service manual is not a training manual. The information contained in this service manual is intended as a guide to help trained, qualified, and authorized technicians safely service this truck.
- The Service Manual is divided into four separate sections, which cover needed information for servicing the truck types. The main subject for each of these sections are as described below.
SECTION SUBJECT
M MACHINE INFORMATION
P PLANNED MAINTENANCE
S SERVICE INSTRUCTIONS
O OPTIONS
TABLE OF CONTENTS:
BT CSX10 20 30 40 WSX22 30 40 WRX30 Master Service Manual 304959-000 – PDF DOWNLOAD
Front Cover 1
Standard Codes 3
Index 5
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 Presentation of Walkie Trucks 33
1 1 Truck Side Views 34
1 1 Intended Truck Application 34
1 2 Prohibited Truck Application 34
1 3 Truck Data 35
1 4 CSX10 Dimensions 36
1 5 CSX20 Dimensions 37
1 6 CSX30 Dimensions 38
1 7 CSX40 Dimensions 39
1 8 WSX22 Dimensions 40
1 9 WSX30 Dimensions 41
1 10 WSX40 Dimensions 42
1 11 WRX30 Dimensions 43
1 12 Data Plate 44
2 Main Components 46
Inch (SAE) and Metric Fasteners 49
1 Introduction 49
2 Nomenclature, Threads 50
3 Strength Identification 51
4 Conversion of Metric and English Units 58
Technical Service Data 61
Ordering Spare Parts 65
Contents, Section P 67
1 Planned Maintenance 67
Introduction, Maintenance 69
1 Jacking Truck Off The Floor 70
1 1 Elevate Rear of Truck 70
1 1 Elevate Either Side of Truck 70
2 Lubricants 71
2 1 Standard 71
2 2 Corrosion 71
2 3 Cold Storage 72
Service Schedule 75
1 Planned Maintenance Schedule 75
2 Planned Maintenance Procedures 80
2 1 Services Performed Daily or Every 8 Operating Hours 80
2 1 1 Battery Discharge Indicator with slow down 80
2 1 2 Hydraulic System 80
2 1 3 Frame/Sheet Metal 81
2 1 4 Wheels/Tires 81
2 1 5 Functions/Operations 81
2 2 Services Performed Monthly or Every 120 Operating Hours 81
2 2 1 Inspection 81
2 2 2 Transmission 81
2 2 3 Brakes 82
2 2 4 Battery 82
2 2 5 Electrical Connections 82
2 2 6 Contactor Tips (NOT Sealed) 82
2 2 7 Motor Brushes 82
2 2 8 Drive Motor 83
2 2 9 Hydraulic Reservoir 83
2 2 10 Frame Lube 83
2 2 11 Pivot Points 83
2 3 Services Performed Every 480 or 960 Operating Hours 84
2 3 1 Drive Motor 84
2 4 Services Performed Annually or Every 1400 Operating Hours 85
2 4 1 Inspection 85
2 4 2 Transmission 85
2 4 3 Battery 85
2 4 4 Hydraulic System 86
2 4 5 Brakes 86
2 4 6 Lift and Carriage Chains 86
Lubrication Chart 87
Oil and Grease Specifications 88
1 Approved Oils and Grease 88
2 CSX Grease & Mast Adjustment Points Location 89
3 WSX Grease & Mast Adjustment Points Location 90
4 WRX Grease & Mast Adjustment Points Location 91
Contents, Section S 93
1 Service Instructions 93
Frame/Chassis 95
1 General 97
2 Main Components 97
Inspection Covers 99
Battery Roller (Optional) 107
1 Battery Cover, Optional (WSX22 “EE” Trucks Only) 109
1 1 Inspection 109
1 2 Removal 109
1 3 Installation 110
2 Battery Rollers 110
2 1 Inspection 110
2 2 Replacement 110
Driver Controls, One Spool 111
1 Removal 113
2 Installation 114
Driver Controls, Two Spool 115
1 Removal 118
2 Installation 119
Decals 121
1 Decal with Protective Sheet 121
2 Decal without Protective Sheet 121
Motor Maintenance Schedule/Troubleshooting 125
1 General Information 125
2 Operating Conditions 125
3 Troubleshooting 126
Motor Repair 133
1 Pump Motor 133
1 1 Pump Motor Removal 134
1 2 Pump Motor Installation 134
2 Drive Motor 135
2 1 Brush Replacement 141
2 2 Drive Motor Removal 141
2 3 Drive Motor Installation 142
3 Component Repair 144
3 1 Disassembly 144
4 Inspection 146
4 1 Drive End head 146
4 2 Commutator End Head 146
4 3 Bearings 146
4 4 Brush and Commutator 147
4 5 Armature 149
4 6 Frame and Field Assembly 150
4 6 1 Testing 150
4 7 Assembly/Testing 151
4 7 1 Bearing Installation 151
4 7 2 Testing 152
Transmission 153
1 System Description 153
2 Troubleshooting 153
2 1 Kick Panel 154
3 Transmission Repair 155
3 1 Removal 156
3 2 Installation 157
4 Transmission Assembly 159
4 1 Disassembly 160
4 2 Assembly 160
5 Axle Seal 162
5 1 Removal 162
5 2 Installation 162
Parking Brake System 165
1 Brake Theory of Operation 167
2 Brake Adjustment 168
3 Brake Shoe Removal / Installation 169
Drive Wheel 171
1 Removal 171
2 Installation 172
3 Tire Pressing Procedure 173
Support/Swivel Wheel 175
1 Maintenance and Adjustments 178
1 1 Caster Adjustment 179
2 Troubleshooting 180
2 1 Stabilizing Caster 180
2 1 1 Caster Replacement 180
Load Wheels 181
1 Removal and Installation 184
Caster Assembly 185
1 Disassembly 186
2 Inspection 187
3 Assembly 188
Steering Arm/Wheel, Tiler Arm (Serial # 25268000 – 27323000) 189
1 Removal 190
2 Inspection 191
3 Installation 192
Steering Arm/Wheel, Tiler Arm (Serial # 27323001 – UP) 193
1 Removal 194
2 Inspection 195
3 Installation 196
Steering Arm/Wheel, Head 197
1 Control Handle Head 198
1 1 Removal 198
1 2 Installation 198
2 Direction Control Switches 199
3 Raise, Lower, and Horn Switches 201
4 Potentiometer 204
4 1 Removal 204
4 2 Installation 205
5 Reverser Assembly Replacement 209
Electrical Functions 211
1 General 211
1 1 Adjustable Settings 211
1 2 References 211
1 3 Key Switch S17 in ON Position 212
1 4 Operating Arm in Drive Position, S10, Brake Switch Closed 212
1 5 Travel Request, Forks First 212
1 6 Travel Request, Forks Trailing 212
1 7 Reversing/Motor Brake Forks First to Forks Trailing Direction 213
1 8 Reversing/Motor Brake Forks Trailing to Forks First Direction 213
1 9 Reverser switch 213
1 10 Lifting Forks 213
1 11 Lowering Forks 214
1 12 Horn 214
2 Options 214
2 1 Lifting Forks (Manual Valve) 214
2 2 Tilting Forks 214
2 3 Side Shifting Forks 214
2 4 Extend/Retract Forks 215
Electrical Symbols 217
Electrical Schematics 223
Battery 229
1 Removal 229
2 Installation 230
3 Battery Maintenance 231
3 1 Battery Inspection and Care 231
3 2 Battery Exterior Cleaning 232
3 3 Charging 232
4 Storage 233
5 Battery History Record 233
Battery Connector 235
1 Location 235
2 Inspection 236
3 Installation 236
200 Amp System Line Contactor 239
1 Replacement 239
1 1 Removal 239
1 2 Installation 239
300 Amp System Line Contactor (CSX30/40 only) 241
1 Maintenance 241
1 1 Removal/Replacement of Contact Tips 242
200/300 Amp System “EE” Line Contactor 243
1 Maintenance 243
1 1 Removal/Replacement of Contact Tips 244
Battery Controller/Hourmeter/Lift Interrupt 247
1 General Information 247
2 Electrical 248
2 1 Voltage 248
3 Battery Controller (BC) 249
3 1 General Information 249
3 1 1 Discharge Adjustment 249
3 2 Reset 251
3 3 Key Switch 251
3 4 Hourmeter 252
4 Troubleshooting 252
4 1 Battery Discharge Indicator (BDI) 252
4 1 1 No Reset 252
4 1 2 Reset After Break in Power 253
4 1 3 No Discharge, Gauge Does Not Run Down 253
4 1 4 No Lockout 253
4 1 5 No Lift 254
4 1 6 Early Lockout 254
4 1 7 LEDs Do Not Light 254
4 2 Hourmeter 255
4 2 1 No Display 255
4 2 2 Hourmeter Glass Icon Does Not Flash 255
4 2 3 Hourmeter Glass Icon Always Flashes 255
Start/Stop Switches 257
1 General 257
1 1 Test/Inspection 257
2 Master Control On/Off Switch (S21) 259
2 1 Inspection 259
2 2 Removal 259
2 3 Installation 259
Light Assemblies 261
1 Warning Lights (Option) 261
1 1 Removal 263
1 2 Installation 263
2 Travel/Back-up Alarm (Option) 264
2 1 Removal 264
2 2 Installation 264
Transistor Controller 265
1 Basics Of Circuit Operation 265
1 1 Control Features 267
2 Maintenance 268
2 1 Safety 268
2 2 Cleaning 268
3 Motor Circuit 269
4 Control Circuit 270
5 Troubleshooting Guidelines 271
5 1 General 273
6 Shorts to Frame Test 274
7 Definitions 278
8 Diagnostics and Troubleshooting 279
8 1 Handset Diagnostics 279
8 2 Troubleshooting 279
8 3 Troubleshooting Chart 281
8 4 Technical Specification 286
8 5 Troubleshooting Chart Using Handset 287
Transistor Controller Troubleshooting 289
1 Troubleshooting Chart Index 289
2 Troubleshooting Charts 290
Hydraulic System 309
1 General 309
2 Description of Function 309
3 Main Components 310
3 1 Lift (Solenoid valve) 310
3 2 Lift (Mechanical Valve) 310
3 3 Lower (Solenoid Valve) 310
3 4 Lower (Mechanical Valve) 310
3 5 Relief Pressure 310
3 6 Compensating Cylinder 311
3 7 Reach (Solenoid valve) 311
3 8 Tilt (Solenoid valve) 311
3 9 Sideshift (Solenoid valve) 311
4 Maintenance 312
5 Adjustments 313
6 Troubleshooting 314
6 1 Primary Malfunctions 315
6 1 1 Failure to raise load 315
6 1 2 Failure to raise load 315
6 1 3 Failure to raise load 316
7 Definitions 316
8 Removal 317
9 Installation 319
Hydraulic Schematics 321
Hydraulic Fluid 327
1 Hydraulic Fluid Selection 327
2 Changing Hydraulic System Fluid 327
3 System Draining 328
4 Refilling System 329
5 Bleeding Hydraulic System 330
Hydraulic Tank 331
1 Removal 332
2 Installation 332
Hydraulic Pump Assembly 333
1 Disassembly 335
2 Inspection 336
3 Assembly 337
One Spool Control Valve 339
1 Operators Controls Removal 340
2 Control Valve Disassembly and Inspection 340
3 Operators Controls Installation 341
Two Spool Control Valve 342
1 Operators Controls Removal 343
2 Control Valve Disassembly and Inspection 343
3 Operators Controls Installation 344
Lift Cylinder, Two Stage Mast 345
1 Lift Cylinder, Two Stage Mast 355
1 1 Removal 355
1 2 Disassembly 356
1 3 Assembly 356
1 4 Installation 356
2 Two Stage Full Freelift Mast Cylinder Repair 357
2 1 Removal 357
2 2 Disassembly 358
2 3 Assembly 358
2 4 Installation 358
3 Two Stage Full Freelift Mast Staging Cylinder Repair 359
3 1 Removal 359
3 2 Disassembly 360
3 3 Assembly 360
3 4 Installation 360
Lift Cylinder, Three Stage Mast 361
1 Repair 364
1 1 Removal 364
1 2 Disassembly 365
1 3 Assembly 365
1 4 Installation 365
Reach Cylinder, WRX30 367
1 Removal 369
2 Disassembly 370
3 Inspection 371
4 Assembly 372
5 Installation 373
Tilt Cylinder 375
1 Removal 377
2 Disassembly 378
3 Inspection 379
4 Assembly 380
5 Installation 381
1 Removal 384
2 Disassembly 385
3 Inspection 386
4 Assembly 387
5 Installation 388
Mast, Two Stage 389
1 Shimming Carriage with Mast on Truck 397
2 Repair 399
2 1 Removal 399
2 2 Disassembly 400
2 3 Assembly 401
2 4 Installation 403
3 Lift Chain 404
3 1 Lift Chain Adjustment: 404
3 2 Lift Chain Maintenance 404
3 3 Lift Chain Inspection 404
3 3 1 Wear 405
3 3 2 Rust and Corrosion 405
3 3 3 Cracked Plates 406
3 3 4 Protruding or Turned Pins 408
3 3 5 Chain Side Wear 409
3 3 6 Chain Anchors and Sheaves 409
3 3 7 Lift Chain Lubrication 409
3 4 Lift Chain Replacement 411
Mast, Three Stage 413
1 Shimming Carriage with Mast on Truck 419
2 Repair 421
2 1 Removal 421
2 2 Disassembly 422
2 3 Assembly 423
2 4 Installation 425
3 Lift Chain 426
Sideshifter, Serial numbers 25268000 – 28077001 427
1 Mounting Instructions 429
1 1 Installation 429
2 Operation 430
3 Maintenance 430
3 1 Lower Slides 430
3 2 Upper Slides 431
3 3 Cylinder 431
Sideshifter, Serial number 28077002 – UP 433
1 Mounting Instructions 435
1 1 Installation 435
2 Operation 436
3 Maintenance 436
3 1 Carriage Removal 437
3 2 Upper Pad Replacement 437
3 3 Lower Pad Replacement 438
3 4 Cylinder 439
4 Troubleshooting 440
4 1 No Sideshifting 440
4 2 Very Slow Sideshifting 440
4 3 Irregular Sideshifting 441
Single Reach, WRX30 443
1 Maintenance 445
1 1 Inspection 445
1 2 Adjustment 446
2 Repair 450
2 1 Disassembly 450
2 1 1 Front Frame Removal 450
2 1 2 Outer Arm Removal 451
2 1 3 Inner Arm Removal 451
2 1 4 Rear Frame Removal 451
2 1 5 Reach Cylinder Removal 452
2 2 Assembly 452
2 2 1 Reach Cylinder Installation 452
2 2 2 Rear Frame Installation 452
2 2 3 Inner Arm Installation 453
2 2 4 Outer Arm Installation 453
2 2 5 Front Frame Installation 454
3 Carriage Bumpers 454
3 1 Reach Adjustment 454
4 Fork Carriage Pivot Pins 456
5 Carriage Roller Bearings 456
5 1 Removal 456
5 2 Installation 456
Forks 457
1 Removal 459
2 Inspection 459
3 Installation 460
Load Backrest 461
1 Removal 462
2 Installation 462
Handset Operation 463
1 Operating Modes 466
2 Revert to Previous Settings 469
3 Handset Self Test 469
Back Cover 476
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PLEASE NOTE:
- This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
- This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
- Require some other service manual or have any queries: please WRITE to us at [email protected]
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