Service Manual en

LHM230, LHM230P
Valid from serial number: 3.121.000-

Order number: 221127-040

Issued: 2005-05-01 ITS

© BT Europe AB
 Issue date Resp. Changes
2005-05-01 ITS Completely new issue

This manual covers following truck models:

T-code Model Serial number

360 LHM230 3.121.000-
726 LHM230P 3.121.000-

© BT Europe AB Service Manual LHM230, LHM230P Approved by: Fredrik Moborg

 Table of contents
Order number Date Valid from serial number T-code
221127-040 2005-05-01 3.121.000- 360, 726

1- Table of contents

General Product Information 1

Presentation of the Truck .............................. 1

2.1.1 Intended application of the truck ........................ 1
2.1.2 Prohibited use of the truck .................................. 1
Truck Data..................................................... 2
Truck Dimensions.......................................... 2
LHM230 .............................................................. 3
LHM230P ........................................................... 4

Maintenance 5

General ......................................................... 5

Safety rules for servicing work....................... 6

3.2.1 Observe the following for service and maintenance 7
3.2.2 Necessary special tools ...................................... 7
3.2.3 Information plates ............................................... 7
Cleaning, washing and lubrication................. 8
3.3.1 Lubrication chart ................................................. 8
Lubrication diagram ............................................ 9

Tow bar 11

General ....................................................... 11

Components parts, LHM230 ....................... 11

4.2.1 Dismantling the tow bar .................................... 12
4.2.2 Replacing the lowering handle ......................... 13
4.2.3 Replace the press roller and valve bar. ............ 13

Hydraulics unit 15

General ....................................................... 15

Component parts......................................... 16
5.2.1 Replacing the hydraulics .................................. 18
5.2.2 Replacing the steering wheel ........................... 18
5.2.3 Replacing the steering wheel axle .................... 18
5.2.4 Replacing thrust bearings ................................. 18
5.2.5 Replacing the pump piston ............................... 19

© BT Europe AB Service Manual LHM230, LHM230P 1

Table of contents
T-code Valid from serial number Date Order number
360, 726 3.121.000- 2005-05-01 221127-040

5.2.6 Replacing the lift piston ..................................... 19

5.2.7 Replacing the lowering valve ............................ 19
5.2.8 Replacing the cone ........................................... 19
5.2.9 Replacing the quick valve ................................. 20
5.2.10 Changing the oil ............................................... 20
5.2.11 Hydraulic diagrams ........................................... 21
LHM230, LHM230P .......................................... 21
LHM230Q ......................................................... 21
LHM230O ......................................................... 21

Chassis 23

General ........................................................ 23
6.1.1 Replacing torsion tubes .................................... 23
6.1.2 Replacing the pressure rod ............................... 23
6.1.3 Replacing the wheel fork .................................. 23
6.1.4 Replacing the bogie fork ................................... 23
6.1.5 Replacing the fork wheel .................................. 23

Specific service instructions for

LHM230P 25

Component parts ......................................... 25

7.1.1 Dismantling/Assembly ...................................... 28
Changing wire.............................................. 28
7.2.1 Fixing the spring ............................................... 29
7.2.2 Replacing the bushing ...................................... 29
7.2.3 Adjusting the functions on the LHM230P .......... 29

Troubleshooting 31

Troubleshooting chart .................................. 31

8.1.1 Troubleshooting hydraulics LHM230 ................ 33
The hydraulics fall ............................................. 33
Leakage ............................................................ 33
Leakage, lowering valve ................................... 34
Leakage top nut ................................................ 34
Malfunctioning quick lift function ....................... 35
The quick lift hydraulics are sinking .................. 35
Leakage at the quick lift valve ........................... 35

2 Service Manual LHM230, LHM230P © BT Europe AB

 General Product Information
Presentation of the Truck
Order number Date Valid from serial number T-code
221127-040 2005-05-01 3.121.000- 360, 726

2- General Product Information

2.1 Presentation of the Truck
LHM230 is the classic truck, suitable for goods handling in a variety of situa-
tions.
The truck has a maximum lift capacity of 2300 kilos and is available in
different versions with a variety of options.
LHM230P comes equipped with a function for start-up assistance. A
coupling between the tow bar and the steering wheel transports the
power from the movement of the pump to the wheel and thus starting
the truck. A function mounted on the handlebar allows you to select the
direction of the start-up power.
LHM230Q is suitable for users handling a large proportion of pallets.
The forks reach the pallet on the first revolution of the pump and lift it on
the second.
LHM230O comes with a safety valve for overloading - an option with
the LHM230. This version comes with preset weight limits for how much
the truck can lift.

2.1.1 Intended application of the truck

The truck must only be used on a hard and even surface e.g. concrete
or asphalt.
Use of the truck is not permitted:
- In areas where the atmosphere contains gases that can cause
fire or explosion
- To transport/lift passengers
- In cold stores, salty or other corrosive environs. A truck in stain-
less steel must be used in these environs.
In addition LHM230P must not be used in wet environs or in environs
with extreme temperature changes.

2.1.2 Prohibited use of the truck

It is not permitted to use the truck for purposes other than those for
which it has been designed and manufactured. Using the truck for the
following applications is therefore not permitted:
- Driving in areas that contain dust or gases which could cause
fires or explosions
- as a tow-truck for trailers.
- to tow other trucks.
- to transport/lift passengers.
- driving on anything other than hard, even surfaces
- in cold stores
- outdoors
- in environments with temperatures below 0° C
© BT Europe AB Service Manual LHM230, LHM230P 1
General Product Information
Truck Data
T-code Valid from serial number Date Order number
360, 726 3.121.000- 2005-05-01 221127-040

2.2 Truck Data

The table provides information about certain technical product data
which may be useful for day-to-day truck operation.

Technical data LHM230 LHM230P

Rated lifting capacity 2300 kg 2300 kg
Weight 65 kg 77 kg
Lifting height 200 mm 200 mm
Turning radius (Wa) 1392 mm 1410 mm
Steering wheel Ø 175 x 60 Ø 175 x 60
Fork wheels, single/bogie Ø 85 x 100 / Ø 85 x 100 /
Ø 85 x 75 Ø 85 x 75
Pumping power, rated load 34 kg 34 kg
Traction power 19 kg*) 22 kg*)

*) Calculated using a nominal load on a level and dry concrete floor

2.3 Truck Dimensions

Dimensions LHM230 LHM230P

x Front axle for back of fork 985 mm 985 mm
y Wheel base 1217 mm 1217 mm
h3 Lift height 200 mm 200 mm
h14 Handle height in neutral mode 1220 mm 1220 mm
h13 Height above lowered fork 85 mm 85 mm
l2 Truck length including back of 356 mm 425 mm
fork
b1 Chassis width 520 / 685 mm 520 / 685 mm
s Fork thickness 45 mm 45 mm
e Fork width 156 mm 156 mm
l Fork length 800 / 910 / 800 / 910 /
1000 / 1070 / 1000 / 1070 /
1150 / 1150 /
1220 mm 1220 mm
b5 Width over fork 520 / 685 mm 520 / 685 mm
m2 Ground clearance, centre of 40 mm 40 mm
wheel base
Ast Aisle width requirement, min. 1756 mm 1825 mm
Pallet size 800x1200 mm
Wa Turning radius 1392 mm 1410 mm

2 Service Manual LHM230, LHM230P © BT Europe AB

 General Product Information
Truck Dimensions
Order number Date Valid from serial number T-code
221127-040 2005-05-01 3.121.000- 360, 726

LHM230
l

280

h3
200 125
x

h13
200 65

280

h3
h 14

180

h3
h13
m2

y
85 122
l2 l
e
b1

b5

wa

© BT Europe AB Service Manual LHM230, LHM230P 3

General Product Information
Truck Dimensions
T-code Valid from serial number Date Order number
360, 726 3.121.000- 2005-05-01 221127-040

LHM230P

e
b1

b5

wa

4 Service Manual LHM230, LHM230P © BT Europe AB

 Maintenance
General
Order number Date Valid from serial number T-code
221127-040 2005-05-01 3.121.000- 360, 726

3- 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 operator’s manual and spare parts catalogue to hand.

3.1 General
• Ensure that the truck undergoes regular maintenance as per Lubri-
cation Diagram to prevent function errors and accidents. Only quali-
fied and trained personnel are permitted to maintain, adjust and re-
pair the truck.
• Only use BT approved spare parts during servicing and repairs.
The following items should be checked on a daily basis:
- That the start-up wire is undamaged prior to use of the truck.
- That the break wire is undamaged prior to use of the truck.
- That the break power is sufficient - please adjust tension on the
break wire if necessary.
We also recommend lubrication and oil change in the hydraulics every
two years.
Any modification or conversion of the truck that affects safe use or func-
tion is not permitted.
Daily inspection/safety check:

Inspection Action
Start-up help Function for forward/neutral/reverse
Steering Function
Break or alternatively Function/adjusting
hand/parking break
Hydraulic system Oil level/Oil leakage
Wheels Damages, remove oil, metal filaments etc
Chassis Damages, remove dirt etc
Lifting/lowering Function for lift/neutral/lowering
Signs Legibility

© BT Europe AB Service Manual LHM230, LHM230P 5

Maintenance
Safety rules for servicing work
T-code Valid from serial number Date Order number
360, 726 3.121.000- 2005-05-01 221127-040

3.2 Safety rules for servicing work

WARNING !
When servicing pallet trucks, PROTECTIVE GLASSES and PROTEC-
TIVE SHOES must be worn.
• Discharge the system pressure before any work commences on the
truck's hydraulic system. (No load on forks).
• Ensure that the area where servicing work is carried out is kept
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 and similar substances used for cleaning maynot be
flushed down drains that are not intended for this purpose. Follow lo-
cal directions that apply to destruction.
• Remove at least 100 mm of paint around the welding/grinding area
using sand blasting equipment or paint remover when welding or
grinding on painted surfaces.
WARNING !
Unhealthy gases
Heated paint emits unhealthy gases.
Remove 100 mm of paint from around the working area.
WARNING !
Risk of cutting, risk of crushing
There is a CUTTING RISK when the pallet truck is lifted by hand at the
forks and end plate.
There is a CRUSHING RISK when the pallet truck is lifted by hand on
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 it may be-
come loose from the locking ring pliers and cause damage.
• When hammering in or out, a locking pin can bounce and cause
damage. Be careful when fitting/removing locking pins.
• When fitting/removing springs, they can spring out of place and
cause damage.

6 Service Manual LHM230, LHM230P © BT Europe AB

 Maintenance
Safety rules for servicing work
Order number Date Valid from serial number T-code
221127-040 2005-05-01 3.121.000- 360, 726

3.2.1 Observe the following for service and

maintenance
• Always replace removed locking pins. Never reuse locking 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.
• Always check that neutral, lifting and lowering mode function after
working on the hydraulics.
• Check that there is no leakage after working 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.

3.2.2 Necessary special tools

Drift diameter: 3mm, 4, 5mm 7, 3mm
Special spanner for top nuts, item no. 08-7245
Special drift for beam seat, item no.: 08-16685
Tool for seals 21060, item no.: 08-13850
Tool for collar 22034, item no.: 08-15043
Special drift for quick seat for ball 22055, item no.: 08-13973
Special drift for quick seat for ball 20065, item no.: 08-13972
Tool for transport sheet, item no.: 08-13468

3.2.3 Information plates

In the event of any guarantee repairs, the machine number and produc-
tion week must always be stated. Always check information plates dur-
ing servicing. If they are damaged and/or difficult to read, new plates
should be ordered from Division Hand Trucks.

© BT Europe AB Service Manual LHM230, LHM230P 7

Maintenance
Cleaning, washing and lubrication
T-code Valid from serial number Date Order number
360, 726 3.121.000- 2005-05-01 221127-040

3.3 Cleaning, washing and lubrication

Cleaning and washing the truck is important for the reliability of the
truck.
• Always clean the start-up help bundle internally on the LHM230P in
the event of operational problems (blockage/jamming of wheels
and/or handlebar).
NOTE!
After cleaning, the truck must be lubricated according to the lubrica-
tion diagram and table below. Cold store oil must be used if operating
in temperatures below -15° C.
Lubrication is recommended at least every other year and always after
washing.

3.3.1 Lubrication chart

Lubrica- Number of lubri- Lubricant

tion Points cation points

Pressure plate 1
Arm bolts 2
Torsion tube 1
Universal grease EP2 or
Push rod 2 equivalent
Push rod 2
Wheel fork 2
Bogie fork 2

8 Service Manual LHM230, LHM230P © BT Europe AB

 Maintenance
Cleaning, washing and lubrication
Order number Date Valid from serial number T-code
221127-040 2005-05-01 3.121.000- 360, 726

Lubrication diagram

BT PRODUCTS AB
MJÖLBY SWEDEN

Q = XXXXKg XXXmm

XXXXmm oXX
XXXXXXX
mm=XXKg
Manufactured 2000-05-15

XXXXXX/XX

Q8 Rembrandt EP2
Q8 Rembrandt EP2

Oil specification
Colder than -15° C Warmer than -15° C

Hindesmith LT Haydn 32

© BT Europe AB Service Manual LHM230, LHM230P 9

Maintenance
Cleaning, washing and lubrication
T-code Valid from serial number Date Order number
360, 726 3.121.000- 2005-05-01 221127-040

This page is intentionally left blank

10 Service Manual LHM230, LHM230P © BT Europe AB

 Tow bar
General
Order number Date Valid from serial number T-code
221127-040 2005-05-01 3.121.000- 360, 726

4- Tow bar

4.1 General
A complete tow bar consists of:
• Tow bar
• Handle
• Lowering handle
• Press roller
• Valve bar

4.2 Components parts, LHM230

1
3

5 2

4
6

11
7

12
13
8

14
9 10

© BT Europe AB Service Manual LHM230, LHM230P 11

Tow bar
Components parts, LHM230
T-code Valid from serial number Date Order number
360, 726 3.121.000- 2005-05-01 221127-040

Pos. Designation
1 Handle
2 Handle (lowering)
3 Logotype
4 Rivet
5 Cover
6 Screw
7 Axle
8 Locking pin
9 Roller
10 Bushing
11 Locking pin
12 Bushing
13 Axle
14 Valve bar

4.2.1 Dismantling the tow bar

WARNING !
Releasing energy.
Brace the pump piston spring when removing the tow bars, as the
spring may spring out of position.
• Remove the valve chain from the lowering arm by placing the lower-
ing handle in "lifting position", press the lowering arm by hand while
pushing the spring to the side.
• Remove the locking pin and axles holding the tow bars.
• Place the transport sheet or similar to hold down the pump pistons
before the new tow bar is fitted.
• Press in the axles and drive in new locking pins.
• Fit the spring on the lowering arm.
• Adjust neutral mode. Adjust using the nut on the valve chain.

12 Service Manual LHM230, LHM230P © BT Europe AB

 Tow bar
Components parts, LHM230
Order number Date Valid from serial number T-code
221127-040 2005-05-01 3.121.000- 360, 726

4.2.2 Replacing the lowering handle

• Remove the spring from the lowering arm.
• Lay the pallet truck on its side.
• Remove the cover from the handle.
• Remove the ball, spring, sleeve and ball.
• Remove the lowering handle.
• Position the new lowering handle. Push up the valve bar to facilitate
assembly.
• Reassemble the components in reverse order.
• Check that the valve bar is around the sleeve.
• Check neutral mode.

4.2.3 Replace the press roller and valve bar.

• Dismantle the tow bar from the hydraulics. See section “4.2.1 Dis-
mantling the tow bar” .
• Dismantle the axle holding the press roller.
• Unhook the valve bar from the sleeve and pull it back.
• Fit a new valve bar 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 bar is positioned on
the correct side of the press roller.
• Fit tow bar and check the neutral position.

© BT Europe AB Service Manual LHM230, LHM230P 13

Tow bar
Components parts, LHM230
T-code Valid from serial number Date Order number
360, 726 3.121.000- 2005-05-01 221127-040

This page is intentionally left blank

14 Service Manual LHM230, LHM230P © BT Europe AB

 Hydraulics unit
General
Order number Date Valid from serial number T-code
221127-040 2005-05-01 3.121.000- 360, 726

5- Hydraulics unit

5.1 General
The hydraulics unit consists of:
• The hydraulic chassis
• Pressure plate
• Thrust bearing
• Steering wheel
• Pump piston
• Lift piston
• Lowering arm
• Lowering valve

© BT Europe AB Service Manual LHM230, LHM230P 15

Hydraulics unit
Component parts
T-code Valid from serial number Date Order number
360, 726 3.121.000- 2005-05-01 221127-040

5.2 Component parts

1
2

3
4
5

7 10

8 11
9 12

13 21
20
19
14 22
15 23
24
17
26 25

16 18 27 28
29
30
31
32
33

35
34
36
38 37

39

Pos. Designation
1 Seal
2 Nut
3 O-ring
4 Locking ring
5 Washer
6 Spring
7 Piston
8 Sealing ring

16 Service Manual LHM230, LHM230P © BT Europe AB

 Hydraulics unit
Component parts
Order number Date Valid from serial number T-code
221127-040 2005-05-01 3.121.000- 360, 726

Pos. Designation
9 U-ring
10 Piston
11 Locking ring
12 Guide ring
13 U-ring
14 Screw
15 Spring
16 Washer
17 Cone
18 Ball
19 Washer
20 Screw
21 Screw
22 Spring
23 Washer
24 O-ring
25 Tracking rod
26 Ball
27 Ball
28 O-ring
29 Valve unit
30 Spring
31 U-ring
32 Screw
33 Washer
34 Steering
35 Piston
36 Locking pin
37 Pressure plate
38 Grease nipple
39 Locking ring

© BT Europe AB Service Manual LHM230, LHM230P 17

Hydraulics unit
Component parts
T-code Valid from serial number Date Order number
360, 726 3.121.000- 2005-05-01 221127-040

5.2.1 Replacing the hydraulics

To make removing easier, pump up the pallet truck to maximum height,
placing, for instance, a piece of wood under the forks at the same
height as the breast plate before removing the hydraulics.
• Remove the locking ring in the cover top.
• Remove the locking pin and arm bolts.
• Lift the hydraulics off.
• Remove the tow bar.
• Fit the tow bar to new hydraulics.
• Lift in and attach new hydraulics.
• Adjust neutral mode and test lift.

5.2.2 Replacing the steering wheel

• Remove the hubcap.
• Remove the locking ring securing the wheel.
• Remove the wheel.
• Fix the wheel, locking ring and hubcap.

5.2.3 Replacing the steering wheel axle

• Remove the steering wheel. See section 5.2.2
• Grind away the colour on the one side of the axle.
• Remove the locking pin and axle.
• Use a plastic hammer or rubber mallet to tap out the axle or other-
wise you risk damaging the locking ring track.
• Fix a new axle.

5.2.4 Replacing thrust bearings

• Remove the steering wheel. See section 5.2.2
• Remove the steering wheel axle. See section 5.2.3. Use a plastic
hammer or rubber mallet to tap out the axle or otherwise you risk
damaging the locking ring track.
• Remove the locking ring, pressure plate and bearing.
• Reassemble in reverse order.

18 Service Manual LHM230, LHM230P © BT Europe AB

 Hydraulics unit
Component parts
Order number Date Valid from serial number T-code
221127-040 2005-05-01 3.121.000- 360, 726

5.2.5 Replacing the pump piston

• Truck in lowered position.
• Remove tow bar, see section 4.2.1
• Remove the spring and washer by loosening the locking ring.
• Pull out the pump piston through the sealing ring.
• Remove the sealing ring.
• Clean the surface for the sealing ring using T-röd.
• Fit a new sealing ring, new pump piston, spring, washer and locking
ring.
• Fit the tow bar.
• Bleed. See section “5.2.10 Changing the oil”

5.2.6 Replacing the lift piston

• Loosen the top nut.
• Remove the lifting piston.
• If necessary, empty the oil and fit a new collar, support ring and lock-
ing ring.
• Fill with oil. See section “5.2.10 Changing the oil”
• Fit the top nut and lifting piston.
• Tighten the top nut (Tightening torque 300 Nm)
• Bleed. See section “5.2.10 Changing the oil”

5.2.7 Replacing the lowering valve

• Lay the pallet 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 “5.2.10 Changing the oil”

5.2.8 Replacing the cone

• Pump up the truck to maximum height.
• Lay the pallet truck on its side.
• Remove the screw, washer, spring and cone.
• Fit a new cone, spring, a new washer and screw. (Tightening torque
35 Nm)
• Bleed. See section “5.2.10 Changing the oil”

© BT Europe AB Service Manual LHM230, LHM230P 19

Hydraulics unit
Component parts
T-code Valid from serial number Date Order number
360, 726 3.121.000- 2005-05-01 221127-040

5.2.9 Replacing the quick valve

• Pump up the truck to maximum height.
• Lay the pallet truck on its side.
• Remove the quick valve.
• Fix a new quick valve. (Tightening torque 35 Nm)

5.2.10 Changing the oil

Use hydraulic oil with viscosity 32. Use oil with viscosity 10 in the event
of operating in a cold store.
Oil quantity 0.34 litres.
• Remove the lifting piston as above, but do not remove the support
ring and collar. If the top nut has to be removed, metal chips may en-
ter the oil container. These must be removed before the new oil is
added.
• Drain the old oil.
• Fill with new oil.
NOTE!
When replacing the oil ensure that no impurities enter into the oil con-
tainer or oil as this may damage the hydraulics.
• Replace the lifting piston and tighten the top nut. (Tightening torque
300 Nm)
• Bleed the hydraulics by pumping a few strokes in the lowered posi-
tion.
• Loosen and then tighten the oil level screw to equalise system pres-
sure.

20 Service Manual LHM230, LHM230P © BT Europe AB

 Hydraulics unit
Component parts
Order number Date Valid from serial number T-code
221127-040 2005-05-01 3.121.000- 360, 726

5.2.11 Hydraulic diagrams

LHM230, LHM230P

LYFTCYLINDER/
LIFT CYLINDER
PUMPCYLINDER/
PUMP CYLINDER

TANK
SÄNK POSITION/LOWERING POSITION
RESERVOIR
NEUTRAL POSITION
LYFTPOSITION/ LIFTING POSITION

LHM230Q
LYFTCYLINDER QUICK/ LYFTCYLINDER STD/
LIFT CYLINDER QUICK LIFT CYLINDER STD

TRYCKUTJÄMNING/
PRESSURE BALANCER
PUMPCYLINDER/
PUMP CYLINDER

150 KG

SÄNK POSITION/ LOWERING POSITION TANK

RESERVOIR
NEUTRAL POSITION
LYFTPOSITION/ LIFTING POSITION

LHM230O

LYFTCYLINDER/
LIFT CYLINDER
PUMPCYLINDER/
MAXLAST/OVERLOAD PUMP CYLINDER

TANK
SÄNK POSITION/LOWERING POSITION
RESERVOIR
NEUTRAL POSITION
LYFTPOSITION/LIFTING POSITION

© BT Europe AB Service Manual LHM230, LHM230P 21

Hydraulics unit
Component parts
T-code Valid from serial number Date Order number
360, 726 3.121.000- 2005-05-01 221127-040

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22 Service Manual LHM230, LHM230P © BT Europe AB

 Chassis
General
Order number Date Valid from serial number T-code
221127-040 2005-05-01 3.121.000- 360, 726

6- Chassis

6.1 General
A complete chassis consists of:
• Chassis
• Torsion tube
• Torsion tube axle
• Pressure rods
• Wheel forks
• Front climbing wheels (only single design)

6.1.1 Replacing torsion tubes

• Remove the locking pin and torsion tube axle.
• Turn the chassis upside down.
• Remove the pressure rod at the torsion tube.
• Reassemble in reverse order.

6.1.2 Replacing the pressure rod

• Remove the locking pin and axles.
• Remove the pressure rod at the torsion tube and wheel fork.
• Reassemble in reverse order.

6.1.3 Replacing the wheel fork

• Remove the locking pin and axles.
• Remove the wheel fork.
• Reassemble in reverse order.

6.1.4 Replacing the bogie fork

• Remove the locking pin and axle.
• Remove the bogie fork.
• Reassemble in reverse order.

6.1.5 Replacing the fork wheel

• Remove the locking pin and axle.
• Remove the wheel.
• Reassemble in reverse order.

© BT Europe AB Service Manual LHM230, LHM230P 23

Chassis
General
T-code Valid from serial number Date Order number
360, 726 3.121.000- 2005-05-01 221127-040

This page is intentionally left blank

24 Service Manual LHM230, LHM230P © BT Europe AB

 Specific service instructions for LHM230P
Component parts
Order number Date Valid from serial number T-code
221127-040 2005-05-01 3.121.000- 360, 726

7- Specific service instructions for

LHM230P

7.1 Component parts

5
1 6
7
2

3 8
4

10
9
11

11 12

35
13

14 15

21
22 17
23
24
18

25 26 20
35 27 28
11
30
29 31

36 38 39 32
37 42
43
48 33

44
45 34
40 46

47
41

© BT Europe AB Service Manual LHM230, LHM230P 25

Specific service instructions for LHM230P
Component parts
T-code Valid from serial number Date Order number
360, 726 3.121.000- 2005-05-01 221127-040

Pos. Designation
1 Handle
2 Axle
3 Catch
4 Rivet
5 Screw
6 Lock
7 Logotype
8 Handle
9 Screw
10 Cover
11 Guide
12 Valve bar (complete)
13 Wire (complete)
14 Axle
15 Locking pin
16 Bushing
17 Locking pin
18 Axle
19 Roller
20 Bushing
21 Locking ring
22 Washer
23 Axle
24 Bushing
25 Roller (complete)
26 Locking pin
27 Axle
28 Screw
29 Lever arm (complete)
30 Bracket

26 Service Manual LHM230, LHM230P © BT Europe AB

 Specific service instructions for LHM230P
Component parts
Order number Date Valid from serial number T-code
221127-040 2005-05-01 3.121.000- 360, 726

Pos. Designation
31 Nut
32 Bushing
33 Driver (complete)
34 Clamp
35 Sign
36 Cover
37 Screw
38 Bearing
39 Wheel rim
40 Direction lever
41 Screw
42 Roller
43 Spring
44 Bushing
45 Locking ring
46 Axle
47 Hub (complete)
48 Wheel (complete)

© BT Europe AB Service Manual LHM230, LHM230P 27

Specific service instructions for LHM230P
Changing wire
T-code Valid from serial number Date Order number
360, 726 3.121.000- 2005-05-01 221127-040

7.1.1 Dismantling/Assembly
• Place the truck with its right side facing the floor and dismantle on
both sides of the hydraulics in the following order:
• Cover (36)
• Locking ring (45)
• Screw (37), use the start-up help function for resistance when loos-
ening the wheel nuts.
• Wheel complete (48)
• Wheel rim (39)
• Direction dial (40)
• Roller (42)
• Spring (43), please note the position of the spring
• Screw (41)
• Hub (47)
• Clamp (34)
• Fix 2 new hubs on the axle (46). Place the right hand hub in the
downward position. Ensure that the bushings slide on the axle (tow
bar loses return force).
• Fix all other parts. Check the start-up help function and adjust the
wire if necessary.
The tightening torque for screws (41) and (37), should be 23 Nm.

7.2 Changing wire

• Remove the wire and its casing (13) from the tow bar, leave the low-
er part of the wire till later.
• Fix the new wire to the tow bar using the two upper spaces (11).
• Remove locking pin (26) and the two axles (27).
• Remove the bracket (30) from the lever arm (29).
• Remove the cover (36) on the wheel.
NOTE!
The truck should be placed with the loosened wheel cover in the up-
wards position.
Warning!
The truck could fall if it is not secured.
• Loosen locking ring (45).
• Lift the wheel (48) slowly. The four rollers (42) will then be freed from
the direction dial (40). Please keep in mind the released energy from
the spring (43).
• Remove the wire from the clamp (34).

28 Service Manual LHM230, LHM230P © BT Europe AB

 Specific service instructions for LHM230P
Changing wire
Order number Date Valid from serial number T-code
221127-040 2005-05-01 3.121.000- 360, 726

• Fix the new wire from the lower clamp through (11) on the tow bar.
Replace the bracket (30) and fix the axle and locking pin.
• Put the handle in neutral mode (1). Fix the wire, clamp, spring, direc-
tion dial and rollers.

7.2.1 Fixing the spring

The spring (43) must be fixed on this side of the direction dial to work
properly and to provide resistance for the wire.

7.2.2 Replacing the bushing

It can be difficult to adjust the neutral mode on LHM230P if the bushing
(44) is worn. Replace the bushing and adjust the wire’s neutral mode.

7.2.3 Adjusting the functions on the

LHM230P
If the truck chugs when the handle is in neutral mode, push the handle
to neutralise the function. Check to see if the wheels lock when pushing
or pulling the truck with the tow bar.
If a problem arises when pulling the truck, there may not be enough ten-
sion in the wire. Tighten the wire by screwing the cable sleeve half a
turn in the downward position, then test the function again. Tighten the
nut.
If a problem arises when pushing the truck, there may be too much ten-
sion in the wire. Loosen the wire a little by screwing the cable sleeve
upward half a turn, then test the function again. Tighten the nut.

Nut

Cable sleeve

© BT Europe AB Service Manual LHM230, LHM230P 29

Specific service instructions for LHM230P
Changing wire
T-code Valid from serial number Date Order number
360, 726 3.121.000- 2005-05-01 221127-040

This page is intentionally left blank

30 Service Manual LHM230, LHM230P © BT Europe AB

 Troubleshooting
Troubleshooting chart
Order number Date Valid from serial number T-code
221127-040 2005-05-01 3.121.000- 360, 726

8- Troubleshooting

8.1 Troubleshooting chart

Error Cause Action

LHM230
The pump does not per-
form complete strokes
Lifting, neutral and lower-
ing mode do not function
correctly
The forks lower after each
pump stroke
It is not possible or it is too
slow to lower
The forks sink when the
lowering handle is in neu-
tral mode
When the lowering handle
is in neutral mode pumping
occurs.
Oil leakage from the lower-
ing valve
Air in hydraulics system
The hydraulics contain too lit-
tle oil
The hydraulics contain too lit-
tle oil
The lowering valve does
not close properly
Leakage past the reverse
valve
Air in the hydraulics system
Leakage at the valve cone
The lowering valve does not
open properly
The lowering valve does not
close properly
Leakage at the valve cone
Leakage past gasket ring in
the bottom plate
Valve ball not affected
The gasket ring is worn or
damaged
Pump 5 strokes with an open lower-
ing valve
Refill oil to level with the refill screw
Refill oil to level with the refill screw
Adjust the valve chain’s extension
using the adjusting screw
Change the ball, and the gasket kit for
the lowering valve. Consists of a col-
lar, O-ring and a washer.
Pump 5 strokes with an open lower-
ing valve
Switch seat, change valve cone as
well as washer.
Adjust the valve chain’s extension
using the adjusting screw
Adjust the valve chain’s extension
using the adjusting screw
Switch seat, change valve cone as
well as washer.
Replace collar as well as O-ring.
Adjust the valve chain’s extension
using the adjusting screw
Replace the gasket kit for the lower-
ing valve

© BT Europe AB Service Manual LHM230, LHM230P 31

Troubleshooting
Troubleshooting chart
T-code Valid from serial number Date Order number
360, 726 3.121.000- 2005-05-01 221127-040

Error Cause Action

LHM230P
The lift or the start-up help
function does not work
properly
The start-up help function
is not activated when
asked for
Wire breakage on the
start-up help function
Lift and start-up help has
been selected simultaneously
Stretched wire
Overload
Return the unwanted function to neu-
tral mode
Adjust the wire stretching with the
adjusting screw
Place clamp (1) in neutral mode for
emergency operation and replace-
ment of wire

LHM230Q
Lifts as a standard version The quick valve is not work-
ing
The ball is missing from the
inner ring or it is not in posi-
tion
Malfunction on the inner ring
Sinking Leakage in the inner tube
gasket
Leakage at ball
1
Replace valve details
Put the ball back or alternatively
replace with a new ball
Replace the inner ring and ball
Replace collar and O-ring
Switch ball seat, change ball

32 Service Manual LHM230, LHM230P © BT Europe AB

 Troubleshooting
Troubleshooting chart
Order number Date Valid from serial number T-code
221127-040 2005-05-01 3.121.000- 360, 726

8.1.1 Troubleshooting hydraulics LHM230

The hydraulics fall

Pump unit is Outside Adjust Punch a new Change

lowering cleaning lowering rod cone valve oil & U-ring
No function seat

NO
NO

Pump unit OK Pump unit OK Pump unit OK

YES NO
YES

YES

Return to Change
customer pump unit

Leakage

Pump unit is Establish &

lowering Outside locate leakage YES
No function cleaning
YES

YES

YES YES
YES
Overload Weld leakage
valve leakage

Top nut Lowering valve Pump piston Quick-lift valve

leakage leakage leakage leakage

YES YES YES YES

See schedule, See schedule, See schedule,

See schedule,
“Top nut “Lowering valve “Quick-lift valve
“Sealing ring leakage”
leakage” leakage” leakage”

YES Change pump YES

unit

© BT Europe AB Service Manual LHM230, LHM230P 33

Troubleshooting
Troubleshooting chart
T-code Valid from serial number Date Order number
360, 726 3.121.000- 2005-05-01 221127-040

Leakage, lowering valve

Outside
Leakage pump Change
cleaning and
piston lowering valve
inspection

Return to Change
YES Pump unit OK NO pump unit
customer

Leakage top nut

Leakage Outside
Change O-ring
top nut cleaning and
and scraper
inspection

Return to Change
YES Pump unit OK NO pump unit
customer

34 Service Manual LHM230, LHM230P © BT Europe AB

 Troubleshooting
Troubleshooting chart
Order number Date Valid from serial number T-code
221127-040 2005-05-01 3.121.000- 360, 726

Malfunctioning quick lift function

Change ball
No quick lift or Outside Change quick Pour out and guide
only standard cleaning lift valve the oil and fill up with
lift
new oil

NO

Pump unit OK Pump unit OK

YES

Return to Change
customer pump unit

The quick lift hydraulics are sinking

Pump unit is Punch a new ball

Change oil, U-ring seat and change
lowering Outside cleaning
and O-ring ball
No function

Return to Change
YES Pump unit OK NO
customer pump unit

Leakage at the quick lift valve

Leakage Outside cleaning Change

quick lift valve and inpection quick lift valve

Return Change
to customer YES Pump unit OK NO pump unit

© BT Europe AB Service Manual LHM230, LHM230P 35

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