BT LHM230 LHM300 Service Manual - PDF DOWNLOAD

Service Manual LHM230, LHM300 Valid from serial number: 3 300 000-

Order number: 232319-040 Issued: 2006-06-19 ITS

© BT Europe AB

en

Document revisions:

Issue date

Order number

Changes

2006-06-19

232319-040

Completely new issue.

This manual covers following truck models:

T-code

Model

360

LHM230

240

LHM230O

361

LHM230Q

362

LHM230X

726

LHM230P

480

LHM300O

481

LHM300X

Serial number

3 300 000-

Various combinations of the above can occur for which this manual is also valid.

© BT Europe AB

Service Manual

LHM230, LHM300

Table of contents Order number 232319-040

Date 2006-06-19

Valid from serial number 3 300 000-

1- 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 5 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 ...........................................................................

Pump phase .....................................................................

Suction phase ...................................................................

Neutral position .................................................................

Lowering phase ................................................................

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

High pressure ...................................................................

Low pressure ....................................................................

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 LHM230, LHM30P ............................................................

4.12.2 LHM230Q .........................................................................

4.12.3 LHM230O .........................................................................

11 11 12 12 12 12 12 13 13 13 13 14 15 15 16 16 16 17 17 18 18 20 20 20 21

5- Tools ...................................................................................................... 23 5.1 Service tools ................................................................................... 23

© BT Europe AB

Service Manual

LHM230, LHM300

1

Table of contents Valid from serial number 3 300 000-

2

Date 2006-06-19

Order number 232319-040

6- Chassis .................................................................................................

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

6.2 Replacing pivot pipes ......................................................................

6.3 Replacing the pressure rod .............................................................

6.4 Replacing the wheel fork.................................................................

6.5 Replacing the bogie fork .................................................................

6.6 Replacing the fork wheel.................................................................

27 27 27 27 27 28 28

7- Specific service instructions LHM230P .............................................

7.1 Removing/fitting wheels ..................................................................

7.2 Replacing the cable ........................................................................

7.3 Fitting the spring .............................................................................

7.4 Replacing the bushing ....................................................................

7.5 Adjusting the functions of LHM230P ...............................................

29 29 30 30 31 31

8- Troubleshooting ...................................................................................

8.1 Troubleshooting chart .....................................................................

8.1.1 Troubleshooting - hydraulics ............................................

Internal leakage ................................................................

External leakage ...............................................................

Defective quick lift function ...............................................

33 33 35 35 35 36

9- Instructions for disposal .....................................................................

9.1 General ...........................................................................................

9.2 The product.....................................................................................

9.3 Methods ..........................................................................................

9.4 Grading of LHM230/LHM230P........................................................

9.5 Draining the oil ................................................................................

9.6 Other ...............................................................................................

37 37 37 37 37 38 38

Service Manual

LHM230, LHM300

© BT Europe AB

Technical data Truck data Order number 232319-040

Date 2006-06-19

Valid from serial number 3 300 000-

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

LHM230

LHM230P

LHM300

Rated lifting capacity

2300 kg

2300 kg

3000 kg

Weight

63 kg

75 kg

105 kg

Lift height

200 mm

200 mm

200 mm

Turning radius (Wa)

1392 mm

1410 mm

1392 mm

Steering wheel

Ø 175 x 60

Ø 175 x 60

Ø 175 x 60

Fork wheels, single/bogie

Ø 85 x 100 / Ø 85 x 75

Ø 85 x 100 / Ø 85 x 75

Ø 85 x 100 / Ø 85 x 75

Pumping power, rated load

34 kg

34 kg

-

Traction force

19 kg*) (nylon wheel)

22 kg*) (powerthane)

-

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

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Service Manual

LHM230, LHM300

1

Technical data Truck data Valid from serial number 3 300 000-

Date 2006-06-19

Order number 232319-040

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2

Service Manual

LHM230, LHM300

© BT Europe AB

Maintenance General Order number 232319-040

Date 2006-06-19

Valid from serial number 3 300 000-

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

LHM230, LHM300

3

Maintenance Safety rules for servicing work Valid from serial number 3 300 000-

Date 2006-06-19

Order number 232319-040

• 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.

4

Service Manual

LHM230, LHM300

© BT Europe AB

Maintenance Cleaning, washing and lubrication Order number 232319-040

Date 2006-06-19

Valid from serial number 3 300 000-

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.

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

2.3 Cleaning, washing and lubrication Cleaning and washing the truck is important for reliability.

• Always clean the jump-start unit internally on LHM230P in the event of a malfunction (blocking/jamming of wheels and/or handles).

NOTE: After washing, the pallet truck should be lubricated as per the table below. Cold store oil should be used when operating at temperatures below -15° C.

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

Pressure rod on chassis body

2

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Service Manual

LHM230, LHM300

5

Maintenance Cleaning, washing and lubrication Valid from serial number 3 300 000-

Date 2006-06-19

Order number 232319-040

Table 1: Lubrication chart Lubrication points

Number of lubrication points

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

LHM230, LHM300

© BT Europe AB

Tow bar General Order number 232319-040

Date 2006-06-19

Valid from serial number 3 300 000-

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

LHM230, LHM300

7

Tow bar Replacing the tow bar Valid from serial number 3 300 000-

Date 2006-06-19

Order number 232319-040

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 ensure that it sticks better when inserted.

• Check that the lowering handle functions correctly.

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Service Manual

LHM230, LHM300

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Tow bar Replacing the handle Order number 232319-040

Date 2006-06-19

Valid from serial number 3 300 000-

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

LHM230, LHM300

9

Tow bar Replacing the press roller and valve rod.

Valid from serial number 3 300 000-

Date 2006-06-19

Order number 232319-040

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Service Manual

LHM230, LHM300

© BT Europe AB

Hydraulic unit General Order number 232319-040

Date 2006-06-19

Valid from serial number 3 300 000-

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

LHM230, LHM300

11

Hydraulic unit Functional description Valid from serial number 3 300 000-

Date 2006-06-19

Order number 232319-040

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.

12

Service Manual

LHM230, LHM300

© BT Europe AB

Hydraulic unit Functional description Order number 232319-040

Date 2006-06-19

Valid from serial number 3 300 000-

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

LHM230, LHM300

13

Hydraulic unit Functional description Valid from serial number 3 300 000-

Date 2006-06-19

Order number 232319-040

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.

14

Service Manual

LHM230, LHM300

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Hydraulic unit Replacing the hydraulics Order number 232319-040

Date 2006-06-19

Valid from serial number 3 300 000-

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.

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Service Manual

LHM230, LHM300

15

Hydraulic unit Replacing the steering wheel shaft Valid from serial number 3 300 000-

Date 2006-06-19

Order number 232319-040

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.

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 (LHM230Q): 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”.

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Service Manual

LHM230, LHM300

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Hydraulic unit Replacing the lift piston Order number 232319-040

Date 2006-06-19

Valid from serial number 3 300 000-

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.

• 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”.

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Service Manual

LHM230, LHM300

17

Hydraulic unit Replacing the valve cone Valid from serial number 3 300 000-

Date 2006-06-19

Order number 232319-040

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 23.

• 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.

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

18

Service Manual

LHM230, LHM300

© BT Europe AB

Hydraulic unit Changing the oil Order number 232319-040

Date 2006-06-19

Valid from serial number 3 300 000-

• 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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Service Manual

LHM230, LHM300

19

Hydraulic unit Hydraulics diagram Valid from serial number 3 300 000-

Date 2006-06-19

Order number 232319-040

4.12 Hydraulics diagram 4.12.1 LHM230, LHM30P

LIFT CYLINDER

PUMP CYLINDER

RESERVOIR

4.12.2 LHM230Q

LIFT CYLINDER QUICK VALVE PUMP CYLINDER

RESERVOIR

20

Service Manual

LHM230, LHM300

© BT Europe AB

Hydraulic unit Hydraulics diagram Order number 232319-040

Date 2006-06-19

Valid from serial number 3 300 000-

4.12.3 LHM230O

LIFT CYLINDER

PUMP CYLINDER

OVERLOAD VALVE

RESERVOIR

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Service Manual

LHM230, LHM300

21

Hydraulic unit Hydraulics diagram Valid from serial number 3 300 000-

Date 2006-06-19

Order number 232319-040

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Service Manual

LHM230, LHM300

© BT Europe AB

Tools Service tools Order number 232319-040

Date 2006-06-19

Valid from serial number 3 300 000-

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.

Service Manual

LHM230, LHM300

23

Tools Service tools Valid from serial number 3 300 000-

Date 2006-06-19

Order number 232319-040

Table 3: Service tools Image

Part number

Use

V 08-16575

For fitting seals on pump cylinder.

V 08-16575-1 (LHM300)

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.

24

Service Manual

LHM230, LHM300

© BT Europe AB

Tools Service tools Order number 232319-040

Date 2006-06-19

Valid from serial number 3 300 000-

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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Service Manual

LHM230, LHM300

25

Tools Service tools Valid from serial number 3 300 000-

Date 2006-06-19

Order number 232319-040

Table 3: Service tools Image

-

26

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

LHM230, LHM300

© BT Europe AB

Chassis General Order number 232319-040

Date 2006-06-19

Valid from serial number 3 300 000-

6- Chassis 6.1 General A complete chassis consists of: • Chassis • Pivot pipe • Pivot pipe shaft • Pressure rods • Wheel forks • Front climber wheels (only single model)

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

• Turn the chassis upside down.

• Remove the pressure rod by the pivot pipe.

• Reassemble in reverse order.

6.3 Replacing the pressure rod • Remove the spiral pin and shafts.

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

• Reassemble in reverse order.

6.4 Replacing the wheel fork • Remove the spiral pin and shafts.

• Remove the wheel fork.

• Reassemble in reverse order.

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Service Manual

LHM230, LHM300

27

Chassis Replacing the bogie fork Valid from serial number 3 300 000-

Date 2006-06-19

Order number 232319-040

6.5 Replacing the bogie fork • Remove the spiral pin and shaft.

• Remove the bogie fork.

• Reassemble in reverse order.

6.6 Replacing the fork wheel • Remove the spiral pin and shaft.

• Remove the wheel.

• Reassemble in reverse order.

28

Service Manual

LHM230, LHM300

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Specific service instructions LHM230P Removing/fitting wheels Order number 232319-040

Date 2006-06-19

Valid from serial number 3 300 000-

7- Specific service instructions LHM230P

1

7.1 Removing/fitting wheels 3

• Lay the truck on its right side on the floor and remove the hydraulics on both sides in the following order: • Remove the cover (1).

• Remove the locking ring (2).

4

• Remove the screws (3). Use the jump-start function as a dolly when loosening the screws for the wheel.

• Remove the complete wheel (4) and wheel rim (5).

• Remove the direction adjuster (6).

5

• Remove roller (7) and spring (8); note position of spring.

6

• Remove the screws (9).

7 •

9

8 10

Remove the hub (10).

• Remove the clamp (11).

• Fit two new hubs on the shaft (12). Position the right hub facing downwards. Check that the bushings slide on the shaft (tow bar draws return force).

2

• Fit the rest of the parts. Check jump-start function and adjust cable if necessary.

12

The tightening torque on the screws (9 and 3) should be 23 Nm.

11

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Service Manual

LHM230, LHM300

29

Specific service instructions LHM230P Replacing the cable Valid from serial number 3 300 000-

Date 2006-06-19

Order number 232319-040

7.2 Replacing the cable • Remove the cable and its casing from the tow bar; leave the lower section of the cable until later.

• Fit the new cable in the tow bar through the two upper bushings.

• Remove the spiral pin and the two shafts.

• Remove the bracket from the link arm.

• Remove the cover from the wheel.

NOTE: Lay the truck down with the loosened wheel cover upwards.

WARNING! The truck may tip if not securely blocked.

• Undo the locking ring • Lift the wheel gently. The four rollers will then come loose from the direction adjuster. Bear in mind the releasing energy of the spring.

• Remove the cable from the clamp.

• Fit the new cable from the lower bushing on the tow bar. Replace the bracket and fit the shaft and spiral pin.

• Move the handle to the neutral position. Fit cable, clamp, spring, direction selector and rollers.

• The cable may need to be adjusted.

7.3 Fitting the spring The spring on the wheel must be fitted on the correct side of the direction adjuster in order to function correctly and provide resistance in the cable (see picture).

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© BT Europe AB

Specific service instructions LHM230P Replacing the bushing Order number 232319-040

Date 2006-06-19

Valid from serial number 3 300 000-

7.4 Replacing the bushing Neutral position can be difficult to adjust if the bushing in the hub is worn. Replace the bushing and adjust the cable’s neutral position.

7.5 Adjusting the functions of LHM230P If the truck seizes when the handle is in neutral position, squeeze the handle in order to neutralise the function. Test whether the wheels lock when pulling or pushing the truck using the tow bar.

If problems occur when pulling the truck, the cable is too loose. Tighten the cable by screwing the cable sleeve downward half a turn, then test the function again. Tighten the nut.

If problems occur when pushing the truck, the cable is too taut. Loosen the cable slightly by screwing the cable sleeve upward half a turn, then test the function again. Tighten the nut.

Nut Cable

© BT Europe AB

Service Manual

LHM230, LHM300

31

Specific service instructions LHM230P Adjusting the functions of LHM230P Valid from serial number 3 300 000-

Date 2006-06-19

Order number 232319-040

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Service Manual

LHM230, LHM300

© BT Europe AB

Troubleshooting Troubleshooting chart Order number 232319-040

Date 2006-06-19

Valid from serial number 3 300 000-

8- Troubleshooting 8.1 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 18

The hydraulics contain too little oil

Top up with oil as per “4.11 Changing the oil” on page 18

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

LHM230 The pump does not perform complete strokes

Lifting, neutral and lowering mode do not function correctly

The forks lower after each stroke

© BT Europe AB

Service Manual

LHM230, LHM300

33

Troubleshooting Troubleshooting chart Valid from serial number 3 300 000-

Fault

Date 2006-06-19

Order number 232319-040

Cause

Action

Lifting or jump-start functions are not operating correctly

Lift and jump-start have been selected at the same time

Reset the function that is not required to neutral position

The jump-start function does not activate when required

Cable has become stretched

Adjust cable extension using adjustment screw

Cable break in the jumpstart function

Overloading

Move clamp (1) to neutral position for emergency operation and replace cable

LHM230P

1 LHM230Q Lifts like a standard model

34

Quick valve out of action

Service Manual

Replace quick piston

LHM230, LHM300

© BT Europe AB

Troubleshooting Troubleshooting chart Order number 232319-040

Date 2006-06-19

Valid from serial number 3 300 000-

8.1.1 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

© BT Europe AB

Service Manual

LHM230, LHM300

Change Pump Unit

35

Troubleshooting Troubleshooting chart Valid from serial number 3 300 000-

Date 2006-06-19

Order number 232319-040

Defective quick lift function No Quick Lift function

Re-assamble Machine and send to customer

Change complete Quick Lift Piston Yes

Functional Pump Unit

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Service Manual

LHM230, LHM300

No

Change Pump Unit

© BT Europe AB

Instructions for disposal General Order number 232319-040

Date 2006-06-19

Valid from serial number 3 300 000-

9- Instructions for disposal 9.1 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.

9.2 The product LHM230/LHM230P is a hydraulic pallet truck primarily designed for lifting loads on standard pallets. The LHM230P version is equipped with a jump-start device. The jump-start unit contains a direction adjuster and driver made of PA. On both models, the handle, lowering pedal, pump spring washer and ball cup in the cover top are made of PA6/PA66.

Most of the rest of the machine is made of steel, except for small quantities of brass in the bushings. The wheels consist, wholly or partially, of plastics such as PUR, PC, etc.

The hydraulic unit contains oil.

9.3 Methods Oil should be regarded as hazardous waste. It should be dealt with as per separate instructions. Other graded materials will be used for resmelting.

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.

9.4 Grading of LHM230/LHM230P The bulk of the machine is most suited to fragmentation. However, prior to this the following actions should be implemented.

© BT Europe AB

Service Manual

LHM230, LHM300

37

Instructions for disposal Draining the oil Valid from serial number 3 300 000-

Date 2006-06-19

Order number 232319-040

9.5 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 of hydraulic oil.

9.6 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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Service Manual

LHM230, LHM300

© BT Europe AB

Instructions for disposal Other Order number 232319-040

Date 2006-06-19

Valid from serial number 3 300 000-

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© BT Europe AB

Service Manual

LHM230, LHM300

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