BT SHM080 SHL080 Service Manual 230326-040 - PDF DOWNLOAD

Service Manual SHM080, SHL080 Valid from serial number: 495600-

Order number: 230326-040 Issued: 2006-09-30 ITS

© BT Europe AB

en

Document revisions:

Issue date

Order number

Changes

2006-09-30

230326-040

Completely new issue.

This manual covers following truck models:

T-code

Model

Serial number

429

SHM080

495600-

426

SHL080

495600-

© BT Europe AB

Service Manual

SHM080, SHL080

Table of contents Order number 230326-040

Date 2006-09-30

Valid from serial number 495600-

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 and oil specification .................................

3 3 3 4 4 5 5

3- Tow bar ................................................................................................... 7 3.1 Tow bar, manual stacker................................................................... 7 3.1.1 Removing the tow bar ......................................................... 7 3.1.2 Removing the lowering handle ........................................... 8 3.1.3 Removing the handle .......................................................... 9 3.1.4 Removing the press roller and valve rod ............................ 9 3.2 Tow bar, electric stacker ................................................................. 10 3.2.1 Removing the tow bar ....................................................... 10 4- Hydraulic unit .......................................................................................

4.1 Hydraulics, manual stacker .............................................................

4.1.1 Removing the hydraulics from the chassis .......................

4.1.2 Removing the lift piston ....................................................

4.1.3 Removing the pump piston and pump cylinder ................

4.1.4 Valve functions .................................................................

Removing the lowering valve ............................................

4.2 Hydraulics, electric stacker .............................................................

4.2.1 Removing the hydraulics from the chassis .......................

4.2.2 Removing the lift piston ....................................................

4.2.3 Removing the hydraulic unit .............................................

4.2.4 Hydraulics diagram ...........................................................

11 11 11 12 12 12 12 13 14 14 15 15

5- Chassis .................................................................................................

5.0.1 Removing the castor .........................................................

5.0.2 Removing the fork wheel ..................................................

5.0.3 Replacing the parking brake .............................................

5.0.4 Removing the fork carriage ..............................................

5.0.5 Removing the lift chain .....................................................

17 17 18 18 18 18

6- Electrical system .................................................................................. 19 6.1 Wiring diagram, electric stacker ...................................................... 19

© BT Europe AB

Service Manual

SHM080, SHL080

1

Table of contents Valid from serial number 495600-

Date 2006-09-30

Order number 230326-040

This page is intentionally left blank

2

Service Manual

SHM080, SHL080

© BT Europe AB

Technical data Truck data Order number 230326-040

Date 2006-09-30

Valid from serial number 495600-

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.

© BT Europe AB

Technical data

SHM080

SHL080

Drive unit

–

Battery 12V

Rated lifting capacity

800 kg

800 kg

Weight without battery

256 kg

295 kg

Permitted guide wheel, polyurethane

Ø 200 x 50 mm

Ø 200 x 50 mm

Fork wheel, nylon

Ø 75 x 75 mm

Ø 75 x 75 mm

Lift height

1600 mm

1600 mm

Mast height

1990 mm

1990 mm

Turning radius (Wa)

1210 mm

1210 mm

Service Manual

SHM080, SHL080

1

Technical data Truck data Valid from serial number 495600-

Date 2006-09-30

Order number 230326-040

This page is intentionally left blank

2

Service Manual

SHM080, SHL080

© BT Europe AB

Maintenance General Order number 230326-040

Date 2006-09-30

Valid from serial number 495600-

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 servicing 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 appropriate training and know-how to perform such work.

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

• Never wear loose articles 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 GOGGLES 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 performed clean. Oil and 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.

© BT Europe AB

Service Manual

SHM080, SHL080

3

Maintenance Safety rules for servicing work Valid from serial number 495600-

Date 2006-09-30

Order number 230326-040

• 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 when lifting the pallet truck by hand.

Bad blocking under a truck can collapse.

The truck must always be secured for repairs.

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

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

• When fitting/removing springs, these 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 on removal.

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

• Always bleed the hydraulics when components have been replaced.

• 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.

4

Service Manual

SHM080, SHL080

© BT Europe AB

Maintenance Cleaning, washing and lubrication Order number 230326-040

Date 2006-09-30

Valid from serial number 495600-

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

• Carry out general cleaning and washing each week.

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

NOTE: There is a risk of damaging the electronics in electric pallet trucks, so take care when cleaning these parts.

After cleaning, the stacker should be lubricated as per the lubrication chart and the table below.

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

2.3.1 Lubrication chart and oil specification Table 1: Lubrication chart Lubrication points

Number of lubrication points

Parking brake

1

Lift chain

1

Mast beams

2

© BT Europe AB

Service Manual

SHM080, SHL080

5

Maintenance Cleaning, washing and lubrication Valid from serial number 495600-

Date 2006-09-30

Order number 230326-040

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

Chain spray

Rexpro

236794

Grease for mast beam

Rembrandt EP2

223690

Service Manual

SHM080, SHL080

© BT Europe AB

Tow bar Tow bar, manual stacker Order number 230326-040

Date 2006-09-30

Valid from serial number 495600-

3- Tow bar 3.1 Tow bar, manual stacker The tow bar consists of: - Tow bar (1) - Handle (2) - Lowering handle (3) - Press roller (4)

3 2

1

12 15

7

14 9 4

13 8 10

6 11

3.1.1 Removing the tow bar The tow bar is mounted on the hydraulics by means of two shafts (6) locked using spiral pins (7). The valve rod (8) is mounted between the lowering handle (3) and the lowering arm (9) using a spring (10) and a lock nut (11).

WARNING! Releasing energy.

Brace the pump piston spring (12) when removing the tow bar, as the spring may spring out of position. © BT Europe AB

Service Manual

SHM080, SHL080

7

Tow bar Tow bar, manual stacker Valid from serial number 495600-

Date 2006-09-30

Order number 230326-040

• Remove the valve chain (13) from the lowering arm by placing the lowering handle in "lifting mode", and pressing the lowering arm by hand while pushing the spring to the side.

• Remove the spiral pin (14) and shafts (15) holding the tow bar. Use a punch to tap out the spiral pins.

• Place a transport sheet or similar there to hold down the pump piston until the new tow bar is fitted.

• Press in the shafts and drive in new spiral pins.

• Fit the spring on the lowering arm.

• Adjust neutral mode. Adjust using the nut on the valve chain.

3.1.2 Removing the lowering handle To facilitate removal, the tow bar should be set to the horizontal position.

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

8

Service Manual

SHM080, SHL080

© BT Europe AB

Tow bar Tow bar, manual stacker Order number 230326-040

Date 2006-09-30

Valid from serial number 495600-

• 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.

3.1.3 Removing 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.

3.1.4 Removing the press roller and valve rod • Disconnect the tow bar from the hydraulics.

• Remove the shaft holding the press roller in place.

• Remove the valve rod.

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

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

• Fit the tow bar and check neutral position.

© BT Europe AB

Service Manual

SHM080, SHL080

9

Tow bar Tow bar, electric stacker Valid from serial number 495600-

Date 2006-09-30

Order number 230326-040

3.2 Tow bar, electric stacker The tow bar consists of: - Tow bar (1) - Spring (2) - Bushings (3) - Spiral pins (4)

1

4 3

2 3 4

3.2.1 Removing the tow bar • Tap out the spiral pins.

• Remove the tow bar.

• Remove the spring.

• Reassemble in reverse order.

10

Service Manual

SHM080, SHL080

© BT Europe AB

Hydraulic unit Hydraulics, manual stacker Order number 230326-040

Date 2006-09-30

Valid from serial number 495600-

4- Hydraulic unit 4.1 Hydraulics, manual stacker The hydraulic unit consists of: - Hydraulics (1) - Lift piston (2) - Pump cylinder (3) - Pump piston (4)

2

5 1 4 3 6

4.1.1 Removing the hydraulics from the chassis WARNING! Risk of crushing.

Make sure that the fork carriage is secured so that it cannot fall down.

• Loosen the lift chain by removing the nuts (5).

• Remove the fork carriage.

• Loosen the screws (6) holding the hydraulics in the chassis.

• Remove the hydraulics.

Reassemble in reverse order. © BT Europe AB

Service Manual

SHM080, SHL080

11

Hydraulic unit Hydraulics, manual stacker Valid from serial number 495600-

Date 2006-09-30

Order number 230326-040

4.1.2 Removing the lift piston • Loosen the top nut.

• Lift up the piston.

• Remove the bushing and seal by loosening the circlip.

4.1.3 Removing the pump piston and pump cylinder • Remove the spring by undoing the top nut using a spanner and removing the washer.

• Undo the lock washer on top of the pump cylinder.

• Remove the washer, valve body, seal and bushing by undoing the nut.

• To remove the quick lift valve, remove parts as above in order to access and remove the two springs, valve cone and ball.

• To remove the pump cylinder, unscrew it using a chain wrench.

NOTE: When the pump cylinder is replaced, the copper washer must always be replaced. The torque should be 125 Nm.

4.1.4 Valve functions 2 1

3

5 4

• Lowering valve (1) • Overload valve (2) • Lowering arm (3)

Removing the lowering valve • Remove the lowering arm by tapping out the locking pin.

• Unscrew the lowering valve.

12

Service Manual

SHM080, SHL080

© BT Europe AB

Hydraulic unit Hydraulics, electric stacker Order number 230326-040

Date 2006-09-30

Valid from serial number 495600-

4.2 Hydraulics, electric stacker

© BT Europe AB

Service Manual

SHM080, SHL080

13

Hydraulic unit Hydraulics, electric stacker Valid from serial number 495600-

Date 2006-09-30

Order number 230326-040

4.2.1 Removing the hydraulics from the chassis 3

5 4 2 1

6 7

To facilitate removal of the high forks, approx. 100 mm, place two wooden blocks between the fork carriage and support arm before disconnecting the hydraulics.

WARNING! Risk of crushing.

Make sure that the fork carriage is secured so that it cannot fall down.

• Loosen the lift chain by removing the nuts.

• Remove the hexagon-head screws (2) holding the hydraulics in the chassis.

• Disconnect the oil hose (1) from the hydraulics.

• Remove the hydraulics.

4.2.2 Removing the lift piston • Undo the top nut (3).

• Lift up the piston.

• Remove the bushing (5) and seal (6) by loosening the circlip (7) using circlip pliers.

14

Service Manual

SHM080, SHL080

© BT Europe AB

Hydraulic unit Hydraulics, electric stacker Order number 230326-040

Date 2006-09-30

Valid from serial number 495600-

4.2.3 Removing the hydraulic unit 2

1

5

6

3

4

The hydraulic unit consists of: - Electric motor (1) - Valve block (2) - Hydraulic pump (3) - Oil tank (4) - Valve (5) • Remove the hydraulic unit by undoing the two hexagon-head screws (6) using a spanner.

4.2.4 Hydraulics diagram

© BT Europe AB

Service Manual

SHM080, SHL080

15

Hydraulic unit Hydraulics, electric stacker Valid from serial number 495600-

Date 2006-09-30

Order number 230326-040

This page is intentionally left blank

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Service Manual

SHM080, SHL080

© BT Europe AB

Chassis Hydraulics, electric stacker Order number 230326-040

Date 2006-09-30

Valid from serial number 495600-

5- Chassis 15 1

6

2

14

5

4 13 3 12

7

9 11

8 10

The chassis consists of: - Mast (1) - Fork carriage (2) - Parking brake (3) - Castor (4) - Fork wheel (5) - Lift chain (6)

5.0.1 Removing the castor • Remove the wheel fork by undoing the screw (7).

• To replace the ball bearing (8), remove the circlip (9) using circlip pliers.

• Remove the wheel by removing the hexagonal screw (10) and nut (11) using a spanner. © BT Europe AB

Service Manual

SHM080, SHL080

17

Chassis Hydraulics, electric stacker Valid from serial number 495600-

Date 2006-09-30

Order number 230326-040

5.0.2 Removing the fork wheel • Undo the screw (12) holding the shaft (13).

• Remove the shaft and fork wheel.

5.0.3 Replacing the parking brake • Undo the screws (14).

• Remove the old brake and replace with a new one.

5.0.4 Removing the fork carriage WARNING! Risk of crushing.

Make sure that the fork carriage is secured so that it cannot fall down.

• Loosen the lift chain by removing the nuts holding the chain in the mast and the fork carriage.

• Undo the limit stop (15) by the masthead.

• Lift the fork carriage straight up through the mast section.

5.0.5 Removing the lift chain WARNING! Risk of crushing.

Make sure that the fork carriage is secured so that it cannot fall down.

• Undo the lift chain by removing the nuts holding the chain in the mast and the fork carriage.

18

Service Manual

SHM080, SHL080

© BT Europe AB

Electrical system Wiring diagram, electric stacker Order number 230326-040

Date 2006-09-30

Valid from serial number 495600-

6- Electrical system

-

M +

X1 FORK LIFT

SHM080, SHL080

S34

250A

Service Manual

10A

F50

F3

EMERGENCY SWITCH OFF

© BT Europe AB

CHARGE CONNECTOR

Q30

12V

+

G1

PUMP CONTACTOR

PUMP MOTOR M3

174543

6.1 Wiring diagram, electric stacker

19

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