OL25P Service Manual

Service Manual en
OPUS OL 25, OL 25 P
Valid from serial number: 579903AA-
Order number: 215858-040

Issued: 2004-08-01 ITS
© BT Europe AB
Issue date Resp. Changes
2003-08-01 ITS Completely new issue.
2004-08-01 ITS Change from OL 20 to OL 25 and OL 25 P
This manual covers following truck models:
T-code Model Serial number

649 OL 20 579903AA-
649 OL 25 579903AA-
649 OL 25 P 579903AA-
© BT Europe AB Service Manual OPUS OL 25, OL 25 P Approved by: Stefan Blom

Table of contents
Valid from serial number T-code
579903AA- 649
Order number Date
215858-040 2004-08-01
1- Table of contents
Technical data – M4 2-1
Tightening torques........................................ 5
General tightening torques ........................... 6
Truck dimensions ......................................... 7
Destruction instructions – M6 3-1
General......................................................... 1
Procedure ..................................................... 1
Abbreviations................................................ 2
Sorting .......................................................... 2
Hoods, hatches (0340) ................................. 3
Hoods, hatches (0340) ................................. 4
Frame/chassis (0300) and

forkframe (0380) 5
Seat, cushions (0620)................................... 6
Wall/floor covering (0670)............................. 7
Internal fittings (0680) ................................... 8
Driver protection (0840) ................................ 9
Electric motors (1700).................................. 10
Drive assembly/gear (2550)......................... 11
Wheels (3500) ............................................. 12
Steering arm (4110)..................................... 13
General electronic equipment (5100) .......... 14
Battery cut out connector/contactor (5190).. 15
Extra I/O module (5730) .............................. 16
© BT Europe AB Service Manual OPUS OL 25, OL 25 PApproved by: Stefan Blom 1- 1

Table of contents
T-code Valid from serial number
649 579903AA-
Date Order number
2004-08-01 215858-040
Hydraulic unit (6100).................................... 17
Hydraulic lines chassis (6230) and main

lift cylinders (6610) .................................. 18
Charger adaptor (9380) ............................... 19
Terminal on board (9410) ............................ 20
Other extra equipment,

tuck log device (9420) 21
Other extra equipment, load support (9500) 22
Other extra equipment, writing table (9500). 23
Other extra equipment, writing table (9500). 24
Other extra equipment, support (9500) ........ 25

collision protection (9500) ....................... 26

working cage (9130)................................ 27
Installation and maintenance

instructions – P1 4-1
Truck installation........................................... 1
4.1.1 Lifting the truck ................................................... 1
4.1.2 Battery installation .............................................. 2
4.1.3 Putting into service ............................................. 2
Introduction, maintenance ............................ 4
4.2.1 Safety rules during maintenance work ................ 4
Cleaning and washing .................................. 5
4.3.1 External cleaning ................................................ 6
4.3.2 Cleaning the motor compartment ....................... 6
4.3.3 Electric components ........................................... 6
Safe lifting ..................................................... 7
1- 2 © BT Europe AB Service Manual OPUS OL 25, OL 25 P Approved by: Stefan Blom

Table of contents
579903AA- 649
Order number Date
215858-040 2004-08-01
Maintenance,
lubrication schedule – P2 5-1
Test drive...................................................... 1
Maintenance schedule.................................. 1
Lubrication schedule..................................... 8
Oil and lubricant

specifications – P3 6-1
Tools – P4 7-1
Super Seal connectors ................................. 1
AMP connectors ........................................... 2

7.2.1 AMP Connectors, 040 series .............................. 3
Molex connectors ......................................... 3
Other tools .................................................... 4
Fork carriage – 0380 8-1
Included components ................................... 1
Disassembly of the fork carriage................... 3
Roller replacement ....................................... 4
Electric drive motor – 1760 9-1
Included components ................................... 1
General......................................................... 3
Mechanical design ........................................ 3
Disassembly of the motor from the truck....... 3
Assembly of the motor in the truck................ 4

Table of contents
649 579903AA-
Date Order number
2004-08-01 215858-040
Service and repairs ....................................... 5

9.6.1 Disassembly of the motor ................................... 5
9.6.2 Disassembly, N side ........................................... 6
9.6.3 Disassembly, D side ........................................... 6
9.6.4 Wearing parts ..................................................... 6
9.6.5 Cleaning .............................................................. 7
Technical data .............................................. 7
Driving unit/gear – 2550 10-1
Included components.................................... 2
10.1.1 Technical data .................................................... 3
Disassembly/Assembly
Leakage from top cover ........................... 3
Assembly is done in reverse. .............................. 3
Replacing the drive axle jointing ring ............ 3
10.3.1 Disassembly ....................................................... 4
10.3.2 Assembly ............................................................ 4
Replacing the wheel bolt............................... 5
Electromagnetic brake – 3370 11-1
Included components.................................... 2
Disassembly ................................................. 2
11.2.1 Inspection ........................................................... 2
Assembly ...................................................... 3
Manual release of the brake ......................... 3
Adjustment.................................................... 3
11.5.1 Adjusting the play ............................................... 3

Table of contents
579903AA- 649
Order number Date
215858-040 2004-08-01
Swivel wheel – 3540 12-1
General......................................................... 1
Main component of swivel wheel .................. 2
Maintenance ................................................. 3
12.3.1 Swivel wheel height inspection .......................... 4
12.3.2 Swivel wheel height adjustment ......................... 5
Adjust the swivel wheel ...................................... 5
Adjustment ......................................................... 5
12.3.3 Replacing the swivel wheel ................................ 5
Disassembly of the swivel wheel assembly ........ 6
12.3.4 Replacing the wheel ........................................... 6
Disassembly ....................................................... 6
Assembly ............................................................ 6
12.3.5 Replacing the wheel bearing .............................. 6
Electrical steering system – 4300 13-1
General......................................................... 1
Electrical steering servo................................ 2

13.2.1 General .............................................................. 2
Steering servo components .......................... 3
Adjustment ................................................... 4
13.4.1 Reference sensor ............................................... 4
13.4.2 Calibration .......................................................... 4
Parameter 36 ...................................................... 5
Parameter 37 ...................................................... 5
Steering unit ................................................. 6
13.5.1 Steering unit handle ........................................... 6
13.5.2 Steering unit controls housing ............................ 8
13.5.3 Steering unit base ............................................ 10
Disassembly/assembly of buttons ............... 12
13.6.1 Replacing the pushbutton/switch ..................... 12
13.6.2 Replacing the lifting/lowering pushbutton ......... 13
13.6.3 Replacing the pushbutton ................................ 13
Replacing the potentiometer........................ 14

Table of contents
649 579903AA-
Date Order number
2004-08-01 215858-040
Inspection and replacement of the steering

unit’s steel belt (Ergo version) ................. 17
Replacing the inductive brake sensor .......... 19
Replacing the viscous damper..................... 22
Electrical systems – 5000 14-1
Electrical equipment overview ...................... 1
Equipment list and electrical diagram ........... 3

14.2.1 Electrical wiring diagram 1 of 6 .......................... 7
14.2.4 Electrical wiring diagram 4 of 6 ........................ 10
14.2.7 Electric wiring diagram OL 25 P 1(7) ................ 13
14.2.10 Electric wiring diagram OL 25 P 4(7) .............. 16
Extra I/O module .......................................... 20
Functional description.................................. 21
14.4.1 Description of steering system ......................... 26
Speed limitation ........................................... 27
Hour meter and battery condition................. 28
Diagnostic and troubleshooting ................... 29

14.7.1 Fault codes ....................................................... 29
14.7.2 Fault code history ............................................. 30
14.7.3 List of fault codes ............................................. 30
14.7.4 Transistor regulator troubleshooting
and error codes ................................................. 36
14.7.5 General ............................................................. 36
14.7.6 Transistor regulator errors ................................ 37
14.7.7 Resetting errors ................................................ 38
14.7.8 Safety ............................................................... 38

Table of contents
579903AA- 649
Order number Date
215858-040 2004-08-01
14.7.9 Built-in Test Function ....................................... 39

Digital inputs/outputs test mode ....................... 40
Transistor regulator inputs ................................ 40
Transistor regulator outputs ............................. 40
Digital input from control sensors ..................... 41
Extra functions .................................................. 41
14.7.10 Display test mode ........................................... 42
Part numbers ............................................... 42
Parameters .................................................. 43
14.9.1 General ............................................................ 43
14.9.2 Viewing parameters -CAN key not connected . 43
14.9.3 Viewing parameters -CAN key connected ....... 44
14.9.4 Setting Driver parameters ................................ 45
14.9.5 Setting Service parameters .............................. 45
14.9.6 List of Driver parameters .................................. 46
14.9.7 Description of Driver parameter ....................... 47
Parameter 1 ...................................................... 47
Parameter 2 ...................................................... 47
Parameter 3 ...................................................... 47
Parameter 4 ...................................................... 47
Parameter 5 ...................................................... 47
Parameter 6 ...................................................... 47
Parameter 7 ...................................................... 47
14.9.8 List of Service parameters ............................... 48
14.9.9 Description of Service parameter ..................... 49
Parameter 10 .................................................... 49
To enter a new PIN-code: ................................ 49
To remove an existing PIN-code: ..................... 50
Parameter 14 .................................................... 50
Parameter 20 .................................................... 51
Parameter 21 .................................................... 51
Parameter 22 .................................................... 51
Parameter 23 .................................................... 52
Parameter 25 .................................................... 53
Parameter 28 .................................................... 53
Parameter 35 .................................................... 53
Parameter 36 .................................................... 53
Parameter 37 .................................................... 54
Parameter 39 .................................................... 54
Technical specifications – Curtis 1243......... 55

Table of contents
649 579903AA-
Date Order number
2004-08-01 215858-040
Hydraulic system – 6000 15-1
OL 25 ............................................................ 1
15.1.1 General ............................................................... 1
15.1.2 Hydraulic drawing and symbol list ...................... 2
Symbol list .......................................................... 2
15.1.3 Adjustments ........................................................ 3
Adjusting the pressure limiting valve .................. 3
15.1.4 Tools ................................................................... 4
OL 25 P......................................................... 5
15.2.1 General ............................................................... 5
15.2.2 Hydraulic drawing and symbol list ...................... 6
Symbol list .......................................................... 7
15.2.3 Description ......................................................... 7
Fork lifting ........................................................... 7
Fork lowering ...................................................... 7
Platform lifting ..................................................... 8
Platform lowering ................................................ 8
Operating pressure ............................................. 8
Relief valve ......................................................... 8
Check valve for the platform cylinder (3) ............ 8
Pressure sensor, B10 ......................................... 8
15.2.4 Adjustments ........................................................ 9
Adjusting the pressure limiting valve .................. 9
15.2.5 Tools ................................................................. 10
Main lift chain system

OL 25 P – 7120 16-1
General ......................................................... 1
Checking the chain setting............................ 1
Chain inspection ........................................... 1

16.3.1 Noise .................................................................. 1
16.3.2 Surface rust ........................................................ 1
16.3.3 Rusty links .......................................................... 1
16.3.4 Stiff links ............................................................. 2
16.3.5 Bolt rotation ........................................................ 2
16.3.6 Loose bolts ......................................................... 2
16.3.7 Outline wear ....................................................... 3
16.3.8 Stretching ........................................................... 4
16.3.9 Damage .............................................................. 5
16.3.10 Damaged discs ................................................. 5

Table of contents
579903AA- 649
Order number Date
215858-040 2004-08-01
16.3.11 Damaged bolts ................................................. 5

16.3.12 Dirty chain ........................................................ 5
Cleaning ....................................................... 5
Lubrication .................................................... 6
Control/computer equipment – 8700 17-1
General......................................................... 1
Connection ................................................... 1
Layout........................................................... 2
17.3.1 Main program screen ......................................... 2
17.3.2 Nodes ................................................................. 2
17.3.3 Icons ................................................................... 3
17.3.4 Tool buttons and menu bar ................................ 4
17.3.5 Information window ............................................ 4
17.3.6 Status bar ........................................................... 4
Connection function ..................................... 4
Disconnection function ................................. 5
Downloading program function ..................... 5

17.6.1 Normal downloading (truck with key) ................. 5
17.6.2 Normal downloading (truck with keypad) ........... 6
17.6.3 Emergency downloading (truck with keypad) ..... 6
17.6.4 Downloading in old versions of logic card .......... 7
17.6.5 Emergency downloading (truck with keypad) ..... 7
Truck report function..................................... 8
Parameters function ..................................... 9
Diagnostics function .................................... 11

17.9.1 Representation of signal colours ...................... 11
17.9.2 “Tiller arm” tab .................................................. 12
17.9.3 “Drive Controller” tab ........................................ 13
17.9.4 “EPS” tab (only OL 20 / 25) .............................. 14
Other menu functions .................................. 16
17.10.1 Save to file ..................................................... 16
17.10.2 Download from file ......................................... 16
17.10.3 Reset CAN adapter ........................................ 16
17.10.4 Delete error code log ...................................... 16
17.10.5 Reset hour meter ........................................... 16

Table of contents
649 579903AA-
Date Order number
2004-08-01 215858-040
17.10.6 Read error code log ........................................ 16

17.10.7 Adjust date and time ....................................... 16
17.10.8 Adjusting the hour meter on older cards ........ 17
17.10.9 Help ................................................................ 17
About TruckCom ............................................... 17
17.10.10 Exit ............................................................... 17
Specifications .............................................. 17
Installation ................................................... 18
17.12.1 Installation on a PC with Windows® 95/98 ..... 18
17.12.2 Installation on a PC with Windows XP/2000 .. 18
17.12.3 Installation on a PC with Windows NT ........... 24
17.12.4 In case of communication problems with CAN 24
17.12.5 To uninstall ..................................................... 24
Operator’s cabin, cabin lifting

OL 25 P – 9130 18-1
General ......................................................... 1
Operator cabin details................................... 2
Adjustment.................................................... 4
Outer side guide ........................................... 5

Technical data – M4
579903AA- 649
Order number Date
215858-040 2004-08-01
2- Technical data – M4
Table 1: Technical data

Model OL 20 OL 25
Drive motor
Type TSL160 A TSL160 A
DS60 DS60
Power, kW 2.5 2.5
Intermittence S2, 60 min S2, 60 min
Minimum carbon brush length, mm 11 11
Nominal commutator diameter, mm 71 71
Minimal commutator diameter, mm 68 68
Resistance, shunt field winding, Ω at 24°C 0.346 0.346
Resistance, armature winding Ω at 24°C 0.0098 0.0098
Weight, kg 23 23
Brake
Type 1EB46-11 1EB46-11
Braking force, Nm 48 48
Power, W 44 44
Resistance, coil, Ω 12 12
Nominal play when applied, mm 0.25-0.38 0.25-0.38
Minimum thickness of brake disc, mm 7.7 7.7
Thickness of new brake disc, mm 9.7 9.7

649 579903AA-
Date Order number
2004-08-01 215858-040

Model OL 20 OL 25
Transmission/gear mechanism
Type 2-stage angle 2-stage angle
gear gear
Gear ratio 14.20:1 14.20:1
Oil volume, litres 1.75 1.75
Oil type Hypoid oil Hypoid oil
at normal temperature SAE 80W/90 SAE 80W/90
at temperatures < -15oC SAE 75W SAE 75W
Wheels
Drive wheel, mm 250x75 250x75
250x105 250x105
Drive wheel load unloaded, short/long chassis, kg 480/500 480/500
Drive wheel load with rated load, short/long chassis, kg 802/863 880/920
Wheel pressure with rated load, kg/cm2 30/32 33/35

24/25 26/27
Wheel nut tightening torque, Nm 130 130
Bogie wheel, fork-mounted, mm 85x75 85x75
Axle load pressure unloaded, short/long chassis, kg 250/270 250/270
Axle load pressure with rated load, short/long chassis, kg 1,918/1,940 2,223
2,243
Wheel pressure with rated load, kg/cm2 47 49
Swivel wheel, mm 150/76 150/76

Axle load pressure unloaded, short/long chassis, kg 270/300 270/300
Axle load pressure with rated load, short/long chassis, kg 495/711 670/800
Wheel pressure with rated load, kg/cm2 34/42 36/44

579903AA- 649
Order number Date
215858-040 2004-08-01

Model OL 20 OL 25
Hydraulic system
Power, kW 1.2 1.2
Intermittence 10% 3%
Minimum carbon brush length, mm 7.5 7.5
Minimal commutator diameter, mm 4.75 4.75
Pressure at rated load, bar 110 120
Overflow pressure, bar 130 170
Pump flow, litres/minute 4.7 4.7
Tank volume, litre 0.5 0.5
Oil type ISO-L-HM32 ISO-L-HM32
at normal temperature ISO-L-HV32 ISO-L-HV32
at temperatures < -15oC
Power steering
Model Power steer- Power steer-
ing ing
PST 24/10 PST 24/10
Power, W 240 240
Torque at rated load 0.68 Nm 0.68
Max. current 60 A 60 A
Resistance,Ω, phase to phase 0.075 0.075
Fuses
Control circuit, F50, F51 3 A, 7.5 A 3 A, 7.5 A
Drive motor, F1 160 A 160 A
Pump motor, F3 125 A 125 A
Power steering, F52 30 A 30 A

649 579903AA-
Date Order number
2004-08-01 215858-040

Model OL 20 OL 25
Battery compartment, Batteries
Battery compartment 212x790x775 212x790x775
Dimensions (LxWxH), mm 303x790x775 303x790x775
Short
Long
Capacity, Ah 300-600 300-600
Weight, kg 300-490 300-490
Drive speed
Unloaded, km/h 12 12
With rated load, km/h 9 9
Lifting/lowering speed
Lift to max. height with load, sec. 4.6 6.4
Lowering with no load, sec. 5.2 4.6
Current consumption
Driving unloaded, A - -
Driving with rated load, A - -
Lifting with no load, A - -
Lifting with rated load, A - -
Hill climbing ability
Unloaded, short/long chassis, % 13/13
With rated load, short/long chassis, % 9/10
Dimensions
Chassis
Short, mm 1,335 1,335
Long, mm 1,420 1,420
Wa with 1,150 mm forks and short chassis, mm 2,196 2,196
Wa with 2,350 mm forks and long chassis, mm 2,410 2,410
Lifting height, mm 225 225
Weight excluding battery
Short chassis, 1,150 mm forks, kg 765 765
Long chassis, 2,350 mm forks, kg 897 897

Tightening torques
579903AA- 649
Order number Date
215858-040 2004-08-01
2.1 Tightening torques
Table 2: Specific tightening torques

Description Quantity Torque Locking Reference
method
Gearbox input 1 130 Nm punch mark See section “10.1
shaft locking nut Included compo-
nents”
Gearbox output 1 400 Nm punch mark See section “10.1
shaft locking nut Included compo-
nents”
Gearbox cover 6 25 Nm Loctite 242 See section “10.1
screw Included compo-
nents”
Wheel fixing bolt 5 90 Nm Loctite 270 See section “10.1
Included compo-
nents”
Gearbox mount- 8 27 Nm See section “10.2
ing screw (M8) Disassembly/
Assembly Leakage
from top cover”
Drive motor 5 45 Nm Punch mark See section “9.5
securing bolt Assembly of the
motor in the truck”
Swivel wheel 1 30-45 See section “12.3.4
locking axle Nm Replacing the
wheel”

General tightening torques
649 579903AA-
Date Order number
2004-08-01 215858-040
2.2 General tightening torques

Millimetre threads M3 to M24.
The following applies under ideal conditions, e.g. steel against steel.
Table 3: General tightening torques

M3 M4 M5 M6 M8 M10
B C B C B C B C B C B C
A Tightening torque in Newtonmetre Nm
8.8 1.15 1.2 2.8 2.9 5.5 5.7 9.5 9.8 23 24 45 47
12.9 2.0 2.1 4.7 4.9 9.3 9.7 16.3 17.0 38.5 40.0 75.8 79.0
M12 M14 M16 M20 M24

B C B C B C B C B C
A Tightening torque in Newtonmetre Nm
8.8 77,7 81 123 128 189 197 369.6 385 638.5 665
12.9 130.5 136 208 217 319.7 333 623 649 1075 1120
A = Strength grade
B = Galvanised, non-oiled bolts
C = Untreated, oiled bolts
NOTE!
Experience has shown that if you adjust the torque wrench to the val-
ues for untreated bolts, you will get the correct torque value for galva-
nised bolts.Do not tighten more than the values set out in the table
otherwise the bolts can be destroyed.

Truck dimensions
579903AA- 649
Order number Date
215858-040 2004-08-01
2.3 Truck dimensions
1425
450
1335-1420 1000-2900
180
450-685
790
Wa

Truck dimensions
649 579903AA-
Date Order number
2004-08-01 215858-040

Destruction instructions – M6
General
579903AA- 649
Order number Date
215858-040 2004-08-01
3- Destruction instructions – M6
OL 20, OL 25, OL 25 P
3.1 General
These instructions have been drawn up as part of BT's environmental
management program. An important motive is, by taking nature into
consideration, to economize with resources. In other words, you should
try to recycle material as far as possible. This is to minimise the dis-
charge of environmentally-hazardous substances.
The dismantling instructions are designed for an F-code (truck family)
and then divided into different C-codes (parts and functions on the
truck.) These C-codes are:
• 0000 Chassis
• 1000 Motors
• 2000 Transmission/drive transmission
• 3000 Brakes/belt/wheel system
• 4000 Steering system
• 5000 Electrical system
• 6000 Hydraulics/pneumatics
• 7000 Working function - lift frame
• 8000 Auxiliary/installation equipment
• 9000 Accessories/extra equipment
The instructions do not tell you the type of material the parts are made
of, but refer you to different material containers where the parts should
be collected. Some plastics are marked, which means some instruc-
tions refer to the marking to determine the collection container to use.
3.2 Procedure
When sorting a component part you must know what plastic parts, liq-
uids, environmentally hazardous substances and metals it incorpo-
rates.

Abbreviations
649 579903AA-
Date Order number
2004-08-01 215858-040
3.3 Abbreviations
Abbreviations for Service Manuals and plastic materials are used in the
dismantling instructions. The abbreviations used are:
ABS = Acrylonitrile-butadiene-styrene
PMMA = Plexiglass
PP = Polypropylene
SM = Service Manual
3.4 Sorting
The sorting method for component parts is based on how you can recy-
cle them and whether they must be handled in a special way.
• Plastics must first and foremost be sorted into recyclable and non
recyclable plastics. Plastics that can be recycled must be subdivided
to differentiate between the different types of plastic. Instructions ei-
ther indicate in which container the plastic should be placed or there
is a reference to the material marking on the plastic component. In
those cases where the container is indicated, the type of plastic is
shown by an abbreviation.
Sorting is not necessary for non-recyclable plastics. These are
placed in the container intended for combustible material.
• Small plastic and rubber items are placed in the container intended
for combustible material.
• Iron and steel scrap are sorted separately.
• Composite scrap that is difficult to dismantle and which contains dif-
ferent metals such as steel, aluminium, copper and other materials,
for example, plastics, should be sorted separately.
• Oil is collected in the intended container.
• Oil filters are collected in the intended container.
• Parts contaminated by oil, such as hydraulic hoses, should be sort-
ed separately.
• Batteries should be returned to the manufacturer, either directly to
the manufacturer or through BT.
• Electronic scrap should be sorted from other scrap.
• Cables should be removed and collected separately.
• Small parts, such as screw, bolts, nuts, washers, etc. are not includ-
ed in the dismantling instructions. These are placed in the container
intended for iron and steel scrap.

Hoods, hatches (0340)
579903AA- 649
Order number Date
215858-040 2004-08-01
3.5 Hoods, hatches (0340)
3.5.1 Dismantling
• Remove the hood (1).
• Remove the plastic handles (2).
• Remove the hatch (3).
3.5.2 Material handling

Hood and hatch should be treated as iron and steel scrap.
The plastic handles and panel should be placed in containers intended
for ABS.

Hoods, hatches (0340)
649 579903AA-
Date Order number
2004-08-01 215858-040
3.6 Hoods, hatches (0340)
3.6.1 Dismantling
• Remove the skidding protectionl (1).
• Remove the battery panel (2).

The skidding protection must be placed in a container intended for com-
bustible material.
The battery panel should be placed in a container intended for iron and
steel scrap.

Frame/chassis (0300) and forkframe (0380)
579903AA- 649
Order number Date
215858-040 2004-08-01
3.7 Frame/chassis (0300) and

forkframe (0380)
3.7.1 Dismantling
• For dismantling see SM.
• Dismantling of wheel see 3500.

The metal pieces should be placed in a container intended for iron and
steel scrap.
Material handling of wheel see 3500.

Seat, cushions (0620)
649 579903AA-
Date Order number
2004-08-01 215858-040
3.8 Seat, cushions (0620)
1
2
3.8.1 Dismantling
• Remove the cushion (1 or 2).

The cushion must be placed in a container intended for combustible
material.

Wall/floor covering (0670)
579903AA- 649
Order number Date
215858-040 2004-08-01
3.9 Wall/floor covering (0670)
1
2
3.9.1 Dismantling
• Remove the carpet (1).
• Remove the the plate (2).

The carpet must be placed in a container intended for combustible
material.
The plate is to be placed in a container intended for iron and steel
scrap.

Internal fittings (0680)
649 579903AA-
Date Order number
2004-08-01 215858-040
3.10 Internal fittings (0680)
1
1
3
3.10.1 Dismantling
• Remove the panels (1).
• Remove the carpet (2).
• Remove the skidding protection (3).
• Remove the foot step (4).

Panels should be placed in containers intended for ABS.
The carpet must be placed in a container intended for combustible
material.
The skidding protection must be placed in a container intended for com-
bustible material.
The foot step must be placed in a container intended for iron and steel
scrap.

Driver protection (0840)
579903AA- 649
Order number Date
215858-040 2004-08-01
3.11 Driver protection (0840)
3.11.1 Dismantling
• Remove the driver protection.

The driver protection should be placed in a container intended for iron
and steel scrap

Electric motors (1700)
649 579903AA-
Date Order number
2004-08-01 215858-040
3.12 Electric motors (1700)
1
3
3.12.1 Dismantling
• Remove the cables.
• Remove the steering motor (1).
• Remove the pump motor including pump (2) (see 6100).
• Remove the drive motor including the electric parking brake from the
gearbox (3).

Cables are to be placed in a container intended for cables.
The motors, pump and electric parking brake should be placed in a
container for dangerous waste.

Drive assembly/gear (2550)
579903AA- 649
Order number Date
215858-040 2004-08-01
3.13 Drive assembly/gear (2550)
3.13.1 Dismantling
• Empty the oil from the gearbox.
• Remove the gearbox from the drive motor (se SM).
• Remove the drive wheel.

The oil should be treated as dangerous waste.
The gearbox is to be placed in a container intended for iron and steel
scrap.

Wheels (3500)
649 579903AA-
Date Order number
2004-08-01 215858-040
3.14 Wheels (3500)
3.14.1 Dismantling
• Remove the drive wheel, support arm wheel, fork wheel and climber
wheel.

The vulcanised wheels should be placed in a container for vulcanised
wheels.
Climber wheels should be placed in a container for fragmentation
scrap.

Steering arm (4110)
579903AA- 649
Order number Date
215858-040 2004-08-01
3.15 Steering arm (4110)
1
3.15.1 Dismantling
• Remove the steering arm from the hatch (1).
• Remove the cable.

The steering arm should be placed in a container for dangerous waste.
The cable is to be placed in a container intended for cables.

General electronic equipment (5100)
649 579903AA-
Date Order number
2004-08-01 215858-040
3.16 General electronic equipment

(5100)
3.16.1 Dismantling
• Remove the cables.
• Remove the battery.

Cables are to be placed in a container intended for cables.
The battery (classified as hazardous waste within the EU) should be
returned to the battery manufacturer or the manufacturer's
representative (see the rating plate on the battery). The battery can
also be handed in to a BT representative, who bears responsibility for
returning the battery to the manufacturer.

Battery cut out connector/contactor (5190)
579903AA- 649
Order number Date
215858-040 2004-08-01
3.17 Battery cut out connector/

contactor (5190)
3.17.1 Dismantling
• Remove the electric panel with battery cut out connector/ contactor
and transistor panel.

All parts should be placed in a container for dangerous waste.

Extra I/O module (5730)
649 579903AA-
Date Order number
2004-08-01 215858-040
3.18 Extra I/O module (5730)
3.18.1 Dismantling
• Remove extra I/O module

All parts should be placed in a container intended for electronic scrap.

Hydraulic unit (6100)
579903AA- 649
Order number Date
215858-040 2004-08-01
3.19 Hydraulic unit (6100)

1710
1
2
3.19.1 Dismantling
• Empty the oil from the hydraulics.
• Remove oil-filter from tank
• Remove the hydraulic cables (see 6230).
• Remove the oil tank (2).
• Remove the hydraulic unit (motor + pump) (see 1710).

Oil should be treated as dangerous waste.
Oil-filter should be placed in a container for dangerous waste.
Hydraulic cables should be placed in a container for oil-contaminated
components.
The tank should be placed in a container for PP.
The motor, together with the pump, should be placed in a container for
dangerous waste.

Hydraulic lines chassis (6230) and main lift cylinders (6610)
649 579903AA-
Date Order number
2004-08-01 215858-040
3.20 Hydraulic lines chassis (6230) and

main lift cylinders (6610)
6610
6100
3.20.1 Dismantling
• Remove the cylinder.
• Empty the oil from the cylinders
• Remove hydraulic cables

The oil should be treated as dangerous waste.
Hydraulic hoses should be placed in a container for oil-contaminated
components.
Cylinder and hydraulic pipes are to be placed in a contained intended
for iron and steel scrap.

Charger adaptor (9380)
579903AA- 649
Order number Date
215858-040 2004-08-01
3.21 Charger adaptor (9380)

2
1
3.21.1 Dismantling
• Charger adaptor (1) comes with the battery.
• Remove the charger adaptor (2).

The charger adaptor (2) should be placed in a container for electronic
scrap.

Terminal on board (9410)
649 579903AA-
Date Order number
2004-08-01 215858-040
3.22 Terminal on board (9410)

1
3.22.1 Dismantling
• Remove housing (1).
• Remove the teminal (2).
• Remove the bracket (3).
• Remove the hose (4).
• Remove the spiral spring from the hose.
The terminal should be placed in a container for dangerous waste
The housing should be placed in a container for ABS.
The bracket and the spiral spring should be placed in a container
intended for iron and steel scrap.
The hose should be placed in a container intended for combustible
material.

Other extra equipment, tuck log device (9420)
579903AA- 649
Order number Date
215858-040 2004-08-01
3.23 Other extra equipment, tuck log

device (9420)
3.23.1 Dismantling
• Remove the truck log device.
• Remove wiring harness.

Truck log device should be treated as dangerous waste.
Wiring harness should be placed in a container intended for cables

Other extra equipment, load support (9500)
649 579903AA-
Date Order number
2004-08-01 215858-040
3.24 Other extra equipment, load

support (9500)
3.24.1 Dismantling
• Remove the load support.
• Remove the finger cover.

The load support and finger cover should be placed in a container
intended for iron and steel scrap

Other extra equipment, writing table (9500)
579903AA- 649
Order number Date
215858-040 2004-08-01
3.25 Other extra equipment, writing

table (9500)
1
3.25.1 Dismantling
• Remove the writing tabel (1).
• Remove the clamp (2).
• Remove the support (3).

The writing table must be placed in a container intended for PMMA.
The clamp and the support should be placed in a container intended for
iron and steel scrap

Other extra equipment, writing table (9500)
649 579903AA-
Date Order number
2004-08-01 215858-040
3.26 Other extra equipment, writing

table (9500)
1
3.26.1 Dismantling
• Remove the writing tabel (1).

The writing table and clamp must be placed in container intended for
combustible material.

Other extra equipment, support (9500)
579903AA- 649
Order number Date
215858-040 2004-08-01
3.27 Other extra equipment, support

(9500)
3.27.1 Dismantling
• Remove the support.

The support should be placed in a container intended for iron and steel
scrap

Other extra equipment, collision protection (9500)
649 579903AA-
Date Order number
2004-08-01 215858-040
3.28 Other extra equipment, collision

protection (9500)
3.28.1 Dismantling
• Remove the collision protection.

The collision protection should be placed in a container intended for
iron and steel scrap

Other extra equipment, working cage (9130)
579903AA- 649
Order number Date
215858-040 2004-08-01
3.29 Other extra equipment, working

cage (9130)
1
2
3
6
5 4
3.29.1 Dismantling
• Remove the 4 screws (6) that holds the working cage.
• Remove the hydraulic hose (7) from the lift cylinder.
• The working cage can now be lifted straight up.
The working cage (1) should be placed in a container intended for iron
and steel scrap.
The wiring harness with chain is dismounted and placed in a container
intended for ABS.
The wiring harness (3) should be placed in a container intended for
cables
The capet (4) should be placed in a container for dangerous waste
The sensing device (5) should be placed in a container intended for
electronic scrap.
Other extra equipment, working cage (9130)
649 579903AA-
Date Order number
2004-08-01 215858-040
This page is intentionally left blank

Installation and maintenance instructions –
P1
579903AA- 649
Order number Date
215858-040 2004-08-01
4- Installation and maintenance

instructions – P1
4.1 Truck installation
4.1.1 Lifting the truck
• Only lift the truck at the indicated lifting points using suitable lifting
equipment.
WARNING!
Risk of tipping.
The truck may tip over if it is lifted in the wrong places.
Always lift the truck at the indicated lifting points.
• Lift the truck at its centre of gravity using another fork lift truck.
• Fasten the truck to the forks of the lifting truck.
• Lift it very carefully
WARNING!
Risk of tipping.
The truck may tip over if it is lifted incorrectly.
Always lift the truck when it has been fastened to the forks of the lift-
ing truck and its centre of gravity between the forks.

P1
649 579903AA-
Date Order number
2004-08-01 215858-040
4.1.2 Battery installation

Check to make sure the battery cabling has been correctly connected
to the battery.
WARNING!
Risk of short-circuiting.
An incorrectly connected battery may cause short-circuiting.
The polarity must match. Compare the markings on the cables with
those on the battery poles.
The battery can be replaced from the sides or from above.
The truck is also supplied with shims. Use these to eliminate any play
between the battery and the battery compartment walls. If required,
install the shims as shown in the picture.
4.1.3 Putting into service

Prior to putting the truck into use, verify the items listed below.
Table 4: Pre-delivery inspection check-list

Pos. no. Inspection item Measure
1 Driving controls Verify correct function, forward/reverse
2 Hydraulic functions Verify correct function
3 Signalling Verify correct function
4 Steering Verify correct function
5 Operating hours Perform maintenance as described in the Maintenance section
6 Platform/Brake switch Verify correct function
7 Hydraulic system Inspect the oil level and check for oil leakage
8 Drive unit Check for noise and oil leakage
9 Brake Verify correct function
10 Chassis Check for damage, remove dirt, etc.
11 Wheels Check for damage, remove oil, chips, etc.
12 Lifting device Check for damage, remove dirt, etc.
13 Battery Inspect the battery acid level and charge level

P1
579903AA- 649
Order number Date
215858-040 2004-08-01
3 2 1 1 2 3
5
12
9
11
8
10
13
• Check to make sure all parameters are set to the desired values:
- Maximum speed.
- Acceleration.
- Automatic speed reduction.
- PIN codes (option).
P1
649 579903AA-
Date Order number
2004-08-01 215858-040
4.2 Introduction, maintenance

To assure maximum safety and minimum downtime, all items in the
service programme should be covered. The service intervals are only
guidelines and need not be strictly followed. The operator of the truck
should adapt these to local requirements, however, it is important that
the minimum requirements as stated by BT are observed.
The service intervals are based on truck operating hours and can be
adapted to most common 8-hour shifts. When calculating the service
intervals, the following operating hours have been used:
Day time: 08.00-17.00 (20 hours/week)
Double shift: 06.00-14.00, 14.00-22.00 (40 hours/week)
Triple shift: 06.00-14.00, 14.00-22.00, 22.00-06.00
(60 hours/week)
Make sure the truck receives the necessary regular maintenance serv-
ice according to the maintenance schedule. The truck's safety, efficien-
cy and service life rely on the service and maintenance the truck
receives.
For service and repairs, only use spare parts approved by BT.
4.2.1 Safety rules during maintenance work

Only technicians who have received the necessary training for service
and repairs of this truck type may carry out service and repair work.
• Do not perform any repair work on the truck unless properly trained
and possessing the necessary skills to perform such work.
• Keep the service site clean. Oil and water on the floor could make it
slippery.
• Never wear loose items and jewellery when working on the truck.
WARNING!
Short-circuiting/Burn injuries.
When working on the truck's electrical system, short-circuiting/burn
injuries may occur if metal objects come into contact with live electri-
cal connections.
Remove any watches, rings and other metal jewellery.
• Unless otherwise indicated in this service handbook, always discon-
nect the battery connector prior to performing maintenance work on
the truck.
• Prior to opening any covers to the drive unit and the electrical sys-
tem, be sure to disconnect the power supply to the truck.
• Prior to commencing any work on the hydraulic system of the truck,
be sure to slowly depressurize the system.

P1
579903AA- 649
Order number Date
215858-040 2004-08-01
• Use paper or a thick paper board to inspect possible hydraulic oil

leaks. Do NOT use your hand.
• Keep in mind that the transmission oil and hydraulic system oil may
be burning hot.
WARNING!
Risk of burn injuries.
Hot transmission and hydraulic oil.
Allow the truck to cool down prior to replacing the oil.
• Use only new and clean oil when refilling the hydraulic oil system.
WARNING!
Risk of damaging the hydraulic system.
If the oil is contaminated, the hydraulic system components will be
damaged.
Always use new and clean oil in the hydraulic system.
• Store and transport replaced oil in accordance with local regulations.
• Do not flush solvents, etc. used for cleaning into drains that are not
specifically suited for this. Follow local regulations with regards to
destruction of oil, solvents, etc.
• Disconnect the battery prior to performing welding work on the truck.
NOTE!
The battery could become damaged.
When using an electric welding system, the welding current could
reach the battery.
Be sure to first disconnect the battery.
• Prior to welding or grinding on painted surfaces, be sure to scrape
off the paint at least 100 mm around the welding/grinding site using
blasting or a paint remover.
CAUTION!
Unhealthy gasses.
Paint, which is heated, generates unhealthy gasses.
Remove the paint 100 mm around the working place.
4.3 Cleaning and washing

Cleaning and washing of the truck is important to assure a high level of
reliability.
• Clean and wash the truck once a week.
NOTE!
The electrical system can become damaged.
Prior to washing, be sure to disconnect the battery by disconnecting
the battery connector.

P1
649 579903AA-
Date Order number
2004-08-01 215858-040
4.3.1 External cleaning

• Remove dirt, chips, etc. from the wheels daily.
• Use a well-known degreasing agent, diluted to a suitable concentra-
tion.
• Wash off loose dirt using lukewarm water.
NOTE!
Seizure, corrosion.
Mechanical parts could become damaged.
Following washing of the truck, lubricate it according to the lubrica-
tion schedule in the Maintenance section.
4.3.2 Cleaning the motor compartment

• Prior to washing, cover all electric motors, connectors and valves.
NOTE!
The electrical system can become damaged.
Electric components must not be washed with a high-pressure jet.
• Wash the motor compartment with a well-known degreasing agent
diluted to a suitable concentration.
• Wash off loose dirt using lukewarm water.
4.3.3 Electric components

• Use compressed air to blow clean the electric motors.
• Clean electric panels, logic cards, connectors, valves, etc. with a rag
moistened with water and a suitable detergent.
NOTE!
Electric components can become damaged.
Avoid breaking the warranty seals on the logic cards.

P1
579903AA- 649
Order number Date
215858-040 2004-08-01
4.4 Safe lifting

Perform all lifts on level, slip-proof and firm surfaces. Avoid newly laid
asphalt on warm summer days.
• Always apply the parking brake to prevent the truck from moving
during lifting. If the brake wheel needs to be lifted, be sure to block
the other wheels to make sure the truck will stand still.
• Select a lifting point that will make the lift as light as possible (one
corner at a time). If the lifting point on the truck are indicated on the
lower part of the chassis, be sure to use this to assure balanced lift-
ing.
• Ensure that the surface where the jack is placed is clean and free
from oil.
• Use clean hands and make sure the jack handle is free from grease
and oil.
• Use the handle supplied with the jack. Too short a handle will require
more strength than necessary. Too long a jack may result in over-
loading of the jack.
• Secure the truck with trestles, etc.:
- As close to the lifted part of the chassis as possible in order to re-
duce the falling height if the truck should collapse.
- To prevent the truck from rolling.
- Never chock up the jack in order to achieve a higher lifting height.
- Never work under a lifted truck unless it has been securely
chocked up.
WARNING!
Risk of crushing.
A poorly chocked up truck may fall down.
Never work under a truck unless it has been securely chocked up us-
ing trestles or other safe hoisting gear.

P1
649 579903AA-
Date Order number
2004-08-01 215858-040

Maintenance, lubrication schedule – P2
Test drive
579903AA- 649
Order number Date
215858-040 2004-08-01
5- Maintenance, lubrication
schedule – P2
5.1 Test drive

Test drive the truck prior to each scheduled lubrication intervention. Lis-
ten for any noise during the test drive. Test the operation of the auto
plug brake and the reversing brake. Check the speed reduction and
steering response while driving the truck from the side. Operate the
hydraulic functions at the end strokes. Check the error log and the hour
meter reading and reset the service hour meter.
Table 5: Test drive schedule

Pos. no. Function
1700. Motors
1700.5 Inspect any noise in the bearing
2550. Drive unit
2550.3 Inspect any noise
3100 Brake
3100.1 Clean and verify correct functioning of the service
brake and parking brake

Maintenance schedule
649 579903AA-
Date Order number
2004-08-01 215858-040
5.2 Maintenance schedule
Table 6: Maintenance schedule

I: Inspect, adjust and replace if necessary. T: Tighten. C: Clean L: Lubricate.
M: Measure and adjust if necessary.
Pos. no. Work to be performed
Interval in hours - can vary depending on 5 20 500 1,000 3,000
application
Interval in days/weeks/months - can vary 1d 1w 6m 12 m 36 m
depending on application
0000. Chassis
0000.1 Inspect all links and tension bolts I
0000.2 Inspect possible damage on the chassis, open I
the battery cover and use it as an aid
0000.3 Inspect all cover locks I
0000.4 Inspect the finger protectors, load protectors I
0000.5 Inspect all plates and stickers I
0380 Fork carrier
0380.1 Inspect for cracking and other damage I
0380.2 Inspect any play in bushings and links I
0380.3 Force grease into the lubricant nipples (Note 6) I/L
0380.4 Inspect the lift limiter switch I
0380.5 Inspect the guide pins for wear and lubricate I/L
(Note 6)
0450 Frame-mounted components
0450.0 Inspect the mounting bolts of the motor plate I
1700. Motors
1700.1 Inspect any play in the connectors I/T1 I/T
1700.2 Inspect the carbon brushes in the drive motor M
1700.3 Clean the drive motor C
1700.4 Tighten all mounting bolts T2
1700.5 Inspect any noise in the bearings I

579903AA- 649
Order number Date
215858-040 2004-08-01

application
2550. Drive unit
2550.1 Check for leakage I3 I
2550.2 Inspect the oil level I
2550.3 Inspect any noise I
2550.4 Inspect the mounting and any play in the guide I
bearing
2550.5 Replace the drive gear oil L4 L
2550.6 Lubricate the gear rim L
3100 Brake
3100.1 Clean and verify correct functioning of the serv- C/I
ice brake and parking brake
3100.2 Inspect brake disc wear and verify correct tight- M
ening torque (48 Nm)
3100.3 Inspect play in the neutral position M
3500. Wheels
3500.1 Remove strings, dirt, etc. I
3500.2 Inspect drive wheel wear and its mounting I
3500.3 Verify that the swivel wheel rotates and turns I
freely. Lubricate the horizontal bearing. Inspect
swivel wheel wear and its mounting
3500.4 Verify that the truck is level in order to achieve M
correct drive wheel pressure

649 579903AA-
Date Order number
2004-08-01 215858-040

application
4110. Steering unit
4110.1 Inspect any steering response restrictions and I
jogging
4110.2 Inspect any play in steering couplings and the I
return spring
4110.3 Inspect mechanical locking of the steering arm I
and its centre position
4110.4 Inspect the gear of the steering servo-unit I
4110.5 Inspect correct mounting of the steering linkage I
on both sides
5000. Electric functions
5000.1 Inspect correct operation of the micro brake I I
switch
5000.2 Inspect correct operation of the emergency stop I I
switch
5000.3 Check lifting/lowering the forks I
5000.4 Inspect correct operation of the platform switch I I
5000.5 Inspect correct operation of the horn I I
5000.6 Inspect cable wear I
5000.7 Inspect correct operation of operator controls I I
5000.8 Inspect the error code log, operating hours and I I
all segments in the display panel
5110. Battery
5110.1 Inspect the electrolyte level: 10-15 mm above M
the cell plates
5110.2 Inspect all battery, truck and charger connec- I
tions
5110.3 Verify that the cell and pole protectors are not I
damaged
5110.4 Inspect the fluid density and temperature M
5110.5 Suck up excess fluid from the battery pan C
5110.6 Verify the battery locking device I

579903AA- 649
Order number Date
215858-040 2004-08-01

application
5400 Power system
5400.1 Clean and inspect the mounting devices C/T
5400.2 Tighten all cable connectors T
5400.3 Inspect the K10 and K30 contactor tips I
5400.4 Inspect contactor mobility I
6100. Hydraulic system
6100.1 Inspect hoses and couplings for leakage I
6100.2 Inspect hoses for wear I
6100.3 Inspect the tank I
6100.4 Replace the oil and clean the filter L5 L
6600. Lift cylinder
6600.1 Check for leakage I
6600.2 Inspect the mounting I
7120 Lifting chain
7120.1 Inspect the lifting chain and chain wheel for I
wear
7120.2 Inspect the adjustment of the lifting chain. I/M
Inspect the chain bolts and the chain mountings.
Retighten the locking nuts and inspect the safety
cotter pins on the chain.
7120.3 Lubricate the lifting chain L

649 579903AA-
Date Order number
2004-08-01 215858-040

application
9130 Operator’s cabin
9130.1 Side guides (Note 6) I/L
9130.2 Outer side guides (Note 6) I/L
9130.3 Screw joint reinforcement I
9130.4 Guide member joint I
9130.5 Cable chain I
1 = Retighten all connections the first time after 500 hours, and then
every 1,000 hours.
2 = Retighten the mounting bolts after 500 hours to a torque of 45 Nm.
3 = Inspect for leakage during initial oil replacement.
4 = Replace the oil the first time after 500 hours/6 months and then eve-
ry
3,000 hours/36 months.
5 = Replace the oil and clean the filter the first time after 500 hours/6
months and then every 1,000 hours/12 months.
6 = Repeat every 250 hours if the truck is operated in cold stores or oth-
er harsh environments.
Unless otherwise indicated, whenever performing service according to
longer service intervals, all service items at shorter intervals should
also be carried out.
.

579903AA- 649
Order number Date
215858-040 2004-08-01
5000
5700
5000
4110
0380
54
3500 3
7120 6600
0000
5100
9130 6100
0450
2550
3500

Lubrication schedule
649 579903AA-
Date Order number
2004-08-01 215858-040
5.3 Lubrication schedule

Table 7: Lubrication schedule
Pos. no. Service item Interval/Operating Lubricant
hours
500 1,000 3,000
h h h
0380 Lubricant nip- L A
ples, guide
pins
2550 Driving gear O4 I O C
2550 Gear rim L E
3500 Swivel wheel L F
6100 Hydraulic sys- O5 O B
tem
7120 Lifting chain S D
9130.1 Side guide S A
9130.2 Side guide A
L = Lubricate I = Inspect O = Oil replacement
4 = Replace the oil the first time before 500 hours and after that every
3,000 hours/36 months.
5 = Replace the oil and clean the filter the first time before 500 hours
and after that every 1,000 hours/12 months.
7120
0380
6100
9130 2550
3500

Oil and lubricant specifications – P3
579903AA- 649
Order number Date
215858-040 2004-08-01
6- Oil and lubricant

specifications – P3
Table 8: Oil and lubricant specification

Lubricant Specification Application
> - 15°C < - 15°C
A Grease S213366 S213366 Bearings and bushings
Q8 Rubens WB Q8 Rubens WB
B Hydraulic oil ISO-L-HM32 ISO-VG32 Hydraulic system
C Transmission oil Hypoid oil Hypoid oil Gears
SAE 80W/90 SAE 75W
D Chain spray See the table See the table Chain lubrication
below below
E Grease Grafloscon Grafloscon Gear rim
A-G1 (Klüber) A-G1 (Klüber)
F Grease BT 755711-040 BT 755701-040 Swivel wheel
Pos. Environmen- Viscosity Recommended products*

tal tempera- class
ture
D > - 40°C VG 15 Klüberoil 4UH 1-15, Klüber Lubrication
< - 30°C
D > - 30°C VG 68 Klüberoil 4UH 1-68N, Klüber Lubrication
< + 5°C Anticorit LBO 160 TT, Fuchs DEA
D > + 5°C VG 150 Klüberoil 4UH 1-150N, Klüber Lubrication
< +45°C
Anticorit LBO 160, Fuchs DEA
Rexoil, Rexnord Kette
D >+ 45°C VG 220 Klüberoil 4UH 1-220N, Klüber Lubrication
<+ 80°C
* Similar products from other manufacturers may be used.

Oil and lubricant specifications – P3
649 579903AA-
Date Order number
2004-08-01 215858-040

Tools – P4
Super Seal connectors
579903AA- 649
Order number Date
215858-040 2004-08-01
7- Tools – P4
7.1 Super Seal connectors
3
3
Figure Number Application

159232 Tools for fitting pins/sleeves
159229 Tools for loosening locks (1)
159230 Tool for fitting secondary locks

1-2 poles (2)
159231 Tool for fitting secondary locks

3-6 poles (2)
159228 Tools for removing pins/sleeves (3)

Tools – P4
AMP connectors
649 579903AA-
Date Order number
2004-08-01 215858-040
7.2 AMP connectors

PT = Power Timer (4,8. 5,8. 6,3 mm)
JPT = Junior Power Timer (2,8 mm)
MPT = Micro Power Timer (1,5 mm)

151080 (PT) Tools for removing pins/sleeves
213296 (JPT) Tools for removing pins/sleeves
213298 (MPT) Tools for removing pins/sleeves
1=163787 Tools for fitting sleeves

2=163788
1=213336 (MPT)
2=213337 (MPT)
1
2
1=213336 (JPT) Tools for fitting pins
2=213549 (JPT) For 0,5-2,5 mm2
1
2

Tools – P4
Molex connectors
579903AA- 649
Order number Date
215858-040 2004-08-01
7.2.1 AMP Connectors, 040 series

213130 Pin removal tool
213129 Tools for fitting pins
7.3 Molex connectors

16
9
8
1
156937 Tools for fitting pins/sleeves
156936 Tools for fitting sleeves/pins

Tools – P4
Other tools
649 579903AA-
Date Order number
2004-08-01 215858-040
7.4 Other tools

156263 Service instrument (CAN)
1=163793 Service instrument for pro-

2=163792 gramme changes
1=155619-001 1= Service instrument for Curtis

2=166161 transistor panel
3=166473 2= Cable for Curtis 1243 and
1207 A
Both cables are 3= Cable for Curtis 1207
included when
ordering 155619-
001

Tools – P4
Other tools
579903AA- 649
Order number Date
215858-040 2004-08-01

08-13022 Driving gear puller

Tools – P4
Other tools
649 579903AA-
Date Order number
2004-08-01 215858-040

Fork carriage – 0380
Included components
579903AA- 649
Order number Date
215858-040 2004-08-01
8- Fork carriage – 0380
8.1 Included components

15
16 35
17
23
22
21
20 19 18
34
33 24
25
26
32
31 27
29
30 28
14
13
12
11
© BT Europe AB Service ManualGuide OPUS OL 25, OL 25 PApproved by: Stefan Blom 8- 1

Included components
649 579903AA-
Date Order number
2004-08-01 215858-040
Pos. Name Notes

11 Roller Initially lubricated
12 Groove ring
13 Cup spring Reduce play using 2-4 cup springs
14 Guide
15 Wheel fork
16 Bushing
17 Axle
18 Lubricant nipple
19 Tensioning pin
20 Axle
21 Lubricant nipple
22 Bushing
23 Sleeve
24 Bushing
25 Axle
26 Washer
27 Screw
28 Axle
29 Bushing
30 Axle
31 Lubricant nipple
32 Bushing
33 Lubricant nipple
34 Rotating pipe
35 Tensioning pin
8- 2 © BT Europe AB Service ManualGuide OPUS OL 25, OL 25 PApproved by: Stefan Blom

Disassembly of the fork carriage
579903AA- 649
Order number Date
215858-040 2004-08-01
8.2 Disassembly of the fork carriage

• Place supports under the chassis on both sides of the truck, as
shown in the picture.
• Disassemble the seat back components, as shown in the picture be-

low.
• Undo the banjo bolt (A) on the hydraulic connector and loosen the
bolts (B) holding the lift cylinder in place.
• Lift out the fork carriage.

NOTE! Keep in mind that the lift cylinder is lying loose in the fork
back.

Roller replacement
649 579903AA-
Date Order number
2004-08-01 215858-040
Assembly is done in reverse.
8.3 Roller replacement

• Remove the guide (14) and the cup springs (13), disassemble the
groove ring (12) and remove the roller (11).
11
12
13
14

Reduce the play between the guide (14) and girder using 2-4 cup
springs (13).

Electric drive motor – 1760
Included components
579903AA- 649
Order number Date
215858-040 2004-08-01
9- Electric drive motor – 1760

D
3
4
5
6
4 7
8
9
10
11
12
13
14
15
16
17
18
19
20 21
22
23
24
25
26

Included components
649 579903AA-
Date Order number
2004-08-01 215858-040
Pos. Name Notes

1 Screw M6x25
2 Screw M5
3 Bearing plate N side
4 Lock ring
5 Washer
6 Bearing 6205 HT24B
7 Guard ring
8 Carbon
9 Carbon bridge
10 Screw M5x20
11 Rotor
12 Wedge 4x6x16
13 Guard
14 Pole connector
15 Stator housing
16 Bearing plate D side
17 Fan
18 Screw M5
19 Tensioning bushing
20 Sealing flange
21 O-ring
22 Seal
23 Bearing 6204 ZC3
24 Lock ring
25 Ring
26 Lock ring

General
579903AA- 649
Order number Date
215858-040 2004-08-01
9.2 General
The drive motor is integrated with the brake and assembled together
with the driving gear to form a complete drive unit.
The drive motor uses an independent excitation design. It consists of a
field winding and armature winding, which are separately controlled
Armature current is transferred in the conventional manner using car-
bon brushes (8 pcs.) lying against the armature commutator.
The rotational direction of the motor can be reversed by changing the
direction of the field current.
9.3 Mechanical design

The motor consists of a housing, in which the stator windings are per-
manently fixed.
In the bearing box at one end, there is a carbon bridge holding four dou-
ble, spring-loaded carbon brushes, constituting the motor's commuta-
tor end. The carbon brushes rest against the rotor commutator and as
such are responsible for feeding rotor current to the rotor windings.
One bearing of the rotor is mounted on the bearing plate at the commu-
tator end.
The rotor bearing at the motor drive end is designed to allow mounting
of the bearing on a guide, which, together with the bearing, is pressed
onto the rotor axle. The rotor axle is centred following final assembly of
the guide in the driving gear housing.
All motor windings are accessible via external connections.
9.4 Disassembly of the motor from the

truck
• Switch off the truck and disconnect the battery connector.
• Remover the motor compartment cover.
• Disconnect the motor cables (A).
• Disassemble the brake (B).
• Unscrew the five screws holding the motor shield against the motor
plate (C).

Assembly of the motor in the truck
649 579903AA-
Date Order number
2004-08-01 215858-040
• Lift out the motor and place it on a clean surface. Cover the driving
gear opening.
It is now possible to commence with the necessary service and repairs
of the motor.
9.5 Assembly of the motor in the truck

• Assembly is done in reverse.
• Place a new O-ring on the sealing flange (22) on the drive axle.
• Carefully lower the motor onto the driving gear while making sure
the seals and gear wheels are not damaged.
• Tighten the five screws holding the motor shield in place against the
motor plate to a torque of 45 Nm.
• Connect the motor cables. Verify that the polarity is correct. Connect
the brake.
• Verify brake operation.

Service and repairs
579903AA- 649
Order number Date
215858-040 2004-08-01
9.6 Service and repairs
9.6.1 Disassembly of the motor

1
3
4
5
6
4 7
8
9
10
11
12
13
14
15
16
17
18
19
20 21
22
23
24
25
26

Service and repairs
649 579903AA-
Date Order number
2004-08-01 215858-040
9.6.2 Disassembly, N side

• Remove the carbon brushes (8).
• Loosen the screws (1).
• Disassemble the bearing plate (3).
• Disassemble the lock rings (4).
• Disassemble the washer (5).
• Disassemble the bearing (6).
9.6.3 Disassembly, D side

• Disassemble the lock ring (26).
• Disassemble the ring (25).
• Disassemble the sealing flange (20).
• Disassemble the lock ring (24).
• Disassemble the bearing (23.
• Disassemble the seal (22).
• Disassemble the fan (17). If necessary, use a slide hammer.
• Disassemble the tensioning bushing (19).
9.6.4 Wearing parts

The following components constitute parts that wear out and need to be
replaced whenever necessary.
• Carbon brushes (8)
• Bearing (6)
• Bearing (23)
• Rotor (11)
The bearing plate (3) and carbon bridge (9) are supplied as a single unit
from the supplier in order to safeguard the truck speed upon replacing
these parts.

Technical data
579903AA- 649
Order number Date
215858-040 2004-08-01
9.6.5 Cleaning
To assure proper truck operation, it is important to keep the motor
clean. Make sure the motor and motor compartment are free from dust,
oil and other contaminants.
If the motor windings and internal compartments are dry, use a vacuum
cleaner with a suitable nozzle to clean the motor. Compressed air may
be used in combination with a vacuum cleaner, however, in this case,
the compressed air should be clean and dry.
If there are deposits on the windings, use a lint-free rag, if necessary
moistened with an organic grease solvent and a volatile cleaning agent
that do not damage the windings. However, do not use too much clean-
ing agent as it will penetrate into the motor parts.
Cleaning agent remains must be removed, using a suitable solvent, if
grease deposits are left on the surface.
If the motor components are heavily contaminated, it may be necessary
to use a solvent that is sprayed onto the parts. It is especially important
for the rotor that the cleaning agent is applied in a manner that avoids
contaminants from penetrating into the motor section.
One method to clean the rotor is to submerge it in solvent. If the rotor is
cleaned in this way, it should always be dried using warm air. While dry-
ing the rotor, make sure the work site is well ventilated. Drying should
continue until several measurements of the insulation resistance have
been made and the measurements are similar and result in passing
results.
9.7 Technical data
Type TSL 160 A-DS60

Power, kW 2.5
Intermittence S2 60 min.
Min. carbon brush length, mm 11
Min. commutator diameter, mm 68
Resistance, shunt field winding, Ω at 0.346
24°C
Resistance, armature winding Ω at 24°C 0.0098
Weight, kg 23

Technical data
649 579903AA-
Date Order number
2004-08-01 215858-040

Driving unit/gear – 2550
579903AA- 649
Order number Date
215858-040 2004-08-01
10- Driving unit/gear – 2550
2
1 3
4
5
6
10
16 17 7
15 8
9
14
11
12
13
Included components
649 579903AA-
Date Order number
2004-08-01 215858-040

Pos. Name Notes
1 Motor gear wheel
2 Locking nut Tightening torque 130 Nm
Centre punch to lock
3 Primary gear wheel
4 Tapered roller bearing
5 Shim
6 Shim
9 Locking nut Tightening torque 400 Nm
Centre punch to lock
10 Cover
11 Screw Tightening torque 25 Nm
Lock using Loctite 242
12 Shim
13 Pinion/crown wheel Gear play 0.09-0.15 mm.
Pretighten the bearing by 2-5/100.
The punched measure in the pin-
ion should be adjusted using
shims.
14 Drive axle
15 Wheel bolt Tightening torque 90 Nm
Lock using Loctite 270
16 Jointing ring Fill the jointing ring with grease
Seal using Loctite 574
Disassembly/Assembly Leakage from top cover
579903AA- 649
Order number Date
215858-040 2004-08-01
10.1.1 Technical data

Truck type OL 25 / OL 20
Gear type 2-stage angle gear
Gear ratio 14.20:1
Oil volume, litres 1.75
Oil type Hypoid oil
Viscosity, normal tempera- SAE 80W/90
ture
Viscosity, <-15°C SAE 75W
10.2 Disassembly/Assembly
Leakage from top cover
• Raise the truck and properly secure it using trestles.
• Unscrew the drive wheel.
• Unscrew the M8 bolts securing the gear unit in the gear cover using
a 6 mm Allen key. Hold the gear unit to prevent it from falling down.

• Seal the gear unit against the cover using Loctite 547.
• Tighten the M8 bolts to a torque of 27 Nm.
10.3 Replacing the drive axle jointing

ring
When replacing the drive axle jointing ring, the gear unit can remain
installed on the truck.
If the drive axle leaks oil, follow the instructions below.
Replacing the drive axle jointing ring
649 579903AA-
Date Order number
2004-08-01 215858-040
10.3.1 Disassembly
7 6 5 2
4
• Remove the drive wheel from the gear unit.
• Remove the lower gear cover and drain the oil (2).
• Loosen the drive axle nut. Remove the nut and the spacer ring (3).
• Carefully knock out the drive axle using a brass mandrel and ham-
mer (4).
• Pull out the bearing from the drive axle using the bearing removal
tool 08-13022 (5).
• Verify that the bearing plates are free from damage. If the plates
have been damaged by the bearing puller, then measure the total
thickness of the spacing washers and replace them prior to assem-
bly (6).
• Remove the jointing ring from the drive axle (7).
10.3.2 Assembly
Assembly of the gear unit after replacement of the drive axle jointing
ring is done in reverse.
Pay special attention to the following during assembly:
• Fill the jointing ring with grease after setting it on the drive axle.
• Ensure that only undamaged spacing washers of equal total thick-
ness as the original spacers are set on the drive axle.
• Press on the bearing on the drive axle, making sure not to damage
the bearing spacing washers.
• During assembly of the drive axle with attached bearing, spacing
washers and jointing ring, make sure the placement of the axle
wedges coincide with the crown wheel wedges and that the bearing
and jointing ring are properly positioned on the axle prior to pressing
the axle into the final position.
Replacing the wheel bolt
579903AA- 649
Order number Date
215858-040 2004-08-01
• Place the spacer ring on the drive axle end and then screw on the
axle nut. Be sure to always use a new nut. Tighten the axle nut to a
torque of 400 Nm, and lock it with one centre punch in the middle.
Lubricate the drive axle nut prior to setting it on the axle.
• Replace the O-ring before mounting the lower cover. Make sure it is
not damaged. Fit the cover and tighten the bolts to a torque of 25
Nm. Lubricate the bolts prior to mounting. Fill with oil according to
the oil filling instructions.
Fit the drive wheel and tighten the wheel nut to a torque of 90 Nm.
Lubricate the wheel nut prior to mounting.
10.4 Replacing the wheel bolt

The wheel bolts on the gear unit are so-called pin bolts. To replace a
wheel bolt, proceed as follows:
• Disconnect the battery connector.

• Lift the machine using a lift jack and properly secure it using trestles
and wooden blocks.
• Remove the drive wheel.
• Wheel bolts with damaged threads can be removed using the pin
bolt tool.
• Broken wheel bolts:
• Method 1: Drill a hole in the centre of the bolt and unscrew the bolt
using an M14 bolt removal tool.
Replacing the wheel bolt
649 579903AA-
Date Order number
2004-08-01 215858-040
• Method 2: If the bolt cannot be removed with the bolt removal tool,
then drill it out.
- Make one centre punch in the bolt centre. Pay attention to correct
centring of the punch.
- Pre-drill a hole through the bolt using a 5 mm drill steel.
Drill out the bolt using an 11.5 mm drill steel.
- Try to remove the bolt remains using pliers, etc. If this is not pos-
sible, remove the bolt remains by cleaning the thread with an
M14x1.5 thread tap.
• Apply a string of LOCTITE 270 onto the wheel bolt thread.
Fit the new wheel bolt using the pin bolt tool.
Tightening torque 90 Nm.
• Fit the drive wheel. Tighten the wheel nuts to a torque of 90 Nm.
• Remove the trestle or wooden blocks and lower the truck to the
ground.
• Reconnect the battery connector.
Electromagnetic brake – 3370
579903AA- 649
Order number Date
215858-040 2004-08-01
11- Electromagnetic brake – 3370
1
2
12 3
11 4
5
10
9 8 7 6
13
A A
A-A
Included components
649 579903AA-
Date Order number
2004-08-01 215858-040

Pos. Name Notes
1 Magnet housing
2 Screw 3 pcs.
3 Pressure plate
4 Sleeve
5 Shims for air gap 1 pc. = 0.5 mm
adjustment 5 pcs. = 0.13 mm in each position
6 Friction plate, brake Nom. thickness: 9.7 mm
disc Min. thickness: 7.7 mm
7 O-ring
8 Hub
9 Mounting plate
10 Screw 3 pcs.
11 Spring 8 pcs.
12 Cable with connector
13 Screw for manual Not included
release M6
11.2 Disassembly
• Lift out the brake assembly from the motor axle.
• Place the brake assembly on a clean surface.
• Gradually unscrew the adjusting screws (2) in order to release the
spring tension evenly and little by little.
11.2.1 Inspection
Inspect all parts for damage and/or wear.
• Be sure to especially examine the brake disc (6) and the wear sur-
face on the pressure plate (3).
• Inspect the springs (11) and spacers (4,5) for damage.
• Inspect the hub splines (8) and the friction plate splines (6) for damage.
• Inspect the magnet plate (1) and pressure plate (3) for swelling/de-
formations and other damage.
Assembly
579903AA- 649
Order number Date
215858-040 2004-08-01
11.3 Assembly
• Carefully clean all parts.
• Assembly of the brake assembly is done in reverse of disassembly.
• Pay attention to the following:
- The holes in the pressure plate (3) must be centred with the cor-
responding holes in the magnet housing.
- The correct number of springs is installed.
- The play of 0.25-0.38 mm is correctly set. Adjustment may be re-
quired.
NOTE!
The friction surfaces must not come into contact with oil or grease
since this will seriously impair braking performance.
13 11.4 Manual release of the brake

The brake can be manually released, e.g. if the brake is broken and the
A A truck needs to be moved to the service area or to facilitate easier cen-
tring of the brake disc during assembly. To release the brake, gradually
screw in the two screws (13) evenly.
WARNING!
Lost braking function.
A-A Braking does not work when the brake has been manually release.
Drive the truck at reduced speed and be very careful.
Do NOT forget to remove the screws after completed work.
11.5 Adjustment
11.5.1 Adjusting the play
9,5 Nm
0,25-0,38 mm 4
5
• Measure the play in three different positions.

• Adjust the play by removing the shims (5).
Adjustment
649 579903AA-
Date Order number
2004-08-01 215858-040
Swivel wheel – 3540
General
579903AA- 649
Order number Date
215858-040 2004-08-01
12- Swivel wheel – 3540
12.1 General
The truck has an adjustable swivel wheel assembly holding a single
wheel. It is easily accessible once the front cover of the chassis has
been removed.
Correct adjustment of the swivel wheel height is very important for the
drive wheel pressure and the braking performance of the truck. This is
why the height of the swivel wheel should be regularly adjusted at inter-
vals of 500 operating hours because of the wear on the drive wheel.
The bearings in the swivel wheel assembly have been sealed and lubri-
cated at the factory. The swivel wheel bearings should be lubricated at
intervals of 500 operating hours.
Main component of swivel wheel
649 579903AA-
Date Order number
2004-08-01 215858-040
12.2 Main component of swivel wheel
1
2
3
7
4
8
5
9 6
10
11
12
13
14
15
16
17
Maintenance
579903AA- 649
Order number Date
215858-040 2004-08-01
Pos. no. Description

1 Locking screw
2 Top plate
3 Locking screw for height adjustment
4 Height adjustment
5 Swivel arm
6 Spacing sleeve
7 Groove ring
8 Wheel fork
9 Wheel axle
10 Spacing bolt
11 Swivel wheel
12 Wheel bearing
13 Spacer
14 Guard
15 Swivel bearing lubricant nipple
16 Swivel bearing
17 Top bolt
12.3 Maintenance
The swivel wheel should be lubricated at regular intervals. As a result of
wear on the drive wheel, the height of the swivel wheel must be
inspected at intervals of 500 operating hours. This is due to the
importance of the relative height of the swivel wheel in relation to the
drive wheel.
Maintenance
649 579903AA-
Date Order number
2004-08-01 215858-040
12.3.1 Swivel wheel height inspection

:
• Park the truck on a level floor.

• Remove the motor cover and the two brackets that keep the cover
closed against the chassis.
• Use a water level and place it on the motor plate in the motor com-
partment.
• If the motor plate is not level, adjust the swivel wheel height as ex-
plained in the following section.
Maintenance
579903AA- 649
Order number Date
215858-040 2004-08-01
12.3.2 Swivel wheel height adjustment
3
4
To achieve the correct pressure on the drive wheel, the swivel wheel
should be adjusted so that the motor plate is level.
Adjust the swivel wheel

• Each time a new swivel wheel and/or drive wheel is mounted on the
truck.
• When during regular maintenance inspection the truck is found not
to be level.
Adjustment
• Park the truck on a level floor.
• Remove the motor cover and the two brackets that keep the cover
closed against the chassis.
• Remove the front cover of the chassis to gain access to the swivel
wheel assembly.
• Turn the swivel wheel to gain access to the lock screw. Loosen the
lock screw, 3, to release the adjusting screw, 4.
• Turn the adjusting screw, 4, until the truck is level.
• Lock the adjusting screw, 4, using the lock screw, 3.
12.3.3 Replacing the swivel wheel

When replacing components in the swivel wheel assembly, it is neces-
sary to always remove the front cover of the chassis. Further, it is easier
to carry out work on the swivel wheel when the entire assembly has
been disassembled from the chassis.
Maintenance
649 579903AA-
Date Order number
2004-08-01 215858-040
Disassembly of the swivel wheel assembly

• Disassemble the swivel wheel assembly by removing the four
mounting bolts.
12.3.4 Replacing the wheel

Disassembly
• Loosen the wheel axle nut and punch out the axle.
• Remove the wheel together with the axle cap and bearing.
Assembly
• Place the axle cap and bearing on the wheel axle prior to assembly.
• Press the wheel axle in place.
• Fit the locking nut on the wheel axle and tighten it to a torque of 30-
45 Nm.
• Always replace the spring washer when replacing the wheel.
NOTE! Verify that the wheel does not seize. It should rotate by means
of hand power.
12.3.5 Replacing the wheel bearing

• Disassemble the wheel from the wheel fork as explained in the pre-
vious section.
• Press out the spacing sleeve and punch out the bearing race on one
of the sides.
• Turn over the wheel and punch out the other bearing race.
• Press a new bearing race into place.
• Place the spacing sleeve in the hub.
• Lubricate the wheel.
• Mount the wheel as explained in the previous section.
Electrical steering system – 4300
General
579903AA- 649
Order number Date
215858-040 2004-08-01
13- Electrical steering system – 4300
13.1 General
The electrical steering system consists of the steering unit (A) and
steering servo (B). A potentiometer in the steering system sends infor-
mation to the electronic module in the steering servo system. When
starting the truck, a drive reference measurement is performed and the
drive wheel position is calibrated using the reference sensor (C)
Electrical steering servo
649 579903AA-
Date Order number
2004-08-01 215858-040
13.2 Electrical steering servo
13.2.1 General
The electrical steering servo consists of twin potentiometers connected
to an electronic module in the motor compartment. The electronic mod-
ule, which is also referred to as the EPS (Electrical Power Steering), is
directly mounted on a Brush-Less Permanently Magnetised servo
motor (BLPM). The motor has a power amplifier that consists of 2-stage
planetary gearing with a gear wheel mounted on a trailing journal and
locked with a nut. The gear wheel is meshed with the gear ring on the
driving wheel gear, and as such the drive unit also handles steering of
the truck.
The steering system is electric and uses a "Steer-By-Wire" design. This
means there is no mechanical contact between the steering unit and
the truck's steering wheel.
The electronic module monitors all electrically connected components.
Monitoring is continuous enabling instant detection of possible cable
interruptions. Electrical faults detected in potentiometers, cables and
the electronic module result in automatic switch-off of the truck's drive
mode and application of the electromechanical brake.
An automatic drive reference mesurement is performed at each start-

up after a no-voltage state. During this calibration, the truck cannot be
driven. The drive reference mode safety-checks the system and simul-
taneously calibrates the wheel position.
Steering is progressive, implying slow-down of the travel speed at large
steering angle throws. This promotes safe and efficient truck travel. A
certain steering response in the steering unit results in an increasingly
greater steering response in the steering wheel. This is a result of the
steering unit being limited to a +/- 60 degree steering response with the
steering wheel providing a -100 to 90 degree steering response.
Steering servo components
579903AA- 649
Order number Date
215858-040 2004-08-01
13.3 Steering servo components

3 2
1
8
9
10
11
10
12
Adjustment
649 579903AA-
Date Order number
2004-08-01 215858-040
Pos. Name
1 Screw
2 Electronic module
3 Seal
4 Motor
5 Drive
6 Washer
7 Nut
8 Screw
9 Guide
10 Nilos ring
11 Pilot bearing
12 Gear rim
13.4 Adjustment
13.4.1 Reference sensor

After replacement or adjustment of the reference sensor, screw it all the
way down until it makes contact with the top of the gear ring (12).Then
screw it upwards two full turns and lock it with the nut. Calibrate the sys-
tem using parameters 36 and 37.
13.4.2 Calibration
Calibration and adjustment of the steering servo is accomplished using
parameters 36 and 37.
Adjustment
579903AA- 649
Order number Date
215858-040 2004-08-01
Parameter 36
Parameter 36 calibrates the steering servo and must be adjusted when
the following components are replaced.
• complete steering servo assembly or parts of the steering servo as-
sembly
• reference sensor
• potentiometer
• following any work on the steering unit
Detailed instructions as to the function of parameter 36 are presented in
C code 5000.
Parameter 37
Parameter 37 adjusts the drive wheel centre position. The wheel can be
adjusted 30 degrees to either side. Prior to adjustment of parameter 37,
parameter 36 must be adjusted to ascertain the wheel's zero position.
Detailed instructions as to the function of parameter 37 are presented in
C code 5000.
Steering unit
649 579903AA-
Date Order number
2004-08-01 215858-040
13.5 Steering unit
13.5.1 Steering unit handle
11
12
26
13
24 14 15
23
25 16
17
20 18
19
22
21
01 32 33 34 35
30 31
29
27
28
36
43
02
37
42 38
46
41
45
40
44 39
Fig. 1Steering unit handle
Steering unit
579903AA- 649
Order number Date
215858-040 2004-08-01
Pos Description Notes

01 Bracket
02 Axle
11 Housing See next illustration
12 Screw
13 Washer
14 Clamp
15 Clamp
16 Screw
17 Screw
18 Cover (Incl. keypad)
19 Screw
20 Screw
21 Screw
22 Housing(lower)
23 Cap(Front)
24 Screw
25 Housing(upper)
26 Handle
27 Bearing
28 Spring
29 Washer
30 Springt
31 Sleeve
32 Screw
33 Washer
34 Washer
35 Bearing
36 Bracket
37 Plate
38 Screw
39 Led
40 Cover plate
41 Sensing device
42 Screw
43 Pin
44 Axle
45 Screw
46 Washer
Steering unit
649 579903AA-
Date Order number
2004-08-01 215858-040
13.5.2 Steering unit controls housing

51
50
13
14
12
15
16
17 24
23
18
19
11 26 25
20
37 21 22
38 36
39
35
33 34
31
30
32
29 27
40
01 41
49
43
48
47
44 46
42
43
41
40
45
Fig. 2Steering unit & controls housing

Steering unit
579903AA- 649
Order number Date
215858-040 2004-08-01
Pos Description Note

01 Speed control
11 Screw
12 Spring
13 Cable tie
14 Screw
15 Screw
16 Display
17 Cable tie
18 Screw
19 Screw
20 Screw
21 Symbol plate(Fork lower)
22 Push-button(Right)
23 Housing
24 Cover(Transparent plastic)
25 Sealing
26 Push-button(Left)
27 Switch
29 Housing
30 Symbol plate(No function)
31 Push-button(Complete)
32 Sealing
33 Housing
34 Symbol plate(No function)
35 Symbol plate(Fork lift)
36 Push-button(Complete)
37 Electronic card
38 Packing
39 Spring
40 Screw
41 Washer
42 Rocker(Left)
43 Bearing
44 Support
45 Spring
46 Axle
47 Arm
48 Stop lug
49 Rocker(Right)
50 Push-button
51 Push-button
Steering unit
649 579903AA-
Date Order number
2004-08-01 215858-040
13.5.3 Steering unit base

01 11
12
13
27 18
14
19
26 15
25 16 20
24 17 21
5590
30
29
22
28
23 31
49 32
33
36 37
34
40 38
35
39
41
42
45
46 44
48
47 43
Fig. 3Steering unit base
Steering unit
579903AA- 649
Order number Date
215858-040 2004-08-01

01 Hub
11 Driver
12 Ball bearing
13 Axle
14 Spring
15 Screw
16 Bearing
17 Screw
18 Screw
19 Washer
20 Damper
21 Insert
22 Ring
23 Screw
24 Distance piece
25 Screw
26 Disc
27 Pin
28 Screw
29 Screw
30 Push-button(Red)
31 Housing(upper)
32 Contact device
33 Conduit entry
34 Screw
35 Clamp
36 Cover
37 Screw
38 Hub(Rear)
39 Screw
40 Screw
41 Clamp
42 Bush
43 Pillar
44 Screw
45 Section
46 Washer
47 Cover
48 Screw
49 Ring(Bearing))
Disassembly/assembly of buttons
649 579903AA-
Date Order number
2004-08-01 215858-040
13.6 Disassembly/assembly of buttons

• Disassemble the keypad (Fig. 1-18).
• While taking hold of the top cover (Fig. 1-11), remove the screws
(Fig. 1-16 & 17).
• Disconnect the cable that is connected to the logic card (Fig. 2-37).
• Remove the screws (Fig. 2-11).
• Carefully lift out the lower cover (Fig. 2-33), while holding a finger be-
tween the lower cover (Fig. 2-33) and the pushbutton (Fig. 2-50) in
order to keep the pushbutton (Fig. 2-50) in place.
NOTE!
Static electricity!
Risk of static discharge that can damage the electronic modules.
Before commencing work on the electronic modules, be sure to take
the necessary measures.
13.6.1 Replacing the pushbutton/switch

(Fig. 2-22 & 27)
• Disassemble the pushbutton
as shown in the picture.
• Disconnect the switch connector on the logic card (4).

• Press out the switch from its holder.
Disassembly/assembly of buttons
579903AA- 649
Order number Date
215858-040 2004-08-01
13.6.2 Replacing the lifting/lowering

pushbutton (Fig. 2-36)
• Remove the pushbutton by in-
serting a flat screwdriver into
the slot (A) as shown in the pic-
ture
A A
• Unscrew the holder (18) to loosen the arm (12).

13.6.3 Replacing the pushbutton (Fig. 2-51)

• Press out the pushbutton laterally with the fingers.
• Insert a screwdriver in the slot

as shown in the picture and
carefully pry loose the push-
button.
• Unscrew the pushbutton holder and arm.

Replacing the potentiometer
649 579903AA-
Date Order number
2004-08-01 215858-040
13.7 Replacing the potentiometer

• Disassemble the rear cover
(A) where the emergency stop
switch is situated.
• Undo the connection block (B)

from the emergency stop
switch by depressing the lock-
ing device on the connection
block.
579903AA- 649
Order number Date
215858-040 2004-08-01
• Separate the switch at the

Ergo arm (C) and pull the en-
tire cable assembly mount
straight up.
C
• Disassemble the pivot covers

(D, E) and the keypad.
D E
649 579903AA-
Date Order number
2004-08-01 215858-040
• Disassemble the top cover and

cut off the two bundling cords
securing the cable. NOTE! It is
important to place new bun-
dling cords at the same places
where the old ones were re-
moved.
• Undo the cable clamp and lift

the potentiometer and its ca-
bling straight up.
• Assembly is done in reverse. NOTE! It is important that clamps and

bundling cords are placed at the same positions as prior to disas-
sembly. After complete assembly, calibrate the steering using pa-
rameters 36 and, if necessary, also parameter 37.
Inspection and replacement of the steering unit’s steel belt (Ergo
579903AA- 649
Order number Date
215858-040 2004-08-01
13.8 Inspection and replacement of the

steering unit’s steel belt
(Ergo version)
• Loosen the front and rear cov-
ers. The steel line is attached
with a screw at each end.
Make sure the line is not dam-
aged.
• If the line needs replacement,

release the line tensioner (A).
Inspection and replacement of the steering unit’s steel belt (Ergo
649 579903AA-
Date Order number
2004-08-01 215858-040
• First loosen the screw at the

emergency stop switch (C),
where the line splits into two.
Then loosen the front screw
(B) and pull out the line. NOTE!
During later assembly, it is im-
portant to use the same type of
screw and washer. If the steer-
ing unit is exposed to excep-
tional lateral forces, the weak-
est link in the design is the
screw (D), which will break.
The truck can still be steered,
however, the steering unit can-
D B
not be locked in its fixed posi-
tions.
• Assemble the line and covers in reverse.
Replacing the inductive brake sensor
579903AA- 649
Order number Date
215858-040 2004-08-01
13.9 Replacing the inductive brake

sensor
• Disassemble the pivot arm
covers (A)
• Disassemble the keypad and

the top cover of the steering
unit.
649 579903AA-
Date Order number
2004-08-01 215858-040
• Cut off the bundling cords and

separate the switch (A).
NOTE! It is important to place
new bundling cords at the
same places where the old
ones were removed
579903AA- 649
Order number Date
215858-040 2004-08-01
• Loosen the screw that holds

the sensor in place and lift it
straight up. The sensor has a
guide pin on the rear side.
• Reassemble in reverse.
Replacing the viscous damper
649 579903AA-
Date Order number
2004-08-01 215858-040
13.10 Replacing the viscous damper

• Disassemble the pivot arm
covers (A)
• Disassemble the cable camp

and the pivot arm covers, and
loosen the 4 screws (B)
579903AA- 649
Order number Date
215858-040 2004-08-01
• Loosen the screws that hold

the ring in place and gently pry
loose the steering head. The
steering head can then be
slanted across the motor com-
partment.
• Remove the screws of the vis-

cous damper and the spacer.
• Assembly is done in reverse.
649 579903AA-
Date Order number
2004-08-01 215858-040
Electrical systems – 5000
Electrical equipment overview
579903AA- 649
Order number Date
215858-040 2004-08-01
14- Electrical systems – 5000
14.1 Electrical equipment overview

X1
S31
M3
Y10
Y45
Y69
P1
S19
A5 Y1
M6 M1 A36
S65 G1
R1
A1 X41
F50
K30
F51
F52
F1 K10
H1
F3
Electrical equipment overview
649 579903AA-
Date Order number
2004-08-01 215858-040
A17
A6
S18:1 S18:2
A2
A2:S20
A2:S19
A2:S22
A2:S21
L1
S10
R2
S21
Equipment list and electrical diagram
579903AA- 649
Order number Date
215858-040 2004-08-01
14.2 Equipment list and electrical

diagram
The following table shows a summary of the major electrical compo-
nents of this truck.
Table 9: Equipment list summary

Sym- Function Description Associated signal Inf.
bol names
Energy and main power isolation
G1 Main electrical power source Traction battery 24 V
X1 Battery connection / isolation Connector
K10 Main contactor Contactor A1:OUT MAIN CON-
TACTOR
Equipment protection
F1 Drive motor protection Fuse 160 A
F3 Pump motor protection Fuse 125 A
F 50 Operating circuit protection A5, Fuse 3A A5:INPUT ENABLE B+
A2
F 51 Operating circuit protection A1 Fuse 7,5 A
F 52 Steer servo motor protection Fuse 30 A A5:POWER SUPPLY
24VDC
Control and Signal processing
A1 Lift, traction and peripherals Transistor regulator
power control
A2 Control of truck functions Electronic card 1
A5 Steering servo Electronic card 2
A6 Display of truck functions Display unit 1
A17 PIN login and data entry Keypad 1
A36 "Spider" expansion unit Logic card
649 579903AA-
Date Order number
2004-08-01 215858-040

bol names
Safety and braking
S21 Emergency switch-off Switch A1:INP.SUPPLY 24VDC
S10 Activation of mechanical brake Inductive sensor A1:OUT.BRAKE A 7
Y1 Mechanical brake Electromagnetic A1:OUT.BRAKE A 7
brake
H1 Audible warning signal -Horn Horn A1:OUT.SIGNAL HORN
S18:1 Horn activation Switch A2:INP.HORN1 4
S18:2 Horn activation Switch A2:INP.HORN2 4
Traction
L1 Speed control and travel direction Hall sensors 6, 7
selector (butterfly)
S19 Man on platform supervision Inductive proximity A1:INP.DRIVER ON 7
switch OLP contact PLATFORM
sheet
M1 Truck traction Motor
Steering
R2 Steering angle signal Potentiometer A5:INP.IN0 , INP.IN1
S65 Drive wheel in centre reference Inductive proximity A5:INP.REFERENCE
switch SWITCH
M6 Drive wheel steering Motor 2
Forks lifting
A2:S19 Fork lifting control Hall sensor 5, 7
A2:S20 Fork lowering control Hall sensor 5, 7
Y10 Fork lowering -hydraulic control Magnetic valve A1:OUT.LOWER VALVE
Y45 Fork lifting/lowering -hydraulic Magnetic valve A1: OUT. FORKS LIFT/ 7
control LOWER VALVE
S31 Lift height limit supervision Inductive proximity A1:INP.LIFT LIMIT 7
switch
P1 Fork Load supervision Pressure sensor A1:INP.LOAD WEIGHT
579903AA- 649
Order number Date
215858-040 2004-08-01

bol names
K30 Fork lifting (Pump motor power Contactor A1:OUT PUMP CON-
switching) TACTOR
M3 Hydraulic pressure Motor
Platform
Y69 Platform lifting/lowering - hydrau- Magnetic valve OUT. PLATFORM LIFT/
lic LOWER VALVE
S103 Lift height indicator Inductive sensor INP. PLATFORM >500
MM
S107 Lift height limiter Inductive sensor INP. PLATFORM LIFT
LIMIT
S214 Platform lowering button Foot switch, lower INP. FOOTSWITCH,
platform LOWER PLATFORM
A2:S19 Platform lifting
A2:S20 Platform lowering
649 579903AA-
Date Order number
2004-08-01 215858-040

bol names
Other
R1 Power supply PTC-resistor 15
Ohm
S1-6 Options Switch 3
X41 CAN communication (external) Connection point
Footnotes to the table above:

1. Situated in the tiller unit and communicates via the CAN bus
2. The steering servo controller, servo motor and mechanics are inte-
grated into one single unit.
3. Optional function
4. S18:1 represents the left side button and S18:2 represents the right
side button.
5.These inputs signals are processed directly via Hall effect sensors
mounted on the A2 card and are handled via the CAN bus.
6. Speed control signals from L1 are processed by Hall element sen-
sors mounted on the A2 card. Sensors A2:S1-9 control speed control
signals for driving in fork direction. Sensors A2:S10-18 control speed
control signals for driving in drive wheel direction.
7. Signals to/ from these elements can be checked via the Built-in Test
function. See “14.7.9Built-in Test Function” on page 39
Order number Date Valid from serial number T-code
215858-040 2004-08-01 579903AA- 649
14.2.1 Electrical wiring diagram 1 of 6
10
T-code Valid from serial number Date Order number
649 579903AA- 2004-08-01 215858-040
B10
215858-040 2004-08-01 579903AA- 649
649 579903AA- 2004-08-01 215858-040
215858-040 2004-08-01 579903AA- 649
649 579903AA- 2004-08-01 215858-040
215858-040 2004-08-01 579903AA- 649
14.2.7 Electric wiring diagram OL 25 P 1(7)
649
14- 14
T-code
TRANSISTOR REGULATOR
A1
119 119 J2-1 CAN HIGH

579903AA-
Sh. 3
© BT Europe AB
120 120 J2-8 CAN LOW
Sh. 3
EMERGENCY SWITCH OFF
X20 X23 X27 S21 X27 X23 X20 Y45
21 21 22 24 1 2 88 J2-9 OUT. FORKS LIFT/LOWER VALVE

Sh. 1
B10
Valid from serial number
24 24 P 63 J2-10INP. LOAD WEIGHT

Sh. 1 4 B C
A
40
Sh. 1 3 CONTACT MAT
Date
X26 S19 X26 X23 X19

(YE) (BN) 65 J2-11INP. DRIVER ON PLATFORM
2004-08-01
Service Manual OPUS OL 25, OL 25 P

X22 S10 X22 X27 X23 X20
(BN) (BK) 57 J2-12
INP. BRAKE
X20 X23 X27 X22

215858-040
(BU)
Order number
S31
(BN) (BK) 49 J2-15INP. LIFT LIMIT
(BU)
Approved by: Stefan Blom

24 J2-16INP. SUPPLY +24V DC

215858-040 2004-08-01 579903AA- 649
649 579903AA- 2004-08-01 215858-040
215858-040 2004-08-01 579903AA- 649
649 579903AA- 2004-08-01 215858-040
8 8 8 8
215858-040 2004-08-01 579903AA- 649
Extra I/O module
649 579903AA-
Date Order number
2004-08-01 215858-040
14.3 Extra I/O module

The extra I/O module is used to increase the number of truck inputs and
outputs. The unit is connected to the standard CAN BUS. On the OL
trucks, it is used for cabin lifting and as a "walkie button".
A2
Electronic card
X41
CAN service connector
A36
CAN
Extra I/O module
A5
Steer servo
TLS
A1
Motor controller
Functional description
579903AA- 649
Order number Date
215858-040 2004-08-01
14.4 Functional description
means constantly on means flashing.

This section gives basic electrical descriptions of the truck’s main func-
tions in tabular form. It describes, in simple terms, what happens when
performing any of the truck’s main operations.
• Event - The main stages in performing any of the truck’s main func-
tions are referred to as “Events”. Each event is numbered.
• Prior events - Indicates the event number which must have taken
place immediately before in order for current event function correct-
ly.
• Action(s) - A required action from the operator for the event to occur
• Influencing elements - conditions which must be fulfilled in order for
the event to occur. Certain parameter settings may also affect the
outcome of the event.
• Resulting conditions - Describes key occurrences which can be
checked to confirm operation.
Note that “resulting conditions” show what is expected when no error
conditions are present. Items shown in square brackets [ ] refer to elec-
trical component designations as stated in the electrical wiring dia-
grams.
649 579903AA-
Date Order number
2004-08-01 215858-040
Table 10: Functional description

Event: 1. Battery connected
Action(s) Connect the traction battery [X1, G1]
Influencing Main power fuses ok [F1, F3]

elements Operating circuit fuses ok [F50, F51, F52]
PTC resistor ok [R1]
Resulting Curtis status LED blinks once every 5 seconds.[A1]

conditions
Event: 2. Switch on (PIN-code entry)
Prior event(s) 1
Action(s)
Enter valid PIN-code and press [A17]
Influencing Emergency switch-off closed [S21]

elements Brake switch open [S10]
Resulting
conditions Power lamp lights. Main display shows hour meter reading
and for 4 seconds followed by battery condition as a per-
centage of full charge and [A6]

Mechanical brake remains on [Y1, A1:OUT.BRAKE A high]
Event: 3. Tiller unit lowered for driving

Prior event(s) 2
Action(s) Lower tiller unit handle
Influencing Man-on platform switch [S19]

elements
Resulting Brake switch closes [S10].
conditions Main contactor ouput goes low [A1:OUT.MAIN CONTACTOR]
Main contactor closes [K10]
579903AA- 649
Order number Date
215858-040 2004-08-01

Event: 4. Traction, forks first
Prior event(s) 3
Action(s) Move butterfly [L1]in forks drive direction.
Influencing Butterfly Hall sensors [A2:S1-9]

elements Man-on platform switch [S19]
Fork load supervision sensor [B10]
Steering angle, Parameter settings. See “14.5Speed limitation” on page 27
Resulting [A1:OUT.BRAKE A] goes low

conditions Brake coil [Y1] energises, mechanical brake releases
Current fed to traction motor field winding (S2 +ve and S1 -ve)
Pulsed current fed to traction motor armature proportional to butterfly deflection
Event: 5. Traction, drive wheel first

Prior event(s) 3
Action(s) Move butterfly [L1]in drive wheel drive direction.
Influencing Butterfly Hall sensors [A2:S10-18]

elements Man-on platform switch [S19]
Fork load supervision sensor [B10], Steering angle, Parameter settings
See “14.5Speed limitation” on page 27
Resulting [A1:OUT.BRAKE A] goes low

conditions Brake coil [Y1] energises, mechanical brake releases
Current fed to traction motor field winding (S2 -ve and S1 +ve)
Pulsed current fed to traction motor armature proportional to butterfly deflection
Event: 6. Neutral braking

Prior event(s) 4 or 5
Action(s) Let butterfly [L1] return to neutral position.

elements Fork load supervision sensor [B10]
Parameter settings
Resulting Traction motor [M1] acts as generator and via transistor controller [A1] converts
conditions the trucks energy of motion into electrical energy thus reducing the truck’s
speed. The excess electrical energy is fed back to the battery helping to
recharge it [G1].
The mechanical brake [Y1, A1:OUT.BRAKE A] activates when the truck comes
to a complete stand still
649 579903AA-
Date Order number
2004-08-01 215858-040

Event: 7. Reverse braking
Action(s) Move butterfly [L1] so as to reverse the direction of travel

elements Fork load supervision sensor [P1]
Resulting Traction motor [M1] acts as generator and via transistor controller [A1] converts
conditions the trucks energy of motion into electrical energy thus reducing the truck’s
speed. The excess electrical energy is fed back to the battery helping to
recharge it [G1]. The braking effect increases the more the butterfly is
deflected
The mechanical brake [Y1, A1:OUT.BRAKE A] activates when the truck comes
to a complete stand still
Event: 8. Mechanical brake operation

Action(s) Move tiller unit handle to upper position
Influencing Brake switch opens [S10]

elements
Resulting The mechanical brake [Y1, A1:OUT.BRAKE A] activates
conditions
Event: 9. Steering
Prior event(s) 2
Action(s) Steer tiller unit handle to left or right
Influencing Steering angle potentiometer [R2]

elements Steering reference switch [S65, A5:INP.REFERENCE SWITCH]
Man on platform switch [S19, A1:INP.DRIVER ON PLATFORM]
Resulting Steer servo motor positions drive wheel according to tiller handle’s deflection
conditions [A5, M6] (See section “14.4.1 Description of steering system” )
579903AA- 649
Order number Date
215858-040 2004-08-01

Event: 10. Fork lifting
Prior event(s) 2
Action(s) Press the lift forks button
Influencing Forks lift button [A2:S19]

elements Battery status ok (>20% charge left)
Lift height limit S31 [A1:INP.LIFT LIMIT] not activated
Resulting [A1:OUT.PUMP CONTACTOR] goes low

conditions Pump contactor [K30] activates
Pump motor [M3] starts
Event: 11. Fork lowering

Prior event(s) 2
Action(s) Press the lower forks button
Influencing Forks lower button [A2:S20]

elements
Resulting [A1:OUT.LOWER VALVE] goes low
conditions Fork lowering hydraulic valve [Y10] activates
649 579903AA-
Date Order number
2004-08-01 215858-040
14.4.1 Description of steering system

The servo steering system on this truck comprises a synchronous DC
motor (M6) with permanently magnetized rotor which is also brushless.
This type of motor is ideal for truck steering applications due to light
weight and high torque even from stand still. The motor directly drives
the drive wheel gear unit, via an integrated 2 stage planetary gear. The
steer motor is controlled by a fully electronic 4-quadrant regulator (A5)
which is mounted directly in the servo motor casing. Hall sensors (H) in
the servo motor provide timing information for commutation control.
The sensors also provide the steer servo with position information. A
double potentiometer (R2) mounted in the tiller unit provides steer
angle information from the operator. Every time the traction battery is
connected and the truck switched on the steer system performs a refer-
ence search for "straight ahead" position. An inductive proximity switch
(S65) mounted in the final drive gear mounting plate registers a change
in state (either ON to OFF or OFF to ON depending on drive wheel's ini-
tial position) and feeds this signal back to the steer servo. From this
point on, the steer servo "knows" the position of the drive wheel. Only
efter the traction battery is next disconnected, is a new reference
search carried out. The steer servo communicates fully via the CAN
bus. All steer servo errors codes are transmitted to the truck's control
system and displayed on the tiller unit's display.
Speed limitation
579903AA- 649
Order number Date
215858-040 2004-08-01
14.5 Speed limitation

The truck’s maximum speed is limited by a combination of travel direc-
tion, fork load, steering angle and operator’s driving position. Driver
parameter settings also affect maximum speed. See “14.9.6List of Driv-
er parameters” on page 46 for more information. The table below sum-
marises the speed limitations and assumes that all relevant driver
parameters are set to 100%. Note that the speeds given are nominal.
Table 11: Summary of speed limitations

Driver position and load (kg) Steer Maximum speed km/h
angle In drive In forks
degrees wheel direction
direction
On platform and load < 500 0 12 10,5
15 12 10
25 11 9,6
60 8,7 7,6
85 7 6
On platform and load 0 12 - 9 10,5 - 7,5
500 to maximum load
15 12 - 9 10 - 7,5
25 11 - 9 9,6 - 7,5
60 8-7 7,6 - 7,5
85 7 6
By side of truck and 0 to 10 6 6
0 to maximum load
By side of truck and 20 to 30 2,5 5,5
0 to maximum load
By side of truck and >30 0 0
0 to maximum load
Travel from platform > 0.5 6 6
metre
Hour meter and battery condition
649 579903AA-
Date Order number
2004-08-01 215858-040
14.6 Hour meter and battery condition

At switch on, the hour meter is displayed and the hour meter symbol
lights for 4 seconds. Fig. 4
The display will then change to show the battery’s remaining capacity
Fig. 4 expressed as a percentage of full charge and the battery symbol lights.
Fig. 5
The truck’s control system stores 5 different elapsed time values in
units of hours. The time value normally shown depends on the setting
of service parameter #20. (See “Parameter 20” on page 51). However,
any of these time values can be temporarily displayed on the hour
meter. To choose which value to display carry out the following proce-
dure:
Fig. 5 • Ensure the battery is connected.
• Ensure the truck is switched off. Press on the keypad.

• Press and hold horn button S18 for at least 1 second, enter a valid
PIN-code and then press on the keypad.

• Hold S18 depressed until “H” is displayed, then release S18. Fig. 6
Hourmeter symbol lights.

Fig. 6
The different hourmeter modes are displayed by repeatedly operating
speed control L1. The actual time value will be displayed momentarily
after the mode is selected.
Table 12: Hour meter modes

Description Display
Key time:
Total time truck has been switched on
Activity time:
Combined time either pump or drive motor has been in operation
(Default display mode)
Drive motor time:
Total time drive motor has been in operation
Pump motor time:

Total time pump motor has been in operation
Remaining time to next service

(Parameter #25 controls the initial value) See “Parameter 23” on page 52 for
more information.
Diagnostic and troubleshooting
579903AA- 649
Order number Date
215858-040 2004-08-01
14.7 Diagnostic and troubleshooting
14.7.1 Fault codes
means constantly on means flashing.

The trucks’s electronic control system incorporates built-in fault code
display and logging. This capability works as a powerful complement in
assessing the cause of eventual truck malfunctions. When a fault code
occurs the code number is displayed and the fault condition LED flash-
es. Fig. 7.
Fig. 7
The codes can be broadly divided into two groups:
• Caution codes - denoted by prefix “C”. These codes alert the opera-
tor to the presence of a caution condition. Caution codes in the
range C50 to C99 will limit the truck’s maximum speed to creep-
speed. The conditions which cause such codes can usually be easi-
ly remedied without further attention. Caution codes C19 to C43 are
not stored in the code history log.
• Error codes - denoted by prefix “E”. These codes alert the operator
to the presence of a fault condition in the truck. Error codes E100
and higher will stop all truck driving functions until the error code is
cleared.
The first time any fault code is displayed it is advisable to check if the
condition persists by switching the truck off completely. i.e. disconnect
the battery and then switch back on. Check to see if the fault code is
again displayed.
649 579903AA-
Date Order number
2004-08-01 215858-040
14.7.2 Fault code history

Up to 50 of the most recently occurred fault codes will be stored in a log
along with the hour meter reading when the fault occurred. When the
fault code log is displayed, it shows the fault codes in chronological
order with the newest code first.
Carry out the following to display the fault code log:
• Ensure the battery is connected.


• Hold S18 depressed until “E” is displayed, then release S18. Fig. 8
Fig. 8 Fault symbol lights.
The most recently occurred error will be displayed. The display will
alternate between the fault code and the hour meter reading when the
fault occurred. If the fault code log contains more than one fault code,
these can be displayed by repeatedly operating the speed control L1.
579903AA- 649
Order number Date
215858-040 2004-08-01
14.7.3 List of fault codes

NOTE!
The text “Restart the truck!” in the following tables always means
switching the truck off completely by removing the battery connector
[X1], reconnecting and then switching the truck on again.
Table 13: List of fault codes

Code Description Possible cause / Hint or Sollution
C19 Default parameter warning Parameter area is probably corrupt. Default values have been
down loaded / Driver specific parameter settings must be re-
entered again if this code is displayed.
C20 Butterfly warning Problem with butterfly sensor [L1].
Butterfly may have been activated during start up or faulty sen-
sor(s).[A2] / Check action of butterfly
C26 Steer servo start up error Steer servo not responding during initialisation.[A5] / Check
wiring connections to steer servo [A5]
C28 Emergency switch warning Emergency switch activated [S21]
No voltage supply to transistor regulator [A1].
Harness problem. / Check emergency switch is not depressed.
Check wiring.
C29 Service time warning Next service is due / Check service counter. It may not be reset
after latest service See “Parameter 23” on page 52 for setting
of parameter #25.
C31 Pressure sensor warning A problem with the pressure sensor or associated wiring [B10]
/ Check voltage is approximately 24 V between the cables 24
and 40 connected to the pressure sensor.
Check voltage between cable 40 and 63 connected to the
pressure sensor. The output voltage should be 0.5 Volt
(unloaded machine) to 4,5 Volt (max load)
C35 Steer servo - Internal tem- Servo internal temperature has exceeded +68 °C / Steering
perature warning activity too intensive See also code E127
C41 Battery undervoltage warn- Battery voltage < 17 volt
ing Battery parameter not correctly adjusted. See “Parameter 21”
on page 51 for setting of parameter #21
Battery due for charging
C42 Battery overvoltage warn- Battery voltage > 33 volt
ing Can be caused by fully-charged battery and energy return feed
to the battery during heavy reverse braking
C43 Transistor regulator ther- Driving may be too intensive
mal cutback Defective transistor regulator [A1]
649 579903AA-
Date Order number
2004-08-01 215858-040

C50 Platform sensor active > 5 Sensor permanently activated, sensor output shorted, sensor
minutes with no truck activ- faulty / Check Operation of sensor [S19]
ity [S19]
C80 Steer servo - Home refer- Supply fault to home reference sensor [S65] Defective home
ence error reference sensor [S65] / Check wiring to sensor
C81 Steer servo - Home refer- Defective home reference sensor [S65] /
ence error Check supply voltage is 12V between wires 95-97 / Check Wir-
ing to sensor
Check condition of [F50]
C82 Steer servo - drive current Steer servo drive current is exceeding 80% of maximum.
warning Steering activity may be too intensive
See also code E132
C90 Communication problem Verify the voltage supplied to the unit (A36: POWER SUPPLY
with the expansion unit 24VDC) and check that the CAN cabling is OK.
(Spider)
C91 Checksum error in the Internal error in the expansion unit
expansion unit (Spider)
E101 Transistor regulator [A1] Incorrect type of transistor regulator is fitted / Check correct
incompatible with the type type of transistor regulator is fitted
of truck
E104 Brake switch transistor out- Defective transistor regulator [A1] / Check cables and mag-
put in transistor regulator netic coil to the brake [Y1]
[A1] shorted
E106 Digital output fault or field Attempting to drive more current than specified from outputs.
current limit OR problem regulating field current.
Internal transistor regulator fault. [A1]
E107 Main contactor not acti- Problem with main contactor tips or cabling (open circuit).
vated [K10] Contactor control wire not connected.
Contactor drive output in controller faulty (off) / Check main
contactor tips. Check control wires to main contactor.
Check contactor drive output goes low. [A1]
E108 Main contactor tips welded Main contactor tips welded.
or open circuit in coil.[K10] Contactor drive output in controller faulty (on) / Check main
contactor tips Check contactor drive output goes high. [A1]
E110 Fault in armature current Possible defect in the transistor regulator [A1].
reading Can be caused by excessive moisture inside regulator. /
Restart the truck
579903AA- 649
Order number Date
215858-040 2004-08-01

E113 Unspecified steer servo Control system has detected a fault condition but is unable to
fault ascertain the exact cause. / Restart the truck
E114 Steer servo phase error Loss of motor phase to steer servo motor. / Check internal
[A5, M6] motor cable connections in steer servo
E115 Steer servo initialisation Faulty Servo
error [A5] Internal logical fault
Wrong parameters / Restart the truck
E116 Steer servo checksum Can occur after new firmware has been loaded into truck /
error [A5] Restart the truck
E117 Not applicable at present -
E118 Command mode error Restart the truck
E119 Steer servo error during Home position (steering straight) not achieved within preset
homing operation (Time time.
out) Home reference sensor [S65] not adjusted correctly
Faulty reference sensor / Check reference sensor gap is
adjusted correctly, check wiring to sensor
E121 Steer servo error -steering Restart the truck
angle value check Check that sum of voltages between wire nos. 92-94 and 93-
94 = 5 Volt
Recalibrate steering (See “Parameter 36” on page 53)
E122 Steer servo -reference sup- Defective steer servo [A5] / Check voltage between wire nos.
ply out of range 91-94 = 4,5 to 5,5 V
E123 Steer servo - Hall sensor Intermittent contacts inside steer servo
fault Defective steer servo [A5] / Check internal contacts in steer
servo [A5]
E124 Steer servo - overvoltage May occur when performing heavy reverse braking on newly
[A5] charged battery (Voltage exceeded 39V) / Restart the truck
E125 Steer servo - internal short Defective steer servo [A5,M6] / Restart the truck
circuit [A5, M6]
E126 Steer servo - current offset Defective steer servo [A5,M6] / Restart the truck
error [A5, M6]
E127 Steer servo - temperature Steering activity too intensive
too high [A5, M6] (>85º C) Defective steer servo [A5,M6] / Restart the truck (See also
code C35)
649 579903AA-
Date Order number
2004-08-01 215858-040

E129 Steer servo - supply under- Battery charge too low
voltage Intermittent connection in servo supply circuit [A5]
Steer servo fuse [F52] faulty or blown. / Check condition of
Fuse [F52]
Charge battery
E130 Steer servo - analogue Faulty steer angle potentiometer [R2]
steer signal input fault Intermittent connection in potentiometer circuit [R2,A5] / Check
wiring to potentiometer [R2]
Move tiller unit handle in all directions to ensure no wiring prob-
lems exist.
steer signal input fault Intermittent connection in potentiometer circuit
[R2,A5:INP.A_IN0] / Check 0,4 to 4.8V between wires 94-92,
check wiring to potentiometer [R2]
lems exist.
E132 Steer servo - current limit Steered portion of drive unit not moving freely./ Check for free
reached movement of drive wheel on floor. Check steering drive train is
free of dirt or other foreign objects.(See also code E82)
steer signal input fault Intermittent connection in potentiometer circuit
[R2,A5:INP.A_IN1] / Check 0,4 to 4.8V between wires 94-93 ,
check wiring to potentiometer [R2]
lems exist.
E134 Steer servo - analogue Faulty steer angle potentiometer [R2] or wiring Short circuit
steer signal input short cir- between [A5:INP.A_IN1 and INP.A_IN0] / Check wiring to
cuit potentiometer [R2],
lems exist.
E135 Steer servo - offset value Requires recalibration / Recalibrate steering (parameter #36)
error See “Parameter 36” on page 53
E136 Steer servo - steer angle Defective potentiometer [R2] / Ensure potentiometer is fitted
potentiometer error correctly.
Recalibrate steering (parameter #36). See “Parameter 36” on
page 53
579903AA- 649
Order number Date
215858-040 2004-08-01

E137 Steer servo - checksum Faulty wiring / Check CAN bus signal cables and connec-
error on received data tions.[A5, A2]
Restart the truck
E138 Steer servo - data not Faulty wiring / Check CAN bus signal cables and connec-
received tions.[A5, A2]
Restart the truck
E139 Steer servo - data trans- Faulty wiring / Check CAN bus signal cables and connec-
mission to servo failed tions.[A5, A2]
Restart the truck
E140 Checksum error Faulty internal micro controller [A2], faulty software
E141 Software problem Faulty internal micro controller [A2], faulty software / New soft-
ware may need loading via CAN
E150 Drive communication error Transistor regulator [A1] does not answer, bad connections or
faulty Transistor regulator [A1].
E151 rive communication trans- Broken CAN-wire.
mit error Transistor regulator [A1] defective
E157 Bus off error CAN-bus problem, wiring harness or hardware problem.[A2] /
Check wiring
E159 Over-run error CAN-bus problem, wiring harness or hardware problem.[A2] /
Check wiring
E160 Not applicable for this truck -
E200 Drive motor field circuit Shunt field open [M1], harness broken, transistor regulator
open defective [A1]. / Check wiring and connections to shunt field
[M1]
E201 M minus error Problem with switch transistor in armature circuit inside tran-
sistor regulator [A1]
Defective transistor regulator [A1].
E202 Power amplifier sensor Armature current sensor fault in transistor regulator [A1].
error Defective transistor regulator [A1].
E214 Power amplifier CAN-time- Transistor regulator reports unexpected loss of data flow from
out tiller head [A2].
649 579903AA-
Date Order number
2004-08-01 215858-040
14.7.4 Transistor regulator troubleshooting

and error codes
STATUS
MODEL VOLTAGE
SERIAL CURRENT
B+ M- 14.7.5 General
Curtis 1243 is a regulator [A1] for controlling shunt motors. Varying the
voltage applied through the armature primarily controls the speed. The
voltage is varied through use of pulse-width modulation (PWM). This
A1
M A2
involves varying the “on” time of the MOS-FET transistors regulating
the armature current.
Switching of the rotational direction is achieved by switching the polari-
ty on the field winding (S1-S2). The regulator is fitted with a four-quad-
rant transistor bridge for the field winding and a single-quadrant transis-
tor bridge for the armature winding.
S1 S2
579903AA- 649
Order number Date
215858-040 2004-08-01
14.7.6 Transistor regulator errors

The table below depicts the error codes that may be shown by the STA-
TUS LED or read using the hand-held terminal.
STATUS
MODEL VOLTAGE
SERIAL CURRENT
Table 14: Transistor regulator error code

STATUS LED Hand-held Explanation Possible cause
terminal dis-
play
LED off - No voltage or Burnt fuse, bad contact, not con-
defective regulator nected, defective regulator
LED on - Defective regulator Defective regulator
1,1 ¤¤ CURRENT Built-in current Armature current sensor fault in motor
SHUNT FAULT shunt defective controller.
1,2 ¤ ¤¤ HW FAILSAFE Power amplifier Motor controller reports unexpected
CAN-timeout loss of data flow from tiller head
1,3 ¤ ¤¤¤ M- SHORTED Internal M- short to Problem with switch transistor in arma-
B- ture circuit inside motor controller
3,1 ¤¤¤ ¤ CONT COIL/FLD Too high current for Attempt to drive more current than
SHORT contactor feeding specified from outputs.
or shorted field Problem to regulate field current.
winding Internal controller fault.
3,3 ¤¤¤ ¤¤¤ FIELD OPEN Open field winding Shunt field open, harness broken,
motor controller defect.
4,1 ¤¤¤¤ ¤ LOW BATTERY Low battery voltage 1. Battery voltage <17 volts
VOLTAGE 2. Corroded battery terminals
3. Loose battery or regulator connec-
tions
4,2 ¤¤¤¤ ¤¤ OVERVOLTAGE Overvoltage 1. Battery voltage > 33 volts
4,3 ¤¤¤¤ ¤¤¤ THERMAL Over-/under-tem- 1. Temp. >85oC or < - 25oC
CUTBACK perature reduction 2. Truck overloaded
3. Wrong installation of transistor regu-
lator
4. Operation under extreme conditions
649 579903AA-
Date Order number
2004-08-01 215858-040
14.7.7 Resetting errors

To reset an error turn S17 to off and then on again.
Error Reset when

OVERVOLTAGE Battery voltage falls below 33 V
THERMAL CUTBACK The temperature is within allowed range
THROTTLE FAULT 1, 2 Error has been fixed
LOW BATTERY VOLTAGE When battery voltage exceeds 16 V
14.7.8 Safety
The regulator is a high-power component. When working on a battery
operated vehicle, necessary precautions should be taken. This
includes, but is not limited to, correct training, use of eye protectors,
avoiding use of lose-fitting clothes, removal of watches and jewellery,
and use of insulated tools only.
WARNING!
Remove all watches, jewellery and always use insulated tools only.
579903AA- 649
Order number Date
215858-040 2004-08-01
14.7.9 Built-in Test Function

The truck’s control system provides a number of useful built-in test
functions
• Connect CAN-key in X41 and press [A17].
• Battery status is shown.
• Press Horn S18 repeatedly to choose Built-in Test mode.

NOTE!
All truck functions operate as normal in this mode. Care should be
taken when operating the truck and reading the display at the same
time!
Table 15: Built-in test modes

Flashing symbol Displayed data
Speed reference value sent to Curtis.
Digital inputs/outputs can be tested. See

the following sections for more details
Battery voltage (V)
Armature current (A)
Field current (A)
PWM Armature in %
Status Curtis
649 579903AA-
Date Order number
2004-08-01 215858-040
Digital inputs/outputs test mode

In the digital inputs/outputs mode, the operation of both inputs and out-
puts can be checked by checking the individual segments of the main
display as given in the following tables.
Transistor regulator inputs

o
Table 16: Transistor regulator inputs check

Segment Function
Lift height limit [S31], input A1:INP.LIFT LIMIT
Mechanical brake [S10], input A1:INP.BRAKE
Man on platform [S19], input A1:INP.DRIVER

ON PLATFORM
Mechanical brake [S10], input A1:OUT.BRAKE

A
Transistor regulator outputs
Table 17: Transistor regulator outputs

check
Segment Function
Fork lowering [Y10], output A1:OUT.LOWER
VALVE
Main contactor [K10], output A1:OUT.MAIN

CONTACTOR
Horn [H1], output A1:OUT.SIGNAL HORN
Mechanical brake [Y1], output A1:OUT.BRAKE

A
Pump contactor [K30], output A1:OUT.PUMP

CONTACTOR
579903AA- 649
Order number Date
215858-040 2004-08-01
Digital input from control sensors
Table 18: Inputs from control sensor check

Segment Function
Forks up [A2:S19]
Fork down [A2:S20]
Extra functions
Table 19: Extra functions check

Segment Function
Extra function 6
Extra function 5
Extra function 4
Extra function 3
Extra function 2
Extra function 1
Part numbers
649 579903AA-
Date Order number
2004-08-01 215858-040
14.7.10 Display test mode

The digital display itself can be tested to verify all the segments of the
display function correctly.
To select Display test mode carry out the following procedure:


Fig. 9
• Hold S18 depressed until “d” is displayed, then release S18. Fig. 11
All number segments on the display and symbol lamps should flash
sequentially. Fig. 10
Fig. 10
14.8 Part numbers

A
• Press S18 and turn on the keypad.
• Press S18 until you read Pn= part numbers.
• You have now chosen Pn= part numbers the symbol “D” on display
will be highlighted to indicate what’s currently shown on display. In
E D C B the start the Pn = part number complete unit will be shown.
• By scrolling with the L1 you can get the following information:
• SPn= Software part number.
• HPn= Hardware part number.
• HSn= Hardware serial number.
Parameters
579903AA- 649
Order number Date
215858-040 2004-08-01
14.9 Parameters
14.9.1 General
The truck’s control system stores a number of parameters. These
parameters are used to configure the truck for correct operation in the
particular application for which it was designed. The parameters are
divided into two groups, Driver parameters and Service parameters.
• Driver parameters (1 to 7) - These parameters are used to tailor the
driving characteristics of a truck for a specific driver or operation. Up
to 10 sets of driver parameters can be stored. Driver parameters can
be adjusted directly without the requirement for a suitable CAN serv-
ice key.1
• Service parameters (10 to 40) - These parameters are used to tai-
lor the truck’s performance / operation characteristics and include all
other parameters not designated as driver parameters. Service pa-
rameters can ONLY be adjusted when a suitable CAN service key is
plugged into the truck.2
14.9.2 Viewing parameters -CAN key not

connected
To select Parameter display mode carry out the following procedure:


• Hold S18 depressed until “P” is displayed, then release S18. Fig. 11
Parameters symbol lights.

Fig. 11
The different parameters are now displayed by repeatedly operating
speed control L1. Driver parameters can be both viewed and changed.1
1.Driver parameters can only be set without a CAN key if parameter #39 is
set to value 3. See “Parameter 39” on page 54
2.Service parameters can be viewed without a CAN key being plugged in but
they cannot be adjusted.
Parameters
649 579903AA-
Date Order number
2004-08-01 215858-040
14.9.3 Viewing parameters -CAN key

connected
• Connect a suitable CAN-service key to X41.

• Press and hold horn button S18 for at least 1 second and then press
on the keypad.
• Hold S18 depressed until “P” is displayed, then release S18. Fig. 12
Parameters symbol lights.

Fig. 12
Operating speed control L1 in the forward direction causes the display
to show the first set of driver parameters. Continued operation of speed
control L1 in fthe forward direction will then cause display to show the
next set of driver parameters (for driver no.2) and so on, up to the last
driver (Driver no. 10). See Fig. 13
Driver parameter no.

Parameter set no. After the ten sets of driver parameters have been displayed, the trucks
Fig. 13 service parameters will be displayed when operating the speed control
L1 in the forward direction
The truck’s service parameters can be displayed first by operating
speed control L1 in the backward direction. This will cause parameter
#40 to be displayed and then parameter #39 etc.1
1.Certain parameters numbers displayed are not active in this truck model.
Parameters
579903AA- 649
Order number Date
215858-040 2004-08-01
14.9.4 Setting Driver parameters

To change the value of a particular driver parameter carry out the fol-
lowing:
• Switch on the truck and log in with the appropriate PIN-code. This is
important if the truck has more than one set of Driver parameters ac-
tive . Any changes made will only be in effect when that particular
“driver” is logged in.
• Select the required parameter.
• Press Horn button S18.
Parameter symbol flashes. .
• Set parameter value by repeatedly operating speed control L1 up or

down
• Press Horn button S18 once to confirm the new setting.
Parameters symbol lights. (stops flashing).
• Switch off the truck by pressing on the keypad

You have now completed a parameter change and the next time you
start the truck the new parameter setting will be valid.
For detailed descriptions and effects of these parameters.see the sec-
tion “14.9.6List of Driver parameters” on page 46
14.9.5 Setting Service parameters

To set any of the Service parameters, a suitable CAN service key must
be plugged into the truck’s external CAN connector [X41]. Service
parameters are not driver specific. When a CAN service key is plugged
in, it is not necessary to enter a PIN-code prior to pressing on the

key pad. Once the CAN service key is plugged in, the procedure is the
same as setting Driver parameters.
For detailed descriptions and effects of these parameters see the sec-
tion “14.9.8List of Service parameters” on page 48.
NOTE!
Truck handling.
Modifying specific truck parameters will change the driving charac-
teristics of the truck.
Do not change any parameters without the necessary know how.
Parameters
649 579903AA-
Date Order number
2004-08-01 215858-040
14.9.6 List of Driver parameters

NOTE!
Before changing any parameters, ensure you have read and under-
stood the procedures for viewing and setting parameters
in sections “14.9.2Viewing parameters -CAN key not connected” on
page 43 and “14.9.6List of Driver parameters” on page 46
See also section “14.5Speed limitation” on page 27 for information
regarding the maximum speeds of the truck.
Table 20: List of Driver parameters

Param- Name Unit Min. Max. Step Std. Note
eter
01 Speed, Fork % 30 100 5 80 30:lowest Speed
direction 100:highest Speed
02 Speed, Drive % 30 100 5 100 30:lowest Speed
wheel direction 100:highest Speed.
03 Acceleration % 10 100 5 100 10:lowest acceleration
100:full acceleration
04 Neutral braking % 40 100 5 80 40: lowest reduction force
effect 100: highest reduction force
05 Travel speed, % 0 100 5 70 0: travel distance
platform > 0.5 100: 6 km/h
metre
06 Speed -Walk- % 40 100 5 70 40:lowest Speed
ing at side 100:highest Speed.
07 Neutral braking % 60 100 5 90 60:reduction force
effect - Walking 100:highest reduction force
at side
Parameters
579903AA- 649
Order number Date
215858-040 2004-08-01
14.9.7 Description of Driver parameter

Parameter 1
Allows for adjustment of the maximum speed of the truck in the fork
direction.
Parameter 2
Allows for adjustment of the maximum speed of the truck in the drive
wheel direction.
Parameter 3
The lower the value of the parameter the longer it takes to accelerate
the truck to maximum speed.
Parameter 4
Defines motor brake force when lever [L1] returns to the neutral posi-
tion.The lower the value of parameter the longer it takes to reduce
speed.
Parameter 5
Adjusts the truck's max. speed when the platform is lifted above 0.5
metre. The value 0 switches off truck travel. The value 100 allows 6 km/
h travel speed with the platform lifted above 0.5 metre.
Parameter 6
Allows for adjustment of the maximum speed of the truck when the
operator is not standing on the platform, i.e. when the operator is walk-
ing along side the truck.
Parameter 7
Defines motor brake force when lever [L1] returns to the neutral posi-
tion and the operator dismounts the truck and walks by the side of the
truck. The lower the value of parameter the longer it takes to reduce
speed.
Parameters
649 579903AA-
Date Order number
2004-08-01 215858-040
14.9.8 List of Service parameters

NOTE!
Before changing any parameters, ensure you have read and under-
stood the procedures for viewing and setting parameters in sections
“14.9.3Viewing parameters -CAN key connected” on page 44 and
“14.9.8List of Service parameters” on page 48
The CAN service key must be connected to the external CAN connec-
tor [X41] before adjusting any Service parameters
KKK
Table 21: List of Service parameters

Parameter Name Unit Min. Max. Step Std. Note
10 PIN-code - 0 9999 1 1 Assignment of up to 10
PIN-codes (10 different
drivers)
14 Creep % -10 10 1 0 This defines how much out-
speed put the controller gives
when you reach the first
speed sensor.
-10 : low speed when
reaching first speed sen-
sor.
10:high speed when reach-
ing first speed sensor.
20 Hour meter - 1 5 1 2 Select which hour meter is
selection normally displayed
21 Battery - 1 20 1 12 Battery size selection
size
22 Machine - 0 1 1 0 0: OL25
type 1: OL25P
23 Disable 0 1 1 0 When this parameter is set
jogging to “1”, it disables the possi-
bility of driving the truck
with the operator walking
alongside.
25 Service h 0 2000 50 100 Setting of service interval-
interval timer.
28 Button - 1 3 1 1 Button selector
selector
35 Log off min 0 20 1 0 Time interval to automatic
log off
Parameters
579903AA- 649
Order number Date
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Table 21: List of Service parameters

Parameter Name Unit Min. Max. Step Std. Note
36 Calibrate - 0 2 1 0 Performs calibration of
steer servo steer servo
37 Steering - -300 300 1 0 Trim steering
offset -300:30 deg. to left
300:30 deg. to right
39 Access 1 4 1 1 State which level of authori-
code zation the driver has to the
Driver parameters
14.9.9 Description of Service parameter

Parameter 10
This parameter stores the active PIN-codes for the truck. The truck can
store up to ten PIN-codes. Each PIN-code has a set of parameters
associated with it, called Driver Parameters. Entering a particular PIN-
code at start-up will make that PIN-code’s Driver parameters active.
This allows up to ten operators to individually adjust the characteristics
of the truck.
On delivery the truck has one default PIN-code stored which is “1“.
To enter a new PIN-code:

• Operate L1 repeatedly in the forward direction to select parameter
#10. After one second, the display will show the PIN-code for this
driver.
• Repeat the step above until parameter#10 for the next driver is dis-
played, the display will either show PIN-code for that driver OR
“0”(zero).
• Repeat the step above until the PIN-code displayed is “0”(zero)
• Press Horn button S18
• Operate L1 to set the desired value of the new PIN-code.1

1.Operating L1 lightly will step the value in increments of 1.

Operating L1 fully will step the value in increments of 100
Valid values are 1 to 9999
Parameters
649 579903AA-
Date Order number
2004-08-01 215858-040
The new PIN-code has now been entered.
To remove an existing PIN-code:

• Operate L1 repeatedly in the forward direction to select parameter
#10. After one second, the display will show the PIN-code for this
driver.
• Repeat the step above until the PIN-code to be removed is dis-
played.
• Operate L1 to set the PIN-code value to “0”(zero).

The selected PIN-code has now been removed.

To check whether a PIN-code will start the truck follow the procedure in
Table 10, “Functional description,” on page 22
Parameter #10 cannot be displayed without the CAN service key.
Parameter 14
Defines the speed you will get when you reach the first speed sensor.
Parameters
579903AA- 649
Order number Date
215858-040 2004-08-01
Parameter 20
This parameter determines which hour meter mode to display during
normal use.
Table 22: Hour meter parameter selection

Value Description Display
1 Key time:
Total time truck has been switched on
2 Activity time:
Combined time either pump or drive motor has been in operation
(Default display mode)
3 Drive motor time:
Total time drive motor has been in operation
4 Pump motor time:

Total time pump motor has been in operation
5 Remaining time to next service

(Parameter #25 controls the initial value)
See “Parameter 23” on page 52 for more information
Parameter 21
Matches the discharge indictation to the characteristics of the battery
fitted.
To adjust the disconnection point of the battery discharge indicator,
measure according to:
• Acid concentration when fully charged battery. To check quality of
battery. Shall be between 1,27-1,29.
• When you get lift cut-out (80% discharged of battery capacity) you
shall have close to 1,14 not less.
Parameter 22
On trucks equipped with platform lifting, parameter 22 must be set to 1.
Parameters
649 579903AA-
Date Order number
2004-08-01 215858-040
The acid concentration can vary depending on battery brand.
Table 23: Battery size parameter

Value Function Battery (Ah)
1
2
3
4
5
6
7
8
9
10 ↑
11 Less discharged
12 600
13 More discharged
14 ↓ 480
15 450
16 375
17 360
18 320, 300
19
20
WARNING!
Ensure you have set the parameter correctly.
The battery may otherwise be irreparably damaged.
Parameter 23
This parameter determines whether the truck can travel forward/
reverse when the operator stands next to the truck.
0= The truck can be driven with the operator standing next to the truck.
1= The truck CANNOT be driven with the operator standing next to the
truck.
Parameters
579903AA- 649
Order number Date
215858-040 2004-08-01
Parameter 25
This parameter determines the time value in hours to the next service
from 0 to 2000 hours in steps of 50 hours. Whenever this value is
changed the timer is reset and will start counting activity time up to the
set value. On reaching the set value caution code 29 (C29) will be
shown on the display.
Parameter 28
Using this parameter you can select which button is to be used for lift/
lower.
1 = Lower lift/lower button activated (default)
2 = Upper lift/lower button activated
3 = Both lift/lower buttons are activated
Parameter 35
This parameter determines the time interval before the truck automati-
cally logs off when truck has been idle. A value of “0”(zero) disables the
function.
Parameter 36
Value 0 - Parameter always returns to this value after calibration
Value 1 - Calibrate steer unit (in centre position)
Value 2 - Calibrate steer arm (in end position - not used on this truck)
This parameter is used to perform a calibration of the steer servo. The
calibration establishes the steering centre position (straight ahead).
Situations which may require that this calibration be performed are:
• The truck deviates from a straight line when steering tiller is in neu-
tral position.
• Occurrences of error codes E121 or E135
Before performing this calibration, ensure the drive wheel in centre sen-
sor [S65] is functioning and correctly adjusted.
To perform calibration perform following procedure:
• Move the steering tiller to the straight ahead position and maintain
this position.
• Select parameter #36 and set its value to 1.
• Switch off the truck by pressing on the keypad.
• Press on the keypad. The display shows “PUSH”

Parameters
649 579903AA-
Date Order number
2004-08-01 215858-040
• Maintain steering unit in straight-ahead position and press horn but-

ton [S18]. Display now shows “End”
• Switch off the truck by pressing on the keypad.
• Press on the keypad. Steering calibration is now complete
Parameter 37
This parameter can be used to “trim” the actual steering position of the
drive wheel in relation to the position of the steering tiller. It should only
be adjusted after having performed a steering calibration (parameter
#36)
A situation which may require that this parameter be adjusted is if the
truck tends to drift away from a straight ahead course when driving over
longer distances Many factors can contribute to this. It is therefore
advisable to make adjustments to this parameter on a trial and error
basis.
Whenever this parameter is adjusted, it is necessary to restart the
truck. (Disconnect and reconnect battery)
Parameter 39
This parameter determines whether the operator has access to the
Driver parameters:
• Value 1 - Key switch -Driver parameters accessible (without CAN
service key)
• Value 2 - Key switch -Driver parameters not accessible (without CAN
service key)
• Value 3 - Driver parameters accessible (without CAN service key)
• Value 4 - Driver parameters not accessible (without CAN service
key)
Technical specifications – Curtis 1243
579903AA- 649
Order number Date
215858-040 2004-08-01
14.10 Technical specifications

– Curtis 1243
Table 24: Technical specification -Curtis 1243

Item Value Unit Explanation
Rated operating voltage 24 Volts
Overvoltage limit 33 Volts
Undervoltage limit 16 Volts Minimum operating voltage
Electrical insulation towards cold 500 V AC Minimum
body
PWM frequency 16 kHz
Max. current of armature winding * 300 Amps for 2 minutes
100 Amps for 1 hour
Max. current of field winding 35 Amps for 2 minutes
20 for 1 hour
Contactor voltage 24 Volts Same as battery voltage
Contactor current 2 Amps Max (current limit at 2.5 amps)
KSI input voltage, Min. 16.8 Volts
KSI input current 50 mA
Logic input voltage >7.5; High Volts
<1; Low
Logic input current 15 mA
Operating temperature -40 to +50 °C
Overtemperature, reduction 85 °C
Undertemperature, reduction -25 °C
* During specific test conditions.
Technical specifications – Curtis 1243
649 579903AA-
Date Order number
2004-08-01 215858-040
Hydraulic system – 6000
OL 25
579903AA- 649
Order number Date
215858-040 2004-08-01
15- Hydraulic system – 6000

15.1 OL 25
15.1.1 General
The hydraulic system consists of a compact hydraulic unit, which
includes a magnetic valve used to lower the forks and a relief valve. It
also includes a pressure sensor and a cylinder used for fork lifting.
OL 25
649 579903AA-
Date Order number
2004-08-01 215858-040
15.1.2 Hydraulic drawing and symbol list

n
Symbol list
Pos. no. Description Function Notes
1 Lift cylinder Lifts the forks
2 Flow regulating valve
3 Pressure limiting valve
4 Non-return valve
5 Filter
M3 Motor Pump motor
P Pump
B10 Pressure sensor Loads exceeding 500 kg Analogue signal.
T Tank 1.2 litres (B20 0.5 litre)
Y10 Valve Fork lowering valve
OL 25
579903AA- 649
Order number Date
215858-040 2004-08-01
15.1.3 Adjustments
Adjusting the pressure limiting valve
The pressure limiting valve has been correctly set at the factory, howev-
er, adjustment may be required if the valve or the entire hydraulic unit is
replaced.
The truck must handle lifts between 2,550 and 2,600 kg (2,050 and
2,100 kg.for OL 20)
1. Locking nut. Use a special tool. See the picture in the ”Tools” sec-
tion.
2. Adjusting screw, pressure limitation.
When turned clockwise, the pressure increases.
When turned counterclockwise, the pressure decreases.
3. Pressure limiting valve. Use a special tool. See the picture in the
”Tools” section.
• Loosen the locking nut (1) using a special tool (see picture 3.2).
Place a load of 2,500 kg (2,000 kg for OL 20) on the forks and verify
that the truck is able to lift this load.
• If the truck can lift 2,500 kg (2,000 kg for OL 20), place an additional
100 kg on the forks. Verify that the truck is able to lift the load.
• If the truck can manage to lift 2,600 kg (2,100 kg for OL 20), adjust
the pressure limiting valve using the adjusting screw (2) by turning it
clockwise with a 4 mm Allen key until it cannot lift the load.
OL 25
649 579903AA-
Date Order number
2004-08-01 215858-040
15.1.4 Tools
• To loosen or tighten the pressure limiting valve, use a 22 mm stand-
ard socket and turn it down to the values shown in picture A below.
• To loosen or tighten the locking nut, use a 10 mm standard socket
and turn it down to the values shown in picture B below.
A B
12
8
26,5 13,5
OL 25 P
579903AA- 649
Order number Date
215858-040 2004-08-01
15.2 OL 25 P
15.2.1 General
The hydraulic system consists of a compact hydraulic unit, which
includes an electromagnetic valve used to lower the forks and a pres-
sure limiting valve. Also a valve plate with a gentle-closing electromag-
netic valves, used for platform and fork lifting, is integrated. Additionally,
the hydraulic system includes a pressure sensor together with an initial
fork lift cylinder.
OL 25 P
649 579903AA-
Date Order number
2004-08-01 215858-040
15.2.2 Hydraulic drawing and symbol list

n
1 2
P
B10
Y69
I
Y45
Y10
5
4 3
P M3
OL 25 P
579903AA- 649
Order number Date
215858-040 2004-08-01
Symbol list
Pos. no. Description Function Notes
1 Lift cylinder Lifts the forks
2 Lift cylinder Lifts the platform Hose rupture valve
3 Flow regulating valve
4 Pressure limiting valve
5 Non-return valve
6 Filter
M3 Motor Pump motor
P Pump
B10 Pressure sensor Loads exceeding 500 kg Analogue signal.
T Tank 1.2 litres (B20 0.5 litre)
Y10 Valve Fork lowering valve
Y45 Valve Gentle-closing electromag-
netic valve for the forks
Y69 Valve Gentle-closing electromag-
netic valve for the platform
15.2.3 Description
Fork lifting
When the fork lifting control is actuated, the pump contactor closes and
the pump motor starts operating. At the same time, the Y45 valve
opens and oils flows through the non-return valve and Y45 to the lift cyl-
inders.
If the lifting movement is interrupted, Y45 closes gently.
Fork lowering
When the fork lowering control is actuated, the electromagnetic valves
Y10 and Y45 open completely to allow the oil in the pressure lines to
flow back into the oil reservoir.
If the lowering movement is interrupted, first Y45 closes slowly and
then Y10 closes. To ensure Y45 is completely closed before Y10 clos-
es, Y10 receives a retarded holding voltage from the truck's logic card.
The lowering speed cannot be adjusted, and is instead determined by
the brake valve for the lowering action in the hydraulic unit valve plate.
OL 25 P
649 579903AA-
Date Order number
2004-08-01 215858-040
Platform lifting
When the platform lifting control is actuated, the pump contactor closes
and the pump motor starts operating. At the same time, the Y69 valve
opens and oil flows through Y69 to the lift cylinder.
If the lifting movement is interrupted, Y69 closes gently.
Platform lowering
When the platform lowering control (pushbutton or foot pedal) is actuat-
ed, the magnetic valves Y10 and Y69 opens completely to allow the oil
in the pressure line to return to the oil reservoir.
If the lowering movement is interrupted, first Y69 closes slowly and
then Y10 closes. To ensure Y69 is completely closed before Y10 clos-
es, Y10 receives a retarded holding voltage from the truck's logic card.
Operating pressure
The operating pressure at rated load is: 120 bar
Relief valve
Relief valve opening pressure: 170 bar
Check valve for the platform cylinder (3)

In case of a ruptured hose, the check valve ensures that the lowering
speed does not exceed 0.6 m/sec. It is designed as a ball washer and
is installed in the hose coupling.
Following dismantling and when later reconnecting the hydraulic hose
to the cylinder, make sure the ball washer is in place.
Pressure sensor, B10

The purpose of the pressure sensor is to provide the truck controller
with a pulse signal to reduce the speed when carrying loads that
exceed 500 kg.
OL 25 P
579903AA- 649
Order number Date
215858-040 2004-08-01
15.2.4 Adjustments
Adjusting the pressure limiting valve
The pressure limiting valve has been correctly set at the factory, howev-
er, adjustment may be required if the valve or the entire hydraulic unit is
replaced.
The truck must handle lifts between 2,550 and 2,600 kg (2,050 and
2,100 kg.for OL 20)
1. Locking nut. Use a special tool. See the picture in the ”Tools” sec-
tion.
2. Adjusting screw, pressure limitation.
When turned clockwise, the pressure increases.
When turned counterclockwise, the pressure decreases.
3. Pressure limiting valve. Use a special tool. See the picture in the
”Tools” section.
• Loosen the locking nut (1) using a special tool (see picture 3.2).
Place a load of 2,500 kg (2,000 kg for OL 20) on the forks and verify
that the truck is able to lift this load.
• If the truck can lift 2,500 kg (2,000 kg for OL 20), place an additional
100 kg on the forks. Verify that the truck is able to lift the load.
• If the truck can manage to lift 2,600 kg (2,100 kg for OL 20), adjust
the pressure limiting valve using the adjusting screw (2) by turning it
clockwise with a 4 mm Allen key until it cannot lift the load.
OL 25 P
649 579903AA-
Date Order number
2004-08-01 215858-040
15.2.5 Tools
• To loosen or tighten the pressure limiting valve, use a 22 mm stand-
ard socket and turn it down to the values shown in picture A below.
• To loosen or tighten the locking nut, use a 10 mm standard socket
and turn it down to the values shown in picture B below.
A B
12
8
26,5 13,5
Main lift chain system OL 25 P – 7120
General
579903AA- 649
Order number Date
215858-040 2004-08-01
16- Main lift chain system

OL 25 P – 7120
16.1 General
Applies to all machines with a mast.
16.2 Checking the chain setting

The lift chains must be adjusted at regular periods due to stretching,
see below. The chain setting is checked during servicing as set out in
the maintenance schedule.
Any adjustment is made with the chain mounting bolts.
Adjust the fork height according to C code 7100, 7420, 7700 and 7800
as applicable.
16.3 Chain inspection

The chains are exposed to two types of wear, outline wear and stretch-
ing. Wear to the bolts and disc holes is caused by stretching. The
chains are also affected by the environment they are used in.
16.3.1 Noise
If lubrication has been insufficient there will be metallic friction on the
chain and this will result in noise.
The chain should be replaced.
16.3.2 Surface rust

Surface rust is easy to recognize as the chain will be reddish brown.
Deep-seated rust has generally started and the chain has impaired
strength.
The chain should be replaced
16.3.3 Rusty links

Fretting corrosion results in a reddish brown powder being visible by
the outer discs. It can also appear as if the chain is bleeding when lubri-
cated.
Chain inspection
649 579903AA-
Date Order number
2004-08-01 215858-040
16.3.4 Stiff links

If it is not possible to pull out the chain to its normal position this can be
because of link rust or seizing.
16.3.5 Bolt rotation

Bolt rotation can be a phenomenon of stiff links. The fault is easy to see
when comparing with a new chain.
The chain should be replaced
.
16.3.6 Loose bolts

If a bolt is loose it will protrude from the side of the chain, which is due
to a stiff link or bolt rotation.
Chain inspection
579903AA- 649
Order number Date
215858-040 2004-08-01
16.3.7 Outline wear
H2 H3
P = Pitch
H2 = Nominal disc height.
H3 = Minimum disc height.
A new lift chain has a specific nominal disc height, defined as H2 in the
figure. As the truck is used the lift chain wears radically, on the side that
runs over the chain sprocket. The minimum disc height is define as H3
in the figure and denotes the minimum permitted value of the disc
height.
Maximal permitted outline wear is 5% of the height H2. If a lift chain
reaches the maximum level of wear, the chain should be replaced.
The nominal and minimum disc heights for respective lift chains are
stated in the table in the chapter “Stretching”.
Chain inspection
649 579903AA-
Date Order number
2004-08-01 215858-040
16.3.8 Stretching
The amount of stretch on a lift chain is measured on the part of the
chain that runs over the chain sprocket. The amount of stretch may, at
the most, be 2% on the most worn section of the chain. Measurement is
suitably made over 300-1000 mm of the chain.
The nominal and maximum permitted chain lengths for lift chains are
stated in the table below.
Table 25: Stretching

Type of Nominal Minimum Pitch P Nominal chain Maximum permitted
chain disc height disc height (mm) length for 20/30/ chain length for 20/
H2 ( mm) H3 (mm) 50 discs (mm) 30/50 discs (mm)
3/4”, 2x3 17.8 16.9 19.05 381/572/953 389/583/972
3/4”, 3x4 17.8 16.9 19.05 381/572/953 389/583/972
3/4”, 4x6 17.8 16.9 19.05 381/572/953 389/583/972
1”, 4x4 23,6 22,4 25,4 508/762/1270 518/777/1295
1”, 6x6 23,6 22,4 25,4 508/762/1270 518/777/1295
Wear to the bolts and around the holes on the discs are a reason why
the chain stretches. The chain should be replaced if stretching is
more than 2%.
Cleaning
579903AA- 649
Order number Date
215858-040 2004-08-01
16.3.9 Damage
The chain should be replaced if damaged in any way.
16.3.10 Damaged discs

If a disc has broken on the chain, this can be due to overloading or cor-
rosion.
16.3.11 Damaged bolts

It can be difficult to discover whether a bolt has broken. It can appear as
bolt rotation and/or that the outer disc is loose.
16.3.12 Dirty chain

If a chain is very dirty it is first and foremost recommended that it is
replaced. It can also be dismantled and cleaned as set out in the chap-
ter “Cleaning”.
16.4 Cleaning
If a chain is very dirty it is recommended that it is replaced.
Dirty chains should be cleaned before they are lubricated, e.g. by
washing with solvent such as diesel or petrol.
The chain should be blown dry using compressed air and lubricated
directly after cleaning
NOTE!
Exercise care with degreasing agent as these can contain abrasives.
Lubrication
649 579903AA-
Date Order number
2004-08-01 215858-040
16.5 Lubrication
Mineral and synthetic oils can be used to relubricate Rexnord chains.
NOTE!
Lubricant must not contain substances such as molybdenum disul-
phide, PTFE or the like.
A lift chain should be offloaded from the weight of the fork carriage
(hanging free) when lubricated.
• Lubrication intervals:
- 500 hours with normal operations
- 100 hours when driving in rugged environments such as cold
stores and corrosive environments.
The chains are sprayed with lubricant. Note the entire chain must be
lubricated, even the fastening bolts. It is especially important that the
part of the chain which runs over the chain sprocket is well lubricated.
The lubricate must comply with the viscosity demands at respective
temperatures as set out in the table below. The following lubricants are
recommended:
Table 26: Recommended Product

Ambient Viscosity Recommended Products*
temperature class
> - 40°C VG 15 Klüberoil 4UH 1-15, Klüber
Lubrication
< - 30°C
> - 30°C VG 68 Klüberoil 4UH 1-68N, Klüber
Lubrication
< + 5°C
Anticorit LBO 160 TT, Fuchs
DEA
> + 5°C VG 150 Klüberoil 4UH 1-150N, Klüber
Lubrication
< + 45°C
Anticorit LBO 160, Fuchs DEA
Rexoil, Rexnord Kette
>+ 45°C VG 220 Klüberoil 4UH 1-220N, Klüber
Lubrication
<+ 80°C
* Equivalent products from another manufacturer may be used.
NOTE!
Do not use a special rust protective agent to prevent
rust on the lift chains.
These agents impair the lubrication of the chains. Regular lubrication
is the best method to prevent rust attack.
Control/computer equipment – 8700
General
579903AA- 649
Order number Date
215858-040 2004-08-01
17- Control/computer equipment –

8700
TruckCom 3.4 User Manual -for trucks using the
“PowerDrive” platform.
This Manual is valid for version 3.4 of TruckCom p/n 182145-007.
17.1 General
TruckCom is a communication program which communicates with
trucks equipped with CAN (Controller Area Network) communication.
It enables the following tasks to be performed:
• downloading truck control software.
• viewing and adjusting driver / truck parameters and hour meters. Ad-
ditionally, the truck’s parameter set (including hour meter values)
can be saved to file and reloaded later.
• viewing diagnostic data for various digital inputs / outputs and ana-
logue data including voltages, currents and certain temperatures.
The program is a Windows program running under Windows® 95/98,
Windows® XP/2000 and Windows® NT.
17.2 Connection
A CAN interface of the CPC-PP type is needed to connect it to the
truck, with attendant cable. The interface is connected to the printer
port on a PC, and the cable is connected between the interface and
truck’s CAN connection.
The CAN interface is supplied with power from the truck electronics and
is protected from any high voltages in the truck if a fault should occur.
Layout
649 579903AA-
Date Order number
2004-08-01 215858-040
17.3 Layout
17.3.1 Main program screen

Information
Menu bar window
Tool
buttons
Nodes
Icons
Status bar
Fig. 14 Main TruckCom program screen

A main window opens when the program is started, consisting of menu
bar, tool buttons, workspace, log window and status window.
17.3.2 Nodes
Devices which are connected to and communicate via the CAN inter-
face are called nodes. The nodes detected on the bus are shown in the
node window. The current node status and input component/informa-
tion is shown with different icons.
Fig. 15 A typical node window dis-

play
Layout
579903AA- 649
Order number Date
215858-040 2004-08-01
17.3.3 Icons
Icon Description
Node OK is shown when contact is made with a
node and no errors have been reported.
Node not connected is shown when there is no

contact with a node in the network.
Node not OK is shown when an error has been

reported by a node. Click on node to obtain more
information.
Program version is shown when information is

available on which software is installed. Click to
obtain more information.
Information is shown when a node has information

on, for example, error codes.
Truck report
See “17.7Truck report function” on page 8
Parameters is shown when a node has information

on a parameter.
Diagnostics
Exit
Connection function
649 579903AA-
Date Order number
2004-08-01 215858-040
17.3.4 Tool buttons and menu bar

The tool button bar allows direct access to the program’s most common
functions. The menu bar allows access to all the program functions.
Explanations of each menu bar item are given in the relevant section.
Search for Disconnect Truck

units from PC Download report
Parameters Diagnostics Information Exit

Fig. 16 Tool button bar
17.3.5 Information window

The right section of the main window contains a status window where
different messages are shown.
To see previous messages, use the scroll arrows in the right margin.
17.3.6 Status bar

There is a status bar at the bottom of the main window, which shows
variable status when the program is run.
REC MACHINE
The following are shown from the left:

Help text "pop-up" via the mouse cursor, connected/not connected to
network, truck type connected, initiation result of CAN interface and the
present time.
17.4 Connection function

To connect the PC the network, select the Scan units function. This can
be done with the menu <Nodes | Scan units> or with the tool button
[Scan nodes].
This should also be done when the truck is supplied with voltage and in
normal drive mode.
The program will now run a check and installation of the CAN interface.
A diagnosis will also be carried out to check which units are connected
in the system. The result of this diagnosis is shown in the Node window.
Disconnection function
579903AA- 649
Order number Date
215858-040 2004-08-01
17.5 Disconnection function

Select the Disconnect function to disconnect from the network. This
can be done with the menu <Nodes | Set PC off-Line > or with the tool
button [Set PC off-Line].
The CAN interface is then reset and the CAN cable can be disconnect-
ed if so required. This enables connection to another truck without hav-
ing to close the program.
17.6 Downloading program function

To download a new program to one of the nodes, select the Download
software function. This can be done with the menu <Tools | Download
software... > or with the tool button [Download].
Type
123456
17.6.1 Normal downloading (truck with key)

Select Open.. to open the file to be downloaded into a node. The file
name, file type and version number are shown in the window for file
information. If it is file for a controller, indicate which type of controller is
to receive the file. Start downloading by selecting Start... and by restart-
ing the truck by turning the key off and on twice.
Restart must be made within 20 seconds from when the Start button
has been activated.
Close the download window when the download is ready, and then dis-
connect the PC from the network. A new connection can now be made
to verify the new program.
Downloading program function
649 579903AA-
Date Order number
2004-08-01 215858-040
17.6.2 Normal downloading (truck with

keypad)
To open the file to be downloaded to a node, select Open… The file
name, file type and version number are displayed in the "File informa-
tion" dialog box. If the file is intended for a controller, be sure to indicate
which type of controller should receive the file. Start downloading by
depressing and then releasing the red key on the keypad.
The truck must be restarted within 20 seconds from the time the Start
key has been actuated.
When downloading has been completed, close the download dialog
box and then disconnect the PC from the network. It is now possible to
reconnect to verify the new application.
17.6.3 Emergency downloading (truck with

keypad)
• Disconnect the battery connector.
• Select OK in the dialog box.
• Keep the red key on the keypad depressed while reconnecting the
battery connector.
• Release the red key to commence downloading.
Downloading program function
579903AA- 649
Order number Date
215858-040 2004-08-01
17.6.4 Downloading in old versions of logic

card
To download to older versions of electronic cards which do not support
restart with key, the button Old card... should be used instead of Start...
Downloading is carried out in the same way, except that restart is done
by using the battery lug instead of the key.
17.6.5 Emergency downloading (truck with

keypad)
E141 will be shown in the truck’s display when starting, if for any reason
there is no program in the electronics card (interrupted downloading).
Communication with the truck via the PC will then be minimised. Use
“E141” to download the program in the card.
On some trucks, a counter, which continuously counts up, is displayed.
NOTE!
Once programmed, the logic cards in some trucks can only be up-
graded with the same basic firmware. In other words, it is not possible
to replace the basic firmware (other machine type).
Truck report function
649 579903AA-
Date Order number
2004-08-01 215858-040
17.7 Truck report function

It is possible to generate a report to a file or disk with the truck’s config-
uration and status. Select menu <Tools | Generate truck report...> or
with the tool button Truck report. Save the report in Report.file.
NAME
Example of information generated in the truck report:

[GENERAL] [ERROR LOG]
REPORT DATE-TIME=2004-01-19 11:11:58 01=104 00007.5
CPC-PP SERIAL No=8002041 02=104 00007.5
MACHINE NUMBER=555555 03=104 00007.5
CUSTOMER=CUSTOMER 1 04=104 00007.5
TECHNICIAN=NONAME 05=104 00007.5
COMPANY=Other -
NOTES=Test report -
-
[CAN NODES] 09=104 00005.0
MAIN CARD=0
CURTIS DRIVE CONTROLLER=16
[MAIN CARD CONFIGURATION]
SOFTWARE=181179-001 [DRIVER PARAMETERS]
HARDWARE=167833-004 1=100
SERIAL NO=53676 2=100
3=75
[DRIVE CONTROLLER CONFIGURATION] -
SOFTWARE=5 -
DRIVE CURRENT LIMIT (A)=300 -
FIELD MAXIMUM (A)=34 100=0
SERIAL NO=52857
MFG Date:=26/05/03
HOUR METERS]
A IGNITION TIME=81
B TOTAL MOVEMENT=7 [TRUCK PARAMETERS]
C DRIVE MOTOR TIME=7 11=0
D PUMP MOTOR TIME=0 12=0
S SERVICE TIME=7 13=0
The contents of certain rows can vary according to truck type.
Parameters function
579903AA- 649
Order number Date
215858-040 2004-08-01
17.8 Parameters function

To change the truck parameters, select the Parameter function. This
can be done with the menu <Tools | Change parameters > or with the
tool button [Parameters].
NOTE!
The truck must in Normal mode (i.e. not Parameter mode) when con-
necting TruckCom. Otherwise TruckCom will report “Unable to deter-
mine truck brand”
The parameter numbers follow the description in the respective truck
Service Manuals.
Fig. 17, Fig. 18 and Fig. 19 show the OL 20 / OL 25 truck
Fig. 17 Driver tab
Parameters function
649 579903AA-
Date Order number
2004-08-01 215858-040
Fig. 18 Truck tab
Fig. 19 Time tab
Diagnostics function
579903AA- 649
Order number Date
215858-040 2004-08-01
17.9 Diagnostics function

To access diagnostics, select the Diagnostic function. This can be done
with the menu <Tools | Diagnostic...> or with the tool button [Diagnos-
tic].
NOTE!
If the value “---” is shown in a field, or a “read status LED” is red, the
communication has been interrupted for some reason and error data
will not be able to be shown.
NOTE!
The tab information displayed in diagnostics mode depends on the
type of truck connected.
17.9.1 Representation of signal colours

The screen dumps shown in the following section have been modified
to improve legibility in black & white print.
BLACK
GREEN
RED
649 579903AA-
Date Order number
2004-08-01 215858-040
17.9.2 “Tiller arm” tab
Clicking on the tiller arm tab will display a dialog showing the following:
• Speed lever -the status of the speed control and travel direction se-
lector. The status of each individual hall element is displayed.
• Buttons -the status of the control buttons is displayed. “Sxx” refers to
the switch designations as given in the circuit diagram.
• Option -the status of the optional function buttons
• Battery -The measured battery voltage
• R14 / R15 -Not used at present
579903AA- 649
Order number Date
215858-040 2004-08-01
17.9.3 “Drive Controller” tab
Clicking on the Drive Controller tab will display a dialog showing the fol-
lowing:
• Status of digital inputs and outputs of the transistor regulator. pin refers
to the motor controller pin designations as given in the circuit diagram.
• Field PWM - The effective drive output supplied to the field circuit as
a percentage.
• Armature PWM -The effective drive output supplied to the armature
circuit as a percentage
• Field current - The current flowing in the field circuit in Amperes.
• Armature current -The current flowing in the Armature circuit in Am-
peres
• Raw throttle data - The received speed control signal as a percentage.
• Temperature - The temperature of the output stage of the transistor
controller in degrees Celcius
• Inp pin 10 -The input voltage from the pressure sensor
“digital o” indicates the digital status of the input.
• Inp pin 11-The input voltage from the man-on platform sensor.
“digital o” indicates the digital status of the input
649 579903AA-
Date Order number
2004-08-01 215858-040
17.9.4 “EPS” tab (only OL 20 / 25)
Clicking on the “EPS” tab will display a dialog showing the following:
“Status”
• “Operational” - Indicates the status of the servo’s control system
• “Power stage enabled” - Indicates status of the servo’s power stage
output.
• “I2T integral” - indicates the status of the overload protection monitor

• “Warning” - indicates whether a warning condition is present in the
steer servo
• “Sleep mode” - whether the servo is in standby (longer period of in-
activity)
• “Error” -indicates whether an error condition is present in the steer
servo
• “Reference switch reached” - indicates status of drive wheel in cen-
tre reference switch
• “Reference position found” - indicates whether a successful steeing
in centre has been performed.
579903AA- 649
Order number Date
215858-040 2004-08-01
“Actual values”
• “Temperature power stage” -the temperature of the output stage of
the steering servo in degrees Celcius
• “DC bus voltage” - supply voltage to steering servo
• “Voltage analog input 1”- the measured d.c. input signal (0) from the
steering potentiometer
• “Voltage analog input 2” - the measured d.c. input signal (1) from the
steering potentiometer
• “Current” - the measured current supplied to the steer servo motor in
Ampere
• “I2T” - the amount of current limitation (overload protection) being
applied as a percentage.
• “Actual velocity” -The measured rotational speed of the steer servo
motor shaft in r.p.m.
Other menu functions
649 579903AA-
Date Order number
2004-08-01 215858-040
17.10 Other menu functions
17.10.1 Save to file

The truck parameters can be saved in the PC for downloading at a later
date.
Select <File | Save to file | Parameters >. All parameters in the nodes
which are connected to the bus will be scanned in and saved in a file.
If only the hour meters are needed, select <File | Save to file | Hour
meters >.
17.10.2 Download from file

A set of parameters can be downloaded from the PC to the truck. Select
<File | Load from file | Parameters >. The parameters in the file will be
copied to the nodes connected to the bus. If only the hour meter set-
tings are needed, select <File | Load from file | Hour meters >.
17.10.3 Reset CAN adapter

If problems should occur when resetting the CAN adapter connected to
the PC, this can normally be done manually by making sure that the
adapter is supplied with voltage and then selecting <Nodes | Reset
CPC-PP >.
17.10.4 Delete error code log

To delete the truck’s error code log, start the truck in parameter mode
and then select < Tools | Erase error log >.
17.10.5 Reset hour meter

To reset the truck’s hour meter, start the truck in drive mode and then
select < Tools | Reset hour meters >.
17.10.6 Read error code log

To show the truck’s error code log, select < Tools | Read error log >.
17.10.7 Adjust date and time

To quickly adjust the truck’s data and time, select < Tools | Adjust date
& time >. The time given in the PC will now be downloaded into the
truck.
NOTE!
This does not apply to trucks without a real-time clock.
Specifications
579903AA- 649
Order number Date
215858-040 2004-08-01
17.10.8 Adjusting the hour meter on older

cards
To adjust the hour meter on trucks with older cards, select
< Tools | Adjust Hour meters >. The time in the PC will then be down-
loaded to the truck.
17.10.9 Help
About TruckCom
To see program information, select <Help | About TruckCom... > or tool
button [About].
17.10.10 Exit
To exit the program, select <File | Exit > or the tool button [Exit].
17.11 Specifications
Table 27: Can interface specification

Description Value Unit
Power consumption 40-120 mA
Supply voltage 11-28 V
Transfer rate 125 kbit/s
Storage temperature -20-80 0
C
Operating temperature 0-60 0
C
Installation
649 579903AA-
Date Order number
2004-08-01 215858-040
17.12 Installation
Note
The program must be installed from the hard disk.
Note
The software application in the computer can be damaged, which is why
the PC installation should be performed by someone with the required
knowledge. BT does not accept any responsibility for any errors that oc-
cur during the installation.
Note
All references to PC operating system actions, menus and commands
are based on the English language version of Windows®.
17.12.1 Installation on a PC with Windows® 95/98

If a previous version of the TruckCom application has been installed on the
PC, it will be necessary to edit the System.ini file.
Start the Msconfig.exe application by selecting the Start button, selecting
Run and then typing msconfig.
Click on System.ini and open the folder (386Enh).
Unmark the option at Device=C:\Windows\Cpcppvd.vxd.
Save the change and close the application.
Now continue with installation
The software application is supplied on a CD or via a network. Start
installation by running X:\SETUP.EXE, where X:\ is the drive on which
the installation application can be found.
Then follow the on-screen instructions.
17.12.2 Installation on a PC with Windows XP/2000

To make the application work, it is necessary to first enter a value in the
Windows® Registry and then make a few changes in the Windows® Con-
trol panel.
Due to the built-in Windows® security, this must be done manually.
The instructions below provide step-by-step guidance to enable these
changes and make the interface operate under Windows XP and Win-
dows 2000.
The changes can be made either before or after TruckCom is installed.
• Open the Registry Editor. To do this, select the Start button, then
Run, type regedit and hit Enter.
Installation
579903AA- 649
Order number Date
215858-040 2004-08-01
• Mark the Enum folder which can be found under

HKEY_LOCAL_MACHINE\SYSTEM\CurrentControlSet inside the
Registry Editor.
Select the Edit option, then Find and type PortName to search for the
correct folder.
NOTE!
The location of the folder differs between different computers (some
may be .. \Enum\Root\.., while others could be ...\Enum\ACPI\... etc.).
Thus be sure to search for the correct folder.
When the folder is found, check that LPTx (x=1, 2, 3, 4) is displayed in

the PortName data field and that the folder name is Device Parameters.
Right-click with the mouse in the right box to enter a new value of the
DWORD type and with the name
EnableConnectInterruptIoctl.
Installation
649 579903AA-
Date Order number
2004-08-01 215858-040
Change the value in data field 1 by right-clicking on the name and

selecting Modify.
Installation
579903AA- 649
Order number Date
215858-040 2004-08-01
EnableConnectInterruptIoctl
The Device Parameters folder should look like the one in the picture.
The Registry change is now complete. Close the Registry Editor.

Changes in Windows® Control Panel
Select the Start button. Choose Settings, then Control Panel and dou-
ble-click on System, then select Hardware.
Click on Device Manager and open Ports (Com & LPT).
Installation
649 579903AA-
Date Order number
2004-08-01 215858-040
Installation
579903AA- 649
Order number Date
215858-040 2004-08-01
Double-click on the LPT port to be changed, and select the Port Set-
tings tab. Check the "Use any Interrupt assigned to the port" option and
click on OK.

Installation
649 579903AA-
Date Order number
2004-08-01 215858-040
17.12.3 Installation on a PC with Windows NT

17.12.4 In case of communication problems

with CAN
Make sure the computer settings for the printer port in the BIOS Setup
are as follows:
Port address: 0378
IRQ: 7
Mode: Output only
For detailed information on how to change the Setup settings, refer to
the User's Guide supplied with the computer.
17.12.5 To uninstall
To uninstall TruckCom under Windows®, select the Start button, Set-
tings, Control Panel, Add/Remove Programs. To uninstall you must
then select the TruckCom Program and click Change/Remove.
Operator’s cabin, cabin lifting OL 25 P – 9130
General
579903AA- 649
Order number Date
215858-040 2004-08-01
18- Operator’s cabin, cabin lifting

OL 25 P – 9130
18.1 General
With the standard chassis, cabin lifting can be considered as an add-
on. Apart from cabin lifting, also the steering controller's hydraulic unit
and lift buttons are different.
NOTE! The operator's cabin must always be suspended by the lifting
chain when the cabin is in the bottom position; it must not rest against
the chassis.
Operator cabin details
215858-040 2004-08-01 579903AA- 649
18.2 Operator cabin details
12
13
49 15
14
48
47
46
45
44
20
42 43
41
40
39
50
37
21
38
36
6610
23
24
35
34 33 32
30
31
25
28
26
27
29
Operator cabin details
579903AA- 649
Order number Date
215858-040 2004-08-01

12 Axel See the subsequent illustration
13 Cotter pin
14 Bussning
15 Chain wheel
16 Lifting chain
17 Axel
18 Cotter pin
19 Anchor bolt
20 Screw
21 Wiring harness complete(With chain)
23 Nut
24 Nut
25 Platform
26 Bracket
27 Screw
28 Screw
29 Rivet
30 Bracket
31 Sensing device
32 Mast frame
33 Screw
34 Nut
35 Sensing device
36 Rivet
37 Bracket
38 Screw
39 Screw
40 Nut
41 Bracket
42 Plate
43 Block
44 Guide
45 Screw
46 Locking ring
47 Ball bearing
48 Guide
49 Screw
50 Screw
51 Washer
52 Screw
Adjustment
649 579903AA-
Date Order number
2004-08-01 215858-040
18.3 Adjustment
The cabin lift uses 8 adjustable side guides, A and B. When lifted to the
highest position, it is possible to adjust the operator cabin side guides
by inserting an Allen key (45) through the holes in the side member C.
Be sure to lubricate the side member according to the lubrication inter-
val (500 hours) indicated in the lubrication chart. Removal of compo-
nents is not required in order to access the adjustors.
NOTE! It is important that the operator's cabin is raised to the topmost
position before adjustment is made.
C
A
47
46
45
44 C
Outer side guide
579903AA- 649
Order number Date
215858-040 2004-08-01
18.4 Outer side guide

The outer side guides (A) can be accessed from the outside once the
operator's cabin has been lifted to the topmost position. Adjust the side
guards (43) using the adjusting screws (39) until any play has been
eliminated. The operator's cabin must be lifted to its topmost position
prior to performing this adjustment.
A
42 43
41
40
39
38
© BT Europe AB
SE-595 81 Mjölby
Sweden
www.bt-industries.com

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OL25P Service Manual

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Service Manual en

Order number: 215858-040

This manual covers following truck models:

T-code Model Serial number

© BT Europe AB Service Manual OPUS OL 25, OL 25 P Approved by: Stefan Blom

Technical data – M4 2-1

General tightening torques ........................... 6

Truck dimensions ......................................... 7

Destruction instructions – M6 3-1

Hoods, hatches (0340) ................................. 3

Hoods, hatches (0340) ................................. 4

Frame/chassis (0300) and

Seat, cushions (0620)................................... 6

Wall/floor covering (0670)............................. 7

Internal fittings (0680) ................................... 8

Driver protection (0840) ................................ 9

Electric motors (1700).................................. 10

Drive assembly/gear (2550)......................... 11

Wheels (3500) ............................................. 12

Steering arm (4110)..................................... 13

General electronic equipment (5100) .......... 14

Battery cut out connector/contactor (5190).. 15

Extra I/O module (5730) .............................. 16

© BT Europe AB Service Manual OPUS OL 25, OL 25 PApproved by: Stefan Blom 1- 1

Hydraulic unit (6100).................................... 17

Hydraulic lines chassis (6230) and main

Charger adaptor (9380) ............................... 19

Terminal on board (9410) ............................ 20

Other extra equipment,

Other extra equipment, load support (9500) 22

Other extra equipment, writing table (9500). 23

Other extra equipment, writing table (9500). 24

Other extra equipment, support (9500) ........ 25

Other extra equipment,

Other extra equipment,

Installation and maintenance

1- 2 © BT Europe AB Service Manual OPUS OL 25, OL 25 P Approved by: Stefan Blom

Oil and lubricant

Super Seal connectors ................................. 1

AMP connectors ........................................... 2

Other tools .................................................... 4

Fork carriage – 0380 8-1

Included components ................................... 1

Disassembly of the fork carriage................... 3

Roller replacement ....................................... 4

Electric drive motor – 1760 9-1

Included components ................................... 1

Mechanical design ........................................ 3

Disassembly of the motor from the truck....... 3

Assembly of the motor in the truck................ 4

© BT Europe AB Service Manual OPUS OL 25, OL 25 PApproved by: Stefan Blom 1- 3

Service and repairs ....................................... 5

Driving unit/gear – 2550 10-1

Electromagnetic brake – 3370 11-1

Manual release of the brake ......................... 3

1- 4 © BT Europe AB Service Manual OPUS OL 25, OL 25 P Approved by: Stefan Blom

Swivel wheel – 3540 12-1

Main component of swivel wheel .................. 2

Electrical steering system – 4300 13-1

Electrical steering servo................................ 2

© BT Europe AB Service Manual OPUS OL 25, OL 25 PApproved by: Stefan Blom 1- 5

Inspection and replacement of the steering

Replacing the inductive brake sensor .......... 19