BT CSX10 CSX20 CSX30 CSX40 LIFT TRUCK SERVICE, PARTS, OPERATOR, WIRING MANUAL

BT CSX10 CSX20 CSX30 CSX40 LIFT TRUCK SERVICE, PARTS, OPERATOR, WIRING MANUAL
LANGUAGE: ENGLISH
FORMAT: PDF
PAGES: 4,225
FILE SIZE: 117MB

MODEL COVERED:

CSX10

CSX20

CSX30

CSX40

WSX22

WSX30

WSX40

WRX30

PART NO: 304959-000

SERIAL NO: 25268000 - UP

ISSUED:

APRIL, 2002

OCTOBER, 1997

OCTOBER, 1996
                  

CONTENTS:

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

EXTRAS INCLUDED:

ELECTRICAL DIAGRAMS

MASTER PARTS MANUALS

OPERATOR MANUALS

PARTS MANUALS