BT SSE135 Operator'S Manual Download

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Maintenance

Summary of Contents for SSE135

Page 1: ...B S 595 81 MJÖLBY SWEDEN Operator s Manual en WARNING Do not use the truck before first reading through the OPERATOR S MANUAL NOTE Keep for future reference SSE135 SSE160 Valid from serial number 962872 Order number 237077 040 Issued 2006 10 24 ITS ...

Page 2: ...regulations and how to keep the truck in a safe condition by following daily service routines Only personnel who have been trained on the operation of this type of truck are permitted to use this truck It is your employer s responsibility to ensure that you have suffi cient knowledge of how to use your truck safely Do not hesitate to contact your supervisor if you feel the slightest uncertainty of...

Page 3: ...ion plate 19 Main components 20 Controls and instruments truck with 360 steering 22 Display and programming 29 Warning codes 32 Error codes 34 Controls and instruments truck with 180 steering 36 Display and programming 43 Warning codes 46 Error codes 48 Accessories 50 Load support 50 Extension forks 50 Stabilisers 50 Height indicator 50 Driving truck with 360 steering 52 Starting the truck 52 Brak...

Page 4: ...n checks 66 Maintenance 68 Cleaning and washing 71 Maintenance chart 72 Lubrication chart 75 Oil and grease specification 75 Transporting and storing the truck 77 The truck s dimensions and weight as standard 77 Lifting the truck 78 Towing and transporting a defective truck 78 Storing the truck 79 Starting after a period of disuse 79 Recycling discarding 80 Discarding the battery 80 Scrapping the ...

Page 5: ... DANGER Warns that an accident will occur if you do not follow the instructions The consequences are serious personal injury or possibly death and or extremely large material damage WARNING Warns that accidents can occur if the instructions are not fol lowed The consequences are serious personal injury or possibly death and or large material damage CAUTION Warns that accidents can occur if the ins...

Page 6: ...in situations where naked flames are prohibited a serious accident can occur GENERAL PROHIBITION If the prohibition is ignored a serious accident can occur Ordinance symbols SAFETY SHOES When the directive for safety shoes is given safety shoes must always be worn to avoid personal injury PROTECTIVE GLASSES When the directive for protective glasses is given protective glasses must always be worn t...

Page 7: ...fication plate The truck must not be used if it is damaged or has faults that affect safety or its safe use The truck may not be used if it has been repaired modified or adjusted unless it has been checked and approved by personnel authorised by BT Operating the truck The truck is designed and produced to be your tool when collect ing and depositing goods at different heights If the truck is to be...

Page 8: ...shall also be reported The truck shall only be driven with care good judgement and in a responsible manner Local regulations regarding personal safety equipment shall be followed The truck should not be driven with oily hands or oily shoes due to the risk of slipping Working area If there are marked truck routes these shall be used The truck should only be driven on hard and even surfaces e g conc...

Page 9: ... within the working area and thereby avoid accidents Always be prepared to stop if other personnel are in the work ing area Keep a safe distance from all vehicles ahead Always keep a safe distance from the edges of loading bays and loading ramps Be attentive to marked risk areas Sound the horn when overtaking and when the attention of other personnel is required Always give way to a loaded truck a...

Page 10: ...y still in the ignition Never park the truck on an incline Never park the truck so that it obstructs emergency exits Never park the truck so that it obstructs traffic or work Handling the battery Always handle the battery and its connections with care Read and follow the instructions carefully before replacing or charging the battery See chapter Battery Always wear protective glasses when working ...

Page 11: ...Safety regulations BT 237077 040 11 ...

Page 12: ... stabilizers 2 A 180 Horn accelerator brake button Hydraulic controls Lifting lowering forks B 360 Horn accelerator brake control travel direction selector Hydraulic controls Lifting lowering forks 3 A Do not walk under an elevated load B Do not stand on the forks 4 Maximum height for rated capacity 5 Lifting points 6 Hydraulic oil filling 7 Serial number 8 Capacity plate 9 Modification plate 10 I...

Page 13: ...Warning and information plates and symbols BT 237077 040 13 3a 3b 2a 2b ...

Page 14: ...r battery indicator and error codes The battery is placed on a roller table easily accessible for inspection replacement and service The stand on stacking vehicle s construction is based on the same advanced tech niques used for BT s reach trucks with easy access to compo nents and simple servicing Intended application of the truck The truck is solely designed and manufactured to handle goods The ...

Page 15: ...ting speed without load m s 9 0 9 0 Operating speed with rated load m s 7 6 7 6 Max operating gradient with rated load 16 12 Rate of lifting without load m s 0 30 0 25 Rate of lifting with rated load m s 0 20 0 15 Rate of lowering without load m s 0 30 0 40 Rate of lowering with rated load m s 0 45 0 46 Weight without battery kg 1140 Tele h3 3350 1520 Tripl h3 6300 Battery 5h discharge 300 360 480...

Page 16: ...Presentation of the truck BT 237077 040 16 Truck dimensions The illustration shows external dimensions for the truck in its standard design ...

Page 17: ...n 1937 2622 2013 2708 h2 Free lift 1476 2143 1465 2143 h3 Lift hight 2800 5400 2900 6300 h4 Mast height max 3317 5921 3443 6958 h6 Load guard height 2290 2290 h7 Instep height 245 245 h13 Height of lowered fork 90 90 l Fork length 1150 1150 l2 Truck length excl forks Short chassis Dx Tx Long chassis Dx Tx 919 938 1033 1052 1079 1079 m1 Floor clearance 28 28 Wa Turning radius short long chassis 178...

Page 18: ...identification plate for the truck in ASME design Item Text Unit A MODEL B NO C RATED CAPACITY kg D WEIGHT WITHOUT BATTERY kg E BATTERY WEIGHT MAX MIN kg kg F BATTERY VOLTAGE V G BATTERY TYPE Item Text Unit A MODEL B NO C RATED CAPACITY kg D WEIGHT WITHOUT BATTERY kg E BATTERY WEIGHT MAX MIN kg kg F BATTERY VOLTAGE V G BATTERY TYPE CLASS ACC TO UL583 A B C D E E F G ...

Page 19: ...on standard or if it has been modi fied after leaving the manufacturer The plate includes informa tion according to the table below Item Text Unit H NO I LIFT HEIGHT mm J ACTUAL CAPACITY kg K LOAD CENTRE DISTANCE mm L THE TRUCK MUST ALWAYS BE DRIVEN WITH LOWERED FORKS EXCEPT WHEN PLACING OR REMOVING LOAD Item Text A Modification plate B Type C Serial number D Place of manufacture E Place of manufa...

Page 20: ...information relating to the truck s oper ating time error codes travel direction parking brake steer ing angle and battery charge status as well as indicating the time of day 6 Serial number The serial number plate fitted to the chassis 7 Cover Easily swivelled to provide good access for servicing 8 Foot pedal With safety switch and automatic parking brake 9 Hydraulic valves The valves are located...

Page 21: ...Main components BT 237077 040 21 ...

Page 22: ... Controls and instruments truck with 360 steering 1 Steering wheel 2 Hydraulic controls 3 Emergency switch off 4 Key switch 5 Display 6 Accelerator brake control 7 Horn 8 Travel direction selector 9 Controls for control console position 10 Safety pedal 11 Cover lock ...

Page 23: ...Controls and instruments truck with 360 steering BT 237077 040 23 11 ...

Page 24: ...mounting Do not use the steering wheel as a handle when entering the truck Instead use the rail on the motor casing WARNING Loose wheel console You can lose control of the truck if the wheel console is loose Tighten the lock handle following adjustment Hydraulic controls 2 There is a maximum of one joystick and two buttons on the con trol panel with which you can control all the hydraulic function...

Page 25: ...sk of an accident Welding work NOTE The battery can be damaged When welding using an electric power source the welding cur rent can enter the battery It is necessary to disconnect the battery Key switch 4 The main power switch for the control current 0 The power is off and the instrument lighting is off 1 The power supply is on The instrument lighting is on and current is fed to all electronic com...

Page 26: ... right hand side The meaning of the codes is explained in the sections Warning codes and Error codes Battery controller D The battery controller shows the actual charge level of the truck s battery 1 Fully charged battery 1 2 Half charged battery 0 Discharged battery The battery controller has an integrated cut out function that dis connects the truck s lifting function when a preset charge level ...

Page 27: ...lected without changing the position of the drive wheel the opposite arrow will light Accelerator brake control 6 The speed is variably controlled by moving the accelerator brake lever forwards from the neutral position The brakes are applied by moving the accelerator brake lever backwards from the neutral position The brakes are applied in two stages first gentle braking and then after a set dela...

Page 28: ... operating position is adjusted often in order to reduce the load on the body Foot pedal 10 Place your foot on the foot pedal when you wish to drive the truck The foot pedal features an integrated automatic parking brake and safety switch This means the parking brake is acti vated if you do not stand on the pedal WARNING Risk of being thrown from the truck The parking brake is actuated if you left...

Page 29: ...gister proceed as follows Open the motor casing Switch on the ignition key to feed voltage to the electronics Press switch SELECT on the electronic card To step through the register one step at a time press SELECT once The programmed parameters will be displayed in the character window C Warning codes and Error codes Parameters Running time The address register s No will be shown on the left hand ...

Page 30: ...Controls and instruments truck with 360 steering BT 237077 040 30 SELECT ...

Page 31: ...x G will be lit and when the parameters are displayed in character window C the character box F will be lit How ever it is not possible to reprogram these parameters from here If this is necessary please contact a trained service technician Quit programming by switching the ignition key off and on once Programming is also stopped if no button is pressed within twenty seconds NOTE Truck handling Th...

Page 32: ...servo electronics on the steering are too hot Jammed steering The steering and driving speed is reduced 13 The height pulse sensor gives no signal when low ering the forks above the fork reference switch Faulty pulse sensor or bro ken cable None 18 The battery in the logic box has reached its lowest voltage level The battery has run down The data stored in the memory will be lost 19 The truck s pa...

Page 33: ...ause of the error 27 Incorrect battery supply The power supply cables to the battery supply are not connected to the battery No effect on the truck The battery display flashes 30 Safety pedal switch acti vated more than 3 minutes whilst the truck has not moved Faulty switch or broken cable The parking brake comes on 31 The left foot pedal is acti vated for more than 3 min utes without the truck mo...

Page 34: ...n displayed Character Error Error Code No Error type Probable cause Effect on the truck 102 Error signal from the servo electronics Faulty servo unit or the emergency stop is on All hydraulic functions except lowering the forks are stopped 120 121 123 127 140 Fault in the electronics Faulty electronics All hydraulic functions except lowering the forks are stopped 122 Too much heat in the servo ele...

Page 35: ... fault step 2 Faulty brakes or cabling All hydraulic functions except lowering the forks are stopped 141 Faulty setting of 180 360 selection Invalid combination of parameter and input All functions on the truck are stopped Code No Error type Probable cause Effect on the truck ...

Page 36: ...36 Controls and instruments truck with 180 steering 1 Steering wheel 2 Hydraulic controls 3 Emergency switch off 4 Key switch 5 Display 6 Travel control 7 Horn 8 Brake lever for the travel brake 9 Controls for control console position 10 Safety pedal 11 Cover lock ...

Page 37: ...Controls and instruments truck with 180 steering BT 237077 040 37 11 ...

Page 38: ...g Do not use the steering wheel as a handle when entering the truck Instead use the rail on the motor casing WARNING Loose wheel console You can lose control of the truck if the wheel console is loose Tighten the lock handle following adjustment Hydraulic controls 2 There is a maximum of one joystick and two buttons on the con trol panel with which you can control all the hydraulic functions The m...

Page 39: ...sk of an accident Welding work NOTE The battery can be damaged When welding using an electric power source the welding cur rent can enter the battery It is necessary to disconnect the battery Key switch 4 The main power switch for the control current 0 The power is off and the instrument lighting is off 1 The power supply is on The instrument lighting is on and current is fed to all electronic com...

Page 40: ... right hand side The meaning of the codes is explained in the sections Warning codes and Error codes Battery controller D The battery controller shows the actual charge level of the truck s battery 1 Fully charged battery 1 2 Half charged battery 0 Discharged battery The battery controller has an integrated cut out function that dis connects the truck s lifting function when a preset charge level ...

Page 41: ...J Option The position of the drive wheel and the truck s direction of travel are indicated by one of the arrows in the diagram When the opposite direction is selected without changing the position of the drive wheel the opposite arrow will light Travel control 6 Drive forwards backwards by moving the travel control for wards backwards The travel speed is infinitely variable Horn 7 The horn sounds ...

Page 42: ...operating position is adjusted often in order to reduce the load on the body Safety pedal 10 Place your foot on the foot pedal when you wish to drive the truck The foot pedal features an integrated automatic parking brake and safety switch This means the parking brake is acti vated if you do not stand on the pedal WARNING Risk of being thrown from the truck The parking brake is actuated if you lef...

Page 43: ...gister proceed as follows Open the motor casing Switch on the ignition key to feed voltage to the electronics Press switch SELECT on the electronic card To step through the register one step at a time press SELECT once The programmed parameters will be displayed in the character window C Warning codes and Error codes Parameters Running time The address register s No will be shown on the left hand ...

Page 44: ...Controls and instruments truck with 180 steering BT 237077 040 44 SELECT ...

Page 45: ...x G will be lit and when the parameters are displayed in character window C the character box F will be lit How ever it is not possible to reprogram these parameters from here If this is necessary please contact a trained service technician Quit programming by switching the ignition key off and on once Programming is also stopped if no button is pressed within twenty seconds NOTE Truck handling Th...

Page 46: ...servo electronics on the steering are too hot Jammed steering The steering and driving speed is reduced 13 The height pulse sensor gives no signal when low ering the forks above the fork reference switch Faulty pulse sensor or bro ken cable None 18 The battery in the logic box has reached its lowest voltage level The battery has run down The data stored in the memory will be lost 19 The truck s pa...

Page 47: ...ause of the error 27 Incorrect battery supply The power supply cables to the battery supply are not connected to the battery No effect on the truck The battery display flashes 30 Safety pedal switch acti vated more than 3 minutes whilst the truck has not moved Faulty switch or broken cable The parking brake comes on 31 The left foot pedal is acti vated for more than 3 min utes without the truck mo...

Page 48: ...n displayed Character Error Error Code No Error type Probable cause Effect on the truck 102 Error signal from the servo electronics Faulty servo unit or the emergency stop is on All hydraulic functions except lowering the forks are stopped 120 121 123 127 140 Fault in the electronics Faulty electronics All hydraulic functions except lowering the forks are stopped 122 Too much heat in the servo ele...

Page 49: ... fault step 2 Faulty brakes or cabling All hydraulic functions except lowering the forks are stopped 141 Faulty setting of 180 360 selection Invalid combination of parameter and input All functions on the truck are stopped Code No Error type Probable cause Effect on the truck ...

Page 50: ...sion forks 1 5 x fork length WARNING Risk for tipping The lifting capacity is reduced when the extension forks and longer loads are handled Always check the truck s total lifting capacity Stabilisers The stabilisers increase the stability of the truck and in doing so allow an increased lifting capacity and higher lifting heights NOTE Increased truck width The stabilisers can collide with fixed obj...

Page 51: ...Accessories BT 237077 040 51 4 2 1 3 ...

Page 52: ...crushing Risk of crushing exists if any part of the body is outside of the operator s cab Always ensure that the whole of your body is inside the protec tive cab Select the travel direction WARNING Function failure Safety can be jeopardised Always check the following safety functions before starting the day s work That the horn and emergency switch off function correctly That the steering function...

Page 53: ...mpartment The steering motor moves the steered drive wheel by means of a chain drive When small steering wheel adjustments are required and when driving at high speed steer the truck with the finger tips on the steering wheel hub For low speed driving and turning the truck rotate the wheel faster with the help of the steering wheel spinner The control characteristics can be adapted to suit the exp...

Page 54: ...he truck carefully Lower the forks fully to the floor Retract the stabilisers Turn the ignition key to the 0 position the parking brake is activated automatically WARNING Unauthorised use Accidents can happen Always remove the ignition key when the truck is left unat tended ...

Page 55: ...part of the body is outside of the operator s cab Always ensure that the whole of your body is inside the protec tive cab Select the travel direction by carefully moving the travel con trol forwards backwards WARNING Function failure Safety can be jeopardised Always check the following safety functions before starting the day s work That the horn and emergency switch off function correctly That th...

Page 56: ...s the steered drive wheel by means of a chain drive When small steering wheel adjustments are required and when driving at high speed steer the truck with the finger tips on the steering wheel hub For low speed driving and turning the truck rotate the wheel faster with the help of the steering wheel spinner The control characteristics can be adapted to suit the experience and requirements of the d...

Page 57: ...he truck carefully Lower the forks fully to the floor Retract the stabilisers Turn the ignition key to the 0 position the parking brake is activated automatically WARNING Unauthorised use Accidents can happen Always remove the ignition key when the truck is left unat tended ...

Page 58: ...ds The load can collide with personnel fixed or moving objects A truck with a protruding load requires more room when cor nering Drive the truck with the load trailing when the load impairs the line of vision If necessary when the operator s vision is impaired ask someone to direct operations so that transportation can take place without the risk of causing personal injury or material damage Drive...

Page 59: ...y and that it is secured correctly Drive at a safe distance from the edge Collecting a load WARNING Risk for falling small goods Injuries to the driver can occur Equip the truck with plexiglass or protective bars on the over head guard WARNING Risk of crushing support Carelessness can cause injuries Keep your hands on the control when raising lowering Slow down and position the truck carefully in ...

Page 60: ...the over head guard WARNING Risk of crushing support Carelessness can cause injuries Keep your hands on the control when raising lowering Slow down and position the truck carefully in front of the rack Lift the forks to the required lifting position Extend the stabilisers if the lift shall occur above the lifting height switch NOTE Increased truck width The stabilisers can collide with fixed objec...

Page 61: ... when the forks come below the lifting height switch CAUTION Lost stability Lowering a loaded pallet when the truck is still moving can result in the load falling off the pallet Never lower a load if the truck is moving Start slowly and then increase the speed ...

Page 62: ...ication plate When changing the battery proceed as follows Press in the emergency switch off Open and drop down the doors to the battery compartment Remove the lock Roll out the dead battery onto the door Disconnect the battery connector from the battery Lift out the discharged old battery Lift in the new battery Connect the battery connector to the battery Roll the new battery into the compartmen...

Page 63: ...s wash the eyes immediately using an eye shower contact a doctor ALWAYS WEAR PROTECTIVE GLASSES AND PROTECTIVE GLOVES WHEN CHECKING THE BATTERY Before charging Park the truck in the assigned charging area Ensure nothing prevents ventilation above the battery Turn the ignition key to the 0 position and remove the key Pull out the connector from the battery recharging socket Make sure the battery ch...

Page 64: ...ry maintenance after recharging WARNING Corrosive acid The battery fluid contains sulphuric acid Fluid spilt on the skin should be rinsed off immediately Wash thoroughly with soap and water If the fluid has come into contact with the eyes wash the eyes immediately using an eye shower contact a doctor ALWAYS WEAR PROTECTIVE GLASSES AND PROTECTIVE GLOVES WHEN CHECKING THE BATTERY Each week Remove al...

Page 65: ...not exceed 50 C Measure the density of the battery fluid using an acid tester Hold the acid tester absolutely vertical and extract sufficient fluid so that the hydrometer float moves freely Correct density values at different fluid temperatures for a fully charged battery Temperature C Density g cm3 15 1 31 0 1 30 15 1 29 30 1 28 45 1 27 ...

Page 66: ... Never use a truck that has faults Pos no Check points Action 1 Steering wheel Check its function 2 Hydraulic functions Check its function 3 Emergency switch off Check its function 4 Running time Carry out maintenance as set out in the table in chapter Maintenance 5 Horn Check its function 6 180 Travel brake 360 Travel direction selector Check its function 7 180 Speed control Travel direction sele...

Page 67: ...Daily service and function checks BT 237077 040 67 9 ...

Page 68: ...the correct training and knowledge to do so Keep the area where you carry out the service clean Oil or water makes the floor slippery Never wear loose objects or jewellery when working on the truck WARNING Short circuiting Burns When working with the truck s electrical system short circuiting burns can occur if a metal object comes into contact with live electrical connections Remove watches rings...

Page 69: ...and the like which are used for cleaning washing into drains that are not intended for this purpose Follow the local directives that apply for disposal Disconnect the battery when welding on the truck NOTE The battery can be damaged When welding using an electric power source the welding cur rent can enter the battery The battery should therefore be disconnected Remove at least 100 mm 4 of paint a...

Page 70: ... set out in the maintenance chart may only be carried out by personnel who have completed main tenance training for this type of truck Maintenance work that may be carried out by trained maintenance personnel All maintenance points as set out in the maintenance chart With uncertainty regarding working procedures consult the Service Manual for the truck Other service and repair work In addition to ...

Page 71: ... should be lubricated as set out in the lubrication chart in chapter Maintenance Cleaning the motor compartment Cover the electric motors connections and valves before washing NOTE Risk of short circuiting The electrical system can be damaged Electrical components must not be cleaned with a high pres sure washing unit Clean the motor compartment using a well known degreasing agent diluted to a sui...

Page 72: ...rive unit 3 1 Check for leakage X 3 2 Check the oil level X 3 3 Check for noises X 3 4 Check the mounting on the support arm X 4 0 Wheels 4 1 Remove string and other rubbish X 4 2 Check for drive wheel wear and the bolts X 4 3 Check that the link wheel is rotating and can swing freely X 4 4 Check for wear and tear on the link wheel and the fork wheels X 4 5 Dismantle and grease the fork wheel s be...

Page 73: ...eakage X 9 2 Check the mountings X 10 0 Mast 10 1 Check for damage and crack formation X 10 2 Tighten the mast mounting X 10 3 Check for play on the rollers X 10 4 Check the electrical limit function X 10 5 Check for wear on the lifting chains and sprockets X 10 6 Check hoses and couplings for leakage X 10 7 Check for wear to the forks and other lifting devices X 11 0 Control console 11 1 Check th...

Page 74: ...Maintenance BT 237077 040 74 ...

Page 75: ... E 4 Lifting chains L D 5 Hydraulic system C O1 B 6 Hinges L A 7 Steering bearings L F 8 Drive gear C O C Lubricant Specification Application area 15 C 15 C A Grease BT 26777 Spray BT 26777 Spray Bearings and bushings B Hydraulic oil ISO L HM32 ISO L HV32 Hydraulic system C Transmission oil Hypoid oil SAE 80W 90 Hypoid oil SAE 75W Gears D Grease BT 26778 Spray BT 26778 Spray Chains and wires E Gre...

Page 76: ...Maintenance BT 237077 040 76 2 1 3 4 ...

Page 77: ...t Height truck without mast mm 2290 Height truck with mast mm Dependent on the mast height SSE135 1937 2622 Dependent on the mast height SSE160 2013 2708 Width mm 900 Length incl forks L 1150 mm mm SSE135 short chassis Dx Tx 2069 2088 SSE135 long chassis Dx Tx 2183 2202 SSE160 Dx Tx 2229 2229 Lowest battery weight kg 300 Ah 278 360 Ah 380 480 Ah 484 584 Ah 493 Weight without battery kg SSE135 Tele...

Page 78: ...ck The towed truck shall always have an operator who can steer and apply the brake when towing using a tow truck and tow rope Tow or transport a defective truck to a repair station as follows Trucks that have a working electrical system Turn the key activate the safety pedal and select the travel direction Tow the truck or push it by hand with the help of another person The service brake can still...

Page 79: ...lic system when stored for peri ods longer than one year see the oil specification in the Lubrication chart in chapter Maintenance Drive unit Block up the truck s drive section to take the load off the drive wheel when stored for periods longer than one week Starting after a period of disuse Before the truck is put into operation after a period of disuse it should undergo a function and safety che...

Page 80: ...ries shall be returned sent to the manufacturer of the battery or its representatives see the sign on the battery for dis posal recycling You can also return batteries to your local BT representative who will then take care of returning the battery to the manufacturer Scrapping the truck The truck consists of parts that contain recyclable metals and plastics Below is a list of those materials used...

Page 81: ...nk Polythene Pump unit Steel and aluminium Hoses Rubber and steel Cylinders Cast iron and steel Electrical system Cables Copper cores with PVC sheaths Electronic board Reinforced glass fibre circuit board laminate Lithium battery Motors Steel copper and aluminium ...

Page 82: ...ed in industrial environment Other information _____________________ Eriksson Lars V P Projects and Product Safety For deliveries to countries outside the European Union differences may occur with regard to requirements for documentation in the local language THE SWEDISH MACHINERY TESTING INSTITUTE Fyrisborgsgatan 3 S 754 50 Uppsala Telefon Telephone 46 18 56 15 00 Telefax 46 18 12 72 44 Modificat...

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BT SSE135, Operator'S Manual

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