Service Manual En: LHM200SC, LHM200SCQ

Service Manual en
LHM200SC, LHM200SCQ
Valid from serial number: 3.164.374-
Order number: 225371-040

Issued: 2005-11-01 ITS
© BT Europe AB
Issue date Resp. Changes
2005-11-01 ITS Completely new issue
This manual covers following truck models:
T-code Model Serial number

805 LHM200SC 3.164.374-
813 LHM200SCQ 3.164.374-
© BT Europe AB Service Manual LHM200SC, LHM200SCQ Approved by: Fredrik Moborg

Table of contents
Order number Date Valid from serial number T-code
225371-040 2005-11-01 3.164.374- 805, 813
1- Table of contents
General Product Information 1
Presentation of the Truck .............................. 1

1.1.1 Intended application of the truck ........................ 1
1.1.2 Prohibited use of the truck .................................. 1
Truck Data..................................................... 2
Truck Dimensions.......................................... 2
LHM200SC ......................................................... 3
Maintenance 5
General ......................................................... 5
Safety rules for servicing work....................... 6

2.2.1 Observe the following for service and maintenance 7
2.2.2 Necessary special tools ...................................... 7
2.2.3 Information plates ............................................... 7
Cleaning, washing and lubrication................. 8
2.3.1 Lubrication chart ................................................. 8
Lubrication diagram ............................................ 9
Tow bar 11
General ....................................................... 11
3.1.1 Dismantling the tow bar .................................... 11
3.1.2 Replacing the lowering handle ......................... 12
3.1.3 Replace the press roller and valve bar. ............ 12
© BT Europe AB Service Manual LHM200SC, LHM200SCQ 1

Table of contents
T-code Valid from serial number Date Order number
805, 813 3.164.374- 2005-11-01 225371-040
Hydraulics unit 13
General ........................................................ 13
4.1.1 Replacing the hydraulics ................................... 13
4.1.2 Replacing the steering wheel ............................ 13
4.1.3 Replacing the steering wheel axle .................... 14
4.1.4 Replacing thrust bearings ................................. 14
4.1.5 Replacing the pump piston ............................... 14
4.1.6 Replacing the lift piston ..................................... 15
4.1.7 Replacing the lowering valve ............................ 15
4.1.8 Replacing the cone ........................................... 15
4.1.9 Replacing the quick valve ................................. 15
4.1.10 Changing the oil ............................................... 16
4.1.11 Hydraulic diagrams ........................................... 17
LHM200SC ....................................................... 17
LHM200SCQ .................................................... 17
Chassis 19
General ........................................................ 19
5.1.1 Replacing torsion tubes .................................... 19
5.1.2 Replacing the push rod ..................................... 19
5.1.3 Replacing the wheel fork .................................. 19
5.1.4 Replacing the bogie fork ................................... 20
5.1.5 Replacing the fork wheel .................................. 20
5.1.6 Dismantling upper/lower forks .......................... 20
Scale 21
General ........................................................ 21
6.1.1 Mechanics ......................................................... 21
6.1.2 Load cells .......................................................... 22
6.1.3 Indicator ............................................................ 23
Display - symbols .............................................. 23
Display indications ............................................ 24
Touch panel ...................................................... 24
6.1.4 Battery .............................................................. 25
Changing battery .............................................. 25
Function ....................................................... 26
6.2.1 Dismantling of scale .......................................... 28
Options ........................................................ 29
6.3.1 Printer ............................................................... 29
Function ............................................................ 29
Dismantling ....................................................... 30
6.3.2 Legal for trade ................................................... 31
2 Service Manual LHM200SC, LHM200SCQ © BT Europe AB

Table of contents
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Wiring and parameters 32
Component configuration ............................ 32

7.1.1 Wiring instructions 2100B ................................. 33
7.1.2 Wiring instructions 2100N ................................ 34
7.1.3 Wiring instructions 2100N with RS-board ......... 35
7.1.4 Wiring instructions calibration board ................ 36
7.1.5 Wiring instructions load cell .............................. 38
Specification ..................................................... 38
7.1.6 Wiring instructions level switch ......................... 39
7.1.7 Wiring instructions printer ................................. 40
Parameter settings ...................................... 41
7.2.1 Changing parameters ....................................... 41
7.2.2 Parameter list ................................................... 42
7.2.3 Factory settings ................................................ 45
Troubleshooting 47
Troubleshooting hydraulics ......................... 47

8.1.1 Troubleshooting chart ....................................... 47
8.1.2 Troubleshooting hydraulics .............................. 49
The hydraulics is not keeping pressure ............ 49
Leakage ............................................................ 49
Leakage, lowering valve ................................... 50
Leakage top nut ................................................ 50
Malfunctioning quick lift function ....................... 51
The quick lift hydraulics are lowering under pres-
sure .................................................................. 51
Leakage at the quick lift valve .......................... 51
Troubleshooting scale ................................. 52
Calibration of scale 59
Calibrating the pallet truck scale.................. 59

9.1.1 Defining zero .................................................... 59
9.1.2 Single point calibration ..................................... 60
Deletion (resetting to zero) of earlier calibrated
points ................................................................ 60
Single point calibration ..................................... 61
Multi-point calibration ....................................... 61
9.1.3 Defining full scale ............................................. 63
To view the calibration number ........................ 63

Table of contents
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Troubleshooting guide 65
10.0.1 Possible problems ............................................ 66
10.0.2 Description of problem and where to look for causes 67
10.0.3 Explanation of possible causes and how to fix them 70
1. Check battery and charger ........................... 70
2. Check mechanism ........................................ 70
3. Check loadcells ............................................. 71
4. Check cabling and load cell calibration board ... 73
5. Calibrate load cell ......................................... 73
6. Check indicator ............................................. 75

General Product Information
Presentation of the Truck
225371-040 2005-11-01 3.164.374- 805, 813
1- General Product Information

1.1 Presentation of the Truck
LHM200SC is a truck with integrated scale that combines the control-
ling function of a very accurate weighing system with the mobility and
the flexible availability of a hand pallet truck. You weigh pallets and con-
tainers during transport, at the place of the handling. You save time
when checking incoming and outgoing goods and during dosing and
filling processes.
LHM200SCQ is suitable for users handling a large proportion of pallets.
The forks reach the pallet on the first stroke of the pump and lift it on the
second.
The truck has a maximum lift capacity of 2000 kg.
1.1.1 Intended application of the truck

The truck must only be used on a hard and even surface e.g. concrete
or asphalt.
LHM200SC and LHM200SCQ can be used for following applications:
- To determine the exact load weight.
- To avoid overloading lorries.
- Checking deliveries by weight.
1.1.2 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
- in environments with temperatures below 0° C

Truck Data
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1.2 Truck Data

The table provides information about certain technical product data
which may be useful for day-to-day truck operation.
Technical data
Rated lifting capacity 2000 kg
Weight 105 kg
Lifting height 205 mm
Turning radius (Wa) 1405 mm
Steering wheel Ø 175 x 60
Fork wheels, single/bogie Ø 85 x 100 /
Ø 85 x 75
Pumping power, rated load 31 kg
Traction power 17 kg*)
*) Calculated using a nominal load on a level and dry concrete floor
1.3 Truck Dimensions
Dimensions
x Front axle for back of fork 970 mm
y Wheel base 1220 mm
h3 Lift height 205 mm
h14 Handle height in neutral mode 1220 mm
h13 Height above lowered fork 90 mm
l2 Truck length including back of fork 370 mm
b1 Chassis width 520 / 685 mm
s Fork thickness 65 mm
e Fork width 170 mm
l Fork length 1150 mm
b5 Width over fork 540 / 700 mm
m2 Ground clearance, centre of wheel 25 mm
base
Ast Aisle width requirement, min. Pallet 1770 mm
size 800x1200 mm
Wa Turning radius 1405 mm

Truck Dimensions
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LHM200SC
l
300
h3
200 130
h13
200 80
300
h3
h14
185
h13
s
m2
y
140
85
l2 l
e
b1
b5
wa

Truck Dimensions
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This page is intentionally left blank

Maintenance
General
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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 operator’s manual and spare parts catalogue to hand.
2.1 General
• Ensure that the truck undergoes regular maintenance as per Lubri-
cation Diagram to prevent function errors and accidents.
• Only qualified and trained personnel are permitted to maintain, ad-
just and repair the truck.
• Only use BT approved spare parts during service and repairs.
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 function is not permitted.
Daily inspection/safety check:
Inspection Action
Steering Function
Scale Function
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

Maintenance
Safety rules for servicing work
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2.2 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 may not 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.

Maintenance
Safety rules for servicing work
225371-040 2005-11-01 3.164.374- 805, 813
2.2.1 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 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.
• When changing wheel, always change both wheels. Concerns both
driving wheels and forkwheels.
It may be useful to have the driver’s manual and spare parts catalogue
to hand.
2.2.2 Necessary special tools

Drift diameter: 3 mm, 4,5 mm 7,3 mm
Special spanner for top nuts, item no. 08-7245
Special drift for beam seat, item no.: 08-15843
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
2.2.3 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.

Maintenance
Cleaning, washing and lubrication
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2.3 Cleaning, washing and lubrication

Cleaning and washing the truck is important for the reliability of the
truck.
• Carry out general cleaning and washing weekly.
• Cleaning with pressorised water or air is not allowed.
NOTE!
The electrical system in the scale can be damaged, clean it gentle.
After cleaning, the truck must be lubricated according to the lubrica-
tion diagram and table below.
Lubrication is recommended at least every other year and always after
washing.
2.3.1 Lubrication chart
Lubrication Number of lubri- Lubricant

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

Maintenance
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Lubrication diagram
Q8 Haydn 32 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

Maintenance
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Tow bar
General
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3- Tow bar
3.1 General
A complete tow bar consists of:
• Bar
• Handle
• Lowering handle
• Press roller
• Valve bar
• and more...
3.1.1 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 catch 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.

Tow bar
General
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3.1.2 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.
3.1.3 Replace the press roller and valve bar.

• Dismantle the tow bar from the hydraulics. See section “3.1.1 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.

Hydraulics unit
General
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4- Hydraulics unit
4.1 General
The hydraulics unit consists of:
• The hydraulic body
• Pressure plate
• Thrust bearing
• Steering wheel
• Pump piston
• Lift piston
• Lowering arm
• Lowering valve
• and more...
4.1.1 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 top cover.
• 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.
4.1.2 Replacing the steering wheel

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

Hydraulics unit
General
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4.1.3 Replacing the steering wheel axle

• Remove the steering wheel. See section 4.1.2
• Grind away the paint 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.
4.1.4 Replacing thrust bearings

• Remove the steering wheel. See section 4.1.2
• Remove the steering wheel axle. See section 4.1.3. 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.
4.1.5 Replacing the pump piston

• Truck in lowered position.
• Remove tow bar, see section 3.1.1
• 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 denatured alcohol.
• Fit a new sealing ring, new pump piston, spring, washer and locking
ring.
• Fit the tow bar.
• Bleed. See section “4.1.10 Changing the oil”

Hydraulics unit
General
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4.1.6 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 “4.1.10 Changing the oil”
• Fit the top nut and lifting piston.
• Tighten the top nut (Tightening torque 300 Nm)
4.1.7 Replacing the lowering valve

• Remove the lowering arm.
• Unscrew the lowering valve.
• Fit a new lowering valve (Tightening torque 35 Nm)
• Fit the lowering arm.
4.1.8 Replacing the cone

• Pump up the truck to maximum height.
• Remove the screw, washer, spring and cone.
• Fit a new cone, spring, a new washer and screw. (Tightening torque
35 Nm)
4.1.9 Replacing the quick valve

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

Hydraulics unit
General
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4.1.10 Changing the oil

Use hydraulic oil with viscosity 32.
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.

Hydraulics unit
General
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4.1.11 Hydraulic diagrams

LHM200SC
LYFTCYLINDER/
LIFT CYLINDER
PUMPCYLINDER/
PUMP CYLINDER
TANK
SÄNK POSITION/LOWERING POSITION
RESERVOIR
NEUTRAL POSITION
LYFTPOSITION/ LIFTING POSITION
LHM200SCQ
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

Hydraulics unit
General
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Chassis
General
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5- Chassis
5.1 General
A complete chassi consists of:
• Chassis
• Torsion tube
• Torsion tube axle
• Pressure rods
• Wheel forks
• Front climbing wheels (only single design)
• Upper/lower forks
• and more...
5.1.1 Replacing torsion tubes

• Remove the locking pin and torsion tube axle.
• Turn the chassis upside down.
• Remove the push rod at the torsion tube.
• Grease the system.
5.1.2 Replacing the push rod

• Remove the locking pin and axles.
• Remove the push rod at the torsion tube and wheel fork.
5.1.3 Replacing the wheel fork

• Remove the locking pin and axles.
• Remove the wheel fork.

Chassis
General
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5.1.4 Replacing the bogie fork

• Remove the bogie fork.
5.1.5 Replacing the fork wheel

• Remove the wheel.
5.1.6 Dismantling upper/lower forks

• Place the truck on the side.
• Remove the four bolts on the underside of the forks that holds the
fork shoe.
• Place the truck on its wheels again and then lift off the upper fork.
When assembling, it’s important that no part of the lower fork, pushrod
or load wheel holder of the pallet truck have mechanical contact with
the upper fork (weighing part).

Scale
General
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6- Scale
6.1 General
The scale has a accuracy with maximum error 0.1% of the applied load.
All the components are developed for mobile use, compact and highly
resistant against shocks and vibrations.
The pallet truck scale consists of the following components:
• Mechanics
• Load cells
• Indicator
• Battery with charger
• and more...
6.1.1 Mechanics
The mechanical parts is the pallet truck chassis with a special fork con-
struction. For the weighing system the pallet truck fork consist of two
parts:
• The lower forks
• The upper forks
Between the lower fork construction and the upper fork, sensors/load
cells are mounted that will sense the force placed on the upper fork.
It is most important that all forces pass through the load cells and that
no part of the basic fork, pushrod or load wheel holder of the pallet truck
have mechanical contact with the upper fork (weighing part).

Scale
General
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6.1.2 Load cells

One of the most important components of the weighing pallet truck are
the load cells.
A load cell is a rectangular steel component, built in the lower forks. The
load cell has a deformation 0.07mm under a load of 1000 kg. This
deformation depends on the weight of the load. In the load cell, electri-
cal resistor, called strain gauges, are glued to the load cell body.
Fig. 1 Strain gauge
The electrical resistance of the strain gauges in the load cells changes
linearly with the deformation of the load cell.
The load cell is connected with 4 wires to the indicator. Two wires, black
and red, supply an input voltage to the load cell. This voltage to the load
cells is called excitation. The output voltage of the load cell, called "sig-
nal", green and white wires, depends on the strain gauge resistance
change.
With a maximum load on the load cells (example: 4 x 1000 kg), the sig-
nal voltage (caused by the change in resistance) is approximately 0.01
Volt. The signal voltage at 100 kg is only 0.0002 Volt. The signal change
level with 1 kg weight change is only 0.000002 Volt. When working with
such small electrical signals, the cabling has to be 100%. Therefore,
the signal is transmitted from the load cells to the indicator via a special
cable. All connections have to be soldered and humidity otherwise cor-
rosion of contacts will cause instability in the reading.

Scale
General
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6.1.3 Indicator
The indicator operates like a ohm/voltmeter. The change in resistance
is measured, translated and displayed as a weight. The indicator is
more accurate then a multimeter but in a very limited voltage range. It
measures micro voltages at extreme high accuracies, independent
from temperature changes and distortion of radio frequencies.
The indicators have a power supply of 12 V. The power consumption of
the indictor is below 20 mA.
Because of the extremely small signal levels the board is very sensitive
to humidity and contact with chemical substances that will influence the
solder contacts.
Display - symbols
The weighing system (including load) is stable
The weight shown is negative
NET The display shows the net weight

Scale
General
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Display indications
The minus sign lights in the display. The following indications can be
shown in the display:
HELP 1 The weighing system has been overloaded.

HELP 2 Taring of negative weight.
HELP 3 Negative signal from the load cell on AD con-
verter / tilted position.
HELP 4 The tare value entered (manually) is too high.
Press key nPT again to delete this help message
and key in a lower tare value.
HELP 7 Signal from the load cell on AD converter is too
high.
LO-BA The battery voltage level is running low. The bat-
tery has to be charged.
Touch panel
Operational func- Entry function

tion
Zero setting and auto- Confirm and digit to the left
matic tare
Tare entry Decreasing flashing digit
Totalising Increasing flashing digit
On / off Clear
NOTE
Operation of a key is not accepted unless the weighing system is sta-
ble (and the sign "load stable" lights up). This means that the indica-
tor only executes commands with a stable load.
WARNING!
When the weighed load surpasses the pre-set maximum, the display
shows: "HELP1". In order to prevent damage to the indicator or load
cells, the weighing system must be unloaded immediately.

Scale
General
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6.1.4 Battery
The battery module contains a sealed lead acid battery of 12 V and 1.2
Ah. This means that with a power consumption of 20 mA, the working
time should be 60 h.
Display indicates “LO-BA” when time to charge.
The charger charges with 300 mA. The battery should be full after 6
hours. However, it can be wise to leave the battery connected to the
charger for a longer time.
Changing battery
Exchanging a battery is easy. Just lift the grey latch and the battery
module clicks out.

Scale
Function
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6.2 Function
The indicator board is powered by the 12 V battery module.
The indicator is connected by 4 wires to each load cell. Two wires, black
and red, are supplying an input voltage to the load cell, called “excita-
tion”.
Each load cell carries a resistor, called “strain gauge”. Bending of the
load cell by applying weight, causes a change of resistance in the strain
gauge, resulting in a changing output voltage.

Scale
Function
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The output voltage of the load cell, back to the indicator via green and
white wires, is called “signal” and depends on the applied weight.
The indicator operates like a Volt or Ohmmeter: the change in signal is
measured and translated into a weight.
By calibrating the scale, the indicator is told which load cell output volt-
age represents 0 kg weight, 200 kg, 500 kg, 2000 kg. Calibration data
are stored in the EEPROM on the board and used by the indicator until
recalibration.
In between the indicator and the load cells is a calibration board: by

adjusting the input voltage of individual load cells via potentiometers,
the four corners of the scale can be fine-tuned in relation to each other.

Scale
Function
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6.2.1 Dismantling of scale

• Undo two bolts to remove the indicator shield and get easy access to
all wiring and modules.
• Load cell calibration board slides out for easy adjustment of corner
weights.
• Four more bolts to undo indicator module.
• Electronics board clicks in and out of module.

Scale
Options
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6.3 Options
6.3.1 Printer
The pallet truck scale can be equipped with a thermal printer. Data
printed on the ticket are: gross, net and tare weight, total weight (when
the weight of several pallets are added up to a total weight per ship-
ment, order or client) with sequence number.
Function
The printer module receives power and data from the indicator board.
Printer is powered by the indicator only while printing.

Scale
Options
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Dismantling
• Undo two screws to dismantle the printer module.
• Click out the printer module by pushing the four clasps with your
screw driver.
• Pull off the connector that links the printer with the indicator board.

Scale
Options
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6.3.2 Legal for trade

When weighing for trade purposes, i.e. invoicing based on weight, the
scale has to be "legal for trade"
First, it has to be built out of certified components. Second, it has to be
tested, stamped and sealed by a certified metrological organisation.
After re-calibration a random number is generated and memorised by
the electronics. This audit trail number is shown on the display during
start up and shall correspond with a trail number on an external sticker.
Thus the accuracy of the scale is guaranteed and verifiable for the user
and his client.
This means that a service technician is not allowed to break the seals,
re-calibrate the scale or change metrological parameter settings unless
he is approved by a certified organisation.
Control of the weighing system before and after a service work is
required! With any suspicions of the accuracy of the weighing system,
a metrological official will have to be called in for re-certification.
Important
Legal for trade systems may only be recalibrated by representatives
of a certified metrological institute.
Theese representatives, approved of working with legal for trade, ex-
ist in every country where also the directions of recalibration frequen-
cy differs.

Wiring and parameters
Component configuration
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7- Wiring and parameters
7.1 Component configuration

LHM200SC:
- 2100B
- Load cell
- Calibration board
LHM200SC with printer:
- 2100N with RS-board
- Load cell
- Calibration board
- Printer
LHM200SC legal for trade:
- 2100N
- Load cell
- Calibration board
- Level switch
LHM200SC legal for trade with printer:
- 2100N with RS-board
- Load cell
- Calibration board
- Printer
- Level switch

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7.1.1 Wiring instructions 2100B

Used in standard unit, not legal for trade and no printer.
Pin Function Colour

1 Load cell - excitation, Brown
0V
2 Load cell - signal White
3 Load cell + signal Green
4 Load cell + excitation, Yellow
2.5 V
5 Not used
6 Power supply, ground, Black
0V
7 Power supply, +12 V Red
8 Not used
9 Not used
10 Not used

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7.1.2 Wiring instructions 2100N

Used in systems that are legal for trade.
Pin Function Colour Remarks

1 Load cell - excitation, 0 V Brown
2 Load cell - sense Pink Approved systems only and
if cable > 1 m
5 Load cell + sense Red Approved systems only and
if cable > 1 m
6 Load cell + excitation, 2.5 V Yellow
7 Load cell cable shield Approved systems only
8 Power supply, ground, 0 V Black
10 Not used
11 Level switch ground Blue Approved systems only
12 Not used
13 Not used
14 Not used
15 Not used
16 Not used
17 Not used
18 Level switch input Brown Approved systems only

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7.1.3 Wiring instructions 2100N with RS-board

Used in system with printer.

1 Load cell - excitation, Brown
2.5 Vac
2 Load cell - sense Pink Approved systems only and
if cable > 1 m
5 Load cell + sense Red Approved systems only and
if cable > 1 m
6 Load cell + excitation, Yellow
2.5 Vac
7 Load cell cable shield Approved systems only
8 Power supply, ground, 0 V Black
10 Printer, ground, 0 V Black With printer option only
11 Printer power supply, +12 V Red Only turned on when printer
command is given
12 RxD, receive data
13 CTS, clear to send "Printer or RS 232 output
only; connected to DTR on
printer; See Wiring instruc-
tions printer"
14 TxD, transmit data "Printer or RS 232 output
only; connected to RxD on
printer; See Wiring instruc-
tions printer"

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15 RTS, ready to send RS 232 output only; for
handshake; connected to
CTS on printer
16 Level switch ground Blue Approved systems only -
printer GND cable also
attached here
17 Level switch input Grey Approved systems only
7.1.4 Wiring instructions calibration board
Connector 1
F N/A N/A N/A
E N/A N/A N/A
D Excitation of load cell D Red
C Excitation of load cell C Red
B Excitation of load cell B Red
A Excitation of load cell A Red
B Excitation (-) of all load Black All wires have to be con-
cells nected together
Y Signal (-) of all load cells White All wires have to be con-
nected together
G Signal (+) of all load cells Green All wires have to be con-
nected together
- Power supply, ground, 0 Black Only systems with inte-
Vdc grated indicator
+ Power supply, +12 Vdc Red Only systems with inte-
grated indicator

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Potentiometers 2
A Load cell A See drawings below
B Load cell B See drawings below
C Load cell C See drawings below
D Load cell D See drawings below
E N/A N/A N/A
F N/A N/A N/A
Connector 3
B Excitation (-) Brown
R Excitation (+) Yellow
Y Signal (-) White
G Signal (+) Green
- Power supply, ground, 0 Blue
Vdc to the indicator
+ Power supply, +12 Vdc to Red
the indicator

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7.1.5 Wiring instructions load cell
Specification
• Nickel plated or stainless.
• Sensitivity 3mVolt per Volt.
• In & output resistance 350 Ohm.
Function Colour
Excitation + Red
Excitation - Black
Signal - White
Signal + Green

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7.1.6 Wiring instructions level switch
Specification
• Switches off at an angle of 2 degrees.
• Accuracy/hysteresis in 0.5 degree.
• Maximum switching value 12 Vdc at 0.5 Amp.
WARNING!
Be careful with the cable from the switch, once forced, the switch
needs to be replaced.
Do not tighten the screws too tight. This will break the components in-
side.
Function Colour
Level switch input Blue
Ground Brown

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7.1.7 Wiring instructions printer
Specification
• Thermal printer.
• Paper is easy to exchange.
• Ink cassette not necessary.

+ Printer power Red Connected to indicator
- Printer power Black Connected to indicator
(switched power)
1 GND: ground Red See indicator wiring instruc-
tions
2 Not used
3 RxD: receive data Green Connected to TxD connector
on indicator
4 Not used
5 DTR: data terminal ready White Connected to CTS connector
on indicator

Parameter settings
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7.2 Parameter settings
7.2.1 Changing parameters

• Switch off the indicator.
• To activate the parameter menu, press the on/off-key for 23 sec-
onds.
- The indicator shows: "P 01".
• Press the “0/T” key.
- The indicator shows the current value of parameter P 01.
• Use keys “up” and “down” to change the current value.
• Confirm with “0/T” key.
- The indicator shows: "P 02". Parameter P 02 can now be
changed in the same way as P 01.
- With the “up” key it is possible to scroll through the parameters,
until the desired parameter is reached.
- When the on/off-key is pressed shortly while a parameter number
is shown in the display, the parameter indication will automatically
jump back to P 01.
• When all desired parameters have been changed, press the “0/T”
key for 3 seconds to leave the parameter menu and to return to the
weighing mode.

Parameter settings
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7.2.2 Parameter list

Listed below are all available parameters.
• Settings for specific options are indicated with an asterisk (*). Con-
tact the producer to check whether you have the correct hardware
for this option. If the hardware is not suitable for a certain function, it
will not be possible to activate or change that function.
• The factory settings for your board can be found in the table. Contact
the producer to check which hardware version you have.
Parameter Function
01 Option RF*: RF-function identification number, to ensure that the correct devices
are in communication. Available identification numbers: 0 - 7.
Option RCS*: delay time for the peakhold function, 0 - 9 seconds.
02 Sets smallest multirange graduation.
0.1 = 0.1 kg
0.2 = 0.2 kg
0.5 = 0.5 kg
1 = 1 kg
2 = 2 kg
5 = 5 kg
10 = 10 kg
20 = 20 kg
50 = 50 kg
03 Sets largest multirange graduation.
0.1 = 0.1 kg
0.2 = 0.2 kg
0.5 = 0.5 kg
1 = 1 kg
2 = 2 kg
5 = 5 kg
10 = 10 kg
20 = 20 kg
50 = 50 kg
Attention: P 02 must always have a lower value than P 03. If, by mistake, a
higher value is set, then the indicator automatically sets the same value for both
parameters, and the multi-interval function is not used.
04 Sets the number of graduations per multirange, per 100 graduations. Available
values 0000 - 9900, for the legal for trade version 500 - 3000*.
Attention: when P 02 and P 03 have equal values, and the multirange is there-
fore inactive, the value for P 04 is represented as ''----".
05 Sets the weighing capacity (full scale), per 100 kg. Available values 00000 -
99900.

Parameter settings
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Parameter Function
06 Sets the motion detection, in graduations per second. When the internal value
varies per second more than the number of set graduations, the load stability
pointer will not light up in the display.
0 = 0.5 graduation (standard for option* approved systems)
1 = 1 graduation
2 = 2 graduations
3 = 4 graduations
07 Option: sets approved/non approved version (in kg or lb).
0 = non approved (in kg)
1 = approved (in kg, prints only positive weights)*
2 = non approved (in lb)
3 = approved (in lb, prints only positive weights)
08 Sets auto-shut off time in minutes. Available values 1- 99 (0 = inactive).
09 Sets number of wires per load cell cable.
4 = 4 wires
6 = 6 wires (prepared for approval)
10 Option: turns off automatic zero correction*. For certain dosage applications.
0 = off
1 = on
11 - 14 Not defined.
15 Option: relay output*. Sets value to being active on net or gross weight.
0 = net
1 = gross
16 Option : relay output*. Choice of this option rather than preset tare function.
0 = preset tare function
1 = set point function
17 Option: peakhold function*. Choice of the peakhold function.
0 = standard function
1 = peakhold function
This option is only available on 2100B boards (which can be recognised at star-
tup by the q on the bottom centre of the screen). From software 7.4 onwards;
when P17 is set to 1, all other relevant parameters will be changed to the correct
setting for peakhold systems (see Factory settings table).
20 Option: printer or printer output*. Sets baud rate. Available values: 600/1200/
2400/4800/9600.
21 Option: printer or printer output*. Sets the number of data bits. Available values:
7/8.
22 Option: printer or printer output*. Sets parity.
E = even
- = none
0 = odd

Parameter settings
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Parameter Function
23 Option: printer or printer output*. Sets number of stop bits. Available values: 1/2.
24 Not defined.
25 Option: printer or printer output*. Sets RS-board function.
2100N
0 = none
1 = PC
2 = printer
3 = RF transmitter
This option is only available on 2100N boards.
26 Option: printer or printer output*. Sets number of line feeds after total print. Avail-
able values: 0-7.
40 Option: approved systems*. Activation of the level switch or movement switch
function.
0 = inactive
1 = level switch active, normally closed
2 = level switch active, normally opened
3 = movement switch active
41 Option: approved systems*. Sets the level switch delay time in seconds. Availa-
ble values: 0-7.
90 Reset to factory settings. When after selection of parameter P 90 the “0/T” key is
pressed, all parameter settings are automatically reset to the factory settings.
NB: Be aware that the factory settings are incorrect for some systems. Make
sure that you have a copy of the correct parameters before resetting the system.
91 Not defined.
92 Sets the low battery auto shut off function. When activated, the indicator will
switch off automatically 2 minutes after the lo-ba indication comes on.
0 = inactive
1 = active
99 Shows software version of the indicator.

Parameter settings
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7.2.3 Factory settings

Listed below are the factory settings.
• Settings for specific options are indicated with an asterisk (*). Con-
tact the producer to check whether you have the correct hardware
for this option. If the hardware is not suitable for a certain function, it
will not be possible to activate or change that function.
• Not defined parameters are indicated with five stripes (-----).
Parameter 2100B Peakhold 2100N

01 4 0
02 5 0.2
03 5 1
04 ----- 1000
05 2500 02200
06 1 1
07 1 0
08 03 / 30 05
09 4 4
10 1 -----
11 - 14 ----- -----
15* 0 0
16* 0 0
17* 1 0
18 - 19 ----- -----
20* ----- 1200
21* ----- 8
22* ----- -
23* ----- 1
24 ----- -----
25* ----- 0
26* ----- 06
27 - 39 ----- -----
40* ----- 0
41* ----- 3
42 - 89 ----- -----
90 RESET RESET
91 ----- -----
92 1 1
93 - 98 ----- -----
99 740 -----

Parameter settings
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Troubleshooting
Troubleshooting hydraulics
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8- Troubleshooting
8.1 Troubleshooting hydraulics
8.1.1 Troubleshooting chart

Error Cause Action
LHM200SC
The pump does not per- Air in hydraulics system Pump 5 strokes with an open lower-
form complete strokes ing valve
The hydraulics contain too lit- Refill oil to level with the refill screw
tle oil
Lifting, neutral and lower- The hydraulics contain too lit- Refill oil to level with the refill screw
ing mode do not function tle oil
correctly The lowering valve does not Adjust the valve chain’s extension
close properly using the adjusting screw
Leakage past the reverse Change the ball, and the gasket kit for
valve the lowering valve. Consists of a col-
lar, O-ring and a washer.
The forks lower after each Air in the hydraulics system Pump 5 strokes with an open lower-
pump stroke ing valve
Leakage at the valve cone Switch seat, change valve cone as
well as washer.
It is not possible or it is too The lowering valve does not Adjust the valve chain’s extension
slow to lower open properly using the adjusting screw
The forks sink when the The lowering valve does not Adjust the valve chain’s extension
lowering handle is in neu- close properly using the adjusting screw
tral mode Leakage at the valve cone Switch seat, change valve cone as
well as washer.
Leakage past gasket ring in Replace collar as well as O-ring.
the bottom plate
When the lowering handle Valve ball not affected Adjust the valve chain’s extension
is in neutral mode pumping using the adjusting screw
occurs.
Oil leakage from the lower- The gasket ring is worn or Replace the gasket kit for the lower-
ing valve damaged ing valve

Troubleshooting
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Error Cause Action

LHM200SCQ
Lifts as a standard version The quick valve is not work- Replace valve details
ing
The ball is missing from the Put the ball back or alternatively
inner ring or it is not in posi- replace with a new ball
tion
Malfunction on the inner ring Replace the inner ring and ball
Sinking Leakage in the inner tube Replace collar and O-ring
gasket
Leakage at ball Switch ball seat, change ball

Troubleshooting
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8.1.2 Troubleshooting hydraulics

The hydraulics is not keeping pressure
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
Establish &
locate leakage YES
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

Troubleshooting
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Leakage, lowering valve
Outside
Leakage lowering Change
cleaning and
valve 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

Troubleshooting
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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 lowering under pressure
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

Troubleshooting
Troubleshooting scale
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8.2 Troubleshooting scale

The most frequently occurring causes for malfunctioning are:
• Power supply: worn out battery, broken fuse or charger problems
• Bad or broken contacts
• Jammed or worn out cabling
• Loose screws or bolts
• Mechanical problems: fork shoe is jammed against the pallet truck
chassis due to deformation or accumulated dirt
• Moisture in the electronics or load cells

Troubleshooting
225371-040 2005-11-01 3.164.374- 805, 813
Problem: Nothing works. The display is dead, even when pressing the keys.
Action: Check the battery and charger
• Testing the battery can be done simply by exchanging one battery module
with another.
• Always check the battery charger: a battery may have been worn down or
broken because of a defective charger. The charger should have an output of
between 12.5 and 13.8V.
Check the battery and charger
• When checking the tension of the battery, make sure the indicator has been
switched on for about 3 minutes: voltage may only drop when power is taken
from the battery. Check the contact points within the battery housing by com-
paring the battery voltage with the voltage at the poles on the back of the
housing.
Check the fuse and the indicator

• Check the safety fuse (located in the indicator housing).
• Check the indicator board: if nothing lights up with +12 Vdc at the right con-
tacts, the board is faulty and should be replaced.
• If there’s no +12V at the indicator, check the cabling and the connections be-
tween the fuse and the indicator board.

Troubleshooting
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Problem: Indicator is unstable, weight readout goes up and down

Action: Check the mechanics of the fork construction:
• Make sure nothing is jammed between the forks and the fork shoe: anything
that obstructs free movement of the fork shoe influences the scale.
Check the load cell cables and the calibration board
• Move the load cell cables, especially where they enter a connector. If the
weight read out reacts, the cable is damaged and should be replaced.
• Take out the calibration board and move it; move the cables connected to the
calibration board; if the read out reacts, a cable is damaged.
• If the calibration board is oxidized, heating the solder points with a solder iron
may help. If not, replace it.
Check the indicator for moisture or loose contacts

• Check the indicator board for moisture and condensation: if necessary, dry it
with warm air. Tell tale signs of moisture are corrosion of components on the
board, particularly the pins between the printed lines.
Check the load cells
• Measure the resistance between any of the load cell wires and the pallet truck
chassis: if the resistance value is not infinite, then one or more load cells has
a moisture problem. Disconnect the four load cells and measure the individual
wires to identify the defective load cell.
• Reconnect the load cells to the indicator one at a time: compare the display
values per load cell, if one load cell value is unstable or differs considerably
from the others, this load cell causes the problem.
• If the indicator read out reacts unstable to each load cell, check the indicator
more thoroughly.

Troubleshooting
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Problem: The same load is weighed several times, but different weights
are shown on the display
Action: Check the load cells:
• Stand on the four corners of the forks: if your weight on the display varies
more than 1 kg, the difference between the four corners may cause different
read outs depending on the distribution of the load over the forks.
Check the load cells:
• Dismantle the fork shoe and place a bolt in the assembly hole of the load cell.
Balance a 20 kg calibration weight on each load cell, read outs of the different
load cells should not differ more than 200 or 400 grams.

• If the difference is larger, adjust the load cells to each other by turning the
small screws of the potentiometers on the load cell calibration board.

Troubleshooting
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• Make sure nothing is jammed between the forks and the fork shoe.
• Load the forks with a large weight, push the tare button to have zero kg net on
the display, then stand on the four corners. If the difference is larger than 1 or
2 kg, it may mean that the fork shoe at high weights is bending so far that it
runs against the lower fork construction.
Problem: The pallet truck scale is accurate at small weights, but inaccu-
rate at larger weights
• Make sure nothing is jammed between the forks and the fork shoe.
• Load the forks with a large weight, push the tare button to have zero kg net on
the display, then stand on the four corners. If the difference is larger than 1 or
2 kg, it may mean that the fork shoe at high weights is bending so far that it
runs against the lower fork construction.
Problem: The pallet truck scale is inaccurate, but the inaccuracy is lin-
ear. For example: at 100 kg the error is 1 kg, at 500 kg the
error is 5 kg, at 1000 kg it is 10 kg.
Action: Recalibrate the scale.

Troubleshooting
225371-040 2005-11-01 3.164.374- 805, 813
Problem: Without a load on the forks the indicator shows a weight (pos-
itive or negative) that cannot be “zeroed out”. The display may
also show HELP 2 (taring of a negative weight), HELP 3 (nega-
tive signal at the AD converter), or HELP 7 (overload / too high
signal at the AD converter).
Action: Recalibrate the zero point of the scale (not allowed for legal for trade systems!).
• The zero reset function only works within a limited zero offset. By recalibrating
the zero point, the indicator will return within normal limits.
• Measure the mV output with a voltmeter between the green and white wires.
Output should be positive and not higher than 0.2 mV for an unloaded scale.
Check the individual load cells if the collective output is too high or negative.
• If a load cell is defective, the signal received by the indicator may be too high
and cause an overload error message.
Check the cabling:
• The problem may be caused by a short circuit in the load cell cabling.
Check the indicator:
• If none of the previous actions help, check whether the indicator board is de-
fective.
Problem: The display does not react to loads being placed on the forks
Action: Take out the battery module:
• Static electricity may cause the indicator to be “stuck”, taking off the power
and restarting the indicator may solve the problem.
Check the calibration points on the indicator:
• If old calibration values have not been deleted before a re-calibration, the
scale may show the same read out for a complete weight range. Delete the
current calibration points and re-calibrate.

Troubleshooting
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Problem: Keys on the indicator keyboard do not work

Action: Check the flat cable between indicator board and keyboard:
• If none of the keys work, the flat cable may be disconnected or broken, inter-
rupting input from the keyboard to the indicator
Check the flat cable connector for moisture
• If some keys work and others don’t, change the keyboard
Check if the indicator is defective
Problem: LCD segments fail on the display

Action: Check the indicator:
• By bending the indicator board, latent breaks in the LCD connector pins may
become apparent. If soldering is not possible, replace the board.
For more detailed information of troubleshooting scale, see Trouble-

shooting guide.

Calibration of scale
Calibrating the pallet truck scale
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9- Calibration of scale
9.1 Calibrating the pallet truck scale

Calibrating the pallet truck scale is done by defining the “zero-point”
and one to three other points along the capacity range, including “full
scale”. All calibration is done over the keyboard of the indicator.
9.1.1 Defining zero

• Make sure there is no load on the forks, then switch on the scale
• Push the 0/T-key for 8 seconds, to activate the zero calibration func-
tion
• The display counts down from AF 08 to AF 00.
• The indicator shows which percentage of the total capacity has been
zeroed, e.g. AP 6.4. This percentage should not be higher than 20.
• The indicator automatically calibrates the zero-point and returns to
standard weighing mode

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9.1.2 Single point calibration

Deletion (resetting to zero) of earlier calibrated
points
• Push the “PT” key for about 18 seconds
- The display will go blank until calibration mode has been
reached.
- The indicator shows the value of the first calibration point, the
lowest indication bar (on the left of the display) is flashing.
• Use the up and down keys to see the three earlier programmed val-
ues on the screen by moving the indication bar up and down.
- When the lowest indication bar is lit, the first (lowest) value is
shown, above that is the second and the highest bar shows the
highest value.
- When calibrating only one point the second and highest values
should be returned to zero.
• Press the “up” or “down” key until the middle calibration value is in
the screen.
- The middle indication bar is flashing.
• Press the “0/T” key.
- The first segment is flashing.
• Use the “up” and “down” keys to set the flashing segment to zero.
• Change to the next segment by pressing the “0/T” key.
• Set all the segments to zero until the indication bar is flashing.
• Press the “up” or “down” key until the highest calibration value is in
the screen.
- The highest indication bar is flashing.
• Repeat the process until all the segments are set to zero.

225371-040 2005-11-01 3.164.374- 805, 813
Single point calibration

• Return to the lowest value.
lowest indication bar is flashing.
• Load the weighing system with a known weight and enter this weight
on the indicator by pushing the “0/T” key shortly.
- The first segment starts flashing.
• Use the “up” and “down” keys to change all segments, confirming
the value per segment by pressing the “0/T” key, until the proper
weight has been entered.
- When each segment has been corrected, the lower indication bar
will flash again.
• Confirm the entered weight by pressing the “0/T” key for 3 seconds.
- The display counts down from AF 08 to AF 00, the first calibration
point has been set.
• Leave calibration mode by pressing the “up” or “down” key until AP
XX appears.
- This number indicates the calibration sensitivity percentage, e.g.
AP 07.
• Press the “0/T” key until the display goes blank.
Multi-point calibration
• Push the “PT” key for about 18 seconds.
- The display will go blank until calibration mode has been
reached.
lowest indication bar is flashing.
• Load the weighing system with a known weight and enter this weight
on the indicator by pressing the “0/T” key shortly.
- The first segment will start flashing.
• Use the “up” and “down” keys to change all segments, confirming
the value per segment by pressing the ”0/T” key, until the proper
weight has been entered.
- When each segment has been corrected, the lower indication bar
will flash again.
• Confirm the entered weight by pressing the “0/T” key for 3 seconds.
- The display counts down from AF 08 to AF 00, the first calibration
point has now been set.
• Press the “up” key.
- The middle indication bar will start flashing and the indicator
shows the value of the second calibration point.

805, 813 3.164.374- 2005-11-01 225371-040
• Load the weighing system with a higher known weight and enter this
weight on the indicator, in the same way as described above.
- Upon confirmation the second calibration point will be set.
• Repeat the procedure for the third calibration point.
• Leave calibration mode by pressing the “up” or “down” key until AP
XX appears.
- This number indicates the calibration sensitivity percentage, e.g.
AP 07.
• Press the “0/T” key until the display goes blank.
After calibration, the indicator automatically switches to a small gradua-
tion. Only after switching the indicator off and turning it on again, will
the indicator activate the chosen graduation.

225371-040 2005-11-01 3.164.374- 805, 813
9.1.3 Defining full scale

• Important: before calibrating full scale (or any other weight), earlier
calibration values must be deleted. Failing to do so may cause errat-
ic behaviour of the scale in certain weight ranges.
• Push the “PT” key for 18 seconds to enter the calibration menu
• Load the pallet truck scale with a calibration weight equalling full
scale and enter the weight using the cursor keys
• Push the enter key to confirm the entered weight, the indicator auto-
matically calibrates the scale, using the weight on the forks
• Push enter again to return to standard weigh mode
NOTE!
In practise, a re-calibration at the clients site is often done with a sim-
ple known weight, e.g. a loaded pallet that is weighed on another
scale.
NO1TE!
During the start-up sequence of the indicator a calibration number is
briefly shown in the display. This number is changed automatically af-
ter each calibration. In case of legal for trade systems, this number is
recorded by the approving official, so that one can always verify
whether a later calibration has been done by non-authorised persons.
To view the calibration number

Switch the system off and then on again.
The indicator shows the following sequence:
- 8888.8 (testing LCD segments)
- P 7.3 (software version)
- 1342 (the calibration number)
- 1234.5 (current weight, standard weigh mode).

805, 813 3.164.374- 2005-11-01 225371-040

Troubleshooting guide
225371-040 2005-11-01 3.164.374- 805, 813
10- Troubleshooting guide
This troubleshooting guide helps you to solve technical problems with

your mobile weighing system.
In addition to troubleshooting, see chapter for calibration and parame-

ter instruction.
10.0.1 Possible problems, lists the most frequently occurring prob-

lems (A, B, C, D etc.). If your problem is listed in this overview, remem-
ber the character and go to 10.0.2.
10.0.2 Description of problem and where to look for causes, con-

nects the problem to possible causes (1, 2, 3, 4 etc.). The most encoun-
tered cause is marked with a “–”. Remember the number(s) of the
cause you should check and go to 10.0.3.
10.0.3 Explanation of possible causes and how to fix them,

explains the possible causes in more detail and describes possible
solutions.

805, 813 3.164.374- 2005-11-01 225371-040
10.0.1 Possible problems

The most frequently occuring causes of malfunctioning of the weighing
systems are:
• Worn out battery
• Bad or broken contacts
• Jammed or worn out cabling
• Loose screws or bolts
• Mechanical problems: the upper part of the fork has contact with the
chassis or lifting mechanics of the pallet truck due to deformation,
wear or accumulated dirt.
• Moisture in the electronics or load cells.
These problems cause 99% of all possible failures and will result
in the following problem descriptions:
A. Nothing works. The display is dead, even when pressing the keys.
B. The indicator is unstable; the weight readout goes up and down.
C. Different weights are displayed for the same load when weighed
several times.
D. The weighing system is accurate with lower weights but inaccurate
with higher weights.
E. The weighing system is inaccurate, however, the inaccuracy is line-
ar, meaning the error is always the same percentage of the weighed
load.
F. Without a load, a positive or negative weight (Help 2 or 3) is dis-
played and it is not possible to reset the display to 0kg. The scale reacts
normally when a load is placed on the scale.
G. An error message indicates over- or underload, with or without load
on the scale.
H. The display does not react to loads being placed on or removed from
the scale.
I. Keys do not work.
J. Segments fail on display.
For error messages displayed on the indicator, please refer to the man-
ual.

225371-040 2005-11-01 3.164.374- 805, 813
10.0.2 Description of problem and where to

look for causes
A Nothing works.
The display is dead, even when pressing the keys.
1 Check battery and charger.
6 Check the indicator.
– Is the safety fuse still good, or is there a bad
contact? Measure the voltage on the back of the
battery holder, with the indicator cover taken
from the housing. If 12Vdc is there, then meas-
ure at the right pins of the indicator, black and
red wires. If the conclusion is that there is some-
where no contact make sure that there is no con-
tact problem in the fuse holder or elsewhere.
B The indicator is unstable; the weight readout goes
up and down.
2 Check the mechanism of the fork construction.
4 Check the load cell cables and the load cell cali-
bration board.
6 Check the indicator for moisture or loose con-
tacts. (6.2) to (6.6)
3 Check the load cells.
– Humidity is the most common cause of an unsta-
ble display reading.
C The same load is lifted several times, but different
weights are displayed.
– The weighing parts may not have contact with
fixed, non weighing parts.

805, 813 3.164.374- 2005-11-01 225371-040
D The weighing system is accurate with small

weights, however, it is inaccurate with heavy
weights.
– Because of the bending of the loading part of the
system, the weighing part has contact with the
rigid part of the system.
The weighing system is inaccurate, however, the in-
accuracy is linear.
This means that with a load of 100 kg the inaccuracy is 1 kg,
with 500 kg it is 5 kg, and with a load of 1000 kg the inaccu-
racy is 10 kg.
– Recalibrate the scale.
E Without a load on the forks the indicator shows a
high positive number or HELP 2, 3 or 7. It is not pos-
sible to reset the display to 0 kg.
– First calibrate the system. Especially the zero
calibration may solve the problem. The zero-
reset has a limited capacity. By correcting the
zero point, the indicator will return within its lim-
its.
4 Check the load cell cabling and load cell calibra-
tion board.
– The problem can be caused by a short circuit.
– When a load cell is defective or has a bad con-
tact, the display will give a higher value that can-
not be reset to zero.
6 Check the indicator.
– The indicator is probably not the cause, but
when no other defect can be found, the indicator
must be checked as well.

225371-040 2005-11-01 3.164.374- 805, 813
F The display does not react to loads being placed on

the scale.
– It can happen that processor locks up. Take out
the battery and but it back in after a few seconds
– Check the calibration procedure. If the system
was originally calibrated with more than one cali-
bration points, these values should be deleted
before calibrating with one point only.
6 Check the indicator. See section “ 6.1 Check the
safety fuses” and “6.5 If the display is unstable
or does not react to weights, check whether the
indicator causes the problem” only.
4 Check the cabling
G Keys do not work
6 Check the indicator
H Segments fail on display
6 Check the indicator

805, 813 3.164.374- 2005-11-01 225371-040
10.0.3 Explanation of possible causes and

how to fix them
1. Check battery and charger
1.1 Check the battery
An old battery may be worn out and a battery charger can be broken.
Systems with a low power consumption will run a battery totally
down to where it will give 8 or 9 V. If no current is drawn from a bat-
tery it will always show 12 V. It is due to the fact that only when pow-
er is taken from the battery the voltage drops. Therefore, in order to
check the tension of the battery, the indicator must be turned on for
several seconds or even minutes. When the voltage drops slowly, it
can be concluded that the battery is worn out.
Testing the battery can be done simply by exchanging one battery
with another.
Always check the battery charger: it should have an output of be-
tween 12.5 and 14 V.
1.2 Replacing the battery
Batteries are subject to wear. When the battery is old or used inten-
sively, it should be replaced, in order to avoid problems.
2. Check mechanism
2.1 Check whether weighing is obstructed mechanically
Weigh yourself while standing on the extreme corners of the system.
Your weight must be identical on all corners. It may vary one 1kg. If
this is the case, it may be concluded that all load cells are working
and the mechanics are fine with small loads.
After finishing this test, load the weighing system with a normal or
heavy load. Using the tare key, the display is reset to zero. Now, with
this weight on the scale, load the corners of the weighing system by
placing your own weight on top or side of the weight that is on the
scale. Each corner should give an identical read-out plus or minus 1
or 2 kg. If the read-outs are not identical and show a difference larg-
er than 1 or 2 kg or is instable, see 2.2.

225371-040 2005-11-01 3.164.374- 805, 813
2.2 Try to determine where there is interference between weighing

and non weighing components
It may be necessary to dismantle the system to see where the inter-
ference occurs. Often there are traces on the paint that indicate the
most likely place. If there is doubt, assemble the weighing system
with paper placed between the weighing and non weighing parts. Af-
ter loading the system to its full capacity and maybe by moving
(shacking) the load side ways, traces on the paper will show where
the friction might be.
Determine what can be done mechanically in order to end this fric-
tion. e.g. align the load cells and the upper fork shoes, allow less
moving space for the lifting mechanics in the forks like the push rod
and the load wheel holder. It might be necessary to align the rods of
the load wheels to prevent them from touching the load cells. It can
be that with an unloaded truck it is not possible to see that friction
does occur. Therefore see if the rods can touch the load cells by
pushing them towards the load cells. Clean the inside of the forks.
2.3 Are the load cells mounted correctly?
The load cells are mounted with bolts. Check that the load cells are
correctly mounted.
2.4 Are the fork shoes mounted freely? (Always check this!)
Underneath the pallet truck you can see whether the fork shoes are
mounted correctly and do not interfere with the frame (basis of the
forks) at the sides. Especially welding of the load wheel axel fixture
can interfere. Sometimes pieces of wood or stone can cause friction
between weighing and non-weighing parts.
3. Check loadcells
3.1 When the weighing system is inaccurate, check whether all
load cells give the same weight
Using your own weight, this is very easy to check. Weigh yourself
while standing on the extreme corners of the system. Your weight
must be identical in all corners. It may vary one graduation. When
the load cells get older, or when one of them has been replaced, the
difference may become somewhat larger. When a large difference
occurs, continue from 3.2.
3.2 Check whether the problem lies with the load cells or with the
mechanism
Dismantle the forks shoe (or the upper part of the fork). Place bolts in
the assembly holes of the load cells. Balance a test weight of ap-
prox. 1% of their capacity on each load cell (on the bolts) and check
whether each load cell gives the same weight. The maximum differ-
ence may only be ½ graduation. When the difference is larger see 5.

805, 813 3.164.374- 2005-11-01 225371-040
3.3 When the indicator shows an error message or is unstable

First try to recalibrate the system.
Turn off the indicator and measure with a ohm/voltmeter whether the
resistance between all load cell wires and the pallet truck chassis is
infinite. No resistance value at all is allowed between the black,
white and green load cell wires to the chassis.
The resistance between disconnected load cell excitation wires;
black and red, should be:
+/- 350 Ohm if one load cell is checked
+/- 87 Ohm if all 4 load cells are checked when connected parallel.
These values should also be measured between the load cell signal
wires; white and green.
With the indicator turned on, between the load cell excitation wires
(black and red) the following values should be measured:
- Standard system and without printer: 3.3 V.
- Legal for trade system and / or with a printer: 2.5 Vac. Because of
a block voltage, depending on the voltmeter, a voltage between
2.2 or 2.5 will be measured. If not, the indicator has a problem.
With the indicator turned on, with no load on the forks, between the
load cell signal wires, green and white, the following values should
be measures:
- Standard system and without printer: 0.000 to 0.002 V. (Vac. for
printer and /or approved systems)
If the signal level is higher or negative, there is a problem with the
load cells. If the signal is only slightly higher, it may be that it works
anyway but may be temporary.
If a problem is found, the last test can be repeated with the individual
load cells connected to see if one or more and which load cell(s)
have the problem.
IMPORTANT!
Instability can be measured with a ohm/voltmeter if there is a big in-
stability or if the ohm/voltmeter is very accurate.
3.4 Check the load cells separately
To see if only one load cell is causing the problem, connect each
load cell separately to the indicator (using the indicator as a voltme-
ter) and compare the displayed values per load cell.
The separate values should be almost identical. The value depends
on the calibration setting. When one value is unstable or differs from
the others considerably, it is necessary to replace this load cell. Be-
fore replacing the load cells, see 4.

225371-040 2005-11-01 3.164.374- 805, 813
3.5 If the display is unstable, check which load cell is defective

When the cables of the load cells are all disconnected, it is possible
to test each load cell separately. Connect each load cell separately
to the indicator in order to see if and which load cell is unstable. If the
indicator reacts unstable at each load cell, check again if the indica-
tor is not the cause for this problem, see 6.
4. Check cabling and load cell calibration board

4.1 Check for damaged cables
Touch the load cell cable or move it roughly. Do this especially there
where the cable enters a connector or there where it is moving or
passes moving parts. The indicator should not react. If it does, the
cable or connector is damaged, oxidized or humid and must be re-
placed. The wires between indicator and load cell calibration board
must be checked as well.
4.2 Check the load cell calibration board
The load cell calibration board should be checked as well. If you
move this board or the cables connected to, without actually touch-
ing the contact points, and the indicator reacts, there is a bad con-
tact.
When the calibration board is oxidised, heating the solder points
with a solder iron can help.
5. Calibrate load cell

5.1 Calibration of load cells
When measuring your own weight on each corner of the forks, the
difference may not be larger than 1 kg. When load cells are older or
if one of them has been replaced, the difference may increase a lit-
tle. Use the load cell with the lowest value as reference value and
correct the other values with the potentiometers on the load cell cal-
ibration board.
This calibration board is mounted in the indicator housing.
Using the load cell calibration board, it is easy to calibrate the load
cells. The four potentiometers fitted on these print plates are marked
A B C D. Each potentiometer can be used to calibrate the corre-
sponding load cell. By turning the potentiometer clockwise, the load
cell will give a higher value. By turning the potentiometer counter-
clockwise, it will give a lower value.

805, 813 3.164.374- 2005-11-01 225371-040
5.2 A calibration example

It is not possible to calibrate the load cells by turning the potentiom-
eters while looking at the display to reach the right value. Changing
the potentiometer influences all load cells. Therefore, do it as fol-
lows:
You checked the load cells and found that load cells A and C show a
value of + 2 kg higher. Unload the system and use the potentiome-
ters to change the value. If the value to be corrected is higher, turn
the potentiometer anti-clockwise to correct this. Check all corners
again (with your own weight) and check whether the correction
made, resulted in a smaller difference. If not, repeat the procedure.
It is possible that it takes about 5 to 10 trials before all values are op-
timal.
The absolute value of the weight shown on the display is not impor-
tant at this stage. It is only important that the 4 values are the same.
If they have the same value recalibrate the scale, see the calibration
manual.
5.3 IMPORTANT: If the load cell has to be calibrated from start
When a new load cell is mounted or when a mistake made at calibra-
tion causes the difference between the values to become too large,
it might be better to start all over again.
Using an Ohmmeter (voltmeter) it is possible to set a value of 5
Ohms between point R and the connection screws A, B, C, and D
(behind the potentiometer, see drawing). When all potentiometers
are set at 5 Ohm, they can be used to correct in both directions and
mistakes are corrected again.
When the load cells have been calibrated it is always necessary to cal-
ibrate the indicator as well. Please refer to the calibration instruction.

225371-040 2005-11-01 3.164.374- 805, 813
6. Check indicator
Warning!
Do not touch the contacts on the board. Static energy can destroy
several components.
With mobile weighing systems, most problems are caused by shocks.
Keep this in mind when trying to locate a problem in the indicator hous-
ing or on the board. Don't be afraid to check and apply heavy shocks to
the indicator. It is the only way to discover problems that occur when the
system is used. It will also show latent problems!
6.1 Check the safety fuses
In the housing of the indicator, a safety fuse is mounted. Check this
fuse with a ohm/volt meter.
6.2 Check the separate components
When the indicator board has been taken out of the housing, it is
possible to see whether everything looks all right, whether other
components are loose or if bending the board changes the problem.
6.3 Check for broken or loose connections
None of the cables to the switch, safety fuse holder or plug should be
loose.
6.4 If the display is unstable, check for moisture
Look for condensation or waterdrops on the plugs. Look closely at
the circuit board, when dismantling the upper plate and pulling out
the plug from the indicator module. Dry it with warm air. If the board
is oxidised, it can help to heat solder points carefully with a solder
iron around the analogue circuit.
6.5 If the display is unstable or does not react to weights, check
whether the indicator causes the problem
Disconnect the indicator from the load cells. If the display will give a
error message. Connect each load cell individually. If the indicator
remains unstable or does not react to the different load cells, most
likely the indicator module is faulty.
6.6 When can you be certain that the indicator board is faulty?
The display is faulty when:
- nothing changes when load cells are being disconnected;
- nothing lights up with +12 Vdc at the right contacts, and function-
ing keyboard;
- the indicator remains unstable, even with only one load cell con-
nected (new load cell as a test);
- the display reacts when the indicator module is subjected to
shocks.

805, 813 3.164.374- 2005-11-01 225371-040
6.7 Check the touch panel

Look at the flat cable. The silver conducting layer is very thin. Wear
in a small area can cause the touch panel to disfunction.
The connector on the flat cable is very sensitive to humidity. Check
for this. If humid, heat this component for a longer period of time.
6.8 Check LCD display on the indicator
By bending the board slightly while functioning, in different directions
and diagonally, broken display contacts can be located

225371-040 2005-11-01 3.164.374- 805, 813

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

Service Manual En: LHM200SC, LHM200SCQ

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Order number: 225371-040

This manual covers following truck models:

T-code Model Serial number

© BT Europe AB Service Manual LHM200SC, LHM200SCQ Approved by: Fredrik Moborg

General Product Information 1

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

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

© BT Europe AB Service Manual LHM200SC, LHM200SCQ 1

2 Service Manual LHM200SC, LHM200SCQ © BT Europe AB

Wiring and parameters 32

Component configuration ............................ 32

Troubleshooting hydraulics ......................... 47

Calibrating the pallet truck scale.................. 59

© BT Europe AB Service Manual LHM200SC, LHM200SCQ 3

4 Service Manual LHM200SC, LHM200SCQ © BT Europe AB

1- General Product Information

1.1.1 Intended application of the truck

1.1.2 Prohibited use of the truck

© BT Europe AB Service Manual LHM200SC, LHM200SCQ 1

1.2 Truck Data

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

1.3 Truck Dimensions

2 Service Manual LHM200SC, LHM200SCQ © BT Europe AB

© BT Europe AB Service Manual LHM200SC, LHM200SCQ 3

This page is intentionally left blank

4 Service Manual LHM200SC, LHM200SCQ © BT Europe AB

© BT Europe AB Service Manual LHM200SC, LHM200SCQ 5

2.2 Safety rules for servicing work

6 Service Manual LHM200SC, LHM200SCQ © BT Europe AB

2.2.1 Observe the following for service and

2.2.2 Necessary special tools

2.2.3 Information plates

© BT Europe AB Service Manual LHM200SC, LHM200SCQ 7

2.3 Cleaning, washing and lubrication

2.3.1 Lubrication chart

Lubrication Number of lubri- Lubricant

8 Service Manual LHM200SC, LHM200SCQ © BT Europe AB

© BT Europe AB Service Manual LHM200SC, LHM200SCQ 9

This page is intentionally left blank

10 Service Manual LHM200SC, LHM200SCQ © BT Europe AB

3.1.1 Dismantling the tow bar

© BT Europe AB Service Manual LHM200SC, LHM200SCQ 11

3.1.2 Replacing the lowering handle

3.1.3 Replace the press roller and valve bar.

12 Service Manual LHM200SC, LHM200SCQ © BT Europe AB

4.1.1 Replacing the hydraulics

4.1.2 Replacing the steering wheel

© BT Europe AB Service Manual LHM200SC, LHM200SCQ 13

4.1.3 Replacing the steering wheel axle

4.1.4 Replacing thrust bearings

4.1.5 Replacing the pump piston

14 Service Manual LHM200SC, LHM200SCQ © BT Europe AB

4.1.6 Replacing the lift piston

4.1.7 Replacing the lowering valve

4.1.8 Replacing the cone

4.1.9 Replacing the quick valve

© BT Europe AB Service Manual LHM200SC, LHM200SCQ 15

4.1.10 Changing the oil

16 Service Manual LHM200SC, LHM200SCQ © BT Europe AB

4.1.11 Hydraulic diagrams

SÄNK POSITION/ LOWERING POSITION TANK

© BT Europe AB Service Manual LHM200SC, LHM200SCQ 17