DOWNLOAD PDF BT Prime-Mover WSX-OS Electric Walkie Straddle Order Selector Service Manual

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Service Manual WSX-OS Electric Walkie Straddle Order Selector Effective Serial Number 272581AA000

WARNING Read and observe all warnings on this unit before operating it.

WARNING DO NOT operate this equipment unless all factory installed guards and shields are properly secured in place.

Part no: 309842-000

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Date: February 18, 1999

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Section

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BT Standard Codes Version no

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000

BT Standard Codes B-Code

= Business area

F-Code

= Product family

T-Code

= Product type

C-Code

= Component function

Worksheet standard W-Code = Working code R-Code

= Reason code

SO-Code = Assortment C-Code List No Function Group

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0

Chassis

0000

1

Drive Motor

1000

2

Drive Gear / Transmission

2000

3

Brake / Wheel System

3000

4

Steering System

4000

5

Electrical System

5000

6

Hydraulic / Pneumatic System

6000

7

Operating Function-lifting Mast / Cylinders

7000

8

Peripheral / Installation Equipment

8000

9

Optionals / Attachments

9000

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Table of Contents BT Standard Codes ............................................................................ 1 Warning Symbols ............................................................................... 5 Prohibitory Symbols .......................................................................... 6 Introduction, service manual ............................................................ 7 Contents, Section M ........................................................................... 9 General product information ........................................................... 11 Inch (SAE) and Metric Fasteners ................................................... 19 Technical service data ..................................................................... 29 Ordering Spare Parts ....................................................................... 33 Contents, Section P ......................................................................... 35 Introduction, Maintenance ............................................................... 37 Service schedule .............................................................................. 39 Lubrication chart .............................................................................. 43 Oil and grease specification ............................................................ 45 Contents, Section S ......................................................................... 47 Support arm chassis ........................................................................ 49 Transmission .................................................................................... 55 Electrical System .............................................................................. 71 Battery Controller / Hourmeter / Lift Interrupt ............................... 83 Transistor Controller ........................................................................ 91 PCB Card ........................................................................................... 99 Hydraulic system, mechanical lowering ...................................... 105 Hydraulic system, electrical lowering .......................................... 107

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Table of Contents

Lift Cylinder .................................................................................... 111 Key pad ............................................................................................ 115

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Warning Symbols Always follow the warnings given in this Instruction Manual and on the truck to avoid accidents and incidents from occurring.

1. Warning Levels Always follow the warnings given in this Instruction Manual and on the truck to avoid accidents from occurring.

Warning levels Warning texts are given in four levels and provide information on the risks, describe the consequences, and instruct how to avoid accidents.

DANGER Warns that an accident will occur if you do not follow the instructions.

The consequences are serious personal injury or possibly death, and/or extremely large material damage.

WARNING Warns that an accident can occur if the instructions are not followed.

The consequences are serious personal injury or possibly death, and/or large material damage.

CAUTION Warns that an accident can occur if the instructions are not followed.

The consequences are personal injury and/or material damage.

NOTE! Marks the risk of a crash/breakdown if the instructions are not followed.

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Prohibitory Symbols

NO SMOKING If smoking occurs in situations where a restriction agains smoking is stated, a serious accident can occur.

OPEN FLAMES PROHIBITED If open flames are used in situations where open flames are prohibited, a serious accident can occur.

GENERAL PROHIBITION If the prohibition is ignored, a serious accident can occur.

1. Ordinance Symbols

SAFETY SHOES When the directive for safety shoes is given, safety shoes shall always be worn to avoid personal injury.

PROTECTIVE GLASSES When the directive for protective glasses is given, protective glasses shall always be worn to avoid personal injury.

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M Introduction, service manual Version no

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000

WSX-OS

Introduction, service manual The information in this Service Manual covers the truck types BT WSX-OS. Federal and State laws require that operators be completely trained in the safe operation of lift trucks.

An Operator’s Manual is attached to every BT lift truck when it is manufactured. If the Operator’s Manual is missing from the truck, a new manual may be obtained by contacting: BT Prime-Mover, Inc. 3305 N Highway 38 Muscatine, Iowa

52761-8800

(319) 262-7700 This service manual is not a training manual. The information contained in this service manual is intended as a guide to help authorized technicians safely service this truck.

The Service Manual is divided into four separate sections which cover different kinds of information needed for servicing these truck types. The main subject for each of these sections is described below.

SECTION

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SUBJECT

M

MACHINE INFORMATION

P

PLANNED MAINTENANCE

S

SERVICE INSTRUCTIONS

O

OPTIONS

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M Introduction, service manual Version no

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WSX-OS

8

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M Contents, Section M Version no

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Contents, Section M 1. Machine Information

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M1.0

GENERAL PRODUCT INFORMATION

M2.0

TECHNICAL SERVICE DATA

M3.0

ORDERING SPARE PARTS

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M Contents, Section M Version no

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PS M1.0 General product information Version no

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WSX-OS

General product information Valid from machine number: 272581AA000 -

1. Presentation of the WSX-OS The trucks BT WSX-OS is a battery powered man-up straddle arm truck. This truck is equipped with a keypad to restrict use and a handle to be controlled by the operator while walking.

The truck has a maximum lifting capacity of 800 lbs.

This truck has a 24V electrical system and the speed is regulated by means of a transistor controller to provide gentle control of acceleration and speed while driving.

The platform is raised by means of a powered hydraulic unit.

The control of the lift is done electrically with the push button on the platform. Lowering is also done by pressing another switch on the platform. When the lowering switch is pressed a warning alarm is sounded to warn of the platform lowering.

The truck is fitted with an hourmeter and a switch to prevent direction control when platform is lifted.

1.1. Intended application of the truck The truck is solely designed and manufactured to handle goods. The trucks should be fitted with the appropriate accessories relevant to the application.

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1.2. Forbidden application of the truck The truck is designed for handling goods indoors. It is not permitted to use the truck for other purposes including the following: - In areas that contain gases which can cause fires or explosions - As a towing truck for trailers - To tow other trucks - To transport/lift passengers - To drive on gravel or grass

1.3. Truck data The table provides information regarding some technical data which is of value with daily use of the truck.

Truck type Lifting capacity rated load, lbs Lift height, inches

WSX-OS 800 90/138

Operating speed without load, mph

1.5

Operating speed with rated load, mph

1.5

Max. operating grade with load, %

0

Service weight without battery, lbs.

2150

Service weight including battery, lbs. (Ah)

2480 (240)

Turning radius (Wa), inches (fork length 45.3 inches)

59.3

Continuous noise level, dB A

< 70

The truck’s lifting capacity, lifting height, and weight can be found on the truck’s type plate.

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1.4. Truck dimensions The diagram shows external dimensions for the truck in its standard design.

89.5” 90.0” 53.0”

74.2”

52.0”

28.5”

59.3” 42.5”

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1.5. Truck data plate The diagram shows the truck’s data plate.

Lift platform data plate The diagram shows the lift platform’s data plate.

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2. Main components 1. Tiller arm: The truck is to be controlled by the operator walking. 204 degrees of steering angle. The brake is applied in the upper and lower position of the tiller arm.

2. Data plate: With model designation, serial number, year of manufacture, service weight, battery weight, classified lifting capacity, battery voltage and manufacturer.

3. Covers: Removable which provides good accessibility when servicing.

4. Instrument: (standard and optional) Combined hourmeter/battery discharge indicator or hourmeter only.

5. Hydraulic control: For controlling lifting and lowering functions.

6. Hydraulic unit: Pump motor, pump, valves and oil tank integrated in a compact unit.

7. Hydraulic valves: The valves are located to provide easy access.

8. Drive unit with brake: Fixed drive unit with a spring applied brake, drive motor, gear and drive wheel combined into a compact unit. Steering bearings between motor and gear.

9. Truck serial number: The serial number plate stamped on the chassis.

10. Electric panel: Removable, which provides good access when servicing. 24 volt electrical system. The traction speed is variably controlled by means of a transistor.

11. Battery: 24V with different Amp hours capacities. The truck can also be equipped with a battery pack (4x6V) with an integrated charger (optional).

12. Battery connector/Recharging connector: The battery is recharged through the removable charging connector.

If the truck is equipped with a battery pack the batteries are charged by connecting the removable charging connector to the integrated charger.

13. Emergency disconnect and battery connector: The battery is charged through this connector.

14. Mast: Guarded by a finger protection which covers the operator’s normal range of reach from the operating position.

15. Emergency lowering lever: The platform can be lowered in an emergency by pulling this lever.

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16. Emergency disconnect on platform: In an emergency all electrical power can be stopped.

17. Keypad: The keypad is used to prevent unauthorized operation of the platform.

18. Tether belt and lanyard: When worn correctly it is designed to prevent a fall from happening, or to minimize bodily injury if a fall should occur.

5 14 18 16 1 17 4 QUARTZ

HOURS

1 10

2

13 3

6

11

12

10

16

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3. Warning and information signs The figure shows the position and significance of the signs located on the truck.

1.

Hydraulic control: Lifting

2.

Hydraulic control: Lowerin

3.

Signal/Horn

4.

Truck warning decal: General warning /information

5.

Hydraulic control: Emergency Lowering

6.

Hydraulic oil level

7.

Truck serial number

8.

Truck data plate

9.

Warning decal: No riding

10. Maximum lift height for rated capacity 11. Warning decal: Do not stand on the forks/Do not walk under lifted load 12. Lifting points 13. Warning decal: Risk of crushing 14. Platform warning decal: General warning /information 15. Platform data plate

16. Safety belt: Always wear tether belt and lanyard.

12

2

1

3

13

Replace any missing or damaged warning decals immediately.

3

3

10 9

16

8 14

6 7

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17

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M1.1 Inch (SAE) and Metric Fasteners Version no

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Inch (SAE) and Metric Fasteners

1. Introduction Threaded fasteners such as bolts, nuts, cap screws, and studs are made to specifications that describe the mechanical strength and hardness of the fastener. A fastener used in a design application is selected in accordance with its specifications. Parts used on this truck are purchased from many countries. There are several standards used by these countries in the manufacture of threaded fasteners. Many of these fasteners are similar but cannot be used as direct replacements.

Service persons must use replacement fasteners that have the same specifications. Fasteners made to each specification have identification marks for that specification.

This specification is commonly called “grade” for SAE standards and “property” for metric standards. This section describes the identification of some common fasteners.

The metric system used is described as SI (International System of Units, also called SI in all languages). The SI system of measurement is described in ISO Standard 1000, 1973.

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M1.1 Inch (SAE) and Metric Fasteners Version no

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2. Nomenclature, Threads The thread design is specified by a series of numbers and letters for inch and metric fasteners (see figure below). The diameter of the shank of the fastener is shown first in the series, e.g. M12=12 mm, M20=20 mm (1/2=1/2 inch, 3/4=3/4 inch).

The number of threads per inch is normally not shown for inch nomenclature and only the UNC (Unified National Coarse) or UNF (Unified National Fine) is shown. This number of threads per inch is not shown because a UNC or UNF fastener has a standard number of threads per inch for a specific diameter.

The length of a shank is often indicated as part of the description of a fastener. This length is shown in inches for inch fasteners and in millimeters for metric fasteners.

A cap screw will have the following description: INCH

METRIC

1/2 x 13 UNC x 1-1/2 A B C D

M12 x 1.75 x 50 A B C

A = SHANK DIAMETER B = NUMBER OF THREADS PER UNIT OF LENGTH C = TYPE OF THREAD D = SHANK LENGTH

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A = THREAD SIZE B = PITCH C = LENGTH

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3. Strength Identification The most common property classes for metric fasteners are 8.8 and 10.9. The property class is marked with a number on the head of the cap screw or on a nut. Property classes less then 8.8 are often not marked. Grades for inch bolts go from 2 to 8. Grade 2 fasteners normally do not have marks. The following tables show the marks that identify the grades and property classes for different fasteners.

WARNING When fasteners must be replaced the new fasteners must be of the same strength or greater than the original fasteners. The new fasteners must also be the correct size.

NOTE! Identification marks are according to bolt strength. The higher the number, or the increase in the number of marks, indicates increased bolt strength.

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M1.1 Inch (SAE) and Metric Fasteners Version no

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Table 1. Bolt and Screw Designations

Types of Fasteners

Metric Fasteners

Inch Fasteners Strength Levels: SAE Grades

Strength Levels: Property Classes

* Markings Not Required 2

5

5.2

7

8

Hex Head Bolts & Cap Screws 5

4.6*

4.8*

5.8*

8.8

4.6

4.8

5.8

8.8

9.8

10.9

12.9

9.8

10.9

12.9

Markings for size M5 and Larger

8

Hex Hea Flange Screws

Same As Above 5

8

12 Point Flange Screws

Hex Socket Head Cap Screws

Markings Not Required

5.1

8.8

12.9

8.8

12.9

4.8*

9.8

4.8

9.8

SEMS

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Table 2. Stud and Nut Designations

Types of Fasteners

Inch Fasteners

Metric Fasteners

Strength Levels: SAE Grades

Strength Levels: Property Classes

* Markings Not Required

* Markings Not Required

5.2*

5*

4.6*

4.8* 5.8*

8.8

4.6

4.8

8.8

9.8 9.8

8*

5.8

10.9 12.9 Markings for size M5 and Larger

12.9

10.9

8.1 or

Studs

Optional Geometric Symbols for Size M5 through M11 ONLY.

2

Hex Nuts

Hex Slotted Nuts

Hex Flange Nuts

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5

5

8

9

5

8

9

5

8

9

10

12

10

12

10

12

8 or

or

Markings Not Required

5

8

9

10

12

5

8

9

10

12

5

8

9

10

12

5

8

9

10

12

Markings Not Required

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Table 3. Torque Nut Designations

Types of Fasteners

Inch Fasteners Strength Levels: SAE Grades

A

Metric Fasteners Strength Levels: Property Classes

B

C

5

9

10

B

C

5

9

10

or All Metal Prevailing Torque Nuts

F

G 9

10

9

10

or All Metal Prevailing Torque Flange Nuts or

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Table 4. Torque Nut with Nylon Insert Designations

Types of Fasteners

Metric Fasteners

Inch Fasteners

Strength Levels: Property Classes

Strength Levels: SAE Grades

5

9

10

5

9

10

or Nylon Insert Prevailing Torque Nuts

Markings Not Require

or or

Markings Not Required

9

10

9

10

or

Nylon Insert Prevailing Torque Flange Nuts

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Table 5. Fastener Torque Values

Size and Pitch

Property, Class 8.8*

Property, Class 10.9**

Property, Class 12.9***

N•m

in.-lb

N•m

in.-lb

N•m

in.-lb

5-6 8-10 20-25

44-53 71-88 177-221

7-8 12-14 30-35

62-71 106-124 ------------

8-10 14-16 ------------

71-88 124-142 -----------

N•m

ft-lb

N•m

ft-lb

N•m

ft-lb

M8 x 1.25 M10 x 1.5

-----------40-45

-----------30-33

----------60-65

22-26 44-48

34-40 70-75

26-30 52-55

M12 x 1.75 M14 x 2

70-80 110-125

30-33 52-59

100-110 155-180

74-81 114-133

115-130 180-210

85-96 133-155

M16 x 2 M20 x 2.5

170-190 340-380

125-140 251-280

240-270 450-500

177-199 332-369

280-320 550-600

207-236 406-443

M24 x 3

580-650

428-479

800-900

590-664

900-1050

664-774

M30 x 3.5

1150-1300

848-959

1600-1800

1180-1328

1850-2100

1364-1549

M36 x 4

2000-2250

1479-1660

2800-3150

2065-2323

3250-3700

2397-2729

M5 x 0.8 M6 x 1 M8 x 1.25

*

Property class 8.8, Protective Treatment CMHC Specification “H” (zinc phosphate), applies also to internally threaded fasteners made of property class 8 material.

** Property class 10.9, Protective Treatment CMHC Specification “H” (zinc phosphate), applies also to internally threaded fasteners made of property class 10 material. *** Property class 12.9, Protective Treatment CMHC Specification “H” (zinc phosphate), applies also to internally threaded fasteners of property class 12 material.

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4. Conversion of Metric and English Units AREA Multiply

By

To Get

Multiply

By

To Get

inches²

6.451

centimeters² (cm²)

centimeters²

0.155

inches² (in²)

feet²

0.093

meters² (m²)

meters²

10.764

feet² (ft²)

LINEAR Multiply

By

To Get

Multiply

By

To Get

inches

25.4

millimeters(mm)

millimeter

0.039

inches (in)

feet

0.305

meters (m)

meter

3.280

feet (ft)

yards

0.914

meters (m)

meter

1.094

yards (yd)

miles

1.609

kilometers (km)

kilometer

0.621

miles (mi)

MASS Multiply

By

To Get

Multiply

By

To Get

ounces (oz)

28.49

grams (g)

grams

0.035

ounces (oz)

pounds (lb)

0.454

kilograms (kg)

kilograms

2.205

pounds (lb)

tons (2000 lb)

907.18

kilograms (kg)

kilograms

0.001

tons (2000 lb)

tons (2000 lb)

0.907

metric ton (t)

metric ton

1.102

tons (2000 lb)

POWER Multiply

By

To Get

Multiply

By

To Get

horsepower

0.746

kilowatts (kW)

kilowatts

1.34

horsepower(hp)

PRESSURE Multiply

By

To Get

Multiply

By

To Get

pounds/in²

6.895

kilopascal (kPa)

kilopascals

0.145

pounds/in² (psi)

pounds/in²

0.007

megapascal (MPa)

megapascals

145.04

pounds/in² (psi)

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TEMPERATURE Multiply

By

To Get

Multiply

By

To Get

(Fahrenheit -32)

0.56

Celsius (C)

(Celsius x 1.8)

+32

Fahrenheit (F)

By

To Get

TORQUE Multiply

By

To Get

Multiply

inch pound

0.113

Newton meter (N•m) Newton meter

8.851

inch pounds in.-lb

feet pound

1.356

Newton meter (N•m) Newton meter

0.738

foot pounds ft-lb

VELOCITY Multiply

By

To Get

Multiply

By

To Get

miles/hour

1.609

kilometer/hour (km/h)

kilometer/hour

0.621

miles/hour (mph)

VOLUME

28

Multiply

By

To Get

Multiply

By

To Get

inches³

16.387

centimeters³ (cm³)

centimeters³

0.061

inches³ (in³)

inches³

0.016

liters

liters

61.024

inches³ (in³)

quarts, U.S.

0.946

liters

liters

1.057

quarts, U.S. (qt)

quarts, U.S.

0.83

quarts, Imp. (qt)

quarts, Imp.

1.205

quarts, U.S. (qt)

gallons, U.S.

3.785

liters

liters

0.264

gallons, U.S. (gal)

gallons, U.S.

0.83

gallons, Imp. (gal)

gallons, Imp.

1.205

gallons, U.S. (gal)

ounces

29.57

milliliters (ml)

milliliters

0.034

ounces (oz)

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Section

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M1.2 Technical service data

Version no

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000

WSX-OS

Technical service data Valid from machine number: 272581AA000 MODEL WSX-OS DRIVE MOTOR Type

TTL 1403-M2

Power

1.2 kW

Duty factor

60%

Min carbon brush length

0.5 inch

Min commutator diameter 1.85 inch Part no

134397

TRANSMISSION/GEAR Type

2-step angular

Gear ratio

19.43:1

Oil volume

1 quart

Oil type

Hypoid oil

Normal temperature

SAE 80W/90

< -15oC

SAE 75W

WHEELS

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Service Manual

Drive wheel

Dia215x70 mm

Wheel pressure without load

1342 lb

Wheel pressure with rated load

1420 lb

Torque wheel bolts

47 ft-lb

Fork wheel

Dia 100x75 mm

Axle pressure with rated load

2412 lbs

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PS M1.2 Technical service data Version no

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000

WSX-OS

MODEL WSX-OS HYDRAULIC UNIT Power

2.0 kW

Revolutions/min at work pressure

2600

Duty factor

9%

Min carbon brush length

0.5 inch

Min commutator thickness/diameter

1.7 inch

Pressure at rated load

900 psi

Relief pressure

1000 psi

Pump flow

6.4 litre/min at 2090 psi

Tank volume

0.92 gallons

Oil type

Hydraulic oil

Normal temperature

ISO-L-HM32

< -15oC

ISO-L-HV32

FUSES Drive motor circuit

29228

Amperage

100 A

Pump motor circuit

29223

Amperage

160 A

Control circuit

122308-075

Amperage

7.5 A

BATTERIES

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Dimension WxLxH

196x645x570 mm

Capacity

240 Ah

Weight

440 lb

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M1.2 Technical service data T-code

WSX-OS

NOTE! Performance may vary up to -10% due to motor and system efficiency tolerance. The performance shown represents nominal values obtained under typical operating conditions.

NOTE! These products and specifications are subject to change without notice.

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PS Version no

Section

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M3.0 Ordering Spare Parts T-code

000

Ordering Spare Parts 1. Locate the fault on the truck.

2. Find out the machine model and serial number.

3. Locate the page with the exploded diagram and find the position number for the part you require.

4. Locate the position number in the table. Select the column for the actual machine model and serial number.

5. Note the part number.

6. Call the local BT dealer and state the part number.

If you cannot find the machine model, serial number, or the article number, call the local BT dealer and he will help you.

© BT Products

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Service Manual

1997-07-15

33

F-code

Section

C-code

PS M3.0 Ordering Spare Parts Version no

T-code

000

34

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Service Manual

1997-07-15

F-code

PS Version no

Section

C-code

P Contents, Section P T-code

000

Contents, Section P 5. Planned Maintenance

© BT Products

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P1.0

INTRODUCTION

P2.0

SERVICE SCHEDULE

P3.0

LUBRICATION MAINTENANCE

P4.0

OIL AND GREASE SPECIFICATION

Service Manual

1997-07-15

35

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PS P Contents, Section P Version no

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000

36

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Service Manual

1997-07-15

F-code

PS

Section

C-code

P1.0 Introduction, Maintenance

Version no

T-code

000

Introduction, Maintenance The schedules of maintenance and lubrication given in this section of the Service Manual cover up to one year’s operation of a truck.

These schedules are based on hourly usage and can be adapted to suit most normal one shift patterns. The following hourly usage figures have been used when calculating the schedule: Single shift- 8 am-5 pm, 25 hours per week usage Double shift- 6 am-2 pm, 2 pm-10 pm, 50 hours per week usage Triple shift- 6 am-2 pm, 2 pm-10 pm, 10 pm-6 am, 75 hours per week usage The schedules are intended only as a guide, not as a rigid structure. Operators of trucks may wish to adapt them to local requirements; but it is emphasized that the schedules represent minimum manufacturer requirements, and all items should be included in a service program to ensure minimum downtime and a high safety status of the equipment.

- Use only spare parts approved by BT. - Always clean the equipment and carry out a full safety check after service.

1. Safe Jacking Procedure 1. Disconnect battery.

2. Read and follow the correct operating procedures for your jack or hoist.

© BT Products

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Service Manual

1997-07-15

37

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Section

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PS P1.0 Introduction, Maintenance Version no

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000

38

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Section

PS

P2.0 Service schedule

Version no

C-code

T-code

000

WSX-OS

Service schedule Valid from machine number: 272581AA000 PM Interval: A=5 Hours or 1 Day

E=500 Hours or 6 Months

B=20 Hours or 1 Week

F=1000 Hours or 12 Months

C=80 Hours or 1 Month

G=3000 Hours or 36 Months

D=250 Hours or 3 Months

© BT Products

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No.

Action

A

1.0

Chassis

1.1

Check the cover lockings

X

1.2

Check for wear on the battery lockings

X

1.3

Check for damage and crack

X

1.4

Check outriggers mounting

X

1.5

Check support arm clamp bolts

X

2.0

Motors

2.1

Check for loose connections

X

2.2

Clean motor

X

2.3

Check mounting bolts

2.4

Check for abnormal bearing noise

3.0

Drive unit

3.1

Check for oil leakage

X

3.2

Check oil leve

X

3.3

Check for noises

X

3.4

Check the drive unit’s oil

4.0

Wheels

4.1

Remove string & debris

4.2

Check drive wheel wear and nuts

X

4.3

Check that support arm wheels rotate and axles are fitted correctly

X

4.4

Check support arm wheel for wear

X

4.5

Dismantle and lubricate support wheel bearing

Service Manual

B

C

D

E

F

G

X X

X

X

1999-02-10

X

39

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PS P2.0 Service schedule Version no

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000

WSX-OS

40

Return

No.

Action

A

B

C

D

E

5.0

Brake

5.1

Clean

X

5.2

Check for wear on brake discs

X

5.3

Check for play in released position

X

6.0

Electrical panel

6.1

Clean and check the mounting

X

6.2

Tighten cable connections

X

6.3

Check contactor points

X

6.4

Check the contactor’s movement

X

7.0

Battery

7.1

Check electrolyte level (10-15mm above cell plate)

X

7.2

Check connections on battery, truck and charger

X

7.3

Check cell and pole guard

X

7.4

Check fluid density and temperature

X

7.5

Check power cables are not cut or fraye

8.0

Hydraulic system

8.1

Check hoses and couplings for leakage

X

8.2

Check pipes and hoses for wear

X

8.3

Check the tank for leakage and its mountings

X

8.5

Check oil leve

X

8.6

Change oil

9.0

Cylinders

9.1

Check for leakage

X

9.2

Check the mountings

X

10.0

Mast and reach carriage

10.1

Check for damage and cracks

X

10.2

Check mast mounting bolt torque

X

10.3

Check for play on the rollers

X

10.4

Check the electrical limit switch function

X

10.5

Check for wear and stretch on the chains and sheaves

X

10.6

Check hoses and couplings for leakage cuts and other damage

X

F

G

X

X

Service Manual

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P2.0 Service schedule

Version no

C-code

T-code

000

WSX-OS

No.

Action

A

B

C

D

E

10.7

Check for wear to the forks and other lifting devices

11.0

Control console

11.1

Check handle mounting

X

11.2

Check the handle brake switch

X

11.3

Check the handle switches

X

11.4

Check the handle reverser switch

X

11.5

Check that the control handle returns to the upright position wit parking brake applie

X

X

10 9 11

1 3 4

4 2

8 6

5

2 7

© BT Products

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41

F

G

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PS P2.0 Service schedule Version no

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000

WSX-OS

42

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Section

PS

P3.0 Lubrication chart

Version no

000

C-code

T-code

WSX-OS

Lubrication chart Valid from machine number: 272581AA000 -

2

3

6 1 4

5

Pos no Service point 1 2 3 4 5 6

Wheel bearings Mast beam Lifting chains Hydraulic system Steering Bearings Drive gear

Interval/Running hours 500h 1000h 3000h L L L C O L C O

Lubricant A F D B G C

L= LubricationC = Check O = Oil change

© BT Products

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1999-02-10

43

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PS P3.0 Lubrication chart Version no

T-code

000

WSX-OS

44

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Service Manual

1999-02-10

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Section

C-code

PS P4.0 Oil and grease specification Version no

000

T-code

WSX-OS

Oil and grease specification Valid from machine number: 272581AA000 -

2. Approved oils and grease

© BT Products

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Lubricant

Specification > - 15°C < - 15°C

Application area

A

Grease

Bearings and bushings

B C D

Hydraulic oil Transmission oil Grease

F G

Grease Grease

BT 26777 (Spray) ISO-L-HM32 SAE 80W/90 BT 26778 (Spray) BT 055-70111 Tex. Ref. C and C #880

Service Manual

BT 26777 (Spray) ISO-L-HV32 SAE 75W BT 26778 (Spray) BT 055-74320 Tex. Ref. C and C #880

1999-02-10

Hydraulic system Gears Chains and wires Mast Steering bearings

45

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PS P4.0 Oil and grease specification Version no

T-code

000

WSX-OS

46

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1999-02-10

F-code

PS Version no

Section

C-code

S Contents, Section S T-code

000

Contents, Section S 1. Service Instructions NO FUNCTION GROUP

C-CODE

0

CHASSIS

0000

1

DRIVE MOTOR

1000

2

DRIVE GEAR / TRANSMISSION

2000

3

BRAKE / WHEEL SYSTEM

3000

4

STEERING SYSTEM

4000

5

ELECTRICAL / PNEUMATIC SYSTEM

5000

6

HYDRAULIC SYSTEM

6000

7

LIFTING MAST / CYLINDERS

7000

8

PERIPHERAL / INSTALLATION

8000

EQUIPMENT 9

© BT Products

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OPTIONS / ATTACHMENTS

Service Manual

1997-04-15

9000

47

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PS S Contents, Section S Version no

T-code

000

48

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Service Manual

1997-04-15

F-code

PS Version no

000

Section

C-code

S1.0 0350 Support arm chassis T-code

WSX-OS

Support arm chassis Valid from machine number: 272581AA000 -

2. General The support arm chassis is bolted to the drive unit chassis to complete the truck. It also has the mounting points for the lifting mast and lift cylinders.

The support arms of the straddle chassis are adjustable in width from 32 inches to 51 inches to suit different pallet sizes.

Normally the support arms are only adjusted prior to a truck being delivered to a customer.

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49

F-code

Section

PS S1.0 Support arm chassis Version no

T-code

000

WSX-OS

C-code

0350

3. Main components 4

5

3 6 2 10

7 1

9

8

Pos no

Description

1

Support arm wheel axle

2

Wheel axle locking circlip

3

Support arm wheel

4

Support arm

5

Mounting bracket to drive unit chassis

6

Support arm safety catch

7

Support arm clamp

8

Support arm locking bolt

9

Lift cylinder mounting bracket

10

Mast mounting bracket

4. Maintenance The support arm clamp bolts need to be checked at the regular 500 hours preventive maintenance service. The torque of the support arm clamp bolts (pos no. 7 in chapter 2) must be checked with a torque wrench set at 88.5 ft-lb.

50

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F-code

PS Version no

000

Section

C-code

S1.0 0350 Support arm chassis T-code

WSX-OS

5. Adjustment of the support arm width B

A

B

3 2 1

To adjust measurement A between the support arms proceed as follows: • Park the truck on a level surface.

• Disconnect and remove the battery from truck to prevent accidental operation.

• Block truck with one side about 1 in. off floor.

Warning!

The truck can tip over.

Do not jack up both support arms at the same time. The truck is a three wheeler.

Jack up one side at the time and support it while working.

• Loosen the bolt at the front of the cross beam (1).

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51

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Section

PS S1.0 Support arm chassis Version no

T-code

000

WSX-OS

C-code

0350

• Loosen the clamp bolts (2).

• Pull out (or push in) the support arm. To get measurement A, measure B = A/2 - 12 inches. Make sure that measurement B is equal on both sides.

If the support arm is pulled out too much the safety catch, 3, will drop into the hole in the arm to stop it from falling out.

• Tighten bolt 1 and lock it with the locking nut.

• Tighten the four clamp bolts, pos 2, with a torque wrench.

Torque value: 88.5 ft/lbs.

6. Exchange of support arms When changing a support arm the job is more extensive than adjusting the arm width.

• Lift out the battery.

• Remove the battery box from the chassis. Remove the two bolts at the bottom of the box.

1

2 • Remove the safety catch from the support arm clamp.

• Jack up the side of the truck where the support arm is to be changed.

• Loosen the bolt at the front of the cross beam, 1.

• Loosen the clamp bolts, 2.

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PS Version no

000

Section

C-code

S1.0 0350 Support arm chassis T-code

WSX-OS

• Pull out the support arm.

• Install the new support arm and adjust the arm width according to chapter 4.

• Lower the truck to the floor.

• After tightening the clamp bolts, fit the safety catch.

• Install the battery box.

• Install the battery.

© BT Products

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1999-02-10

53

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Section

PS S1.0 Support arm chassis Version no

T-code

000

WSX-OS

54

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C-code

0350

Service Manual

1999-02-10

F-code

Section

PS

S2.0 2550 Transmission

Version no

000

C-code

T-code

WSX-OS

Transmission Valid from machine number: 272581AA000 -

1. General technical description

© BT Products

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Service Manual

1999-02-10

55

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Section

C-code

PS S2.0 Transmission

2550

Version no

T-code

000

WSX-OS

1.1. Technical data Data

Description

Type

2-step angular

Upper gear wheels

Angle spur gear

Lower gear wheels

Angle gear 90 degrees

Gear ratio, overall

19.43:1

Gear ratio, upper gear

4:1

Gear ratio, lower gear

4.86:1

Oil volume

1.0 litre

Oil type, normal temperature SAE 80W/90

56

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Oil type, < -15oC

SAE 75

Oil change

First time: 250 hours Regular change: 3000 hours

Service Manual

1999-02-10

F-code

Section

PS

S2.0 2550 Transmission

Version no

C-code

T-code

000

WSX-OS

1.2. Gear components

1

2 3 4 5 A

12 11

6

10

9

© BT Products

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8

7

Pos No

Component

1

Primary gears

2

Upper pinion bearing

L2

3

Bearing shim

S2

4

Bearing shim

S1

5

Lower pinion bearing

L1

6

Set of pinion and crown gears

7

Inner drive shaft bearing

Service Manual

1999-02-10

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PS S2.0 Transmission

2550

Version no

T-code

000

WSX-OS

58

Return

Pos No

Component

8

Bearing shim

S3

9

Outer drive shaft bearing

L4

10

Bearing shim

S4

11

Drive shaft

12

Drive shaft seal

A

Measurement, pinion height

Service Manual

65 mm

1999-02-10

F-code

Section

PS

S2.0 2550 Transmission

Version no

000

C-code

T-code

WSX-OS

1.3. Special tools

Pos No

Tool

1

Bearing with drawer: part no = 08-13022

2

Dial indicator with magnetic bracket

3

Feeler gauge

4

Micrometer 0-25 mm (0-1 inch)

5

Spring balance 0-10 kg (0-22 lbs.)

6

Measuring gauge: part no = 06-13020

7

Assembly axle: part no. = 08-13021

2. Removing the gear from the truck • Lift the machine so the bolts for the driving gear are accessible from beneath.

The truck can also be laid on the side after removal of the battery and sealing off the hydraulic system.

• Remove the drive wheel (17 mm) © BT Products

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1999-02-10

59

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C-code

PS S2.0 Transmission

2550

Version no

T-code

000

WSX-OS

• Drain the oil by removing the lower gear cover ( 6 mm allen key).

• Remove the nuts (13 mm) holding the gear and motor together.

• Take the driving gear out of the machine.

• Installing the driving gear into the truck is made in the reversed order.

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F-code

Section

PS

S2.0 2550 Transmission

Version no

000

C-code

T-code

WSX-OS

3. Change of seal on the drive shaft • Remove the gear from the truck as shown in chapter 2.

• Remove the upper gear cover (6 mm allen key).

• Knock out the locking on the drive shaft nut.

• Remove the drive shaft nut (36 mm).

• Knock the drive shaft out with a plastic hammer or press it out.

• Remove the crown wheel and bearing L3.

• Remove the old seal and replace. © BT Products

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1999-02-10

61

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PS S2.0 Transmission

2550

Version no

T-code

000

WSX-OS

62

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S2.0 2550 Transmission

Version no

000

C-code

T-code

WSX-OS

• Put the drive shaft in place and place the inner ring of the bearing L3 in the gear housing.

• Put the crown gear onto the splines of the drive shaft and a new washer and nut.

Tighten the drive shaft nut to 300 Nm (217 ft-lb) with a torque wrench.

• Lock the shaft nut with a punch into the groove in the shaft.

• Install the covers to the gear with new gaskets.

Tightening torque: 26.6 Nm (19.5 ft-lb) • Install the driving gear into the truck.

Tightening torque: 26.6 Nm (19.5 ft-lb) Fill with new oil.

• Install the drive wheel Tightening torque: 65Nm (47.7 ft-lb)

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1999-02-10

63

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C-code

PS S2.0 Transmission

2550

Version no

T-code

000

WSX-OS

4. Reconditioning of the gear • Remove the gear from the truck as shown in chapter 2.

• Remove the gear covers (6 mm allen key).

• Knock out the locking on the drive shaft nut.

• Remove the drive shaft nut (36 mm spanner).

• Knock the drive shaft out with a plastic hammer or press it out.

• Remove the crown wheel and bearing L3.

• Press or knock out the bearing cups for bearing L3 and L4 and remove the shim-pack S3 from the gear housing.

• Remove the bearing L4 from the drive shaft by using the puller, part no. 08-13022. Remove the shim S4 from the shaft.

• Knock out the locking on the pinion nut. Remove the nut (22 mm spanner) and the primary gear wheel.

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PS

S2.0 2550 Transmission

Version no

000

C-code

T-code

WSX-OS

• Knock out the pinion with a plastic hammer or press it out.

Remove the bearing L2 and shim S2.

• Remove the bearing L1 from the pinion with the puller, part no. 08-13022.

• Press or knock the cups for the bearings L1 and L2 out and remove the shim-pack S1 from the housing. Remove the old seal ring.

• Clean the covers, gear housing and drive shaft with a suitable solvent.

• Install new races for the bearings L1 and L2 into the gear housing with 0.5 mm shim S1.

• Install the new bearing L1 on the new pinion.

• To determine shim needed assemble the pinion, bearing L2 and primary gear with the old nut and shim. Till there is no axial play enough thickness of shim S2 so that there is no axial play. Tighten the nut to 30 Nm (22.5 ft/lbs.) using the old nut.

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65

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C-code

PS S2.0 Transmission

2550

Version no

T-code

000

WSX-OS

• Install the new races for the bearings L3 and L4 into the gear housing WITHOUT shim S3.

• Install the assembly axle part no. 08-13021 with the bearing L4 into the gear housing. Place the bearing L3 and the crown wheel onto the axle. Make sure that there is enough shim S4 for the bearing L4 so that there is no axial play on tool 08-13021. Tighten the axle nut to 100 Nm (72 ft/lb) using the old nut.

• Measure the pinion height with the measuring gauge, part no. 08-13020, between the surface of bearing L1 and the pin on tool 08-13021. Use shims or feeler gauge together with the measuring gauge to get the correct thickness of shim S1. Built-in measure pinion height = 65 mm, measuring gauge length 59 mm + the radius of the pin 5 mm + 1 mm shim or feeler gauge thickness. The difference from 65 mm gives you the thickness of shim S1.

• Install the measured shim thickness under bearing L1 race.

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PS

S2.0 2550 Transmission

Version no

000

C-code

T-code

WSX-OS

• Assemble the pinion, bearings, and primary gear wheel with shim thickness S2 so that there is no axial play on the pinion. Zero-play, when having tightened the pinion nut 70 Nm (50.5 ft-lb). When needed, adjust S2 so that the play is zero.

• Install the assembly axle with bearings, crown wheel, and shim as previously. Tighten the nut 300 Nm (217 ft/lbs.)

• Measure the flank clearance with the crown wheel in three different positions. Carefully point the dial indicator 90° to the gear tooth surface.

• Shim (S3) bearing L3 so that a flank clearance of 0.10-0.15 mm is attained. Remove the same shim thickness from S4 that is fitted on S3 before the tool with bearings and crown wheel is reassembled.

• Check the flank clearance and measure the axial play on the tool 08-13021.

• Adjust the drive shaft axial play to zero-play by adjusting shim S4.

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67

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C-code

PS S2.0 Transmission

2550

Version no

T-code

000

WSX-OS

• Check the gear tooth impression with engineer’s blue.

Adjust shim S1 when needed. S2 is to be adjusted, and reduced if S1 is increased, and increased if S1 is reduced, correspondingly to the change on S1. Check the axial play on the pinion.

• Install the tool 08-13021 with bearings and crown wheel.

Check the flank clearance. Adjust shim S3 when needed.

S4 is to be adjusted, and reduced if S3 is increased, and increased if S3 is reduced, correspondingly to the change on S3. Check the axial play on tool part no. 08-13021.

• Check the gear tooth impression. When the impression is correct install a new washer and pinion nut. Tighten the nut 70 Nm (50 ft-lb) and lock it with a punch in the key groove.

• When the gear tooth impression and the axial play is correctly adjusted remove tool part no. 08-13021. Shimpack S4 is shifted over to the drive shaft and bearing L4 is placed on the shaft.

• Install the new seal ring in the gear housing.

• Put the drive shaft into the housing and put bearing L3 in place.

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Section

PS

S2.0 2550 Transmission

Version no

000

C-code

T-code

WSX-OS

• Put the crown wheel onto the splines of the drive shaft and install a new washer and nut.

Tighten the drive shaft nut 300 Nm (217 ft-lb) with a torque wrench. Check the axial play on the drive shaft. It shall be zero. Lock the nut with a punch in the groove on the shaft.

• Check the force needed to rotate the gear with the spring balance.

Maximum value: 6-6.5 kg

• Install the covers onto the gear with new gaskets.

Tightening torque: 26.6 Nm (19.5 ft-lb) • Install the driving gear into the truck.

Tightening torque: 26.6 Nm (19.5 ft-lb) Fill up with new oil.

• Install the drive wheel.

Tightening torque: 65 Nm (47.7 ft-lb)

© BT Products

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Service Manual

1999-02-10

69

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C-code

PS S2.0 Transmission

2550

Version no

T-code

000

WSX-OS

70

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Service Manual

1999-02-10

F-code

Section

PS

S5.0 5000 Electrical System

Version no

000

C-code

T-code

WSX-OS

Electrical Syste Valid from machine number: 272581AA000 -

1. Electrical panel, components.

RV1 F50

A2

F10

K11 K13 K30

F3 A1

H1

© BT Products

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71

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C-code

PS S5.0 Electrical System

5000

Version no

T-code

000

WSX-OS

2. List of symbols.

72

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Symbol

Description

Function

Remark

A1

Transistor controller

A2

Connection card

BT

Battery

F3

Fuse

Pump motor circuit

160A

F10

Fuse

Drive motor circuit

100A

F50

Fuse

Control circuit

7.5A

H1

Horn

K11

Contactor

Drive direction

Platform direction

K13

Contactor

Drive direction

Steer wheel direction

K30

Contactor

Pump motor

M1

Motor

Drive

M3

Motor

Pump

P1

Indicator

Hour meter

P3

Indicator

Battery indicator/Hour meter

R1

Potentiometer

Speed

RV1

Potentiometer

Speed reduction

S10

Switch

Brake

Service Manual

5 - 0 kOhm

1999-02-10

F-code

Section

PS

S5.0 5000 Electrical System

Version no

000

© BT Products

Return

C-code

T-code

WSX-OS

Symbol

Description

Function

Remark

S15

Switch

Drive direction

Platform direction

S16

Switch

Drive direction

Steer wheel direction

S17

Switch

Key

S18

Switch

Horn

S20

Switch

Reverser

S41

Switch

Platform lower

S52

Switch

Platform lift

Y41

Magnetic valve

Platform lower

Service Manual

1999-02-10

For optional electric lowering.

Always connected

When having optional electric lowering

73

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Section

PS S5.0 Electrical System Version no

T-code

000

WSX-OS

C-code

5000

2.1. Circuit diagram 1(4)

74

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F-code

Section

PS

S5.0 5000 Electrical System

Version no

000

C-code

T-code

WSX-OS

2.2. Circuit diagram 2(4)

© BT Products

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T-code

000

WSX-OS

C-code

5000

2.3. Circuit diagram 3(4)

76

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F-code

Section

PS

S5.0 5000 Electrical System

Version no

000

C-code

T-code

WSX-OS

2.4. Circuit diagram 4(4)

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PS S5.0 Electrical System Version no

T-code

000

WSX-OS

5000

3. DESCRIPTION OF FUNCTION 3.1. General The transistor controller (A1) regulates the infinitely variable speed control. When starting the truck, the controller checks the closing sequence of the micro switches in the circuit. The controller is equipped with a light emitting diode (LED) showing system status and potentiometers for adjusting the current limit and acceleration, placed under a sliding cover.

106

111 204

105

110

104 103

207

203 202

206

109 201

205

102

108

101

107

409

417

408

416

407

415

406

The electrical system has a connection card (A2) to group all connections of the control circuits for input and output signals to the transistor controller. The connection card is equipped with LED’s for indication of input or output signals and a potentiometer for adjustment of the maximum speed.

414

405 301

302

404

413

403 402

412 411

3.2. Adjustable settings:

410 401

Setting

Std. value

Min. value

Max. value

Current limit

150 Amp

100 Amp

150 Amp

Acceleration

0.8 s

0.1 s

3s

3.6 mph

1.9 mph

3.6 mph

Maximum speed, without load

3.3. References: For more information about adjustment of the speed potentiometer, the transistor controller, and the connection card, see C-code 5330, 5460 resp. 5710.

The description is divided into different phases which correspond to the operational sequence steps. For each sequence step the correct LED pattern is shown below. A filled circle denotes LED is emitting light.

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S5.0 5000 Electrical System

Version no

000

C-code

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3.4. Key switch S17 in the ON position 106

111 204

105

110

104

207

203 202

206

103

109 201

205

102

108

101

107

409

417

408

416

407

415

406

414

405 301

302

When S17 closes, the transistor controller will check that S10 is not closed. If this is the case, operation is not permitted.

404

413

403 402

412 411 410

401

Battery voltage on A2-terminal 202, LED 202 lights up. A2 (-) return terminal 409. Battery voltage to A1.16 through A2terminal 410, LED-status starts to flash.

3.5. The operating arm in drive position, S10, brake switch closed 106

111 204

105

110

104

207

203 202

206

103

109 201

205

102

108

101

107

409

417

408

416

407

415

406

414

405 301

302

404

413

403 402

412 411 410

401

When the operating arm is pulled down to the driving position, S10 is activated and closes, and at the same time the brake is mechanically released. Voltage obtained through terminal 109 and 408 to A1.15. LED 109 lights up on the hour meter terminal 206 and the shunt field terminal 301.

The transistor controller now regulates the current through the shunt field, 1.2 A, (-) return through terminal 302, 417 and A1.1.

3.6. Driving, platform direction 106

111 204

105

110

104

207

203 202

206

103

109 201

205

102

108

101

107

409

417

408

416

407

415

406

414

405 301

302

404

413

403 402

412 411 410

401

When the thumb control is activated for driving in the platform direction, S15 will close.

Battery voltage to terminal 101 and 411 to A1.11, LED 101 lights up. Battery voltage to K11 from terminal 403 A1.2 now gives (-) return to K11, (-)input on terminal 401, LED 401 lights up.

Depending on the position of the speed potentiometer (R1) and the adjustment of potentiometer RV1, A1.8 will receive a voltage between 4.8-0.25 V. The motor current now passes through F10, the series field D2-D1, K11, the armature A2-A1 and K11 to battery negative through A1 (M-).

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Section

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PS S5.0 Electrical System Version no

T-code

000

WSX-OS

5000

3.7. Driving, steer wheel direction

106

111 204

105

110

104

207

203 202

206

103

109 201

205

102

108

101

107

409

417

408

416

407

415

406

414

405 301

302

404

413

403 402

412 411 410

401

When the thumb control is activated for driving in the steer wheel direction, S16 will close. The transistor controller checks that S10 is closed before S16 closes. If not, driving is blocked.

Battery voltage to terminal 102 and 412 to A1.12, LED 102 lights up. Battery voltage to K13 from terminal 403, A1.3 now gives (-) return to K13, (-)input on terminal 402, LED 402 lights up.

Depending on the position of the speed potentiometer (R1) and the adjustment of potentiometer RV1, A1.8 will receive a voltage between 4.8-0.25 V. The motor current now passes through F10, the series field D2-D1, K13, the armature A1-A2 and K13 to battery negative through A1 (M-).

3.8. Reversing/motor brake platform direction to steer wheel direction S15 returns to open position while S16 closes. The current in the series field causes the motor to work as a generator since the drive wheel is rotating in the opposite direction.

The transistor controller detects the generated current at connection A2, and reduces the series field current to 60A. When the drive wheel rotates in the right direction and the potential at connection A2 becomes positive, acceleration is done according to adjusted values of current limit and acceleration.

During the plugging sequence, the armature current passes in the circuit A2-A1, K13, A2 (the brake diode of the transistor controller), M- and K13.

3.9. Reversing/motor brake steer wheel direction to platform direction S16 returns to open position while S15 closes. The current in the series field causes the motor to work as a generator since the drive wheel is rotating in the opposite direction.

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S5.0 5000 Electrical System

Version no

000

C-code

T-code

WSX-OS

The transistor controller detects the generated current at connection A2 and reduces the series field current to 60A. When the drive wheel rotates in the right direction and the potential at connection A2 becomes positive, acceleration is done according to adjusted values of current limit and acceleration.

During braking sequence, the armature current passes in the circuit A1-A2, K11, A2 (the brake diode of the transistor controller), M- and K11.

3.10. Reverser switch

106

111 204

105

110

104

207

203 202

206

103

109 201

205

102

108

101

107

409

417

408

416

407

415

406

414

405 301

302

404

413

403 402

412 411 410

401

Possible breaks in the wiring for the reverser switch is continuously checked by the transistor controller. It sends a small pulsed current through the circuit from A1.10, terminal 416, 111, wire 32, S20, wire 32, terminal 110, 415 and A1.13.

S20 is activated causing terminal 110, 415 and A1.13 to become positive. A1 now interrupts the (-)return to K13 which opens. At the same time A1 will provide (-) at A1.3 to K11, LED 401 lights up.

The motor will now be connected for motor braking at a maximum current limit 150A, and subsequently accelerate in the platform direction until S20 returns to its neutral position.

When S20 returns to its neutral position, (+) disappears from terminal 110, A1 will interrupt the (-)return at A1.3 to K11, and the truck will stop.

In order to be able to start again if S16 is still activated, the transistor controller must be returned to the inactive position by letting the speed potentiometer return to the neutral position, after which a new direction of travel can be chosen.

106

111 204

105

110

104 103

207

203 202

206

109 201

205

102

108

101

107

409

417

408

416

407

415

406

414

3.11. Lifting the platform

405 301

302

404

413

403 402

412 411 410

401

The micro switch S52 closes. K30 receives (+)voltage through terminal 105, 203, battery controller or the jumper, terminal 201 and 405, LED 105 and 405 light up.

(-)return through wire 40. K30 closes and the pump motor M3 starts.

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1999-02-10

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PS S5.0 Electrical System Version no

T-code

000

WSX-OS

5000

3.12. Horn 106

111 204

105

110

104

207

203 202

206

103

109 201

205

102

108

101

107

409

417

408

416

407

415

406

414

405 301

302

404

413

403 402

412

The horn switch S18 is activated. The horn, H1, receives (+) voltage through terminal 107 and 406, LED 107 lights up. (-) return through wire 40.

411 410

401

4. Options 106

111 204

105

110

104 103

207

203 202

206

109 201

205

102

108

101

107

409

417

408

416

407

415

406

414

4.1. Electrical lowering of the platform

405 301

302

404

413

403 402

412 411 410

401

When lowering the platform S41 is activated. The magnetic valve, Y41, receives (+) voltage through terminal 106 and 204, LED 106 lights up. (-) return through wire 40.

5. Wire Coupler Not used on all trucks.

5.1. Electrical wire coupler Trucks using tiller control handle shown on the left has a wire coupler between handle/frame and head harnesses. Below are the pin and wire locations of the coupler and handle/ frame.

Pin # Truck Wire # 1 22-1 2 34 3 33 4 38 5 37 6 22-4 7 -8 39 9 36 10 22-3 11 132-1 12 31 13 35 14 -15 -16 --

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Handle Wire # 6 2 3 4 5 Unmarked -8 Unmarked Unmarked 11 6 Unmarked ----

Description Horn Power platform direction Steer wheel direction Lower Raise Raise Power --Horn Potentiometer Wiper Lower Power Emerg. Reverse N/O Emerg. Reverse Com. Potentiometer -------

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PS S5.1 5230 Battery Controller / Hourmeter / Lift Interrupt Version no

T-code

001

Battery Controller / Hourmeter / Lift Interrupt 1. General Information This instrument consists of a single, quartz hourmeter (H), a 10 bar multicolored battery discharge controller (BC), and a lockout relay. The lift lockout relay is operated so that if there is a current passing through the relay contacts when the instrument registers empty battery the contacts stay closed until the current ceases. There will be no lockout of the lift during the lift operation. The hourmeter features a liquid crystal display (LCD) which has six segment digits with a decimal point before the last digit. This provides resolution of 0.1 hours or 6 minutes.

Battery Display LED 2 Red, 3 Yellow, 5 Green

Hourmeter LCD

2. Electrical 2.1. Voltage This instrument is supplied as a pin selectable dual voltage unit with the voltage of 12/48 VDC.

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PS S5.1 5230 Battery Controller / Hourmeter / Lift Interrupt Version no

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001

2.1.1. The Contact Voltage and Current Ratings for Switching Resistive Loads.

Open Contact Voltage

200

VDC

Max

Closed Contact Current

3

ADC

Max

Volt Ampere Product

50

W

Max

2.1.2. Memory Retention The instrument contains an internal battery (BC) which allows memory retention when external power is removed. Typical battery life is 10 years. The hourmeter has a solid state, nonvolatile memory which does not require battery backup.

3. Battery Controller (BC) 3.1. General Information The BC measures the state of the battery. The charge is indicated on a column of ten LEDs. Right: 1 - fully charged battery Left:

0 - empty battery

When the battery is fully charged the LED to the right will be illuminated. As the battery discharges LEDs to the right will stop glowing and show the current discharge level. When the battery is 70 percent discharged the two LEDs from the left will flash alternately to warn the driver that he should recharge the battery. When the battery is 80 percent discharged the last LED is lit, and the relay is opened.

3.1.1. Discharge Adjustment The BC features an adjustable discharge setting. The setting designators K-U are at the rear of the gauge. The initial factory setting is N but will depend on the battery and machine type.

The given settings are approximate and might need to be fine tuned to get a 100 percent correct lockout for a specific application.

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PS S5.1 5230 Battery Controller / Hourmeter / Lift Interrupt Version no

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001

Battery Ah 180 210 240

L-M M-N N-O

L-M means that you adjust on the line between L and M. N-O means that you adjust on the line between N and O. An hydrometer can be used for precise adjustment. When the bottom two LEDs are flashing on and off the specific gravity of the battery electrolyte should not be lower than 1.14. If they start to flash at higher specific gravity the discharge U potentiometer should be turned counterclockwise (towards K). If the two LEDs start to flash at a specific gravity below 1.14 turn the potentiometer clockwise (towards P).

The letter designations for the voltage per cell (VPC) multipliers at empty battery are specified as tabulated below .

8

7

6

5

4

3

2

1

SETTING

VPC

SETTING

VPC

K

1.57

P

1.82

L

1.63

Q

1.84

M

1.68

R

1.86

N

1.73

S

1.91

O

1.78

T

1.93

O P Q R S K DISCHARGE T

N M L

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PIN NO:

FUNCTION

1

Hourmeter (-)

2

Key switch (+)

3

Relay arm (+)

4

Relay NC (-)

5

Battery (-)

6

Hourmeter (+)

7

24 Volt (+)

8

48 Volt (+)

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001

NOTE! The discharge adjustments can be made at any time during a working cycle before lift lockout.

However, discharge potentiometer adjustments made late in a working cycle have little or no effect in delaying the lift lockout in that particular working cycle. Normally discharge potentiometer.

Adjustments are made before or at the beginning of a working cycle to effectively change the discharged profile of that working cycle. Once lift lockout does occur, the gauge must be reset before discharge potentiometer. adjustments can have an effect.

3.2. Reset The instrument is supplied with a fixed reset voltage setting.

This factory-set reset voltage brings the BC to full regardless of its previous level. The reset will be done when the battery has been charged and connected to the machine.

3.3. Key Switch The electronics of the BC and the LCD of the hourmeter are energized as long as the machine battery remains connected to the gauge. The display of the BC is turned on and off by the key switch.

12 Volt and 300 AMP Controllers The key switch also enables timing function of the hourmeter.

With the key switch ON, the hourmeter can be activated by the connection number 6 at the rear of the BC. With the key switch OFF, the hourmeter will not respond to the connection number 6, and the LCD of the hourmeter will be off.

400 AMP Controllers The drive transistor controller enables the timing function of the hourmeter, whenever there is current going to the drive motor. Also, the timing function is enabled whenever S52 raise switch is closed.

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PS S5.1 5230 Battery Controller / Hourmeter / Lift Interrupt Version no

T-code

001

3.4. Hourmeter Hourmeter operation is indicated by flashing of the hourglass icon on face of LCD. The flash rate is 15 times a minute with a duty cycle of 3 seconds on and 1 second off. When hourmeter is not in operation the icon is visible but does not flash.

4. Troubleshooting This section is separated into two parts: Battery Discharge Indicator and Hourmeter.

4.1. Battery Discharge Indicator (BDI) 4.1.1. No Reset There are two ways to reset the instrument.

Using the open circuit reset the instrument must first have a break in the power and then measure a voltage greater than 2.09 volts per cell across its pin 7 or 8 and pin 5. Verify that a leakage voltage is not present across these terminals by disconnecting one of the lines supplying battery voltage to the instrument. Replace this connection and measure the voltage across the gauge at its pin 7 or 8 and pin 5. It must be above 2.09 volts per cell. If it is, and the gauge does not reset to indicate full charge, the instrument is defective.

The second method of resetting the instrument is by using the high voltage reset. This reset function also has two requirements to reset the instrument. The voltage across pin 7 or 8 and pin 5 must be above 2.35 volts per cell and must remain above this level for six minutes continuously. Measure the voltage across these pins and verify that it is greater than 2.35 volts per cell. Also, verify that it remains above this level for a minimum of six minutes. If these two conditions are met, and the instrument does not reset, it is defective.

4.1.2. Reset After Break in Power If the voltage of the batteries to which the instrument is connected is below 2.09 volts per cell, and the gauge was not formerly indicating full, it should not reset to full after a break in power. If it does its memory cell is depleted. This will not affect the discharge function of the instrument if it is always © BT Products

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PS S5.1 5230 Battery Controller / Hourmeter / Lift Interrupt Version no

T-code

001

connected to a fully charged battery and allowed to track its discharge without break in power.

NOTE! New instruments are shipped from the factory with a full reading in their memory. The first time the instrument is connected to the truck’s battery it will always show a full charge. It is either resetting to full because the battery is fully charged or if the battery is not fully charged it is repeating the information in its memory which is a full reading (typical 10 year battery life).

4.1.3. No Discharge, Gauge Does Not Run Down The instrument monitors loaded battery values. When connected to a partially discharged battery the gauge will not run down until it observes that the loaded values of the battery are at or below gauge current state. A working time of at least 30 minutes is required for the gauge to run from full to empty.

To verify that the instrument will run down, measure across pin 7 or 8 and pin 5. A voltage less than 2.0 volts per cell is required to bring the gauge indication downwards from a full reading.

4.1.4. No Lockout The LED display must be alternately flashing the two leftmost red LEDs for lockout to occur.

The J output functions like an SCR. At lockout, pins 3 and 4 will open as long as lift is inactive.

To test this output: 1. Remove the wire leading to pin 3 when at lockout.

2. Replace the wire, and then try to lift. If the lift ceases to operate the instrument is good, but there is a leakage current somewhere in the lift circuit.

3. Check across the lift switch. After replacing the wire, if the lift operates, the instrument is defective.

4.1.5. No Lift First, verify that the gauge is not at lockout with its two red LEDs alternately flashing. The relay outputs should be closed 88

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PS S5.1 5230 Battery Controller / Hourmeter / Lift Interrupt Version no

T-code

001

above lockout and should read zero ohms with an ohmmeter across pins 3 and 4. If not at lockout test the lift switch and contactor.

4.1.6. Early Lockout It is very important that the instrument is installed so that its pins are reading the true battery voltage. Any voltage drops caused by long lines, switches, fuses, or poor connections will be seen by the instrument as a deeper discharged battery.

1. To check for voltage drops use a voltmeter with its positive lead on the battery’s positive terminal and the meter’s negative lead on pin 7 or 8 (whichever pin B+ is connected to). Load the battery and record this measurement.

2. Repeat this procedure with the voltmeter’s positive lead on pin 5 and its negative lead on the battery’s negative terminal, and record the voltage measured.

3. Add the two voltage readings. This total should be less than 1 percent of the nominal battery voltage. Voltage higher than this will cause the instrument to calculate battery state-of-charge from incorrect readings.

4.1.7. LEDs Do Not Light The battery discharge indicator LEDs are illuminated by the keyswitch, pin 2.

Verify that battery voltage is present across pin 2 and pin 5. If voltage is present and the LEDs do not light, the instrument is defective.

4.2. Hourmeter 4.2.1. No Display The LCD of the hourmeter will illuminate when power is applied at pin 7 or 8 and pin 5. If battery voltage is measured across these pins and the LCD does not turn on, the instrument is defective.

4.2.2. Hourmeter Glass Icon Does Not Flash If the icon does not flash, the hourmeter is not accumulating

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PS S5.1 5230 Battery Controller / Hourmeter / Lift Interrupt Version no

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time. The key switch pin 2 must be on at B+, pin 7 or 8 must be connected to B+, and one or both of the hourmeter lines must be active. If the key switch is on, one or both inputs are correct, and the hourmeter icon does not flash, the instrument is defective.

4.2.3. Hourmeter Glass Icon Always Flashes When the icon is flashing, the hourmeter is accumulating time. Turn the truck’s key switch off. This should remove voltage from pin 2 of the instrument. Should voltage be present at pin 2 and the hourmeter’s icon continues to flash, the instrument is defective.

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PS Version no

000

Section

C-code

S5.2 5460 Transistor Controller T-code

WSX-OS

Transistor Controller Valid from machine number: 272581AA000 -

1. Motor circuit The transistor controller has four terminals for the high current circuits according to the table below.

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Terminal

Connecting

M-

Output to motor armature

B-

Negative connection to battery

B+

Positive connection to battery/series field

A2

Plug diode to motor armature

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T-code

000

WSX-OS

C-code

5460

2. Control circuit The transistor controller has an integrated 16-pin connector to provide the low power logic control connections. The designation of the pins are according to the table below.

Pin No

Connecting

CONTACTOR DRIVERS P1

Shunt field driver output

P2

Platform direction contactor driver output

P3

Steer wheel direction contactor driver output

P4

Not connected

THROTTLE CONNECTIONS P5

Not connected

P6

Not connected

P7

Throttle: pot low

P8

Throttle: 2-wire 5 kOhm-0 input

BASIC CONTROL SIGNALS

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P9

Not connected

P10

Emergency reverse check output

P11

Drive platform direction input

P12

Drive steer wheel direction input

P13

Emergency reverse input

P14

Speed range selection input

P15

Brake switch input

P16

Key switch input (KSI) Service Manual

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PS Version no

Section

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S5.2 5460 Transistor Controller T-code

000

WSX-OS

3. Technical specification The technical specification for the BT version of the Curtis 1207 transistor controller is according to the table below.

PARAMETER

RANGE

STD SETTING

UNITS

Operating voltage

24

24

Volt

Maximum voltage

45

Volt

Overvoltage point

Minimum operating voltage

16

Volt

Undervoltage point

Electrical isolation to heatsink

500

Volt ac

Minimum

Frequency

15

kHz

Contactor voltage

24

Volt

Contactor current

1

Amp

Shunt driver current

2

KSI input current

80

mA

Logic input current

10

mA

Logic input threshold

8

Volt

Ambient operating temperature

-40 - +50

oC

Heatsink over temperature cutback

85

oC

Heatsink under temperature cutback

-25

oC

1.2

Variable

Variable

Current limit, Main

100-150

150

Amp

100

Amp

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Maximum (current limit at 2 amp)

Amp

Plug braking

Current limit, Low speed, Main

DESCRIPTION

1999-02-10

At 24 Volt

Plug current dependant upon throttle position

Maximum current in low speed mode

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T-code

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PARAMETER

STD SETTING

UNITS

DESCRIPTION

Current limit, Plug

60

Amp

Maximum plug current in the series field

Current limit, Low speed, Plug

60

Amp

Maximum plug current in the series field in low speed mode

Current limit, Emergency reverse

150

Amp

Maximum field current in emergency reverse

Current limit, Low speed, Emergency reverse

150

Amp

Maximum field current when in low speed for emergency reverse

Throttle type

5k-0

Ohm

Minimum duty cycle

0

%

Speed (duty factor) at minimum throttle setting

Low speed

70

%

Maximum speed (duty factor) in low speed mode

Emergency reverse speed

50

%

Speed during emergency reverse

0.8

Sec

Time to reach full output from zero output

Acceleration rate

RANGE

0.1 - 3

4. Adjustment panel

The adjustment panel is located on top of the controller under a sliding protective cover. The panel provides access to a set of adjustable potentiometers, a connector for a hand held terminal, and the STATUS LED.

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S5.2 5460 Transistor Controller T-code

WSX-OS

4.1. Adjustable Potentiometers: MAIN and ACCEL potentiometers can be adjusted with a screwdriver within the range given in the technical specification.

NOTE! In the BT version of the Curtis 1207 only two of the potentiometers are used, MAIN and ACCEL. The other three potentiometers are disabled from factory.

4.2. Connection of hand held terminal: To adjust the parameters with the hand held terminal the corresponding potentiometer must be set to ”off”.

4.3. Status LED: The LED displays flashing codes to indicate controller status.

The codes are listed with explanations in section 6.

5. Maintenance There are no serviceable parts inside the transistor controller.

No attempt should be made to open the controller.

OPENING THE CONTROLLER WILL VOID THE WARRANTY! It is, however, recommended that the controller exterior be cleaned periodically. Cleaning the controller gives a good opportunity to check the controller’s diagnostic history file with the hand held terminal, if available.

5.1. Safety The controller is inherently a high power device. When working around any battery powered vehicle proper safety precautions should be taken. These include, but are not limited to, proper training, wearing eye protection, avoiding loose clothing, removing watches and jewelry, and using insulated wrenches. © BT Products

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T-code

000

WSX-OS

C-code

5460

WARNING Risk of short circuits.

Remove all watches and jewelry, and always use insulated tools.

5.2. Cleaning Although the controller requires virtually no maintenance if properly installed, the following minor maintenance is recommended on a regular 250 hour basis.

1.Remove power by disconnecting the battery.

2. Discharge the capacitors in the controller, by connecting a load (such as a contactor coil or the horn) across the controller’s B+ and B- terminals, before doing any work on the controller.

3. Remove all dirt or corrosion from the bus bar area. The controller should be wiped clean with a moist rag. Allow it to dry before reconnecting the battery.

4. Make sure the connections to the bus bars are tight.

Use two well insulated wrenches for this task in order to avoid stressing the bus bars.

6. Diagnostics and troubleshooting

During normal operation, with no faults present, the Status LED flashes a single flash at approximately 1 flash/second. If the controller detects a fault, a 2-digit code is flashed continuously until the fault is corrected. See table below.

If using a hand held terminal for the diagnostics, switched over to diagnostic mode, the diagnostic information can be read in the terminal display. See table below.

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WSX-OS

LED CODE

TERMINAL LCD DISPLA

EXPLANATION

POSSIBLE CAUSE

1,2

¤ ¤¤

HW FAIL-SAFE

hardware fail-safe error

1. Controller defective

1,3

¤ ¤¤¤

M- FAULT

M- output shorted

1. M- output shorted to ground.

2. Direction contactor not closing.

3. Direction contactor not closing fast enough.

4. Internal motor short to ground.

1,4

¤ ¤¤¤¤

SRO

SRO fault

1. Improper sequence of KSI, brake and direction inputs.

2. Brake or direction switch circuit open.

2,1

¤¤ ¤

THROTTLE FAULT 1

5kOhm-0 or wiper fault

1. Throttle input wire open.

2. Throttle input wire shorted to ground or B+.

3. Throttle pot defective.

4. Wrong throttle type.

2,2

¤¤ ¤¤

BB WIRING CHECK

emerg. reverse wiring fault

1. BB wire open.

2. BB check wire open.

2,3

¤¤ ¤¤¤

HPD

HPD sequencing fault

1. Improper sequence of KSI, brake, throttle inputs.

2. Misadjusted throttle.

2,4

¤¤ ¤¤¤¤

THROTTLE FAULT 2

pot low, broken or shorted

1. Pot low wire open.

2. Pot low wire shorted.

3. Wrong throttle type.

3,1

¤¤¤ ¤

CONT DRVR OC

driver output overcurrent

1. Direction contactor coil shorted.

2. Shunt field shorted.

3,2

¤¤¤ ¤¤

DIR CONT WELDED

welded direction contactor

1. Direction contactor stuck closed.

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Service Manual

1999-02-10

97

F-code

Section

C-code

PS S5.2 Transistor Controller Version no

T-code

000

WSX-OS

5460

LED CODE

TERMINAL LCD DISPLA

EXPLANATION

POSSIBLE CAUSE

3,4

¤¤¤ ¤¤¤¤

MISSING CONTACT

missing contactor or shunt

1. Direction contactor open coil.

2. Direction contactor missing.

3. Shunt field open.

4. Wire to shunt or direction contactor open.

4,1

¤¤¤¤ ¤

LOW BATTERY VOLTAGE

low battery voltage

1. Battery voltage <16 volts.

2. Corroded battery terminal.

3. Loose battery or controller terminal.

4,2

¤¤¤¤ ¤¤

OVERVOLTAGE

overvoltage

1. Battery voltage > 45 volts.

2. Vehicle operating with charger attached.

4,3

¤¤¤¤ ¤¤¤

THERMAL CUTBACK

over-/undertemperature cutback

1. Temperature >85 oC or < 25 oC. 2. Excessive load on vehicle.

3. Improper mounting of controller.

4. Operation in extreme environments.

98

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Service Manual

1999-02-10

F-code

Section

C-code

PS

S5.3

5710 PCB Card

Version no

000

T-code

WSX-OS

PCB Card Valid from machine number: 272581AA000 -

7. The PCB The PCB is a card to create a common connection point in the electrical system for the different wiring harnesses. The card is equipped with green LED’s on the inputs from micro switches and red LED’s on the outputs to the contactors. This will simplify the tracing of faults in the wiring or the switches.

The card is also equipped with a potentiometer for adjustment of the maximum speed.

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Service Manual

1999-02-10

99

F-code

Section

C-code

PS PCB Card

S5.3

5710

Version no

T-code

000

WSX-OS

8. Connectors and adjustments 1

5

4

2

3

100

Return

Position

Connection/Adjustment

1

Key switch (S17), battery -, instrument, magnetic valve (Y41)

2

Battery +, armature voltage, contactors, horn

3

Shunt field

4

RV1, adjustment of maximum speed

5

Micro switches

Service Manual

1999-02-10

F-code

Section

C-code

PS

S5.3

5710 PCB Card

Version no

T-code

000

WSX-OS

9. Terminals and LED’s

106

111 204

105

110

104

207

203 202

206

103

109 201

205

102

108

101

107

409

417

408

416

407

415

406

414

405 301

302

404

413

403 402

412 411 410

401

Terminal No

LED No

Connection

Function

101

101

I

Driving, platform direction

102

102

I

Driving, steer wheel direction

103

O

Speed control

104

I

Reference value, speed

105

105

I

platform lift

106

106

I

platform lower, always connected even if the option electrical lowering is fitted

107

107

I

Horn

O

24 V (+)

I

Brake

110

I

Reverser (S20)

111

I

Reverser (S20)

201

I

Battery controller/ Lift interrupt

108 109

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109

Service Manual

1999-02-10

101

F-code

Section

C-code

PS PCB Card

S5.3

5710

Version no

T-code

000

WSX-OS

Terminal No

LED No

Connection

Function

202

202

I

24 V (+)

203

O

Battery controller/ Lift interrupt

204

O

To magnetic valve, when having the option electrical lowering of the platform

205

O

24 V (+)

206

O

Hour meter

301

O

Shunt field(+)

302

O

Shunt field(-)

401

401

I

Contactor (-), platform direction

402

402

I

Contactor (-), steer wheel direction

O

Contactor drive direction, common (+)

403 404 405

102

Return

Not connected 405

O

Contactor, pump motor

406

O

Horn

407

I

24 V (+)

408

O

Output signal, brake released

409

I

(-)

410

O

24 V (+), to transistor controller

411

O

Driving, platform direction

412

O

Driving, steer wheel direction

413

I

Speed control

414

O

Reference value, speed

415

O

Reverser, (S20)

416

O

Reverser, (S20)

Service Manual

1999-02-10

F-code

Section

C-code

PS

S5.3

5710 PCB Card

Version no

000

Terminal No 417

LED No

Connection

Function

I

Shunt field(-)

T-code

WSX-OS

I = Input, green LED O = Output, red LED

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Service Manual

1999-02-10

103

F-code

Section

C-code

PS PCB Card

S5.3

5710

Version no

T-code

000

WSX-OS

104

Return

Service Manual

1999-02-10

F-code

Section

C-code

PS S6.0 6000 Hydraulic system, mechanical lowering Version no

T-code

000

WSX-OS

Hydraulic system, mechanical lowering Valid from machine number: 272581A000 -

1. General The hydraulic system consists of a compact hydraulic unit, including a mechanical lowering valve, pressure relief valve, and the cylinder for the lift of the platform.

2. Description of function 2.1. Hydraulic diagram and components Hydraulic Pressure Switch

1

A

M

B

A C

2

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Service Manual

1999-02-10

105

F-code

Section

C-code

PS S6.0 6000 Hydraulic system, mechanical lowering Version no

T-code

000

WSX-OS

2.2. Main components Pos No

Description

Remark

1

Lift Cylinder

Platform lift

2

Hydraulic Unit

A = Check valve B = Lowering valve C = Relief valve M = Pump motor

2.3. Description 2.3.1. Lift When the pump motor starts, the oil flows through the pump and check valve to the lift cylinder.

2.3.2. Lower When the lowering valve is affected by the lower lever inside chassis, it opens to let the oil in the pressure lines return to the oil tank. The lowering speed is regulated by the movement of the lever.

2.3.3. Operating pressure The operating pressures at rated load are: 1. WSX-OS: 900 psi 2.3.4. Relief valve The relief valve opens at the following pressures: 1. WSX-OS: 1000 psi 2.3.5. Hydraulic pressure switch The hydraulic pressure switch is a normally closed snap action switch. When oil flows from the hydraulic pump unit to the cylinder, the pressure switch opens and directional travel is disabled.

106

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Service Manual

1999-02-10

F-code

Section

C-code

PS S6.1 6000 Hydraulic system, electrical lowering Version no

T-code

000

WSX-OS

Hydraulic system, electrical lowering Valid from machine number: 272581A000 -

1. General The hydraulic system consists of a compact hydraulic unit, including a mechanical lowering valve, an electromagnetic lowering valve, pressure relief valve, and the cylinder for the lift of the platform.

2. Description of function 2.1. Hydraulic diagram and components Hydraulic Pressure Switch

1

A

M

B

A C

2

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Service Manual

1999-02-10

107

F-code

Section

C-code

PS S6.1 6000 Hydraulic system, electrical lowering Version no

T-code

000

WSX-OS

2.2. Main components Pos No

Description

Remark

1

Lift Cylinder

Platform lift

2

Hydraulic Unit

A = Check valve B = Lowering valve C = Relief valve D = Electro-magnetic lowering valve M = Pump motor

2.3. Description 2.3.1. Lift When the pump motor starts, the oil flows through the pump and check valve to the lift cylinder.

2.3.2. Lower When the lowering valve is affected by the lower lever inside chassis, it opens to let the oil in the pressure lines return to the oil tank. The lowering speed is regulated by the movement of the lever.

2.3.3. Lower, electrical When the electro-magnetic valve is energized electrically from the push button on the handle, it opens fully to let the oil in the pressure lines return to the oil tank. The lowering speed is regulated by a restriction in the hydraulic unit.

2.3.4. Operating pressure The operating pressures at rated load are: 1. WSX-OS: 900 psi 2.3.5. Relief valve The relief valve opens at the following pressures: 1. WSX-OS: 1000 psi 2.3.6. Hydraulic pressure switch The hydraulic pressure switch is a normally closed snap action switch. When oil flows from the hydraulic pump unit to 108

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Service Manual

1999-02-10

F-code

Section

C-code

PS S6.1 6000 Hydraulic system, electrical lowering Version no

000

T-code

WSX-OS

the cylinder, the pressure switch opens and directional travel is disabled.

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Service Manual

1999-02-10

109

F-code

Section

C-code

PS S6.1 6000 Hydraulic system, electrical lowering Version no

T-code

000

WSX-OS

110

Return

Service Manual

1999-02-10

F-code

Section

C-code

PS

S7.0

7310 Lift Cylinder

Version no

T-code

000

WSX-OS

Lift Cylinder 10

11

7 1 12

2 3 4 9

5

8

6

9 13 14 15 16

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POS. NO

DESCRIPTION

1K

Wiper, cylinder

2K

POS. NO

DESCRIPTION

POS. NO

DESCRIPTION

7

Rod, cylinder

13

Plunger assembly

Seal, rod

8K

Guide

14

Spring

3K

Ring, wear

9K

Ring, retainer

15

Plug

4

Bearing

10K

Seal, washer

16

O ring

5K

Ring, backup

11K

Screw

K

Kit, seal

6K

O ring

12

Tube, cylinder

Service Manual

1999-02-10

111

F-code

Section

C-code

PS S7.0 Lift Cylinder

7310

Version no

T-code

000

WSX-OS

1. Cylinder Repair 1.1. Removal 1. Park the truck on a level surface and apply the brake.

2. Fully extend the cylinder rod to inspect the rod for gouges or pits. If gouges or pits are detected, then the cylinder must be removed for repair.

3. Lift the carriage approximately 6 inches. Block the carriage to prevent lowering.

WARNING When blocking mast columns to prevent lowering always block both side of the column. If not the truck could tip over on its side.

4. Lower cylinder so the chains, hoses, and electric cables are loose. Disconnect the battery 5. Remove sheave head bar clamps.

6. Remove chains, hoses, and electric cables from the sheave head.

7. Remove the sheave head from the cylinder rod.

8. Clean the exterior of the lift cylinder WARNING Be extremely careful when working with solvent. Even a small explosion or fire could cause injury or death.

WARNING Compressed air used for cleaning MUST be reduced to less than 30 p.s.i., and then only with effective chip-guarding and personal protective equipment.

112

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F-code

Section

C-code

PS

S7.0

7310 Lift Cylinder

Version no

000

T-code

WSX-OS

1.2. Disassembly 1. Remove gland nut (4) from the cylinder tube.

2. Remove and discard packing, back-up ring, O ring, rod wiper and bearing retainer from the gland nut.

Use care NOT to damage the inside of the gland nut.

1.3. Assembly 1. Install new wear ring, O ring, back-up ring, packing, and rod wiper in the gland. The “lip” of the wiper must face outward. It is not necessary to replace wear ring (8), unless the rod was removed for repair.

1.4. Installation 1. Install sheave head, chains, hoses and electric cables.

2. Connect battery.

3. Test for proper operation.

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Service Manual

1999-02-10

113

F-code

Section

C-code

PS S7.0 Lift Cylinder

7310

Version no

T-code

000

WSX-OS

114

Return

Service Manual

1999-02-10

F-code

Section

C-code

PS

S8.0

8520 Key pad

Version no

000

T-code

WSX-OS

Key pad

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Service Manual

1999-02-10

115

F-code

Section

C-code

PS Key pad

S8.0

8520

Version no

T-code

000

WSX-OS

116

Return

Service Manual

1999-02-10

F-code

Section

C-code

PS

S8.0

8520 Key pad

Version no

000

© BT Products

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Service Manual

1999-02-10

T-code

WSX-OS

117

F-code

Section

C-code

PS Key pad

S8.0

8520

Version no

T-code

000

WSX-OS

118

Return

Service Manual

1999-02-10

F-code

Section

C-code

PS

S8.0

8520 Key pad

Version no

000

© BT Products

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Service Manual

1999-02-10

T-code

WSX-OS

119

F-code

Section

C-code

PS Key pad

S8.0

8520

Version no

T-code

000

WSX-OS

120

Return

Service Manual

1999-02-10

F-code

Section

C-code

PS

S8.0

8520 Key pad

Version no

000

© BT Products

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Service Manual

1999-02-10

T-code

WSX-OS

121

F-code

Section

C-code

PS Key pad

S8.0

8520

Version no

T-code

000

WSX-OS

122

Return

Service Manual

1999-02-10

F-code

Section

C-code

PS

S8.0

8520 Key pad

Version no

000

© BT Products

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Service Manual

1999-02-10

T-code

WSX-OS

123

F-code

Section

C-code

PS Key pad

S8.0

8520

Version no

T-code

000

WSX-OS

124

Return

Service Manual

1999-02-10

F-code

Section

C-code

PS

S8.0

8520 Key pad

Version no

000

© BT Products

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Service Manual

1999-02-10

T-code

WSX-OS

125

F-code

Section

C-code

PS Key pad

S8.0

8520

Version no

T-code

000

WSX-OS

126

Return

Service Manual

1999-02-10

F-code

Section

C-code

PS

S8.0

8520 Key pad

Version no

000

© BT Products

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Service Manual

1999-02-10

T-code

WSX-OS

127