BT LHM200SC LHM200SCQ LHM200SCO Service Manual - PDF DOWNLOAD

Service Manual LHM200SC, LHM200SCQ, LHM200SCO Valid from serial number: 3 300 000-

Order number: 232020-040 Issued: 2006-06-19 ITS

© BT Europe AB

en

Document revisions:

Issue date

Order number

Changes

2006-06-19

232020-040

Completely new issue.

This manual covers following truck models:

T-code

Model

Serial number

805

LHM200SC

3 300 000-

813

LHM200SCQ

3 300 000-

830

LHM200SCO

3 300 000-

© BT Europe AB

Service Manual

LHM200SC, LHM200SCQ, LHM200SCO

Table of contents Order number 232020-040

Date 2006-06-19

Valid from serial number 3 300 000-

T-code 805, 813, 830

Table of contents 1- Technical data ........................................................................................ 1 1.1 Truck data ......................................................................................... 1 2- Maintenance ...........................................................................................

2.1 General .............................................................................................

2.2 Safety rules for servicing work ..........................................................

2.2.1 Observe the following for servicing and maintenance ........

2.2.2 Information plates ...............................................................

2.3 Cleaning, washing and lubrication ....................................................

2.3.1 Lubrication chart .................................................................

3 3 3 4 4 5 5

3- Tow bar ...................................................................................................

3.1 General .............................................................................................

3.2 Replacing the tow bar .......................................................................

3.3 Replacing the lowering handle ..........................................................

3.4 Replacing the handle ........................................................................

3.5 Replacing the press roller and valve rod. ..........................................

7 7 8 8 9 9

4- Hydraulic unit .......................................................................................

4.1 General ...........................................................................................

4.2 Functional description .....................................................................

4.2.1 Standard ...........................................................................

4.2.2 Quick lift ............................................................................

4.2.3 Overloading ......................................................................

4.3 Replacing the hydraulics .................................................................

4.4 Replacing the steering wheel ..........................................................

4.5 Replacing the steering wheel shaft .................................................

4.6 Replacing thrust bearings ...............................................................

4.7 Replacing the pump piston and pump piston seals .........................

4.8 Replacing the lift piston ...................................................................

4.9 Replacing the lowering valve ..........................................................

4.10 Replacing the valve cone ................................................................

4.11 Changing the oil ..............................................................................

4.12 Hydraulics diagram .........................................................................

4.12.1 LHM200SC .......................................................................

4.12.2 LHM200SCQ ....................................................................

4.12.3 LHM200SCO ....................................................................

11 11 12 12 13 14 15 15 15 16 16 16 17 17 17 19 19 19 20

5- Tools ...................................................................................................... 21 5.1 Service tools ................................................................................... 21 6- Chassis .................................................................................................

6.1 General ...........................................................................................

6.1.1 Replacing pivot pipes .......................................................

6.1.2 Replacing the pressure rod ..............................................

6.1.3 Replacing the wheel fork ..................................................

6.1.4 Replacing the bogie wheel ...............................................

6.1.5 Replacing the fork wheel ..................................................

6.1.6 Removal of upper/lower forks ........................................... © BT Europe AB

Service Manual

LHM200SC, LHM200SCQ, LHM200SCO

25 25 25 25 25 26 26 26 1

Table of contents T-code 805, 813, 830

Valid from serial number 3 300 000-

Date 2006-06-19

Order number 232020-040

7- Scale ......................................................................................................

7.1 General ...........................................................................................

7.1.1 Mechanics ........................................................................

7.1.2 Load sensor ......................................................................

7.1.3 Indicator ............................................................................

7.1.4 Battery ..............................................................................

7.2 Function ..........................................................................................

7.2.1 Removing the scale ..........................................................

7.3 Optional extras................................................................................

7.3.1 Printer ...............................................................................

7.3.2 Commercial weighing status .............................................

27 27 27 28 29 31 32 34 35 35 37

8- Electronics and parameters ................................................................

8.1 Truck configurations........................................................................

8.1.1 Circuit card 2100B ............................................................

8.1.2 Circuit card 2100N ............................................................

8.1.3 Circuit card 2100N with RS card ......................................

8.1.4 Circuit card, calibration card .............................................

8.1.5 Load sensor ......................................................................

8.1.6 Tilt switch ..........................................................................

8.1.7 Printer ...............................................................................

8.2 Parameter settings..........................................................................

8.2.1 Changing parameters .......................................................

8.2.2 Parameter list ...................................................................

8.2.3 Basic settings ...................................................................

39 39 40 41 42 43 45 46 47 48 48 48 51

9- Troubleshooting ...................................................................................

9.1 Troubleshooting chart .....................................................................

9.1.1 Troubleshooting - hydraulics ............................................

9.2 Troubleshooting - scale...................................................................

53 53 54 56

10- Calibrating the scale ..........................................................................

10.1 Calibrating the pallet truck scale .....................................................

10.1.1 Determining the zero point ...............................................

10.1.2 Single-point calibration .....................................................

10.1.3 Determining full load .........................................................

63 63 63 64 67

11- Troubleshooting ................................................................................. 68 11.0.1 Possible problems ............................................................ 69 11.0.2 Description of problem and probable causes .................. 71 11.0.3 Explanation of probable causes and how to remedy them .... 73 12- Instructions for disposal ...................................................................

12.1 General ...........................................................................................

12.2 The product.....................................................................................

12.3 Methods ..........................................................................................

12.4 Grading of LHM200SC....................................................................

12.4.1 Removing the battery. ......................................................

12.4.2 Draining the oil ..................................................................

12.4.3 Removing the electronic components ..............................

12.4.4 Other .................................................................................

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81 81 81 81 82 82 82 82 82

© BT Europe AB

Technical data Truck data Order number 232020-040

Date 2006-06-19

Valid from serial number 3 300 000-

T-code 805, 813, 830

1- Technical data 1.1 Truck data The table provides information on certain technical product data which may be useful for day-to-day truck operation.

Technical data Rated lifting capacity

2000 kg

Weight

105 kg

Lift height

205 mm

Turning radius (Wa)

1405 mm

Steering wheel

Ø 175 x 60

Fork wheels, single/bogie

Ø 85 x 100 / Ø 85 x 75

Pumping force, rated load

31 kg

Traction force

17 kg*)

*) Estimated with rated load on level, dry concrete floor

© BT Europe AB

Service Manual

LHM200SC, LHM200SCQ, LHM200SCO

1

Technical data Truck data T-code 805, 813, 830

Valid from serial number 3 300 000-

Date 2006-06-19

Order number 232020-040

This page is intentionally left blank

2

Service Manual

LHM200SC, LHM200SCQ, LHM200SCO

© BT Europe AB

Maintenance General Order number 232020-040

Date 2006-06-19

Valid from serial number 3 300 000-

T-code 805, 813, 830

2- Maintenance WARNING! For your own safety, do not carry out any servicing work without first having read and understood the general directions. It may be useful to have the driver’s manual and spare parts catalogue to hand.

Ensure the truck receives regular maintenance. The truck's safety, efficiency and service life are dependent on the service and maintenance it receives.

Only use spare parts approved by the truck manufacturer for servicing and repairs.

2.1 General Only persons trained in servicing and repairing this type of truck are qualified to carry out servicing and repair work.

• Do not carry out any maintenance work on the truck if you do not have the correct training and know-how to carry out such work.

• Keep the area where servicing work is done clean. Oil or water will make the floor slippery.

• Never wear loose objects or jewellery when working on the truck.

Any modification or conversion of the truck that affects safe use or functions is not permitted.

2.2 Safety rules for servicing work WARNING! When servicing pallet trucks, PROTECTIVE GLASSES and PROTECTIVE SHOES must be worn.

• Discharge the system pressure before any work commences on the truck's hydraulic system. (No load on forks.)

• Keep the area where servicing work is done clean. Oil or water may cause a risk of slipping.

NOTE: For all work on the hydraulic system, maximum cleanliness must be observed.

Dismantled parts must be cleaned and inspected carefully.

• Store and dispose of used oil in accordance with local directives.

• Solvents or similar items used for cleaning maynot be washed down drains that are not intended for this purpose. Follow local directives on disposal.

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Service Manual

LHM200SC, LHM200SCQ, LHM200SCO

3

Maintenance Safety rules for servicing work T-code 805, 813, 830

Valid from serial number 3 300 000-

Date 2006-06-19

Order number 232020-040

• If welding or grinding is to be carried out, remove at least 100 mm of paint from around the welding/grinding area using sanding equipment or paint stripper.

WARNING! Harmful gases Heated paint gives off harmful gases.

Remove 100 mm of paint from around the working area.

WARNING! Risk of cuts, risk of crushing There is a RISK OF CUTS when the pallet truck is lifted by hand from the forks and end plate.

There is a RISK OF CRUSHING when the pallet truck is lifted by hand from the chassis by the hydraulics.

WORK GLOVES must be used for lifting the pallet truck by hand.

Bad blocking under a truck can collapse.

The truck must always be secured for repairs.

• When fitting/removing locking rings, there is a risk that the locking ring may come loose from the locking ring pliers and cause damage.

• When hammering in or out, spiral pins can bounce and cause damage. Be careful when fitting/removing spiral pins.

• When fitting/removing springs, they can spring out of position and cause damage.

2.2.1 Observe the following for servicing and maintenance • Always replace removed spiral pins. Never reuse spiral pins, as they may have lost their flexibility when removed.

• Replace lock rings, o-rings, collars, washers, seals, etc. if they look like they have been damaged when removed.

• Always bleed the hydraulics when components have been replaced.

See section “4.11 Changing the oil”.

• Always check that neutral, lifting and lowering modes function after work on the hydraulics. Some adjustment may be necessary.

• Check that there is no leakage after work on the hydraulics.

• Watch for any oil spills when components in the hydraulics have been replaced.

It may be useful to have the driver’s manual and spare parts catalogue to hand.

2.2.2 Information plates The truck’s serial number is shown on the information plate. Always check information plates during servicing. If they are damaged and/or difficult to read, new plates must be ordered from Division Hand Trucks.

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LHM200SC, LHM200SCQ, LHM200SCO

© BT Europe AB

Maintenance Cleaning, washing and lubrication Order number 232020-040

Date 2006-06-19

Valid from serial number 3 300 000-

T-code 805, 813, 830

The hydraulics also have a production number, which is shown on the hydraulics (see picture).

2.3 Cleaning, washing and lubrication It is essential to clean and wash the pallet truck regularly to guarantee reliability.

• Carry out general cleaning and washing each week.

• Cleaning using compressed air or a high-pressure washer is not recommended.

NOTE: There is a risk of the scale’s electronics being damaged, so take care when cleaning.

After cleaning, the pallet truck should be lubricated as per the table below.

Lubrication is recommended at least every other year and always after washing.

2.3.1 Lubrication chart Table 1: Lubrication chart Lubrication points

Number of lubrication points

Pressure plate

1

Arm bolts

2

Pivot pipe

1

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Service Manual

LHM200SC, LHM200SCQ, LHM200SCO

5

Maintenance Cleaning, washing and lubrication T-code 805, 813, 830

Valid from serial number 3 300 000-

Date 2006-06-19

Order number 232020-040

Table 1: Lubrication chart Lubrication points

Number of lubrication points

Pressure rod on chassis body

2

Pressure rod on fork wheel

2

Wheel fork

2

Bogie fork

2

Table 2: Oil and grease specification Type of lubricant

Specification

Grease

6

Product name

Item number

OKQ8 Rubens WB

213366

Hydraulic oil >-15°C

ISO-VG32 Quality level: ISO 6743-4 category HM DIN 51524 part 2 category HLP

BT hydraulic oil 32

1 litre: 233328-001 5 litres: 233328-002

Hydraulic oil <-15°C

ISO-VG27.5 Quality level: ISO 6743-4 category HV DIN 51524 part 3 category HVLP

Statoil 131

1 litre: 233916-001 5 litres: 233916-002

Service Manual

LHM200SC, LHM200SCQ, LHM200SCO

© BT Europe AB

Tow bar General Order number 232020-040

Date 2006-06-19

Valid from serial number 3 300 000-

T-code 805, 813, 830

3- Tow bar 3.1 General A complete tow bar consists of: • Tow bar • Handle • Lowering handle • Press roller • Valve rod

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Service Manual

LHM200SC, LHM200SCQ, LHM200SCO

7

Tow bar Replacing the tow bar T-code 805, 813, 830

Valid from serial number 3 300 000-

Date 2006-06-19

Order number 232020-040

3.2 Replacing the tow bar WARNING! Releasing energy.

Brace the pump piston spring when removing the tow bar, as the spring may spring out of position. Use tools for locking the pump piston. See section “5.1 Service tools”.

• Remove the valve rod from the lowering arm by placing the lowering handle in “lifting position” and pushing in the lowering arm by hand while pushing the valve rod to the side.

• Remove the spiral pin and shaft holding the tow bar.

• Fit a new tow bar.

• Push in the shaft.

• Fit the shaft.

NOTE: The tow bar shaft has special bevelling that must face downward. If this is fitted the wrong way, neutral position cannot be adjusted.

• Tap in a new spiral pin.

• Fit the valve rod and adjust neutral position. Adjust using the nut on the valve rod.

3.3 Replacing the lowering handle • Lay the truck on its side.

• Undo the screws and remove the cover.

• Unhook the valve rod.

• Remove the ball, spring, sleeve and ball.

• Place a new lowering handle in position.

• Push into the steel casing, insert a ball and spring followed by another ball.

• Carefully replace the cover and screw it tight. It is essential to press the cover right down otherwise the top ball will bounce out of position. Grease the top ball to keep it in place during assembly.

• Check that the lowering handle functions correctly.

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© BT Europe AB

Tow bar Replacing the handle Order number 232020-040

Date 2006-06-19

Valid from serial number 3 300 000-

T-code 805, 813, 830

3.4 Replacing the handle • Remove the cover and unhook the valve rod.

• Remove the polymer rivets by cutting off the head using a sharp knife and pushing the remainder of the rivet into the tow bar. Then remove the handle by pulling it straight up.

• Fit the new handle. Insert four new rivets, hook on the valve rod and replace the cover.

NOTE: The plastic can be heated if necessary when fitting the tow bar. It should be heated at approximately 150° for around 3 min.

3.5 Replacing the press roller and valve rod.

• Disconnect the tow bar from the hydraulics.

• Remove the shaft and spiral pin holding the press roller. Then remove the roller.

• Unhook the valve rod from the lowering arm and pull it out.

• Fit a new valve rod and check that it is correctly positioned around the lowering arm. If necessary, open the handle cover to check.

• Fit a new press roller. Check that the valve rod is positioned on the correct side of the press roller.

• Fit the tow bar and check and adjust (if necessary) neutral position.

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Service Manual

LHM200SC, LHM200SCQ, LHM200SCO

9

Tow bar Replacing the press roller and valve rod.

T-code 805, 813, 830

Valid from serial number 3 300 000-

Date 2006-06-19

Order number 232020-040

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Service Manual

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© BT Europe AB

Hydraulic unit General Order number 232020-040

Date 2006-06-19

Valid from serial number 3 300 000-

T-code 805, 813, 830

4- Hydraulic unit 4.1 General The hydraulic unit consists of: • Pump unit housing • Pressure plate • Thrust bearing • Steering wheel • Pump piston • Lift piston • Lowering arm • Lowering valve

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Service Manual

LHM200SC, LHM200SCQ, LHM200SCO

11

Hydraulic unit Functional description T-code 805, 813, 830

Valid from serial number 3 300 000-

Date 2006-06-19

Order number 232020-040

4.2 Functional description 4.2.1 Standard

5

1

2 3 4

Pump phase When the pump piston (1) is pushed down, the oil pressure opens the valve cone (2) and seals the ball (3). The oil passes into the lift cylinder (4) and the lift piston (5) rises.

Suction phase When the pump piston (1) moves upwards, the oil passes from the oil tank through the lowering valve and into the pump cylinder. In this position the valve cone (2) is closed due to the pressure in the lift cylinder (4).

Neutral position The lowering valve forces the ball (3) to move, opening the channel between the pump cylinder and the oil tank. The oil can then flow freely once the pump piston (1) is activated.

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Service Manual

LHM200SC, LHM200SCQ, LHM200SCO

© BT Europe AB

Hydraulic unit Functional description Order number 232020-040

Date 2006-06-19

Valid from serial number 3 300 000-

T-code 805, 813, 830

Lowering phase The lowering valve forces the ball (3) and valve cone (2) to move. Once the valve cone opens, the oil flows through the valve from the lift cylinder (4) to the oil tank.

4.2.2 Quick lift

5

1

6 2 3 4

7

High pressure When the pump piston (1) is pushed down, the oil pressure opens the ball valve (6). The oil passes through the valve to the other side of the pump piston (1). The oil pressure opens the cone valve (2) and seals the ball (3). The oil can then pass into the lift cylinder (4). When the pump piston (1) moves upwards, the oil flows through the ball valves (7) to the pump cylinder.

Low pressure When the pump piston (1) is pushed down, the ball valve (6) is closed.

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Service Manual

LHM200SC, LHM200SCQ, LHM200SCO

13

Hydraulic unit Functional description T-code 805, 813, 830

Valid from serial number 3 300 000-

Date 2006-06-19

Order number 232020-040

4.2.3 Overloading

6

1 5 2 3 4

When the pump piston (1) is pushed down, the oil pressure opens the valve cone (2) and seals the ball (3). The oil passes into the lift cylinder (4). In the event of overloading, the overload valve (5) opens and the oil passes back to the oil tank (6).

NOTE: The overload valve is preset at the factory and must not be adjusted except when being repaired.

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© BT Europe AB

Hydraulic unit Replacing the hydraulics Order number 232020-040

Date 2006-06-19

Valid from serial number 3 300 000-

T-code 805, 813, 830

4.3 Replacing the hydraulics To facilitate removal, pump the pallet truck up to maximum height, placing a block of wood or similar under the forks at the same height as the breastplate before disconnecting the hydraulics.

• Remove the locking ring from the cover top.

• Remove the spiral pin and arm bolts.

• Lift out the hydraulics and remove the plastic bearing housing without damaging the inside.

• Remove the tow bar.

• Connect the tow bar to new hydraulics.

• Lift in new hydraulics. Make sure that the bearing housing is secured to the lift piston before fitting the hydraulics in the cover top.

• Adjust neutral position and test lift.

4.4 Replacing the steering wheel

• Remove the hub cap.

• Remove the locking ring holding the wheel in place.

• Remove the wheel.

• Fit wheel, locking ring and hub cap.

4.5 Replacing the steering wheel shaft • Remove the steering wheel.

• Sand off the paint on one side of the shaft to simplify removal.

• Remove the spiral pin and shaft.

• Use a plastic hammer or rubber mallet to tap out the shaft to prevent the risk of damaging the locking ring groove.

• Fit a new shaft and replace the wheels.

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Service Manual

LHM200SC, LHM200SCQ, LHM200SCO

15

Hydraulic unit Replacing thrust bearings T-code 805, 813, 830

Valid from serial number 3 300 000-

Date 2006-06-19

Order number 232020-040

4.6 Replacing thrust bearings • Remove the steering wheel.

• Remove the steering wheel shaft. Use a plastic hammer or rubber mallet to tap out the shaft to prevent the risk of damaging the locking ring groove.

• Remove the locking ring, pressure plate and bearing.

• Reassemble in reverse order.

NOTE: Make sure that the bearing is facing the right way. The ring with the smallest inner diameter is fitted against the underside of the hydraulics.

• Lubricate the bearing.

4.7 Replacing the pump piston and pump piston seals • Make sure that the forks are lowered.

• Remove the tow bar.

• Remove the spring and washer by loosening the locking ring.

• For quick lift (LHM200SCQ): Remove locking ring under seal.

• Pull out the pump piston through the sealing ring.

• Remove the sealing rings.

• Clean the contact surfaces for the sealing rings.

• Fit new sealing rings, new pump piston, spring, washer and locking ring.

• Fit the tow bar.

• Bleed. See section “4.11 Changing the oil”.

4.8 Replacing the lift piston • Remove the lift piston from the cover top.

• Remove the bearing housing from the lift piston.

• Remove the lift piston from the pump body.

• Remove seals.

• If necessary, drain the oil and fit a new seal.

• Replace new lift piston in pump body.

• Fit a new scraper.

• Fit the bearing housing on the lift piston.

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© BT Europe AB

Hydraulic unit Replacing the lowering valve Order number 232020-040

Date 2006-06-19

Valid from serial number 3 300 000-

T-code 805, 813, 830

• Fill with oil and bleed. See section “4.11 Changing the oil”.

NOTE: Take care when fitting/removing the bearing housing from the lift piston in order to prevent damage to the housing.

4.9 Replacing the lowering valve • Lay the truck on its side.

• Remove the lowering arm.

• Unscrew the lowering valve.

• Fit a new lowering valve (Tightening torque 35 Nm) • Fit the lowering arm.

• Bleed. See section “4.11 Changing the oil”.

4.10 Replacing the valve cone • Pump the truck up to maximum height.

• Lay the truck on its side.

• Remove the screw, washer, spring and valve cone.

• Fit a new valve cone, spring, a new washer and screw. (Tightening torque 35 Nm) • Bleed. See section “4.11 Changing the oil”.

4.11 Changing the oil When changing the oil in the hydraulics, use service tool V10-16572.

See table 3 on page 21.

• Always use loads of around 200-400 kg.

• Pump the load up to maximum lift height. Place the tool beside the top of the hydraulic unit to check how much oil needs to be added for topping up.

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Service Manual

LHM200SC, LHM200SCQ, LHM200SCO

17

Hydraulic unit Changing the oil T-code 805, 813, 830

Valid from serial number 3 300 000-

Date 2006-06-19

Order number 232020-040

• Lay the truck on its side and press the piston to the top.

• Unscrew the cone valve and top up with oil to the required level.

• Screw down the cone valve, but leave a gap of 0.5-1 mm. Push the piston down until the oil begins to ooze out of the cone valve.

Tighten the cone valve fully.

NOTE: It is extremely important to press down the piston, in order to reduce the air pressure in the oil tank. If this is not done, the scraper may come loose.

NOTE: Be very careful when replacing the oil to ensure that no impurities get into the oil tank or oil, as this may damage the hydraulics.

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LHM200SC, LHM200SCQ, LHM200SCO

© BT Europe AB

Hydraulic unit Hydraulics diagram Order number 232020-040

Date 2006-06-19

Valid from serial number 3 300 000-

T-code 805, 813, 830

4.12 Hydraulics diagram 4.12.1 LHM200SC

LIFT CYLINDER

PUMP CYLINDER

RESERVOIR

4.12.2 LHM200SCQ

LIFT CYLINDER QUICK VALVE PUMP CYLINDER

RESERVOIR

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LHM200SC, LHM200SCQ, LHM200SCO

19

Hydraulic unit Hydraulics diagram T-code 805, 813, 830

Valid from serial number 3 300 000-

Date 2006-06-19

Order number 232020-040

4.12.3 LHM200SCO

LIFT CYLINDER

PUMP CYLINDER

OVERLOAD VALVE

RESERVOIR

20

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Tools Service tools Order number 232020-040

Date 2006-06-19

Valid from serial number 3 300 000-

T-code 805, 813, 830

5- Tools 5.1 Service tools Table 3: Service tools Image

Part number

Use

V 10-16692

For removal of lift piston seal.

1. Place the tool in the correct position and make sure that the hook hooks into the seal.

2. Turn the tool.

3. Pull the tool upwards NOTE: Make sure that the tool’s hook does not damage the inside of the pump housing.

V 08-16599

© BT Europe AB

For locking the pump piston.

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Tools Service tools T-code 805, 813, 830

Valid from serial number 3 300 000-

Date 2006-06-19

Order number 232020-040

Table 3: Service tools Image

Part number

Use

V 08-16575

For fitting seals on pump cylinder.

1. Insert the seal into the tool.

2. Draw the sleeve over the seal.

3. Tool assembled.

4. Insert the tool into the cylinder.

5. Push the piston downwards.

6. Push until the piston reaches the bottom of the cylinder.

7. Push until the piston reaches the bottom of the cylinder.

8. Pull the tool upwards.

9. Remove the tool.

V 08-16590

For pressing the pump piston down when the tow bar has been removed.

1. Insert the tool into the shaft opening.

2. Perform pumping motions using the tool.

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© BT Europe AB

Tools Service tools Order number 232020-040

Date 2006-06-19

Valid from serial number 3 300 000-

T-code 805, 813, 830

Table 3: Service tools Image

Part number

Use

V 08-16573

For fitting the tow bar bushings.

V 10-16572

For checking the oil level in the hydraulic unit.

1. Position the tool on top of the hydraulic unit. Read off the quantity of oil required for topping up.

2. If the tool shows 0 cl, there is sufficient oil in the hydraulics. If the tool shows 10 cl, for example, the hydraulics need topping up with 10 cl of oil. In other words, the graduation on the tool shows how much oil is required to top up the hydraulics.

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23

Tools Service tools T-code 805, 813, 830

Valid from serial number 3 300 000-

Date 2006-06-19

Order number 232020-040

Table 3: Service tools Image

-

24

Part number

Use

V 08-16685

For tapping in the valve cone.

V 08-16668

For inserting scraper into lift cylinder.

V 08-13850

For inserting scraper into pump cylinder.

Service Manual

LHM200SC, LHM200SCQ, LHM200SCO

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Chassis General Order number 232020-040

Date 2006-06-19

Valid from serial number 3 300 000-

T-code 805, 813, 830

6- Chassis 6.1 General The complete chassis consists of the following components: • Chassis • Pivot pipe • Pivot pipe shaft • Pressure rods • Wheel forks • Climber wheels, front (only on single-wheel model) • Upper/lower forks • etc...

6.1.1 Replacing pivot pipes • Remove the spiral pin and pivot pipe shaft.

• Turn the chassis upside down.

• Remove the pressure rod by the pivot pipe.

• Assembly takes place in reverse order.

• Lubricate the system.

6.1.2 Replacing the pressure rod • Remove the clamp bolt and shafts.

• Remove the pressure rod by the pivot pipe and wheel fork.

• Assembly takes place in reverse order.

• Lubricate the system.

6.1.3 Replacing the wheel fork • Remove the clamp bolt and shafts.

• Remove the wheel fork.

• Assembly takes place in reverse order.

• Lubricate the system.

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Service Manual

LHM200SC, LHM200SCQ, LHM200SCO

25

Chassis General T-code 805, 813, 830

Valid from serial number 3 300 000-

Date 2006-06-19

Order number 232020-040

6.1.4 Replacing the bogie wheel • Remove the clamp bolt and shaft.

• Remove the bogie fork.

• Assembly takes place in reverse order.

• Lubricate the system.

6.1.5 Replacing the fork wheel • Remove the clamp bolt and shaft.

• Remove the wheel.

• Assembly takes place in reverse order.

6.1.6 Removal of upper/lower forks • Lay the pallet truck on its side.

• Loosen the four bolts on the underside of the forks holding the fork connector.

• Set the pallet truck on its wheels again and lift up the upper fork.

• Assembly takes place in reverse order.

When reassembling it is essential to ensure that no part of the lower fork, pressure rod or load wheel holder on the pallet truck has mechanical contact with the upper fork (the weighing element).

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Service Manual

LHM200SC, LHM200SCQ, LHM200SCO

© BT Europe AB

Scale General Order number 232020-040

Date 2006-06-19

Valid from serial number 3 300 000-

T-code 805, 813, 830

7- Scale 7.1 General The scale has a margin of error of a maximum of 0.1 % of the load. All components have been designed for mobile use, are compact and can withstand knocks and vibrations.

The pallet truck scale consists of the following components: • Mechanics • Load sensor • Indicator • Battery with charger • etc...

7.1.1 Mechanics The mechanical components comprise the pallet truck chassis and a special fork structure. The pallet truck’s weighing system consists of two components: • The lower forks • The upper forks Special sensors, load sensors, are fitted between the upper and lower fork and these register the load placed on the upper fork.

It is extremely important that the entire load be borne by the load sensors and that no part of the lower fork structure, pressure rod or wheel bracket on the pallet truck has mechanical contact with the upper fork (i.e. the weighing element).

© BT Europe AB

Service Manual

LHM200SC, LHM200SCQ, LHM200SCO

27

Scale General T-code 805, 813, 830

Valid from serial number 3 300 000-

Date 2006-06-19

Order number 232020-040

7.1.2 Load sensor One of the most important components in the weighing system is the load sensors.

A load sensor is a rectangular steel block installed inside the forks. The load sensor will be distorted 0.07 mm by a 1000 kg load. In other words, distortion of the steel block is due to the weight being lifted. The load sensor contains an electrical resistor that acts as a strain gauge.

Fig. 1 Strain gauge The electrical resistor in the strain gauge present in every load sensor changes linearly in relation to the distortion of the load sensor.

The load sensor has four wires connected to an indicator. The red and black wires supply power to the load sensor. The voltage fed to the load sensor is a holding current. The load sensor’s output voltage, i.e. the signal, is conducted via the green and white wires and is caused by the change in resistance in the strain gauge.

With maximum load on the load sensors (e.g. 4 x 1000 kg) the signal voltage (caused by the change in the resistance) is approximately 0.01 volts. The signal voltage with a 100 kg load is only 0.0002 volts. With a load of just 1 kg, the signal voltage changes to only 0.000002 volts.

When working with such weak electrical signals the wires must be in 100 % perfect condition. Bearing this in mind, the signal is transferred from the load sensors to the indicator via a special cable. All connections must be soldered and have a vapour barrier because corrosion of the terminals can otherwise result in unstable readings.

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Service Manual

LHM200SC, LHM200SCQ, LHM200SCO

© BT Europe AB

Scale General Order number 232020-040

Date 2006-06-19

Valid from serial number 3 300 000-

T-code 805, 813, 830

7.1.3 Indicator The indicator functions in the same way as an ohm/voltmeter. The change in the electrical resistance is measured, interpreted and displayed in the form of a declaration of weight. The indicator is more precise than a universal instrument, but has a very limited voltage range. It measures microvoltages with a very high level of accuracy and is not affected by temperature fluctuations or radio interference.

The indicators have a 12 V power supply. The indicator’s power consumption is less than 20 mA. Bearing in mind the extremely weak signal levels, the card is very sensitive, since moisture and chemical substances can affect the terminal solders.

Display - symbols The scale’s reading (including load) is stable

The weight displayed is negative NET

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Service Manual

The weight displayed is a net weight

LHM200SC, LHM200SCQ, LHM200SCO

29

Scale General T-code 805, 813, 830

Valid from serial number 3 300 000-

Date 2006-06-19

Order number 232020-040

Display indications A minus sign may also be shown in the display. The following indications may appear in the display.

HELP 1

The scale has been overloaded.

HELP 2

Taring a negative weight.

HELP 3

Negative signals from the AD transducer’s load sensor/pallet truck tilting.

HELP 4

Tare has been set too high (manually). Press the nPT button once to delete this help message and specify a lower tare.

HELP 7

The signal from the AD transducer’s load sensor is too high.

LO-BA

The battery’s voltage is low. The battery must be charged.

Touch screen Button

Function

Resetting and automatic taring

Confirms and moves one character to the left

Tare input

Reduces the flashing figure

Cumulative weighing

Increases the flashing figure

Power switch

Deletes

NOTE! Commands from the buttons are only accepted when the scale is stable (when the “Stable scale” symbol is lit). In other words, the indicator only executes commands when the load is stable.

WARNING! If the load being weighed exceeds the preset maximum weight, the display shows: “HELP1”. In such cases you must unload the scale immediately in order to prevent damage to the indicator and load sensors.

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Service Manual

LHM200SC, LHM200SCQ, LHM200SCO

© BT Europe AB

Scale General Order number 232020-040

Date 2006-06-19

Valid from serial number 3 300 000-

T-code 805, 813, 830

7.1.4 Battery The battery is a sealed lead battery of 12 V and 1.2 Ah. Since the power consumption is 20 mA, the battery should last for 60 hours of work.

The display shows “LO-BA” when the battery needs charging.

The charger uses a current of 300 mA. The battery can be charged fully in 6 hours. However, it is a good idea to leave the battery connected to the charger for longer than that.

Battery replacement It is easy to replace the battery . Simply lift the grey lock tab and pull out the battery.

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Service Manual

LHM200SC, LHM200SCQ, LHM200SCO

31

Scale Function T-code 805, 813, 830

Valid from serial number 3 300 000-

Date 2006-06-19

Order number 232020-040

7.2 Function The scale’s electronics card is powered by a 12 V battery.

The indicator is connected by 4 wires to each load sensor. The red and black wires supply power to the load sensor as a holding current.

Each load sensor contains a resistor that acts as a strain gauge. As soon as any weight is placed on the load sensor, the sensor is distorted, resulting in a change in the resistor in the strain gauge, and, consequently, a change in the output voltage.

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Service Manual

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© BT Europe AB

Scale Function Order number 232020-040

Date 2006-06-19

Valid from serial number 3 300 000-

T-code 805, 813, 830

The load sensor’s output voltage is a signal that is proportional to the weight, and is transmitted back to the indicator via the green and white wires.

The indicator functions as a voltmeter or ohmmeter. Changes in the signal level are measured and converted into a weight value.

Calibrating the scale programs the load sensor with an output voltage corresponding to weights of 0 kg, 200 kg, 500 kg and 2000 kg. The calibration data is stored in an EEPROM circuit on the card, and this data is used by the indicator until the system is recalibrated.

There is a calibration card between the indicator and load sensors. By adjusting the input voltage from the various load sensors using potentiometers it is possible to fine-tune the four corners of the ‘scale’ in relation to one another.

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Service Manual

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33

Scale Function T-code 805, 813, 830

Valid from serial number 3 300 000-

Date 2006-06-19

Order number 232020-040

7.2.1 Removing the scale • The indicator module’s casing can be removed by undoing the two screws, thus allowing you access to all wires and modules.

• The load sensors’ electronics card can be extracted for simple adjustment of the corner weights.

• Undo four more screws to detach the entire indicator module.

• The electronics card can be snapped securely into the module.

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Service Manual

LHM200SC, LHM200SCQ, LHM200SCO

© BT Europe AB

Scale Optional extras Order number 232020-040

Date 2006-06-19

Valid from serial number 3 300 000-

T-code 805, 813, 830

7.3 Optional extras 7.3.1 Printer A printer can be connected to the scale on the pallet truck. The following information can be printed: gross weight, net weight and tare, total weight (when the weights from several pallets are accumulated to give a total weight per consignment, order or customer) with order number.

Function The printer obtains power from the indicator circuit card, and data is received from the same card. The printer is only supplied with power by the indicator during printing.

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LHM200SC, LHM200SCQ, LHM200SCO

35

Scale Optional extras T-code 805, 813, 830

Valid from serial number 3 300 000-

Date 2006-06-19

Order number 232020-040

Removal • Undo the two screws to detach the printer module.

• Press down the four catches with a screwdriver and remove the printer module.

• Disconnect the terminal connection from the indicator circuit card.

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Service Manual

LHM200SC, LHM200SCQ, LHM200SCO

© BT Europe AB

Scale Optional extras Order number 232020-040

Date 2006-06-19

Valid from serial number 3 300 000-

T-code 805, 813, 830

7.3.2 Commercial weighing status Commercial weighing status is required in order to use the pallet truck’s scale for invoicing purposes, i.e. when invoices are issued based on the weight recorded.

Firstly, the scale must be manufactured using approved components.

Secondly, it must be tested, labelled and sealed by a certified metrological institute. After recalibration, a random number is generated and stored in the electronics. This number is an audit trail that is shown in the display when the scale is switched on, and it must tally with the same tracking number on an external sticker. This guarantees the accuracy of the scale and it can be used as proof for both the user and the company’s customers.

The pallet truck’s service technician must not break the seal, recalibrate the scale or alter the metrological parameter settings unless he is suitably authorised by a metrological certification institute.

The scale must be checked before and after servicing work! If there is any doubt regarding the accuracy of the scale, a metrological inspector must be contacted to re-certify the scale.

Important Scales with commercial weighing status may only be recalibrated by inspectors from a certified metrological institute.

Inspectors of commercial weighing equipment can be found in all countries, and they comply with the relevant country’s legislation regarding calibration of scales.

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LHM200SC, LHM200SCQ, LHM200SCO

37

Scale Optional extras T-code 805, 813, 830

Valid from serial number 3 300 000-

Date 2006-06-19

Order number 232020-040

This page is intentionally left blank

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Service Manual

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© BT Europe AB

Electronics and parameters Truck configurations Order number 232020-040

Date 2006-06-19

Valid from serial number 3 300 000-

T-code 805, 813, 830

8- Electronics and parameters 8.1 Truck configurations LHM200SC: - 2100B - Load sensor - Calibration card LHM200SC with printer: - 2100N with RS card - Load sensor - Calibration card - Printer LHM200SC with commercial weighing status: - 2100N - Load sensor - Calibration card - Tilt switch LHM200SC with commercial weighing status and printer: - 2100N with RS card - Load sensor - Calibration card - Printer - Tilt switch

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Service Manual

LHM200SC, LHM200SCQ, LHM200SCO

39

Electronics and parameters Truck configurations T-code 805, 813, 830

Valid from serial number 3 300 000-

Date 2006-06-19

Order number 232020-040

8.1.1 Circuit card 2100B Used in standard version, but not for models with commercial weighing status and printer.

40

Terminal

Function

Colour

1

Load sensor - holding current, 0 V

Brown

2

Load sensor - signal

White

3

Load sensor + signal

Green

4

Load sensor + holding current, 2.5 V

Yellow

5

Not used

6

Power supply, earth, 0 V

Black

7

Power supply, +12 V

Red

8

Not used

9

Not used

10

Not used

Service Manual

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© BT Europe AB

Electronics and parameters Truck configurations Order number 232020-040

Date 2006-06-19

Valid from serial number 3 300 000-

T-code 805, 813, 830

8.1.2 Circuit card 2100N Used on models with commercial weighing status.

Terminal

Function

Colour

1

Load sensor - holding current, 0V

Brown

2

Load sensor - sensing

Pink

3

Load sensor - signal

White

4

Load sensor + signal

Green

5

Load sensor + sensing

Red

6

Load sensor + holding current, 2.5 V

Yellow

7

Load sensor, cable shield

8

Power supply, earth, 0 V

Black

9

Power supply, +12 V

Red

10

Not used

11

Tilt switch, earth

12

Not used

13

Not used

14

Not used

15

Not used

16

Not used

17

Not used

18

Tilt switch, input

© BT Europe AB

Service Manual

Comments

Only approved systems and with cable of > 1 m

Only approved systems and with cable of > 1 m

Only approved systems

Blue

Only approved systems

Brown

Only approved systems

LHM200SC, LHM200SCQ, LHM200SCO

41

Electronics and parameters Truck configurations T-code 805, 813, 830

Valid from serial number 3 300 000-

Date 2006-06-19

Order number 232020-040

8.1.3 Circuit card 2100N with RS card Used on models with printer.

Terminal

Function

Colour

1

Load sensor - holding current, 2.5 V AC

Brown

2

Load sensor - sensing

Pink

3

Load sensor - signal

White

4

Load sensor + signal

Green

5

Load sensor + sensing

Red

6

Load sensor + holding current, 2.5 V AC

Yellow

7

Load sensor, cable shield

8

Power supply, earth, 0 V

Black

9

Power supply, +12 V

Red

10

Printer, earth, 0 V

Black

Only with printer option

11

Printer power supply, +12 V

Red

Activated only on print command

12

RxD, Receive Data

13

CTS, Clear To Send

“Only printer or RS 232 output; connected to DTR on the printer. (See printer instructions re. wiring)”

14

TxD, Transmit Data

“Only printer or RS 232 output; connected to RxD on the printer. (See printer instructions re. wiring)”

42

Service Manual

Comments

Only approved systems and with cable of > 1 m

Only approved systems and with cable of > 1 m

Only approved systems

LHM200SC, LHM200SCQ, LHM200SCO

© BT Europe AB

Electronics and parameters Truck configurations Order number 232020-040

Date 2006-06-19

Valid from serial number 3 300 000-

T-code 805, 813, 830

Terminal

Function

15

RTS, Ready To Send

16

Tilt switch, earth

Blue

Only approved systems – printer’s earth cable is also connected here

17

Tilt switch, input

Grey

Only approved systems

Colour

Comments Only RS 232 output (for handshake); connected to CTS on the printer

8.1.4 Circuit card, calibration card

Connection 1 Terminal

Function

Colour

Comments

F

Not present

Not present

Not present

E

Not present

Not present

Not present

D

Holding current, load sensor D

Red

C

Holding current, load sensor C

Red

B

Holding current, load sensor B

Red

A

Holding current, load sensor A

Red

B

Holding current (-) from all load sensors

Black

All wires must be connected together

Y

Signal (-) from all load sensors

White

All wires must be connected together

G

Signal (+) from all load sensors

Green

All wires must be connected together

-

Power supply, earth, 0 V DC

Black

Only systems with built-in indicator

+

Power supply, +12 V DC

Red

Only systems with built-in indicator

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Service Manual

LHM200SC, LHM200SCQ, LHM200SCO

43

Electronics and parameters Truck configurations T-code 805, 813, 830

Valid from serial number 3 300 000-

Date 2006-06-19

Order number 232020-040

Potentiometers 2 Terminal

Function

A

Load sensor A

See the drawing below.

B

Load sensor B

See the drawing below.

C

Load sensor C

See the drawing below.

D

Load sensor D

See the drawing below.

E

Not present.

Not present.

Not present.

F

Not present.

Not present.

Not present.

Comments

Colour

Comments

Connection 3 Terminal

Function

Colour

B

Holding current (-)

Brown

R

Holding current (+)

Yellow

Y

Signal (-)

White

G

Signal (+)

Green

-

Power supply, earth, 0 V DC for the indicator

Blue

+

Power supply +12 V DC for the indicator

Red

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© BT Europe AB

Electronics and parameters Truck configurations Order number 232020-040

Date 2006-06-19

Valid from serial number 3 300 000-

T-code 805, 813, 830

8.1.5 Load sensor

Specification • Nickel-plated or stainless steel.

• Sensitivity 3 mVolt per Volt.

• Input & output resistance 350 ohms.

© BT Europe AB

Function

Colour

Holding current +

Red

Holding current -

Black

Signal -

White

Signal +

Green

Service Manual

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45

Electronics and parameters Truck configurations T-code 805, 813, 830

Valid from serial number 3 300 000-

Date 2006-06-19

Order number 232020-040

8.1.6 Tilt switch

Specification • Switches off the scale at an incline of more than 2º • Accuracy/hysteresis of 0.5º.

• Maximum cut-off value 12 V DC at 0.5 Amp. WARNING! Exercise care with the cable from the switch. If it breaks, the switch must be replaced.

Do not tighten the screws too much. This can damage the components in the switch.

46

Function

Colour

Tilt switch, input

Blue

Earth

Brown

Service Manual

LHM200SC, LHM200SCQ, LHM200SCO

© BT Europe AB

Electronics and parameters Truck configurations Order number 232020-040

Date 2006-06-19

Valid from serial number 3 300 000-

T-code 805, 813, 830

8.1.7 Printer

Specification • Thermal printer • Simple paper replacement • No ink cartridge required

Terminal

Function

Colour

Comments

+

Printer power supply

Red

Connected to the indicator

-

Printer power supply

Black

Connected to the indicator (connected to power switch)

1

GND: earth

Red

See indicator instructions re. wiring

2

Not used

3

RxD: Receive Data

Green

Connected to the terminal TxD on the indicator

4

Not used

5

DTR: Data Terminal Ready

White

Connected to the terminal CTS on the indicator

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47

Electronics and parameters Parameter settings T-code 805, 813, 830

Valid from serial number 3 300 000-

Date 2006-06-19

Order number 232020-040

8.2 Parameter settings 8.2.1 Changing parameters • Switch off the indicator.

• Press and hold the power switch for 23 seconds to access the parameter menu.

- The indicator shows: “P 01”.

• Press the “0/T” button.

- The display shows current value for parameter P 01.

• Use the “up” and “down” buttons to change the current value.

• Confirm using the “0/T” button.

- The display shows: “P 02”. Parameter P 02 can now be changed in the same way as P 01.

- You can scroll through the parameters using the “up” button to reach the required parameter.

- You can quickly return to parameter P 01 by pressing the power switch briefly when a parameter number is displayed.

• Once all the parameters have been changed as required, press and hold the “0/T” button for 3 seconds to exit the parameter menu and return to weighing mode.

8.2.2 Parameter list All available parameters are described below.

• Settings for optional equipment are marked with an asterisk (*). Contact the manufacturer to check whether your pallet truck is equipped with the hardware in question. If a particular function is not provided by the hardware, it will not be possible to activate or make changes to the parameters of that function.

• The basic settings of the electronics card are given in the table. Contact the manufacturer to find out which hardware version the pallet truck uses.

48

Parameter

Function

01

RF* option: ID number of the RF function confirming that matching equipment is communicating correctly. Available ID numbers: 0 - 7.

RCS* option: delay for the peak indicator’s indications, 0 - 9 seconds.

Service Manual

LHM200SC, LHM200SCQ, LHM200SCO

© BT Europe AB

Electronics and parameters Parameter settings Order number 232020-040

Date 2006-06-19

Valid from serial number 3 300 000-

T-code 805, 813, 830

Parameter

Function

02

Specifies minimum weight graduation.

0.1 = 0.1 kg 0.2 = 0.2 kg 0.5 = 0.5 kg 1 = 0,1 kg 2 = 0,2 kg 5 = 0,5 kg 10 = ,10 kg 20 = ,20 kg 50 = ,50 kg

03

Specifies maximum weight graduation.

0.1 = 0.1 kg 0.2 = 0.2 kg 0.5 = 0.5 kg 1 = 0,1 kg 2 = 0,2 kg 5 = 0,5 kg 10 = ,10 kg 20 = ,20 kg 50 = ,50 kg Note: P 02 must always have a smaller value than P 03. If you accidentally enter a higher value, the scale automatically sets both parameters to the same value, which means that the weight graduation function is not used.

04

Specifies the number of graduations per weight graduation, i.e. per 100 graduations. Possible values 0000 - 9900, but for the model with commercial weighing status 500 - 3000*.

Note: If the values for P 02 and P 03 are the same, and weight graduations are thus not used, P 04 is automatically set to “----”.

05

Sets the scale capacity (full scale) per 100 kg. Possible values 00000 - 99900.

06

Specifies movement detection in graduations per second. If the system’s registered value per second exceeds the set movement graduation, the “Stable scale” indication in the display will not come on.

0 = 0.5 graduation (standard on systems with commercial weighing status, option*) 1 = 1 graduation 2 = 2 graduations 3 = 4 graduations

07

Option: switches between has/does not have commercial weighing status (in kg or lb).

0 = does not have commercial weighing status (in kg).

1 = has commercial weighing status (in kg, only prints positive weights)* 2 = does not have commercial weighing status (in lb) 3 = has commercial weighing status (in lb, only prints positive weights)*

08

Sets shutdown automatically (in minutes) Possible values 1- 99 (0 = not active).

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LHM200SC, LHM200SCQ, LHM200SCO

49

Electronics and parameters Parameter settings T-code 805, 813, 830

50

Valid from serial number 3 300 000-

Date 2006-06-19

Order number 232020-040

Parameter

Function

09

Specifies number of wires per load sensor cable.

4 = 4 wires 6 = 6 wires (equipped for commercial weighing status)

10

Option: switches off automatic zero correction*. Used in specific dosing applications.

0 = off 1 = on

11 - 14

Not used

15

Option: relay output*. Gives the value as net or gross weight.

0 = net weight 1 = gross weight

16

Option: relay output*. Selects preset tare.

0 = preset tare 1 = set point

17

Option: display of peak values*. Decides whether the peak value display should be kept or not.

0 = standard display 1 = peak value display kept This option is only available with a 2100B card (can be identified by the fact that “q” lights up at the bottom of the display when the system is activated). From software package 7.4 inclusive: when P17 is set to 1, all other related parameters change to the correct settings for the peak value display (see the table with basic settings).

18 - 19

Not used

20

Option: printer or printer output*. Sets transfer rate. Possible values: 600/1200/ 2400/4800/9600.

21

Option: printer or printer output*. Specifies data bit length. Possible values: 7/8.

22

Option: printer or printer output*. Sets parity.

E = even = none 0 = odd

23

Option: printer or printer output*. Specifies the number of stop bits. Possible values: 1/2.

24

Not used

25

Option: printer or printer output*. Specifies RS card function.

2100N 0 = none 1 = PC 2 = printer 3 = RF transmitter This option is only available on a 2100N card.

26

Option: printer or printer output*. Specifies the number of line feeds after printing a total weight. Possible values: 0 - -7.

Service Manual

LHM200SC, LHM200SCQ, LHM200SCO

© BT Europe AB

Electronics and parameters Parameter settings Order number 232020-040

Date 2006-06-19

Valid from serial number 3 300 000-

T-code 805, 813, 830

Parameter

Function

27 - 39

Not used

40

Option: System with commercial weighing status*: Activates the tilt switch or movement detector.

0 = not active 1 = tilt switch active, usually closed 2 = tilt switch active, usually open 3 = movement detector active

41

Option: System with commercial weighing status*: Sets tilt switch’s delay in seconds. Possible values: 0-7.

42 - 89

Not used

90

Resetting to the basic settings. If parameter P 90 is selected and you press the “0/T” button, all parameter settings are reset to the basic settings. NOTE: The basic settings can be incorrect for certain pallet trucks. Make sure that you have a copy of the correct parameters for the pallet truck in question before the parameters are reset.

91

Not used

92

Initiates automatic shutdown if battery voltage is low. When this parameter is active, the scale shuts off automatically 2 minutes after the symbol for low battery voltage comes on.

0 = not active 1 = active

93 - 98

Not used

99

Shows the scale’s software version.

8.2.3 Basic settings The pallet truck’s basic settings are shown below.

• Settings for optional equipment are marked with an asterisk (*). Contact the manufacturer to check whether your pallet truck is equipped with the hardware in question. If a particular function is not provided by the hardware, it will not be possible to activate or make changes to the parameters of that function.

• Parameters that are not used are indicated by five dashes (-----).

Parameter

2100B with peak value indication

2100N

01

4

0

02

5

0.2

03

5

1

04

-----

1000

05

2500

02200

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51

Electronics and parameters Parameter settings T-code 805, 813, 830

52

Valid from serial number 3 300 000-

Date 2006-06-19

Order number 232020-040

Parameter

2100B with peak value indication

2100N

06

1

1

07

1

0

08

03 / 30

05

09

4

4

10

1

-----

11 - 14

-----

-----

15*

0

0

16*

0

0

17*

1

0

18 - 19

-----

-----

20*

-----

1200

21*

-----

8

22*

-----

-

23*

-----

1

24

-----

-----

25*

-----

0

26*

-----

06

27 - 39

-----

-----

40*

-----

0

41*

-----

3

42 - 89

-----

-----

90

RESET

RESET

91

-----

-----

92

1

1

93 - 98

-----

-----

99

740

-----

Service Manual

LHM200SC, LHM200SCQ, LHM200SCO

© BT Europe AB

Troubleshooting Troubleshooting chart Order number 232020-040

Date 2006-06-19

Valid from serial number 3 300 000-

T-code 805, 813, 830

9- Troubleshooting 9.1 Troubleshooting chart Fault

Cause

Action

Air in the hydraulic system

Pump five strokes with lowering valve open.

The hydraulics contain too little oil.

Top up with oil as per “4.11 Changing the oil” on page 17.

The hydraulics contain too little oil.

Top up with oil as per “4.11 Changing the oil” on page 17.

The lowering valve is not closing properly.

Adjust the valve chain’s extension using the adjusting nut.

Leakage past non-return valve

Replace ball and washer.

Air in the hydraulic system

Pump five strokes with the lowering handle in the lowered position.

Leakage at the valve cone

Reverse base, replace valve cone and washer.

Lowering does not function or goes too slowly

The lowering valve is not opening properly.

Adjust the valve chain’s extension using the adjusting nut.

The forks lower when the lowering handle is in neutral position

The lowering valve is not closing properly.

Adjust the valve chain’s extension using the adjusting nut.

Leakage at the valve cone

Reverse base, replace valve cone and washer.

Leakage at seal in the lift cylinder

Replace seal.

Pumping occurs when the lowering handle is in neutral position

Valve ball not activated

Adjust the valve chain’s extension using the adjusting nut.

Oil leakage at lowering valve

Sealing ring worn or damaged

Replace packing set for lowering valve.

Quick valve out of action

Replace quick piston.

LHM200SC The pump does not perform complete strokes

Lifting, neutral and lowering mode do not function correctly

The forks lower after each stroke

LHM200SCQ Lifts like a standard model

© BT Europe AB

Service Manual

LHM200SC, LHM200SCQ, LHM200SCO

53

Troubleshooting Troubleshooting chart T-code 805, 813, 830

Valid from serial number 3 300 000-

Date 2006-06-19

Order number 232020-040

9.1.1 Troubleshooting - hydraulics Internal leakage Inside Leakage: Lowering Pump Unit

Wipe off / Clean outside of Pump Unit

Adjust lowering rod from handle

Punsh new cone seat

No

No

Punsh new ball seat in overload valve

Change U-ring for the Lift Piston

No

Functional Pump Unit

Functional Pump Unit

Functional Pump Unit

Yes

Yes

Yes

Functional Pump Unit

Yes

No

Change Pump Unit

Re-assamble Machine and send to customer

External leakage Leakage thru Pump Body

No

Outside Leakage

Wipe off /Clean the Pump Unit

Leakage thru Lowering Valve

Change Lowering Valve

Functional Pump Unit

Yes

Leakage thru Cone valve

Change Cupper Washer on cone Valve

Functional Pump Unit

Yes

Leakage thru Pump Cylinder

Change U-ring and Wiper ring in Pump Cylinder

Functional Pump Unit

Yes

Leakage thru Lift Cylinder

Change Wiper Ring in Lift Cylinder

Functional Pump Unit

Yes

Leakage thru Overload Valve

Change O-ring in Overload Valve

Functional Pump Unit

Yes

No

Establish the leakage area No

No

No

Re-assamble Pump Unit and send back to customer

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Change Pump Unit

© BT Europe AB

Troubleshooting Troubleshooting chart Order number 232020-040

Date 2006-06-19

Valid from serial number 3 300 000-

T-code 805, 813, 830

Defective quick lift function No Quick Lift function

Re-assamble Machine and send to customer

Change complete Quick Lift Piston Yes

Functional Pump Unit

© BT Europe AB

Service Manual

No

Change Pump Unit

LHM200SC, LHM200SCQ, LHM200SCO

55

Troubleshooting Troubleshooting - scale T-code 805, 813, 830

Valid from serial number 3 300 000-

Date 2006-06-19

Order number 232020-040

9.2 Troubleshooting - scale The most common causes of a malfunction are as follows: • Power supply: discharged battery, damaged fuse or problems with the charger • Bad or broken contact • Crushed or cut cables • Loose screws or bolts • Mechanical problem: the fork connector catches on the pallet truck chassis as a result of distortion or a lot of dirt • Moisture in the electronics or load sensors

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© BT Europe AB

Troubleshooting Troubleshooting - scale Order number 232020-040

Date 2006-06-19

Valid from serial number 3 300 000-

T-code 805, 813, 830

Table 4: Troubleshooting chart Problem:

Nothing is working. The display remains blank even when the buttons are pressed.

Action:

Check the battery and charger.

• The simplest way to test the battery is to replace the battery module.

• Always check the battery charger. The battery may have discharged or been damaged as a result of a defective charger. The charger must have an output voltage between 12.5 and 13.8 V. Checking the battery and charger • When checking the battery’s voltage, you must check that the indicator has been switched off for around 3 minutes. It may be that the voltage only drops when power is being drawn from the battery. Check the contact points on the battery cover by checking the battery voltage at the poles on the back of the cover.

Check the fuse and indicator • Check the fuse (in the indicator housing).

• Check the indicator’s circuit card: If nothing comes on when there is +12 V DC at the correct contact points, the card is broken and must be replaced.

• If the indicator is not receiving +12 V, you must check the cables and connections between the fuse and the indicator’s circuit card.

© BT Europe AB

Service Manual

LHM200SC, LHM200SCQ, LHM200SCO

57

Troubleshooting Troubleshooting - scale T-code 805, 813, 830

Valid from serial number 3 300 000-

Date 2006-06-19

Order number 232020-040

Table 4: Troubleshooting chart Problem:

Unstable indicator, weight indication increases/decreases

Action:

Check the fork structure mechanics: • Check that nothing is jammed between the forks and fork connector: the scale’s results are affected by foreign objects preventing free movement of the fork connector.

Check the load sensor cables and calibration card • Try moving the load sensor cables close to the connection. If weight indication is affected, this indicates that the cable is damaged and must be replaced.

• Take out the calibration card and jiggle it. Jog the cables connected to the calibration card slightly. If the reading is affected, this indicates that the cable is damaged.

• If the calibration card is oxidized, you can remedy the problem by heating the solders with a soldering iron. Otherwise, replace the card.

Check the indicator for moisture and loose connections • Check the indicator’s circuit card for moisture and condensation: if necessary, dry the card using hot air. Signs of moisture problems are corrosion on the card’s components, particularly on the pins between the printed lines.

Check the load sensors • Measure the resistance between the load sensor cables and the pallet truck chassis: if the measured resistance is not infinite, this means that one or more of the load sensors is affected by moisture. Disconnect the four load sensors and remeasure the individual cables to determine which load sensor is defective.

• Reconnect the load sensors to the indicator one at a time: Compare the displayed values for each load sensor. If the value from a particular load sensor is unstable or differs markedly from the others, then that load sensor is the cause of the problem.

• If the indicator reading reacts unsteadily to each of the load sensors, the indicator should be inspected.

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© BT Europe AB

Troubleshooting Troubleshooting - scale Order number 232020-040

Date 2006-06-19

Valid from serial number 3 300 000-

T-code 805, 813, 830

Table 4: Troubleshooting chart Problem:

The same load is weighed repeatedly, but the display shows differing weight indications

Action:

Check the load sensors: • Position yourself on the four corners of the forks. If the weight shown by the display differs by more than 1 kg, the difference between the four corners may cause differing readings depending on the weight distribution on the forks.

Check the load sensors: • Remove the fork connector and insert a bolt into the load sensor’s mounting hole. Balance a 20 kg calibration weight on each load sensor. The weight indications must not differ by more than 200 or 400 gram between load sensors.

Check the load sensors: • If the difference is greater, the load sensors must be adjusted relative to each other by turning the small adjustment screws on the potentiometers on the load sensors’ calibration card.

© BT Europe AB

Service Manual

LHM200SC, LHM200SCQ, LHM200SCO

59

Troubleshooting Troubleshooting - scale T-code 805, 813, 830

Valid from serial number 3 300 000-

Date 2006-06-19

Order number 232020-040

Table 4: Troubleshooting chart Action:

Check the fork structure mechanics: • Check that nothing is jammed between the forks and fork connector: • Place a heavy weight on the forks, press the tare button so that the net weight is displayed as zero kilos, and then position yourself on the four corners of the forks. If the difference is more than 1 or 2 kg, this may indicate that the fork connector is bending so much under heavy loads that it is touching the lower fork structure.

Problem:

The reading from the pallet truck scale is correct for light weights but incorrect for heavy weights

Action:

Check the fork structure mechanics: • Check that nothing is jammed between the forks and fork connector: • Place a heavy weight on the forks, press the tare button so that the net weight is displayed as zero kilos, and then position yourself on the four corners of the forks. If the difference is more than 1 or 2 kg, this may indicate that the fork connector is bending so much under heavy loads that it is touching the lower fork structure.

Problem:

The reading from the pallet truck scale is wrong and the discrepancy is linear. Example: with 100 kg the error is 1 kg, with 500 kg the error is 5 kg, and with 1000 kg it is 10 kg.

Action:

Recalibrate the scale.

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© BT Europe AB

Troubleshooting Troubleshooting - scale Order number 232020-040

Date 2006-06-19

Valid from serial number 3 300 000-

T-code 805, 813, 830

Table 4: Troubleshooting chart Problem:

When the forks are empty the indicator shows a weight (positive or negative) that cannot be “cleared”. The display may also show HELP 2 (taring a negative weight), HELP 3 (negative signal from AD transducer) or HELP 7 (overload/signal from AD transducer too high).

Action:

Recalibrate the scale in order to reset it (NOTE: Not permitted for scales with commercial weighing status!).

• The resetting function only works with limited displacement from zero. Recalibrating the zero point returns the weight indications to normal limitations.

Check the load sensors: • Remeasure the output signal in mV using a voltmeter connected between the green and white wire. The output signal must be positive and may not exceed 0.2 mV with an empty scale. Check the load sensors individually if the output signal is too high or is negative.

• A defective load sensor can produce a signal that is too high and also cause an overload message to be displayed.

Check the cables: • The problem may have been caused by a short circuit in the load sensors’ wiring.

Check the indicator: • Check whether the indicator’s circuit card is defective if none of the above solve the problem.

Problem:

The display does not react to loads placed on the forks

Action:

Remove the battery module: • Static electricity can cause the indicator to “freeze”. The problem can be solved by switching off the power supply and restarting the indicator.

Check the indicator’s calibration points: • If old calibration values have not been deleted prior to recalibration, the scale may show the same value for totally different weights. Delete the existing calibration points and recalibrate the scale.

© BT Europe AB

Service Manual

LHM200SC, LHM200SCQ, LHM200SCO

61

Troubleshooting Troubleshooting - scale T-code 805, 813, 830

Valid from serial number 3 300 000-

Date 2006-06-19

Order number 232020-040

Table 4: Troubleshooting chart Problem:

The buttons on the indicator are not working

Action:

Check the flat cable between the indicator’s circuit card and the keypad.

• If any of the buttons are not working, this may be due to the flat cable not being connected or being damaged, thus preventing transfer of signals from the buttons to the indicator.

Check if there is moisture in the flat cable.

• If certain buttons do not work, but others do, the keypad must be replaced.

Check whether the indicator is defective.

Problem:

The LCD segment in the display is not working

Action:

Check the indicator: • If you carefully bend the indicator’s circuit card, you can detect any concealed breaks in the LCD element’s contact pins. Replace the card if it is not possible to solder the pins.

See Troubleshooting for detailed instructions regarding troubleshooting for the scale.

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© BT Europe AB

Calibrating the scale Calibrating the pallet truck scale Order number 232020-040

Date 2006-06-19

Valid from serial number 3 300 000-

T-code 805, 813, 830

10- Calibrating the scale 10.1 Calibrating the pallet truck scale To calibrate the pallet truck scale, specify a “zero point” and one to three other points in the weight range, including “full load”. Calibration is performed via the indicator keypad only.

10.1.1 Determining the zero point • Check that there is no load on the forks and then turn on the power to the scale.

• Press and hold the 0/T button for 8 seconds to activate the calibration function.

• The display counts down from AF 08 to AF 00.

• The indicator shows what percentage of the total capacity has been reset, e.g. AP 6.4. This percentage may be a maximum of 20.

• The indicator automatically calibrates the zero point and then returns to the mode for normal weighing.

© BT Europe AB

Service Manual

LHM200SC, LHM200SCQ, LHM200SCO

63

Calibrating the scale Calibrating the pallet truck scale T-code 805, 813, 830

Valid from serial number 3 300 000-

Date 2006-06-19

Order number 232020-040

10.1.2 Single-point calibration Deleting (resetting) previous calibrations • Press and hold the “PT” button for around 18 seconds - The display remains empty until calibration mode is accessed .

- The indicator shows the value of the first calibration point, and the lowest indication bar (left side of the display) flashes.

• The three previous programmed values can be checked on the screen by moving the indication bar up or down using the up and down button.

- When the lowest indication bar lights up, the first (lowest) value is displayed, and above this bar are the second and third bars showing the highest value.

- When calibrating just one point, the values for the next and the highest value should be zero.

• Press and hold the “up” or “down” button until the middle calibration value is shown.

- The middle indication bar flashes.

• Press the “0/T” button.

- The first segment flashes.

• Use the “up” and “down” buttons to reset the flashing segment to zero.

• Move to the next segment using the “0/T” button.

• Reset all segments until the indication bar starts flashing.

• Press and hold the “up” or “down” button until the highest calibration value is shown.

- The highest indication bar flashes.

• Repeat this process until all segments have been reset.

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© BT Europe AB

Calibrating the scale Calibrating the pallet truck scale Order number 232020-040

Date 2006-06-19

Valid from serial number 3 300 000-

T-code 805, 813, 830

Single-point calibration • Return to lowest value.

- The indicator shows the value of the first calibration point, while the lowest indication bar flashes.

• Place a load of a known weight on the scale and specify the weight on the indicator by briefly pressing the “0/T” button.

- The first segment starts to flash.

• Use the “up” and “down” buttons to change all segments, and confirm the value of each segment using the “0/T” button until the correct weight has been entered.

- The bottom indication bar will begin flashing again once each segment has been corrected.

• Confirm the entered weight by pressing and holding the “0/T” button for 3 seconds.

- The display now counts down from AF 08 to AF 00, at which point the first calibration point has been set.

• You can exit calibration mode by pressing the “up” or “down” button until AP XX appears.

- This figure indicates calibration sensitivity as a percentage, e.g.

AP 07.

• Press the “0/T” button until the reading in the display disappears.

Multipoint calibration • Press and hold the “PT” button for around 18 seconds - The display remains empty until calibration mode is accessed .

- The indicator shows the value of the first calibration point, while the lowest indication bar flashes.

• Place a load of a known weight on the scale and specify the weight on the indicator by briefly pressing the “0/T” button.

- The first segment starts to flash.

• Use the “up” and “down” buttons to change all segments, and confirm the value of each segment using the “0/T” button until the correct weight has been entered.

- The bottom indication bar will begin flashing again once each segment has been corrected.

• Confirm the entered weight by pressing and holding the “0/T” button for 3 seconds.

- The display now counts down from AF 08 to AF 00, at which point the first calibration point has been set.

• Press the “up” button.

- The middle indication bar starts flashing while the indicator displays the value of the second calibration point.

© BT Europe AB

Service Manual

LHM200SC, LHM200SCQ, LHM200SCO

65

Calibrating the scale Calibrating the pallet truck scale T-code 805, 813, 830

Valid from serial number 3 300 000-

Date 2006-06-19

Order number 232020-040

• Place a load of a known weight, larger than before, on the scale and specify the weight on the indicator according to the explanations above.

- The second calibration point is registered once you confirm it.

• Repeat this procedure for the third calibration point.

• You can exit calibration mode by pressing the “up” or “down” button until AP XX appears.

- This figure indicates calibration sensitivity as a percentage, e.g.

AP 07.

• Press the “0/T” button until the reading in the display disappears.

The indicator switches automatically to a small weight graduation once calibration is complete. The selected weight graduation is activated once the indicator has been switched off and then switched on again.

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© BT Europe AB

Calibrating the scale Calibrating the pallet truck scale Order number 232020-040

Date 2006-06-19

Valid from serial number 3 300 000-

T-code 805, 813, 830

10.1.3 Determining full load • Important: Before full load (or any other weight) can be calibrated, any previous calibration points must be deleted. If this is not done, the scale may exhibit erratic behaviour for certain weight graduation ranges.

• Press and hold the “PT” button for 18 seconds to access the calibration menu.

• Place a load on the pallet truck scale equivalent to the truck’s maximum load and enter the weight using the arrow keys.

• Press the “Enter” button to confirm the entered weight. The indicator then automatically calibrates the scale guided by the weight on the forks.

• Press “Enter” once to return to normal weighing mode.

NOTE: In practice, recalibration is generally performed by the customer using a single, known weight, e.g. a pallet that has been weighed on another scale.

NOTE: When the power to the indicator is switched on, a calibration number appears briefly in the display. This number changes automatically after each calibration. With pallet trucks with commercial weighing status, this number is recorded by an authorised inspector to enable them to determine whether any subsequent recalibration has been performed by a non-authorised individual.

Checking the calibration number Switch off the scale and then switch it on again.

The indicator shows the following information: - 8888.8 (test of LCD segment) - P 7.3 (software version) - 1342 (calibration number) - 1234.5 (current weight, normal weighing mode). © BT Europe AB

Service Manual

LHM200SC, LHM200SCQ, LHM200SCO

67

Troubleshooting Calibrating the pallet truck scale T-code 805, 813, 830

Valid from serial number 3 300 000-

Date 2006-06-19

Order number 232020-040

11- Troubleshooting The troubleshooting section will help you to solve any technical problems affecting the mobile weighing system.

See also the section on calibration and parameter settings.

11.0.1 Possible problems deals with the most common problems that can arise (A, B, C, D, etc.). If your problem is included here, you should note the letter and go to section 11.0.2.

11.0.2 Description of problems and probable causes links the problem with a probable cause (1, 2, 3, 4, etc.). The most common cases are indicated by “–”. Note the number(s) beside the cause to be checked and continue to section 11.0.3.

11.0.3 Explanation of probable causes and how to remedy them explains probable causes in more detail together with appropriate action.

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© BT Europe AB

Troubleshooting Calibrating the pallet truck scale Order number 232020-040

Date 2006-06-19

Valid from serial number 3 300 000-

T-code 805, 813, 830

11.0.1 Possible problems These are some of the most common causes of faults that affect the scale: • Discharged battery • Bad or broken contact • Crushed or cut cables • Loose screws or bolts • Mechanical problem: The upper fork structure is in contact with the pallet truck chassis or lifting mechanism as a result of distortion, wear or lots of dirt.

• Moisture in the electronics or load sensors These problems account for 99 % of all faults that arise on the pallet trucks and result in the following problem definitions: A. Nothing is working. The display remains blank even when the buttons are pressed.

B. The indicator reading is unstable; weight indication goes up and down.

C. Differing weight indications for the same load weighed repeatedly.

D. The scale is exact for light weights, but the indication is incorrect for heavier weights.

E. The scale reading is incorrect, but the reading error is linear, i.e. the faulty reading is proportional to the weighed load.

F. A positive or negative weight is displayed (Help 2 or 3) with no load and the display cannot be reset to 0 kg. The scale reacts normally when you place a weight on it.

G. An error message indicates overload or underload with or without a load on the scale.

H. The display does not react to loads placed on or taken off the scale I. The buttons are not working.

J. The segments on the display are not working.

See the operating instructions regarding possible error messages shown in the display.

© BT Europe AB

Service Manual

LHM200SC, LHM200SCQ, LHM200SCO

69

Troubleshooting Calibrating the pallet truck scale T-code 805, 813, 830

Valid from serial number 3 300 000-

Date 2006-06-19

Order number 232020-040

This page is intentionally left blank

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© BT Europe AB

Troubleshooting Calibrating the pallet truck scale Order number 232020-040

Date 2006-06-19

Valid from serial number 3 300 000-

T-code 805, 813, 830

11.0.2 Description of problem and probable causes A

B

C

D

Nothing is working.

The display remains blank even when the buttons are pressed.

1

Check the battery and charger

6

Check the indicator.

–

Is the fuse undamaged and is there good contact? Measure the voltage at the back of the battery holder after the indicator casing has been removed.

If there is 12 V DC, you must remeasure the indicator’s right pin at the red and black wires. If the conclusion is poor contact, you must check whether the contact problem is in the fuse holder or elsewhere.

The indicator reading is unstable; weight indication goes up and down.

2

Check the fork structure mechanics:

4

Check the load sensor cables and calibration card.

6

Check the indicator for moisture and loose connections (6.2) to (6.6)

3

Check the load sensors.

–

Moisture is the most common cause of unstable display readings.

The same load is lifted repeatedly, but the weight indications are different.

2

Check the fork structure mechanics:

3

Check the load sensors.

–

Weighing components must not be in contact with fixed, non-weighing components.

The scale indication is exact for light weights, but incorrect for heavy weights.

2

Check the fork structure mechanics:

–

The weighing components may be in contact with fixed, non-weighing components as a result of distortion.

The scale indication is wrong, but the faulty reading is linear.

This means, for example, that a load of 100 kg has a faulty reading of 1 kg, a load of 500 kg a faulty reading of 5 kg, and a load of 1000 kg a faulty reading of 10 kg.

–

© BT Europe AB

Recalibrate the scale.

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71

Troubleshooting Calibrating the pallet truck scale T-code 805, 813, 830

E

F

G

Order number 232020-040

–

Begin by calibrating the system. Special zero calibration may solve this problem. However, zero calibration has a limited effect. Readjusting the zero point returns the weight indications to normal limitations.

4

Check the load sensor cables and calibration card.

–

The problem may be caused by a short circuit.

3

Check the load sensors.

–

If a load sensor is defective or has poor contact, you may get a reading too high to be remedied by resetting.

6

Check the indicator.

–

The indicator is probably not the cause, but if no other fault can be found, it should be inspected.

The display does not react to loads placed on the scale.

–

The processor may be “freezing”. Remove the battery, wait several seconds and then re-insert it.

–

Check the calibration process. If the system was originally calibrated with more than one calibration point, these points must be deleted before recalibration with just a single point.

6

Check the indicator. See section “ 6.1 Checking the fuses”.and “6.5 If the display reading is unstable or does not react to weights, you should check whether the indicator is causing the problem”.

4

Check the cables.

The buttons are not working Check the indicator.

The segments on the display are not working.

6

72

Date 2006-06-19

A positive weight or the HELP 2, 3 or 7 message is displayed even though the scale is empty. The display cannot be reset to 0 kg.

6

H

Valid from serial number 3 300 000-

Check the indicator.

Service Manual

LHM200SC, LHM200SCQ, LHM200SCO

© BT Europe AB

Troubleshooting Calibrating the pallet truck scale Order number 232020-040

Date 2006-06-19

Valid from serial number 3 300 000-

T-code 805, 813, 830

11.0.3 Explanation of probable causes and how to remedy them 1. Checking the battery and charger 1.1 Checking the battery An old battery may be run down or the battery charger may be broken. Systems with low power consumption discharge a battery completely to a point where it only yields 8 or 9 V. If no power is being drawn from the battery, 12 V is always shown. This is because the voltage only falls when power is being drawn from the battery.

Therefore, when checking the battery’s voltage, the indicator must first receive power for several seconds or even minutes. If the voltage then drops slowly, you can conclude that the battery is run down.

The simplest way to test the battery is to replace the battery module.

Always check the battery charger. The charger must have an output voltage between 12.5 and 14 V. 1.2 Changing the battery Batteries run down over time. When the battery gets old or has been used a lot, it is best to replace it in order to avoid problems.

2. Control mechanism 2.1 Check whether the scale’s mechanics are jammed mechanically Weigh yourself by standing on the four corners of the forks. Your weight must be identical on all four corners. The indication may vary by up to 1 kg. If so, then all load sensors are working normally and the mechanics are working well with light weights.

After this test the scale should be loaded with a normal or heavy load. Use the tare button and reset the display. Leave the weight on the scale and then stand on or beside the load. Each corner must show the same indication with a deviation of plus or minus 1 to 2 kg.

If the readings are not identical or the deviation is greater than 1 or 2 kg or if it is unstable, continue to section 2.2.

© BT Europe AB

Service Manual

LHM200SC, LHM200SCQ, LHM200SCO

73

Troubleshooting Calibrating the pallet truck scale T-code 805, 813, 830

Valid from serial number 3 300 000-

Date 2006-06-19

Order number 232020-040

2.2 Trying to determine why weighing and non-weighing components are in contact with each other It may be necessary to dismantle the pallet truck in order to locate the fault. There are usually scratches in the paint where mechanical parts are jamming. If in doubt, you can position a sheet of paper between weighing and non-weighing components. When the scale is then loaded with a maximum load and the load is moved laterally, traces on the paper can indicate where friction is occurring in the system.

Determine what is mechanically feasible to eliminate the friction, e.g. alignment of the load sensors and the upper fork connectors, reduction of the lifting mechanism’s movement margin by adjusting the pressure rods or load wheel holder. It may be necessary to adjust the load wheels’ pressure rods to prevent them touching the load sensors. Remember that friction cannot always be detected on an empty pallet truck. So check whether the lifting rods can touch the load sensors when you press them against the sensors. Clean the forks internally.

2.3 Have the load sensors been fitted correctly?

The load sensors have been secured with bolts. Check that the load sensors are fitted correctly.

2.4 Have the fork connectors been fitted correctly? (Always check this point!)

Check the underside of the pallet truck to see if the fork connectors have been fitted correctly and that they are not catching on the frame (the forks’ frame) at the sides. One common cause is friction in the load wheel shaft’s welded joint. Sometimes bits of wood or pebbles can cause friction between weighing and non-weighing components.

3. Checking the load sensors 3.1 If the scale’s indication is incorrect, you must check whether all load sensors are showing the same weight indication Use your own weight to check this. Weigh yourself by standing on the four corners of the forks. Your weight must be identical on all four corners. There may be a variation in graduation. As the load sensors age or if one of them is replaced, the difference may sometimes be considerable. Continue to section 3.2 if the difference is substantial.

3.2 Checking whether the problem is due to the load sensors or the mechanism Remove the fork connector (or the upper fork section). Insert bolts into the mounting holes on all the load sensors. Place a test weight of approximately 1 % of their capacity on each load sensor (on the bolts) and check whether each load sensor shows the same value.

The greatest difference must be no more than a ½ graduation. Continue to section 5 if the deviation is greater.

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Troubleshooting Calibrating the pallet truck scale Order number 232020-040

Date 2006-06-19

Valid from serial number 3 300 000-

T-code 805, 813, 830

3.3 If the indicator shows an error message or the reading is unstable First try recalibrating the system.

Switch off the indicator and use an ohmmeter/voltmeter to measure whether the resistance in all wires between the load sensors and the pallet truck chassis is infinite. No resistance is permitted between the black, white and green wires between the load sensors and chassis.

The resistance between the disconnected excitation wires from the load sensors, i.e. the black and red wire, must be: +/- 350 ohm when one load sensor is checked +/- 87 ohm if all 4 load sensors are checked and they are connected in parallel.

These values must also be remeasured between the load sensors’ signalling circuits, i.e. the white and green wire.

When the indicator is receiving power, the following values must be displayed when the load sensors’ excitation wires (black and red) are remeasured: - Standard system without printer: 3.3 V. - System with commercial weighing status with/without printer: 2.5 V AC. As a result of a block voltage and depending on the voltmeter, a voltage of 2.2 or 2.5 volts may be measured. If not, the problem is with the indicator.

When the indicator is receiving power and the forks are empty, the following values must be measured between the load sensors’ signalling circuits (green and white): - Standard system without printer: 0.000 to 0.002 V. (V AC, with printer and/or trucks with commercial weighing status) If the signal level is higher or negative, the load sensors are the cause. If the signal is only a little higher, the load sensors can still be used, but it is likely that this is only a short-term solution.

If the cause is found, the final test should be repeated with just one load sensor connected at a time to determine which load sensor(s) is causing the problem.

IMPORTANT: An unstable reading can be measured using an ohmmeter/voltmeter if the deviation is large or if the ohmmeter/voltmeter provides a high level of accuracy.

3.4 Checking each load sensor, one at a time In order to determine if only one load sensor is causing the problem, each load sensor must be connected separately to the indicator (and the indicator used as a voltmeter), and the measured values from the load sensors must be subsequently compared.

The different values must be almost identical. The value depends on the calibration setting. If a value is unstable or differs considerably from the other values, the load sensor in question must be replaced.

See section 4 before replacing a load sensor.

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Troubleshooting Calibrating the pallet truck scale T-code 805, 813, 830

Valid from serial number 3 300 000-

Date 2006-06-19

Order number 232020-040

3.5 If the reading is unstable, you must check which load sensor is defective Each load sensor can be tested separately once the wires to all load sensors have been disconnected. Connect one load sensor at a time to the indicator to check which sensor is producing an unstable reading. If the reading on the indicator is unstable for all the load sensors, you should inspect the indicator, as it may be defective.

4. Checking cables and the load sensors’ calibration card.

4.1 Checking whether the cables are damaged Wiggle the cable from the load sensor vigorously. This is particularly important at the point closest to the connection and where it runs along or passes moving parts. The indication must not be affected. If the indication is affected, this suggests that the cable or the connection is damaged, oxidised or has been affected by moisture and must be replaced. Check the cables between the indicator and the load sensors’ calibration card as well.

4.2 Checking the load sensors’ calibration card The load sensors’ calibration card must also be checked. If the display is affected when you jog the card or the connected cables without touching the actual contact points, this indicates that there is a bad contact somewhere.

If the calibration card is oxidised, you can remedy the problem by heating the solders with a soldering iron.

5. Calibration of the load sensors 5.1 Calibrating the load sensors When you weigh yourself on the corners of the forks, the difference between the weight indications must be no greater than 1 kg. The difference may be slightly greater if the load sensors have aged or one of them has been replaced. Use the load sensor with the lowest weight indication and adjust the values of the others using the potentiometers on the load sensors’ calibration card.

The calibration card is in the indicator housing.

It is simple to calibrate the load sensors using the load sensors’ calibration card. The four potentiometers are located on the circuit card and are labelled A, B, C, D. Each potentiometer is used to calibrate the corresponding load sensor. Turn the potentiometer clockwise to increase the load sensor’s indication. Turn the potentiometer anticlockwise to reduce the indication.

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Troubleshooting Calibrating the pallet truck scale Order number 232020-040

Date 2006-06-19

Valid from serial number 3 300 000-

T-code 805, 813, 830

5.2 Calibration example You cannot calibrate the load sensors by turning a potentiometer while looking at the display to achieve the correct indication. When a potentiometer is adjusted, this affects all the load sensors. So do as follows: If you have inspected the load sensors and concluded that load sensors A and C are showing +2 kg too much: Unload the system and adjust the value using the potentiometers. If the value to be adjusted is too high, turn the potentiometer anticlockwise to correct. Then check all corners again (with your own weight) and see whether the correction has made any difference. If not, repeat. It can take 5 to 10 attempts before all the values are optimised.

It is not vital for your exact weight to be shown in the display in this situation. What is essential is for the 4 values to be identical. Once the values are the same, the scale must be recalibrated as per the instructions in the calibration manual.

5.3 IMPORTANT: Calibration of a newly-fitted load sensor When fitting a new load sensor, or when a calibration has resulted in a large difference in the values, it is best to start again.

Use an ohmmeter (voltmeter) and set 5 ohms between point R and the connection screws A, B, C and D (behind the potentiometer, see drawing). Once all the potentiometers have been set to 5 ohms, you can turn them to correct any reading error.

The indicator must be calibrated after calibrating the load sensors.

See the calibration instructions.

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LHM200SC, LHM200SCQ, LHM200SCO

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Troubleshooting Calibrating the pallet truck scale T-code 805, 813, 830

Valid from serial number 3 300 000-

Date 2006-06-19

Order number 232020-040

6. Checking the indicator Warning!

Do not touch the circuit card’s contacts. Static electricity can damage the card components.

A common cause of faults affecting mobile weighing system is collisions and hard knocks. Remember this when tracing faults in the indicator housing and on the circuit card. Don’t be afraid to check the indicator by hitting it. This is the only way of detecting problems that occur during use of the system. It may even reveal hidden faults!

6.1 Checking the fuses There is an electrical fuse in the indicator housing. Remeasure the fuse using an ohmmeter/voltmeter.

6.2 Checking the individual parts Remove the circuit card from the indicator and check whether everything seems OK, whether any of the components are loose or whether bending the card solves the problem.

6.3 Checking whether the connections are disconnected or loose It is essential that the cables to the power switch, fuse holder and contact are not loose.

6.4 Checking for possible moisture problems if the reading is unstable Check whether there is any condensation or drops of water on the contacts. Look carefully for signs of this on the circuit card when the cover plate is removed and the contact disconnected from the indicator. Dry the card using hot air. If there is oxidation on the card, you can carefully solder the area around the analogue circuit using a soldering iron.

6.5 If the display reading is unstable or does not react to weights, you should check whether the indicator is causing the problem Disconnect the indicator from the load sensors. If the indicator displays an error message: Connect each load sensor individually. If the indication is still unstable or does not react to the different load sensors, it is likely that the indicator module is defective.

6.6 When can you be sure that the indicator’s circuit card is defective?

The display is defective if: - the reading does not change when the load sensors are disconnected; - no lights come on with +12 V DC on the correct terminals and the keypad is working; - the reading remains unstable when only one load sensor is connected (try a new load sensor for confirmation); - the reading is affected when the indicator module is subjected to a knock.

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Troubleshooting Calibrating the pallet truck scale Order number 232020-040

Date 2006-06-19

Valid from serial number 3 300 000-

T-code 805, 813, 830

6.7 Checking the touch screen Check the flat cable. The silver coating is conductive, but very thin.

Wear in just a small area can cause the touch screen to malfunction.

The flat cable’s contact is highly sensitive to moisture. Check the contact. If it has been affected by moisture, this can be remedied by heating the components for a prolonged period.

6.8 Checking the indicator’s LCD display By gently flexing the circuit card in various directions while the display is active, you can locate broken contact points.

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Troubleshooting Calibrating the pallet truck scale T-code 805, 813, 830

Valid from serial number 3 300 000-

Date 2006-06-19

Order number 232020-040

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Instructions for disposal General Order number 232020-040

Date 2006-06-19

Valid from serial number 3 300 000-

T-code 805, 813, 830

12- Instructions for disposal 12.1 General These instructions have been drawn up as part of BT's environmental management programme. It is BT's opinion that it is necessary, as far as practicable, to reuse materials and to minimise the release of hazardous substances. From an environmental perspective it is of course best to keep using the product. When this is no longer possible, you should investigate whether it is possible to reuse the parts that are still working. However, if this is not possible, the incorporated material should be recycled. In order to assist with this task, we have produced these instructions for scrapping.

12.2 The product LHM200SC is a hydraulic pallet truck equipped with instruments for weighing lifted loads. The scale unit is built into a plastic casing on top of the truck with the load-sensing cells built into the forks. There are electronics in the scale components and in the separate battery charger. The scale unit contains a lead/acid battery. Cables with copper conductors connect the scale unit to the load cells. The indicator housing is ABS plastic and the pallet truck handle is PA6/PA66.

The bulk of the machine is made of steel, except for small quantities of brass in the bushings and plastics such as PUR, PC, etc.

The hydraulic unit contains oil.

12.3 Methods Batteries, oil and electronics should be regarded as hazardous waste.

These should be dealt with as per separate instructions. Other graded materials will be used for re-smelting.

If the waste is homogenous but ungraded, it will be manually graded before being re-smelted.

Ungraded complex waste is fragmented and machine sorted before being re-smelted.

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Instructions for disposal Grading of LHM200SC T-code 805, 813, 830

Valid from serial number 3 300 000-

Date 2006-06-19

Order number 232020-040

12.4 Grading of LHM200SC The bulk of the machine is most suited to fragmentation. However, prior to this the following actions should be implemented.

12.4.1 Removing the battery.

• The battery is in the scale unit. Keep the catch out of the way and remove the battery.

• The battery must be returned to the battery manufacturer or their representative. (Please refer to notice on battery.) The battery can also be handed in to a local BT agent who will ensure that it is returned to the manufacturer.

12.4.2 Draining the oil • Tap out the spiral pins and remove both arm bolts from the pressure plate.

• Undo the locking ring up in the cover top.

• Remove the hydraulic unit.

• Carefully lift out the lift piston and drain the oil into containers designed for waste oil. The hydraulics contain approximately 0.34 litres hydraulic oil of the type Q8 Haydn 32.

12.4.3 Removing the electronic components • Turn the machine upside down. Loosen the four bolts holding the upper frame. The upper frame is pure steel scrap • Undo the load cells, 2 bolts in each, cut the cables and place the cells in containers for electronic scrap.

• The plastic casing from the scale unit can easily be separated from parts with electronic components. Place the plastic parts in containers for plastic scrap (ABS). Electronic components, including any printers, should be placed in containers for electronic scrap.

• The screws securing and holding together the scale unit should be placed in containers for steel scrap.

12.4.4 Other The remainder is most suited to fragmentation before being sorted and sent for re-smelting as individual materials. It is possible to grade plastic components, as these are marked with a material code.

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Instructions for disposal Grading of LHM200SC Order number 232020-040

Date 2006-06-19

Valid from serial number 3 300 000-

T-code 805, 813, 830

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© BT Europe AB SE-595 81 Mjölby Sweden www.bt-industries.com