BT SSE135 Operator's Manual

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Operator's Manual

SSE135/SSE160

Valid from serial number: 962872-

Order number: 237077-040

Issued: 2006-10-24 ITS

BT Products AB

S-595 81 MJÖLBY SWEDEN

WARNING!

Do not use the truck before

first reading through the

OPERATOR'S MANUAL.

NOTE!

Keep for future reference.

Valid only for serial number:

Table of Contents

Summary of Contents for BT SSE135

Page 1 Do not use the truck before first reading through the OPERATOR’S MANUAL. NOTE! Keep for future reference. Operator’s Manual SSE135/SSE160 Valid from serial number: 962872- Order number: 237077-040 Issued: 2006-10-24 ITS Valid only for serial number: BT Products AB S-595 81 MJÖLBY SWEDEN © BT...
Page 2 Always follow the warnings given in this Operator’s Manual and on the truck to avoid accidents and incidents from occurring. BT Products AB © BT 237077-040...
Page 3: Table Of Contents
Starting the truck ................52 Braking ................... 53 Steering ..................53 Parking the truck ................54 Driving truck with 180° steering ............55 Starting the truck ................55 Braking ................... 56 Steering ..................56 Parking the truck ................57 © BT 237077-040...
Page 4 Lifting the truck ................78 Towing and transporting a defective truck ........78 Storing the truck ................79 Starting after a period of disuse ............79 Recycling/discarding ................ 80 Discarding the battery ..............80 Scrapping the truck ................. 80 © BT 237077-040...
Page 5: Safety Regulations
CAUTION! Warns that accidents can occur if the instructions are not fol- lowed. The consequences are personal injury and/or material dam- age. NOTE! Marks the risk of a crash/breakdown if the instructions are not followed. © BT 237077-040...
Page 6 When the directive for safety shoes is given, safety shoes must always be worn to avoid personal injury. PROTECTIVE GLASSES When the directive for protective glasses is given, protective glasses must always be worn to avoid personal injury. © BT 237077-040...
Page 7: General Safety Regulations
The truck may not be used if it has been repaired, modified or adjusted unless it has been checked and approved by personnel authorised by BT. Operating the truck The truck is designed and produced to be your tool when collect- ing and depositing goods at different heights.
Page 8 • It is prohibited for persons to be present in the area around the truck when there is a risk of personal injury, e.g. areas that can be reached by falling goods, lowering load handling devices or in the truck’s manoeuvring area. © BT 237077-040...
Page 9 Enter with the load first. No other personnel should be in the lift. • When the load impairs the line of vision, always drive with the load to the rear. © BT 237077-040...
Page 10 Maintenance instructions should be followed to prevent faults and accidents, see the Maintenance chart in chapter Mainte- nance. Only qualified and BT trained personnel are permitted to maintain, adjust or repair the truck. All replacement parts shall be BT approved spare parts.
Page 12: Warning And Information Plates And Symbols
3. A) Do not walk under an elevated load B) Do not stand on the forks 4. Maximum height for rated capacity 5. Lifting points 6. Hydraulic oil filling 7. Serial number 8. Capacity plate 9. Modification plate 10. Identification plate © BT 237077-040...
Page 14: Presentation Of The Truck
The battery is placed on a roller table, easily accessible for inspection, replacement and service. The stand on stacking vehicle’s construction is based on the same advanced tech- niques used for BT’s reach trucks, with easy access to compo- nents and simple servicing. Intended application of the truck The truck is solely designed and manufactured to handle goods.
Page 15: Truck Data
Battery (5h discharge) 300/360/480/584 300/360/480/484 Weight of battery, kg 278/380/484/493 278/380/484/493 Continuous noise level, dB A < 70 < 70 Vibration level, m/s The truck’s lifting capacity, lift height and weight can be found on the truck’s identification plate. © BT 237077-040...
Page 16: Truck Dimensions
Presentation of the truck Truck dimensions The illustration shows external dimensions for the truck in its standard design. © BT 237077-040...
Page 17 Instep height Height of lowered fork l Fork length 1150 1150 Truck length excl. forks Short chassis Dx/Tx 919/938 - / - Long chassis Dx/Tx 1033/1052 1079/1079 Floor clearance Wa Turning radius short/long 1785/1898 - /1898 chassis © BT 237077-040...
Page 18: Identification Plate
BATTERY WEIGHT BATTERY VOLTAGE BATTERY TYPE The illustration shows the identification plate for the truck in ASME-design. Item Text Unit MODEL RATED CAPACITY WEIGHT WITHOUT BATTERY BATTERY WEIGHT BATTERY VOLTAGE BATTERY TYPE — CLASS ACC TO UL583 © BT 237077-040...
Page 19: Capacity Plate
The plate includes informa- tion according to the table below. Item Text Modification plate Type Serial number Place of manufacture Place of manufacture Modification number Date © BT 237077-040...
Page 20: Main Components
14. Control circuit fuse: 10A, BT part no. 122308-100. 15. Fuse for electrical steering wheel: 20 A, BT part no. 122308-200. 16. Drive motor fuse: 160 A, BT part no. 29223. 17. Pump motor fuse: 200 A, BT part no. 29673.
Page 22: Controls And Instruments Truck With 360° Steering
360° steering 1. Steering wheel 2. Hydraulic controls 3. Emergency switch off 4. Key switch 5. Display 6. Accelerator/brake control 7. Horn 8. Travel direction selector 9. Controls for control console position 10. Safety pedal 11. Cover lock © BT 237077-040...
Page 24 Press the buttons to activate the function. Function Lever A Lift forks Lower forks Button B Project stabiliser (optional) Button C Retract stabiliser (optional) NOTE! When the key is in the 0 position none of the hydraulic functions can be used. © BT 237077-040...
Page 25 The main power switch for the control current. The power is off and the instrument lighting is off . The power supply is on. The instrument lighting is on and current is fed to all electronic components. © BT 237077-040...
Page 26 A further 10% of the battery’s capacity can be used before the battery controller cuts out the lifting func- tion. The hour meter registers the time the drive motor and/or the pump motor are operating. © BT 237077-040...
Page 27 • Press button 4 to select the travel direction. If you are unsure of the activated direction of travel see the travel direction indi- cator (A) on the display (3). Press once to travel in the direc- tion of the forks. Press once more to change the travel direction. © BT 237077-040...
Page 28 Always ensure that the whole of your body is inside the protec- tive cab. The parking brake does not release until you have selected a travel direction. Cover lock (11) • Loosen the screw and swing out the entire motor casing to inspect the motor. © BT 237077-040...
Page 29: Display And Programming
• Warning codes and Error codes • Parameters • Running time The address register’s ”No” will be shown on the left-hand side and ”the value” on the right-hand side. Character window (B) indicates the programmed time of day. © BT 237077-040...
Page 31 Programming is also stopped if no button is pressed within twenty seconds. NOTE. Truck handling. The handling characteristics of the truck will change if you change any of the truck specific parameters. Do not change any parameters without possessing the necessary know-how. © BT 237077-040...
Page 32: Warning Codes
Incorrect zero position sig- Faulty potentiometer or bro- Function depending on the nal from potentiometer for ken cable or the potentiom- cause of the error. raise/lower. eter was activated when the ignition was switched on. © BT 237077-040...
Page 33 3 min- cable. utes without the truck moving. By-pass switch for lift Faulty switch or broken The parking brake comes height limit activated more cable. than 3 minutes whilst the truck has not moved. © BT 237077-040...
Page 34: Error Codes
Faulty in the steering Faulty motor or broken All hydraulic functions except motor cable. lowering the forks are stopped. Brake fault Faulty brakes or cabling All hydraulic functions except step 1 lowering the forks are stopped. © BT 237077-040...
Page 35 Effect on the truck Brake fault Faulty brakes or cabling All hydraulic functions except step 2 lowering the forks are stopped. Faulty setting of Invalid combination All functions on the truck are parameter and input stopped 180°/360° selection © BT 237077-040...
Page 36: Controls And Instruments Truck With 180° Steering
1. Steering wheel 2. Hydraulic controls 3. Emergency switch off 4. Key switch 5. Display 6. Travel control 7. Horn 8. Brake lever for the travel brake 9. Controls for control console position 10. Safety pedal 11. Cover lock © BT 237077-040...
Page 38 Press the buttons to activate the function. Function Lever A Lift forks Lower forks Button B Project stabiliser (optional) Button C Retract stabiliser (optional) NOTE! When the key is in the 0 position none of the hydraulic functions can be used. © BT 237077-040...
Page 39 The main power switch for the control current. The power is off and the instrument lighting is off . The power supply is on. The instrument lighting is on and current is fed to all electronic components. © BT 237077-040...
Page 40 A further 10% of the battery’s capacity can be used before the battery controller cuts out the lifting func- tion. The hour meter registers the time the drive motor and/or the pump motor are operating. © BT 237077-040...
Page 41 The horn sounds as long as the button is pressed. Brake lever for the travel brake (8) • Brake by pressing the button. • The brakes are applied in two stages, first gentle braking and then after a set delay full braking. © BT 237077-040...
Page 42 Always ensure that the whole of your body is inside the protec- tive cab. The parking brake does not release until you have selected a travel direction. Cover lock (11) • Loosen the screw and swing out the entire motor casing to inspect the motor. © BT 237077-040...
Page 43: Display And Programming
• Warning codes and Error codes • Parameters • Running time The address register’s ”No” will be shown on the left-hand side and ”the value” on the right-hand side. Character window (B) indicates the programmed time of day. © BT 237077-040...
Page 45 Programming is also stopped if no button is pressed within twenty seconds. NOTE. Truck handling. The handling characteristics of the truck will change if you change any of the truck specific parameters. Do not change any parameters without possessing the necessary know-how. © BT 237077-040...
Page 46: Warning Codes
Incorrect zero position sig- Faulty potentiometer or bro- Function depending on the nal from potentiometer for ken cable or the potentiom- cause of the error. raise/lower. eter was activated when the ignition was switched on. © BT 237077-040...
Page 47 3 min- cable. utes without the truck moving. By-pass switch for lift Faulty switch or broken The parking brake comes height limit activated more cable. than 3 minutes whilst the truck has not moved. © BT 237077-040...
Page 48: Error Codes
Faulty in the steering Faulty motor or broken All hydraulic functions except motor cable. lowering the forks are stopped. Brake fault Faulty brakes or cabling All hydraulic functions except step 1 lowering the forks are stopped. © BT 237077-040...
Page 49 Effect on the truck Brake fault Faulty brakes or cabling All hydraulic functions except step 2 lowering the forks are stopped. Faulty setting of Invalid combination All functions on the truck are parameter and input stopped 180°/360° selection © BT 237077-040...
Page 50: Accessories
The stabilisers can injure persons outside the truck. Ensure that nobody is within the truck’s operating area. Height indicator The height indicator shows the forks’ actual height within the head lift area. The height is shown digitally on a display. © BT 237077-040...
Page 52: Driving Truck With 360° Steering
- That the hydraulic functions are operational. • Start gently by accelerating slowly until you reach the desired speed. WARNING! Dangerous driving. Accidents can occur. Always drive with care, good judgement and responsibility as set out in the general safety regulations. © BT 237077-040...
Page 53: Braking
WARNING! Risk of slipping. You can lose control of the truck if your hands or shoes are oily. Always dry your hands and shoes before driving. © BT 237077-040...
Page 54: Parking The Truck
• Retract the stabilisers. • Turn the ignition key to the 0 position (the parking brake is activated automatically). WARNING! Unauthorised use. Accidents can happen. Always remove the ignition key when the truck is left unat- tended. © BT 237077-040...
Page 55: Driving Truck With 180° Steering
• Start gently by carefully activating the travel control until you reach the desired speed. WARNING! Dangerous driving. Accidents can occur. Always drive with care, good judgement and responsibility as set out in the general safety regulations. © BT 237077-040...
Page 56: Braking
WARNING! Risk of slipping. You can lose control of the truck if your hands or shoes are oily. Always dry your hands and shoes before driving. © BT 237077-040...
Page 57: Parking The Truck
• Retract the stabilisers. • Turn the ignition key to the 0 position (the parking brake is activated automatically). WARNING! Unauthorised use. Accidents can happen. Always remove the ignition key when the truck is left unat- tended. © BT 237077-040...
Page 58: Transporting Loads
A loaded truck can overturn when attempting to turn on an incline. Never turn a loaded truck on an incline. WARNING Increased braking distance. The braking distance is increased when travelling downhill. Drive at a reduced speed, use the truck’s motor brake. © BT 237077-040...
Page 59: Collecting A Load
Ensure that nobody is within the truck’s operating area. • Drive the truck forward so that the forks are positioned as far as possible under the load. • Lift the forks so that the load is lifted free. © BT 237077-040...
Page 60: Depositing A Load
• Drive the truck forward so that the load is positioned correctly on the rack. • Lower the forks so that they clear the load. • Reverse the truck. • Lower the forks to the transporting position and drive carefully away from the rack. © BT 237077-040...
Page 61 Lost stability. Lowering a loaded pallet when the truck is still moving can result in the load falling off the pallet. Never lower a load if the truck is moving. • Start slowly and then increase the speed. © BT 237077-040...
Page 62: Battery
• Ensure the ignition key is in the 0 position. WARNING! Falling battery. When changing the battery, it can be dropped. Always lift the battery using an approved lifting device and use a battery yoke intended for the battery. © BT 237077-040...
Page 63: Charging The Battery
Short-circuits, naked flames and sparks in the vicinity of the battery can cause an EXPLOSION. Always switch off the charging current BEFORE removing the battery connector. Provide good ventilation, especially if the battery is charged in a confined area. © BT 237077-040...
Page 64: Battery Maintenance
• Fill using distilled water. The fluid level should be 10 - 15 mm above the cell plates. • Refit all of the cell caps. • Rinse off and dry the battery. • Suck up the fluid through the pipe that juts out between the cells on the battery. © BT 237077-040...
Page 65 Hold the acid tester absolutely vertical and extract sufficient fluid so that the hydrometer float moves freely. Correct density values at different fluid temperatures for a fully charged battery: Temperature °C Density g/cm 1.31 1.30 1.29 1.28 1.27 © BT 237077-040...
Page 66: Daily Service And Function Checks
Check for damage, remove dirt and the like Wheels Check for damage, remove oil, metal chips and the like Hydraulic system Check the oil level and for oil leakage Drive unit Inspect abnormal noises and leakage Safety pedal/Parking brake Check its function © BT 237077-040...
Page 68: Maintenance
250 driving hours. The truck´s safety, efficiency and service life is dependent on the service and maintenance it is given. Only use BT approved spare parts when service and repair work are carried out. BT recommends that you contact your closest BT representative to sign a service and maintenance agreement to ensure the truck’s operating economy and safety.
Page 69 • When working underneath the truck, support the truck on trestle-blocks. WARNING! Risk of crushing. A badly supported truck can fall. Never work under a truck that is not supported on trestle- blocks and secured by a lifting device. © BT 237077-040...
Page 70 Service Manual for the truck. Other service and repair work. In addition to the maintenance points in the maintenance chart, all service and repair work should be carried out by personnel with special training for this type of truck. © BT 237077-040...
Page 71: Cleaning And Washing
• Clean the electrical panels, electronic boards, contactors, connections, solenoid valves, etc. using a damp cloth and a cleaning agent. NOTE! Risk of short-circuiting. Electrical components can be damaged. Do not break the guarantee seal on the electronic board. © BT 237077-040...
Page 72: Maintenance Chart
Dismantle and grease the fork wheel´s bear- ings Brakes Clean Check the brake discs for wear Check the play in the released position Electrical components Clean and check the mounting Tighten cable connections Check contactor points Check the contactor’s movement © BT 237077-040...
Page 73 11.3 Check the emergency stop. 11.4 Check the gas cartridge’s capacity and locking mechanism 12.0 Pedals 12.1 Check the functioning of the foot pedal Change filter after 50 - 100 hrs, and then every 1000 hrs. © BT 237077-040...
Page 75: Lubrication Chart
Transmission oil Hypoid oil Hypoid oil Gears SAE 80W/90 SAE 75W Grease BT 26778 BT 26778 Chains and wires (Spray) (Spray) Grease BT 055-70111 BT 055-74320 Side shift forks Grease Staburags Staburags Steering bearings NBU 8EP NBU 8EP © BT 237077-040...
Page 77: Transporting And Storing The Truck
The truck’s dimensions and weight Height, truck without mast 2290 Height, truck with mast Dependent on the mast height, SSE135 1937 - 2622 Dependent on the mast height, SSE160 2013 - 2708 Width Length incl. forks (L = 1150 mm).
Page 78: Lifting The Truck
The truck’s drive wheel must be lifted off the ground. Truck that has no electrical power: • Tow by means of a tow-truck and trailer. The truck’s drive wheel must be lifted off the ground. © BT 237077-040...
Page 79: Storing The Truck
Before the truck is put into operation after a period of disuse it should undergo a function and safety check as set out in the chapter Daily service and function checks. • Carry out preventive maintenance as set out in the instruc- tions, 250 hours interval. © BT 237077-040...
Page 80: Recycling/Discarding
Spent batteries shall be returned /sent to the manufacturer of the battery or its representatives (see the sign on the battery) for dis- posal/recycling. You can also return batteries to your local BT- representative who will then take care of returning the battery to the manufacturer.
Page 81 Pump unit Steel and aluminium Hoses Rubber and steel Cylinders Cast iron and steel Electrical system Cables Copper cores with PVC sheaths Electronic board Reinforced glass fibre circuit board laminate Lithium battery Motors Steel, copper and aluminium © BT 237077-040...
Page 82 *THE SWEDISH MACHINERY TESTING INSTITUTE, Fyrisborgsgatan 3, S-754 50 Uppsala Telefon/Telephone: +46 18-56 15 00, Telefax: +46 18-12 72 44. Modification no _______________________________________________ __________________________________________________________________ Place & date of issue Signature __________________________________________________________________ (Company) (Clarification of signature) © BT 237077-040...

This manual is also suitable for:

Sse160 Sse135l Sse160l

BT SSE135 Operator's Manual

Safety Regulations

Warning and Information Plates and Symbols

Presentation of the Truck

Main Components

Controls and Instruments Truck with 360° Steering

Controls and Instruments Truck with 180° Steering

Accessories

Driving Truck with 360° Steering

Driving Truck with 180° Steering

Transporting Loads

Battery

Daily Service and Function Checks

Maintenance

Transporting and Storing the Truck

Recycling/Discarding

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Summary of Contents for BT SSE135

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