(Op 1000se Hse Opw 1200se Hse) Workshop

Master Service Manual (MSM)
Product family OH
BT OP 1000SE
BT OP 1000HSE
BT OPW 1200SE
BT OPW 1200HSE
Part number: 165782-040

© BT Industries AB Issued: 1998-06-02 SSD
F-code Section C-code
OH
Contents Master Service Manual (MSM)
IIssued by Approved by Version no T-code
SSD Iréne Karlsson 001 175-178
Contents
Master Service Manual (MSM)
Part number: 165782-040
Issued: 1998-06-02
Valid from serial number:
T-code Model Serial No Notes

175 OP 1000SE 290610AA-
176 OP 1000HSE 290610AA-
177 OPW 1200SE 290610AA-
178 OPW 1200HSE 290610AA-
1 Document list
Section C-code T-code Document Issued
Introduction 1996-05-09
M Content, M 1998-03-24
M1 Operator’s manual 1998-04-28
M2 General Product Information 1998-03-23
M4 Technical data 1998-04-29
M6 Ordering Spare Parts 1994-11-28
M7 Quality Parts 1998-04-30
M8 Recommended Spare Parts 1998-04-30
P Content, P 1994-12-20
P1 Introduction, maintenance 1998-03-11
P2 Preventive maintenance 1998-03-11
P3 Oil and grease specification 1998-03-11
© BT Industries AB Service Manual 2000-03-30 English 1 (2)

OH
Contents Master Service Manual (MSM)
Version no T-code
001 175-178
Section C-code T-code Document Issued

S Content S 1998-04-09
S0 0000 Taking delivery of the truck 1999-04-13
S2 2550 Transmission, Gear 1998-03-26
S3 3370 Brake 1998-03-26
S4 4200 Wire guidance 2000-01-20
S5 5000.1 175-176 Electrical system 1998-05-14
5000.2 175-176 Electrical system 1998-05-14
5460 Transistor regulator 1998-05-14
5710 Electronic card 1998-04-29
5750 Safety/proximity switch/sensor 1999-06-03
S6 6000 Hydraulic system 1998-04-28
S7 7120 Lifting chains 1998-09-16
7310 Lift cylinder 1998-09-16
2 (2) Service Manual 2000-03-30 English

OH
Introduction to BT’s Service Manual
Parts K Hallman 001
Introduction to BT’s
Service Manual
This Service manual contains product information regarding
the current trucks including the technical data and instructions
for maintenance and service. It includes the operator’s
Instruction Manual, Spare Part Handbook and oil and grease
specifications:
M Machine information
P Preventive maintenance
S Service instructions
O Options
At the top of each page you can find information on which
section the page belongs: Section M 5.0 means that it is
Product improvements; F-code means it deals with this spe-
cific truck family; T-code means specific products; Date and
Version number give information on when the page was
issued and which version.
It is our ambition to send modification notifications concerning
improvements to you as soon as possible. It’s stated on the
notifications which section/s in the binder should be replaced;
note that the entire section should be replaced! Notifications
should be inserted immediately so that the binder always con-
tains current service information.
When contacting BT’s technical support always have the
actual Service Manual close at hand. If you have any views
regarding the Service Manual, please contact your training
officer at BT who will forward your views to the technical doc-
umentation department.
This document can be available on different media and will
have different part numbers. Please see the following exam-
ple:
123456-040=An English document on paper
123456-04F=The same document but on fiche
© BT Products AB Service Manual 1994-12-02 English 1 (2)

OH 76876
Introduction to BT’s Service Manual
Version no T-code
001

OH M
Contents, M
SSD
Contents, M
1. Truck information
M1 Operators Manual
M2 Product information
M3 Product sheet
M4 Technical service data
M5 Product improvements
M6 Spare Part ordering
M7 Spare Part Handbook
M8 Recommended Spare Parts

OH M1
Operator’s manual
SSD C Nylin 001 175-178
Operator’s manual
Valid from machine number:
T-code Model Machine N° Note

175 OP 1000SE 290610AA-
176 OP 1000HSE 290610AA-
177 OPW 1200SE 290610AA-
178 OPW 1200HSE 290610AA-
1. General
An Operator´s Manual is supplied with every truck. If, for any
reason, the customer does not obtain an Operator´s Manual,
they can be ordered from BT. In the table below, you can see
which Operator´s Manuals are available for this machine
series.
1.1. Issued operator’s manuals
T-kod Ordering no Valid for machine

number
175 155414 290610AA-
176 155414 290610AA-
177 155414 290610AA-
178 155414 290610AA-
In this Service Manual can be found a typical Operator´s Man-

ual for the machine series. We have chosen this for your own
safety when you are working with the truck.
© BT Products AB Service Manual 1998-04-28 English 1

OH M2
General Product Information
SSD C Nylin 001 175-178


175 OP 1000SE 290610AA-
176 OP 1000HSE 290610AA-
177 OPW 1200SE 290610AA-
178 OPW 1200HSE 290610AA-
1. Presentation of the truck
BT OP/OPW is developed to meet the market’s increased demands

of efficient material handling equipment and high performance,
good ergonomics and reliability.

OH M2
Version no T-code
001 175-178
BT OP/OPW is designed so that order picking can be carried out in

a ergonomic manner. The cab and operator’s position can easily be
adapted so that a good working position and a view of the load are
comfortable and safe.
BT OP/OPW has a torsionally stiff mast which promotes safe and
efficient handling at high heights. The maximum travel speed can
be engaged up to a height of 3 metres due to the truck’s excep-
tional stability, resulting in high performance and low handling
costs.
The truck has a 48 V electrical system and is controlled by a finger
top operated joystick. Each movement is monitored by micro-com-
puters and takes place under controlled acceleration/retardation
procedures. The smooth travel and lifting action contribute towards
the high level of operator comfort.
1.1. Intended application of the truck

The truck is solely designed and manufactured to handle indoor
order picking. The truck should be fitted with the appropriate acces-
sories relevant to the application.
1.2. Forbidden application of the truck

The truck is designed for indoor order picking. It is not permitted to
use the trucks for other purposes including the following:
- In areas that contain dust or gases which can cause fires or
explosions
- As a tow-truck for trailers
- To tow other trucks
- To transport/lift passengers

OH M2
Version no T-code
001 175-178
2. Truck data
The table provides information regarding some technical data,
which is of value with daily use of the truck.
Model designation OP OPW

Lifting capacity classified load, kg 1000 1200
Centre of gravity, distance, mm 600 600
Operating speed without load, m/s 2.5 2.5
Operating speed with classified load, m/s 2.5 2.5
Rate of lifting, without load, m/s 0.33 0.33
Rate of lifting, with rated load, m/s 0.24 0.24
Rate of lifting , with 500 kg load, m/s 0.28 0.28
Rate of lowering, without load, m/s 0.38 0.38
Rate of lowering, with rated load, m/s 0.38 0.38
Rate of lifting, initial lift, without load, m/s 0.33 -
Rate of lifting, initial lift, with rated load, m/s 0.25 -
Rate of lowering, initial lift, without load, m/s 0.25 -
Rate of lowering, initial lift, with rated load, m/s 0.30 -
Weight without battery, kg 2750 2635
(fork height=7000 mm)
Battery (5h discharge), V (Ah) 48 (315-520) 48 (315-520)
Weight of battery, kg 550-750 550-750
Propulsion motors, kW 3.7 3.7
Intermittence, % 60 60
Lifting motor, kW 7.55 7.55
Motor, initial lift, kW 2 -
Intermittence, % 20
Control system Electro- Electro-
mechanical mechanical
Driving brake Electro- Electro-
Parking brake Electro- Electro-
Continuous noise level, dB (A) 61 61
Vibration level, m/s2 <0.5 <0.5

OH M2
Version no T-code
001 175-178
3. Truck dimensions
3.1. OP1000SE/OP1000HSE

OH M2
Version no T-code
001 175-178
Dimensions OP 1000SE OP 1000HSE

Chassis width (B), mm 1020 1250
Width between rails, min. (B1), mm B+200/300 B+200/300
Cabin width (B2), mm 1000/1200/1400/1460 1000/1200/1400/1460
Truck length excl. forks (L2), mm 1912 1912
Fork length (l), mm 800/1000/1150 800/1000/1150
Turning radius (WA), mm 1666 1666
Dimensions OP 1000SE
H1 2450 2650 2925 3175 3425 3675 3925 4175 4425 4675 4925
Height of
truck min.,
mm
H4 5655 6055 6605 7105 7605 8105 8605 9105 9605 10105 10605
Height of
truck max.,
mm
H7 3550 3950 4500 5000 5500 6000 6500 7000 7500 8000 8500
Platform
height, mm

OH M2
Version no T-code
001 175-178
3.2. OPW1200SE/OPW1200HSE
H7

OH M2
Version no T-code
001 175-178
Dimensions OPW 1200SE OPW 1200HSE

Chassis width (B), mm 1020 1250
Width between rails, min. (B1), mm B+200/230 B+200/230
Cabin width (B2), mm 1000/1200/1400/1460 1000/1200/1400/1460
Truck length excl. forks (L2), mm 1912 1912
Fork length (l), mm 800/1000/1150 800/1000/1150
Turning radius (WA), mm 1666 1666
Dimensions OPW 1200SE

H1 2450 2650 2925 3175 3425 3675 3925 4175 4425 4675 4925
Height of
truck min.,
mm
H4 5655 6055 6605 7105 7605 8105 8605 9105 9605 1010 1060
Height of 5 5
truck max.,
mm
H7 3550 3950 4500 5000 5500 6000 6500 7000 7500 8000 8500
Platform
height, mm

OH M2
Version no T-code
001 175-178
4. Identification plate
The diagrams shows the type plates used on the truck.
Item Text Unit

A MODEL
B SERIAL NO
C RATED CAPACITY kg
D WEIGHT WITHOUT BATTERY kg
E BATTERY WEIGHT MAX kg
MIN kg
F BATTERY VOLTAGE V
Item Text Unit

H NO
I LIFT HEIGHT mm
J ACTUAL CAPACITY kg
K LOAD CENTRE mm

OH M2
Version no T-code
001 175-178
5. Main components
2
1. Identification plate:
With model designation, serial number, year of manufacture,
weight without battery, battery weight, rated capacity, battery
voltage and manufacturer.
2. Mast
3. Emergency lowering valve:
Valve for emergency lowering under the guard.
4. Load carrier

OH M2
Version no T-code
001 175-178
6. Controls and instruments
6.1. OP1000
6.2. OPW1200

OH M2
Version no T-code
001 175-178
1. Adjustable writing surface

2. Right-hand deadman’s handle.
3. Emergency switch off
4. Joystick for driving forwards/backwards, travel brake and lift-
ing/lowering of the operator cage
5. Ignition
6. Indication “steering wheel straight”
Indication ”truck OK”
7. Vertical setting of the control panel
8. Horn
9. Lifting/lowering controls, initial lift (not OPW)
10. Left-hand deadman's handle
11. Steering wheel
6.2.1. Right-hand deadman’s handle (2)

When you keep your hand on the right-hand deadman's handle the
parking brake is released and you can use the drive/hydraulic func-
tions.
6.2.2. Emergency switch off (3)

The truck is equipped with emergency switch off (see illustr.). Press
in the emergency switch off to cut the power supply in the event of:
• An accident.
• Emergency situation, risk of an accident.
• With welding work.
NOTE!
The battery can be damaged.
When welding using an electric power source the welding current
can enter the battery.
It is necessary to disconnect the battery.
6.2.3. Joystick for driving forwards/backwards, travel

brake and lifting/lowering of the operator cage (4)
• Drive forwards/backwards by moving the joystick forwards/back-
wards.
• Brake by moving the joystick to the right.
• Raise/lower the operator cage by moving the joystick upwards/
downwards.
6.2.4. Horn (8)

The horn sounds as long as the button is pressed.

OH M2
Version no T-code
001 175-178
6.2.5. Left-hand deadman’s grip (10)

The control is used to ensure that the driver is in the operator cage.
When driving outside narrow aisles the driver, after the gates have
been closed, needs to briefly touch the control so that the truck will
run. If the gates are opened and then closed the control must be
touched again.
If the truck is to be driven with open gates, where permitted, any
operations must be started within 5 seconds of touching the control.
The next function must take place within 5 seconds of completing
the previous operation otherwise the control must be touched
again.
When driving in narrow aisles you must hold your hand on the con-
trol for the truck to function.
6.2.6. Steering wheel (11)

Steering takes place with the help of a servo control system.

OH M2
Version no T-code
001 175-178
13
12
14
12. Battery controller and hour meter

13. Warning lamp (flashes when the driver grips the right-hand
deadman’s handle).
6.2.7. Battery controller and hour meter (12)

The battery indicator shows the actual charge level of the truck’s
battery.
1 Fully-charged battery
1/2 Half-charged battery
0 Discharged battery
The battery indicator has an integrated cut-out feature that discon-
nects the truck’s lifting function when a preset charge level is
reached. This prevents overloading the battery and increases the
running economy of the truck. When the battery has reached a
charge level equivalent to 70% discharge a warning signal is given
by flashing lamps. A further 10% of the battery’s capacity can be
used before the battery indicator cuts out the lifting function.
The hour meter registers the time the truck is operating.
6.2.8. Emergency driving function

In the event of a steering fault in narrow aisles, rail or wire guided, it
can be difficult to manoeuvre the truck out of the narrow aisle.
You can drive the truck out of the narrow aisle, at half creep speed,
irrespective of which fault has occurred by engaging the emer-
gency driving function.

OH M2
Version no T-code
001 175-178
If the operator cage is in the raised position - lower it to the lowest

position.
Limitations that guarantee the driver’s safety are still active. This
means the driver must touch the left-hand deadman’s grip within 5
seconds, before he can drive if the gates are open.
If the truck is in a wire guided aisle then the wire guidance button
must be reset and the truck driven manually out of the aisle. To be
able to drive the truck the driver does not have to hold the left-hand
deadman’s grip while the emergency driving function is engaged.
The emergency driving function is engaged as follows:
1. Follow the indicating lamp’s 2 second interval, located on the

instrument panel, or if a buzzer is fitted the signal’s 2 second
interval.
2. Move the joystick to its maximum forward position (driving)
immediately after turning the ignition key on. Keep the joystick
in this position briefly until the lamp goes out or the buzzer
stops.
3. Move the joystick to its maximum backwards position (driving)
within 2 seconds. Keep the joystick in this position briefly until
the lamp goes out or the buzzer stops.
4. Move the joystick to its maximum right-hand position (braking)
within 2 seconds. Keep the joystick in this position briefly until
the lamp goes out or the buzzer stops.
5. Move the joystick to its neutral position and wait until the lamp
flashes three times or the buzzer sounds three times in 2 sec-
ond intervals.
6. You can now drive the truck at a low speed. Drive carefully as
the truck has several of its monitoring circuits disconnected.
• Reset the emergency driving function by switching the truck off.
6.2.9. Emergency switch off (14)

The truck is equipped with emergency switch off (see illustr.). Press
in the emergency switch off to cut the power supply in the event of:
• An accident.
• Emergency situation, risk of an accident.
• With welding work.
NOTE!
When welding using an electric power source the welding current
can enter the battery.
It is necessary to disconnect the battery.
6.2.10. Emergency lowering valve

The emergency lowering only affects lowering of the operator cage.

OH M2
Version no T-code
001 175-178
6.2.11. Button for continued lift with lifting height limit

(accessory) (15)
Keep the button held in at the same time as the right-hand joystick
is activated. Lifting/driving stop at the same time as the switch is
released, however, lowering can take place without activating the
switch.
WARNING!
Obstacles in the roof
Collision risk
Exercise extra care when the truck is operated.
6.2.12. Button for wire guided operations (accessory) (16)

• Press the button when driving in an aisle with wire guidance.
6.2.13. Button for working light (accessory) (17)

• Press the button to switch on the truck’s working light.
6.2.14. Evacuation line

An evacuation line is placed by the mast in the operator cage. Find
out where it is located and ensure that the package is still sealed.
When the line has been used it should be thrown away. The line
should only be used in emergency situations!

OH M2
Version no T-code
001 175-178
6.3. Control lever OPW with lifting table

(accessory)
1. Indication ”truck OK”

2. Right-hand deadman's handle.
4. Button for the box lock
5. Button for the lift table up and down
6. Horn
7. Joystick for driving forwards/backwards, travel brake and lifting/
lowering of the operator cage.
8. Indication “steering wheel straight”
6.3.1. Right-hand deadman’s handle (2)

When you keep your hand on the right-hand deadman's handle the
parking brake is released and you can use the drive/hydraulic func-
tions.
The left-hand deadman’s handle, on the manoeuvre control in the
mast direction, is used as a deadman’s handle for the left hand irre-
spective of the direction of travel.

OH M2
Version no T-code
001 175-178
6.3.2. Button for the box lock (4)

• Press the button when you wish to lock or unlock the boxes. The
boxes must be locked to be able to lift/lower the cage or drive
the truck forwards/backwards.
6.3.3. Button for the lift table up and down (5)

• Press the button when you wish to lift or lower the table. The lift
table must be lifted to the same height as the cage’s gate to be
able to drive with a lifted cage height above 0.8 m.

OH M4
Technical data
SSD C Nylin 001 175-178
Technical data
T-code Model Serial No. Notes.

175 OP 1000SE 290610AA-
176 OP 1000HSE 290610AA-
177 OPW 1200SE 290610AA-
178 OPW 1200HSE 290610AA-
Model OP 1000SE/HSE OPW1200SE/HSE

Drive motor
Type Prestolite MWC 4001 Prestolite MWC 4001
Output, kW 5.0 5.0
Min.carbon brush length, mm 14 14
Min. commutator diameter, mm 73 73
Transmission/gear change
Type 2-step angle transmis- 2 step angle transmis-
sion sion
Gear transmission 16.13:1 16.13:1
Oil volume, litres 2.6 2.6
Oil type Hypoid oil Hypoid oil
Normal temperature SAE 80W/90 SAE 80W/90
< -15oC SAE 75W SAE 75W
Drive wheel
Wheel dimensions, mm Dia. 310 x 110 Dia. 310 x 110
Material in wheel Vulkollan Vulkollan
Wheel pressure without load, 1779.32 kg/cm2 1733.31 kg/cm2
450Ah battery/7000 mm (with load cage,
platform height, kg l=1100mm, b=1470mm)

OH M4
Technical data
Version no T-code
001 175-178

Wheel pressure with rated load, 1177. 23kg/cm2 983. 21kg/cm2
450Ah battery/7000mm (with load cage,
Moment pulling of 85 85
wheel bolts, Nm
Support arm wheel
Wheel dimension, mm Dia. 230x85 Dia. 230x85
Material in wheel Vulkollan Vulkollan
Wheel pressure without load, 819. 29 kg/cm2 897. 31 kg/cm2
Wheel pressure with rated load, 1620. 46 kg/cm2 1873. 50 kg/cm2
Hydraulic unit, main lift
Pump motor, type MWA 4002 MWA 4002
Output, kW 7.55 7.55
Rev./min. during working pressure 1250 1250
Min. carbon brush length, mm 12.5 12.5
Min. commutator diameter, mm 74 74
Working pressure during rated 140 140
load, bar
Safety pressure, bar 160 160
Pump flow during load, litres/min. 24 24
Tank volume, litres 40 40
Oil type Mineral oil Mineral oil
Normal temperature ISO-L-HM 32 ISO-L-HM 32
< - 15oC ISO VG 32 ISO VG 32
Hydraulic unit, forks
Pump motor, type T 82 K -
Output, kW 2 -

OH M4
Technical data
Version no T-code
001 175-178

Rev./min. during working pressure 2800 -
Intermittence, % 20 -
Min. carbon brush length, mm 12.5 -
Min. commutator diameter, mm 41.5 -
Working pressure during rated 150 -
load, bar
Safety pressure, bar 160 -
Pump flow during load, litres/min. 7 -
Tank volume, litres 2.5 -
Oil type Mineral oil -
Normal temperature ISO-L-HM 32 -
< - 15oC ISO VG 32 -
Fuses
Drive motor circuit, F1 P/N
Current strength, A 160 160
Pump motor circuit, main lift, F3 P/N 29221 P/N 29221
Current strength, Ampere 250 250
Pump motor circuit, forklift, F4 P/N 22224 -
Current strength, A 50 -
Steering motor circuit, F60 P/N 122308-200 P/N 122308-200
Current strength, A 20 20
Operating circuit, F61 P/N 122308-075 P/N 122308-075
Current strength, A 7.5

OH M4
Technical data
Version no T-code
001 175-178

Batteries
Dimensions BxLxH, max. mm 330 Ah, 403x813x593 330 Ah, 403x813x593
450 Ah, 403x813x765 450 Ah, 403x813x765
Weight, kg 330 Ah, 545 330 Ah, 545
450 Ah, 710 450 Ah, 710
Travel speeds
Outside narrow aisle, lowered cab 2.5 2.5
(lh < 1.2m) and lowered forks, m/s
Outside narrow aisle, cabin height 1.1 1.1
between 1.2 m and 3.0 m, lowered
forks and steering angle < 10o
Outside narrow aisle, cabin height 0.7 0.7
between 1.2 m and 3.0 m, lowered
forks and steering angle >10o
Outside narrow aisle, cabin height 0.7 -
> 0.3m
In narrow aisle with light control, 2.5 2.5
cabin height under 2.5 m
In narrow aisle with light control, Optipace 2.5 - 0.7 Optipace 2.5 - 0.7
cabin height between 2.5 m and
7.5 m
cabin height over 7.5 m
cabin height under 2.5 m
In narrow aisle with light control, Optipace 2.5 - 0.7 Optipace 2.5 - 0.7
cabin height between 2.5 m and
6.5 m
cabin height over 6.5 m
Lift-/lower speeds
Cab lift without load, m/s 0.33 0.33
Cab lift with rated load 0.24 0.24

OH M4
Technical data
Version no T-code
001 175-178

Forklift without load, m/s 0.33 -
Forklift with rated load, m/s 0.25 -
Cab lowering without load, m/s 0.38 0.38
Cab lowering with rated load, m/s 0.38 0.38
Fork lowering without load, m/s 0.25 -
Fork lowering with rated load, m/s 0.30 -
Current usage
Driving without load, A
Driving with rated load, A
Cab lift without load, A
Cab lift with rated load, A
Forklift without load, A -
Forklift with rated load, A -
Weight
Truck without battery, platform 2696, (without load) 2797, (with load cage,
height 7 m, kg l=1100mm, b=1470mm)
Truck with 450 Ah, platform height 4416, (with load 1000kg) 4717, (with load cage,
7 m, kg l=1100mm, b=1470mm
and load 1200kg)
Note:
The absence of certain data in the table can occur because a
corresponding test has not yet been done or information is not
available at present.

OH M6
Ordering Spare Parts
SSD K Hallman 001
Ordering Spare Parts

• Localise the fault on the truck.
• Find out the machine type and machine number.
• Find the machine type and machine number in the spare
part catalogue’s list of contents.
• Look up the page with the exploded diagram and locate the
position number for the part you require.
• Look up the position number in the table. Select the column
with regard to the actual machine type and machine
number.
• Note the article number.
• Call the Truck Centre and state the article number.
The Truck Centre will now order the actual article via compu-
ter from BT Parts. The article is delivered by DDD during the
night and the next day you will have the part. (If you place the
order after 4.30 pm the delivery will be delayed.)
If you cannot find the machine type, machine number or the
article number call the Truck Centre and they will help you.

OH M7
Quality Parts
SSD Göran Franzén 001 175-178
Quality Parts
T-code Model Serial No

175 OP 1000SE 290610AA-
176 OP 1000HSE 290610AA-
177 OPW 1200SE 290610AA-
178 OPW 1200HSE 290610AA-
1. Issued Quality Parts
Model Order number Issued

OP 1000SE,HSE /C 152605 1996-05
OPW 1200SE,HSE /C
OP 1000/OPW 1200 155502 1997-01
OPW 1200 Space 152618 1996-05
OPW 1200 Space 155503 1997-01

OH M8
Recommended Spare Parts (RSP)
SSD Göran Franzén 001 175-178
Recommended Spare Parts (RSP)

T-code Model Serial No

175 OP 1000SE 290610AA-
176 OP 1000HSE 290610AA-
177 OPW 1200SE 290610AA-
178 OPW 1200HSE 290610AA-
1. Issued RSP
Model Serial no Issued

OP - OPW 1000/1200 254019AA -293320AA 1997-02-12
OP - OPW 1000/1200 293321AA - 1997-02-12

OH P
Content, P
SSD 001
Content, P
1. Preventive Maintenance
P1 Introduction
P2 Maintenance chart, Lubrication chart
P3 Oil and grease specification
P4 Tools

OH P1
Introduction, maintenance
SSD C Nylin 001 175-178
All points in the service program should be carried out to
attain the highest safety and the least possible downtime. The
service intervals are only a guide and do not need to be fol-
lowed to the letter. The operator may adapt them to local con-
ditions, but it is important that the intervals comply with BT’s
minimum requirements.
The service intervals are based on the running times and can
be adapted to most normal 8 hour shifts. The service interval
may be shortened if the truck is used more frequently or in
more demanding situations, e.g cold store, dusty or corrosive
situations. The following running times have been used when
calculating the intervals:
- Day time: 08.00-17.00 (20 hr./week)
- 2-shifts: 06.00-14.00, 14.00-22.00 (40 hr./week)
- 3-shifts: 06.00-14.00, 14.00-22.00,22.00-06.00
(60 hr./week)
Ensure the truck is given a regular maintenance service after
every 500 driving hours. The truck’s safety, efficiency and
service life is dependent on the service and maintenance it is
given.
Only use BT approved spare parts when service and repair
work are carried out.
1. Safety regulations with mainte-

nance work
Only personnel that have been trained in the service and
repair of this type of truck are authorised to carry out service
and repair work.
• Do not carry out any maintenance work on the truck unless
you have the correct training and knowledge to do so
• Keep the area where you carry out the service clean. Oil or
water makes the floor slippery
• Never wear loose objects or jewellery when working on the
truck
WARNING!
Short-circuiting/Burns.
When working with the truck’s electrical system, short-
circuiting/burns can occur if a metal object comes into con-
tact with live electrical connections.
Remove watches, rings or other types of metal jewellery.
OH P1
Version no T-code
001 175-178
• Always disconnect the battery by pulling out the battery

isolator when carrying out maintenance work on the truck
unless otherwise stated in this Service Manual
• Always switch off the truck’s power supply before opening
the covers on the drive unit or electrical system
• Relieve the system pressure slowly before starting work on
the truck’s hydraulic system
• Use paper or a rigid sheet of cardboard when checking for
oil leakage. Never use your hand
• Bear in mind that the oil in the transmission or the hydraulic
system can be hot
WARNING!
Risk of burns.
Hot transmission and hydraulic oil.
Let the truck cool before changing the oil.
• Only fill the hydraulic system with new and clean oil
WARNING!
The hydraulic system can be damaged.
If the oil is contaminated hydraulic components can be
damaged.
Always use new and clean oil in the hydraulic system.
• Store and dispose of changed oil in accordance with local
directives
• Do not release solvents and the like, which are used for
cleaning/washing, into drains that are not intended for this
purpose. Follow the local directives that apply for disposal
• Disconnect the battery when welding on the truck
NOTE!
When welding using an electric power source the welding
current can enter the battery.
The battery should therefore be disconnected.
• Remove at least 100 mm of paint around the welding/
grinding area through sand-blasting or the use of a paint
stripper when welding or grinding on painted surfaces
CAUTION!
Harmful gases.
Paint that is heated gives off harmful gases.
Remove 100 mm of paint from the work area.

OH P1
Version no T-code
001 175-178
2. Cleaning and washing

Cleaning and washing of the truck is important to ensure the
truck’s reliability.
• Carry out general cleaning and washing weekly
NOTE!
Risk of short-circuiting.
The electrical system can be damaged
Disconnect the battery before washing by pulling out the
battery connector.
2.1. External cleaning

• Remove rubbish, etc. from the wheels daily
• Use a well-known degreasing agent, diluted to a suitable
concentration
• Rinse off loose grime using tepid water
NOTE!
Jamming, corrosion.
Mechanical components can be damaged.
After washing, the truck should be lubricated as set out in
the chapter Maintenance and lubrication chart.
2.2. Cleaning the motor compartment

• Cover the electric motors, connections and valves before
washing
NOTE!
The electrical system can be damaged.
Electrical components must not be cleaned with a high
pressure washing unit.
• Clean the motor compartment using a well-known
degreasing agent, diluted to a suitable concentration
• Rinse off loose grime using tepid water

OH P1
Version no T-code
001 175-178
2.3. Electrical components

• Blow electric motors down using compressed air
• Clean the electrical panels, electronic boards, contactors,
connections, solenoid valves, etc. using a damp cloth and
a cleaning agent
NOTE!
Electrical components can be damaged.
Do not break the guarantee seal on the electronic board.
3. Safe lifting
All lifting must be carried out on a flat, non-slip and firm sur-
face. Avoid new laid asphalt or asphalt on a hot summer’s
day.
• Activate the parking brake to prevent the truck from moving
during the lift. If the lift applies to the brake wheel, chock
the other wheels so that the truck stands still
• Select a lifting point so that the lift is as easy as possible
(one corner at a time). If the truck has marked lifting points
on the under side of the chassis these can be used to
obtain a well balanced lift
• Ensure that the surface under the jack is clean and free
from oil and grease
• Ensure that your hands and the jack’s lever are free from
oil and grease
• Use the lever that belongs to the jack. A lever that is too
short requires more force than is necessary. If the lever is
too long there is a risk of the jack being overloaded
• Support the truck:
- as close to the part of the chassis that is lifted as possi-
ble to reduce the falling height if the truck tips over
- so that the truck cannot roll
• Never lift up the jack in order to lift higher
• Never work under a lifted truck unless it is well supported
WARNING!
Risk of crushing.
A badly supported truck can fall.
Never work under a truck that is not supported on trestle-
blocks and secured by a lifting device.

OH P2
Preventive maintenance
SSD C Nylin 001 175-178

175 OP 1000SE 290610AA-
176 OP 1000HSE 290610AA-
177 OPW 1200SE 290610AA-
178 OPW 1200HSE 290610AA-
1. Maintenance chart
Item Work to carry out

Interval in hours 5 20 80 160 250 500 1000
Interval in days/weeks/months 1d 1w 1m 2m 3m 6m 12 m
0000 Chassis
0000.1 Examine wear on door catches and X
cover for the battery compartment
0000.2 Examine cracking or damage X
0500 Operator’s cab
0500.1 Check fastening bolts X
0500.2 Examine cracking or damage X
0600 Operator control
0600.1 Check functioning of joystick X
0600.2 Check fastening X
0600.3 Check functioning of steering wheel X
0600.4 Check the deadman’s handle X
0600.5 Check functioning of signal horn X
0600.6 Check functioning of emergency stop X X
0600.7 Examine damage to driver’s seat X
1700 Drive motors
1700.1 Examine loose connections X
1700.2 Check carbon brushes X
1700.3 Clean the motor X
1700.4 Check the attachment bolts X

OH P2
Version no T-code
001 175-178

2550 Drive unit
2550.1 Examine leakage X
2550.2 Check the oil level X
2550.3 Change oil in the drive gear Ca C
2550.4 Examine dissonance X
3370 Brake
3370.1 Clean X
3370.2 Examine wear on brake disks X
3370.3 Check working in neutral position X
3500 Wheels
3500.1 Remove strings and other rubbish X
3500.2 Examine wear on drive wheels and X
bolts
5000 Electric panel
5000.1 Clean and check the attachment X
5000.2 Tighten the cable attachments X
5000.3 Check the contact tips X
5000.4 Check the movability of the contacts X
5000.5 Check functioning of the emergency X X
brake
5110 Battery
5110.1 Check the electrolyte level, 10-15 mm X
over the cell plates
5110.2 Check the connections to the battery, X
the truck and the charger
5110.3 Check that the cell and terminal pro- X
tection are undamaged
5110.4 Check the liquid density and the tem- X
perature
5810 Pump motor
5810.1 Examine gaps in the connections X
5810.2 Check the carbon brushes X
5810.4 Check the attachment bolts
5830 Steering motor
5830.1 Examine gaps in the connections X
5830.2 Check the carbon brushes X

OH P2
Version no T-code
001 175-178

6000 Hydraulic system

6000.1 Check the tank X
6000.3 Change oil and oil filter Bc B
6000.4 Change air filter X
6100 Hydraulic unit, initial lift
6100.1 Check the tank X
6100.3 Change air filter X
b
6100.4 Change oil and oil filter B B
7100 Mast
7100.1 Check fastenings of the air cylinders X
7100.2 Lubricate the lifting chains A
7100.4 Lubricate the mast rails at guide roll- A
ers and lateral guide rollers
7100.5 Lubricate the chain rollers’ plant areas D
7160 Initial lift
7160.1 Check the lift cylinder’s fastening X
7160.2 Lubricate the lifting chains A
7160.4 Lubricate the mast rails at guide roll- A
ers and lateral guide rollers
7160.5 Lubricate the chain rollers’ plant areas D
7160.6 Adjust the forks X
9100 Lifting table (accessory)
9100.1 Lubricate all bearings E
a-c) After 50-100 hours, thereafter every 1000th hour

OH P2
Version no T-code
001 175-178

OH P2
Version no T-code
001 175-178

OH P2
Version no T-code
001 175-178

OH P2
Version no T-code
001 175-178

OH P3
Oil and grease specification
SSD C Nylin 001 175-178
Oil and grease specification


175 OP 1000SE 290610AA-
176 OP 1000HSE 290610AA-
177 OPW 1200SE 290610AA-
178 OPW 1200HSE 290610AA-
Lubricant Specification
> - 15°C < - 15°C
A Grease BT 055 73100 (Tin) BT 055 73100 (Tin)
BT 055 73040 (Spray) BT 055 73040 (Spray)
B Hydraulic oil ISO-L-HM 32 ISO VG 32
C Transmission oil Hypoid oil SAE 80W/90 Hypoid oil SAE 75W
D Grease Wolfracoat Cd Wolfracoat Cd
E Oil Rando HD22

OH S
Content, S
SSD
Content, S
1. Service instructions
C-code
S0 Chassis 0000
S1 Primary motor 1000
S2 Transmission/Drive gear 2000
S3 Brakes/Wheels/Band 3000
S4 Steering 4000
S5 Electrical functions 5000
S6 Hydraulics/Pneumatics 6000
S7 Working functions, lift mast/Cylinders 7000
S8 Peripheral equipment 8000
S9 Accessories/Extra equipment 9000

OH S0 0000
Taking delivery of the truck
Issued by Approved by Version no T-code
SSD C Nylin 001 175-178

T-code Model Serial number Notes

175 OP 1000SE 290610AA-
176 OP 1000HSE 290610AA-
177 OPW 1200SE 290610AA-
178 OPW 1200HSE 290610AA-
1 General
Use a truck and an overhead crane to unpack the truck.
1.1 Getting the truck in order

• Cut away the band (1) holding the forks onto the pallet.
• The mast struts are located inside the mast. Cut away the
band (1) holding the struts and remove these for later
mounting (applies to HSE).
• Cut away the four bands holding the truck onto the pallets.
• Fasten a rope to the upper section of the mast, see pic. 1.
• Fasten two ropes behind the support arm wheels.
• Lift the truck using a truck and an overhead crane.
• Remove the two wedges, pos. 1, at the roof cabin, see
pic. 2.
• Remove the band (1) and boards in the cabin.
• Mount the mast struts (applies to HSE).
• Install the fort apparatus. The parts are located in an
enclosed box.
• Remove the plugs in the initial lift hose and connect it.
Important
During lie-down transport of an OP/OPW, the tanks are
plugged to prevent oil leakage. It is absolutely necessary
that the included air filters are installed before driving the
machine in any way.
• Install battery rollers, hatches and forks. Parts are located
in an accompanying box.
• Execute preventative maintenance described for the
prescribed 250 hour interval, see section P2.
OH S0 0000
Version no T-code
001 175-178
• Try, if possible, to re-use the pallets and other packing as

much as possible.

OH S2 2550
Transmission, Gear
SSD C Nylin 001 175-178
Transmission, Gear

175 OP 1000SE 290610AA-
176 OP 1000HSE 290610AA-
177 OPW 1200SE 290610AA-
178 OPW 1200HSE 290610AA-
1. General
The drive shaft, together with motor, pilot bearing, brake and
transmitter for measuring speed make up a complete drive
unit.
The gear in this truck is a 2-step angular gear with conical
roller bearings for the drive shaft and pinion. The bearings are
pre-tensioned approx. 5/100 of a millimeter to minimize the
risk of play in the bearings.
This service instruction covers descriptions for dismantling

the gear from the truck and re-fitting, filling/exchanging of oil
and measures, in case of leakage. A complete overhaul of the
gear is such an extensive job that it should only be done in a
workshop by specially trained personnel.

OH S2 2550
Transmission, Gear
Version no T-code
001 175-178
2. Gear components/data
The main components and data of the gear are shown in the
picture and tables below.
2.1. Component identification
Pos No. Component

1 pilot bearing
2 Steering chain rim
3 Gear wheels, primary step
4 Pinion bearings

OH S2 2550
Transmission, Gear
Version no T-code
001 175-178
Pos No. Component

5 Shims, pinion bearings
6 House, gear mounting
7 Pinion
8 Lower cover
9 Crown wheel
10 Drainage plug
11 O-ring
12 Drive shaft bearings
13 Locking ring
14 Spacer
15 Drive shaft
16 Drive shaft sealing
17 Seal protection
18 Shims, drive shaft bearings
19 Gear housing
2.2. Technical gear data
Truck type OP 1000SE/HSE OPW 1200SE/HSE

Gear, type 2-step angular 2-step angular
Gear ratio 16,13:1 16,13:1
Oil volume 2,6 liter 2,6 liter
Oil type Hypoid oil Hypoid oil
Oil, Normal SAE 80W/90 SAE 80W/90
temperature
Oil, < -15o C SAE 75W SAE 75W

OH S2 2550
Transmission, Gear
Version no T-code
001 175-178
2.3. Dismantled gear

OH S2 2550
Transmission, Gear
Version no T-code
001 175-178
3. Dismantling/fitting
3.1. Dismantling of drive unit from truck:
1. Open the doors of the motor compartment.

2. Lift up the truck using a jack so that the wheel is lifted off
the ground, then block under the truck in a safe manner.
3. Drain off the oil from the drive gear.
4. Remove the motor cables and the speed measurement
cables.
5. Loosen and remove the M10 bolts that hold the drive unit
on the chassis.
6. Lift out the drive unit from the truck with mechanical aid.
7. Place the drive unit on a bench or the like.
3.2. Fitting the drive unit in truck:

1. Lift the drive unit into position on the chassis.
2. Bolt the drive unit in position using the M10 bolts and tigh-
tening torque of 145 Nm. The bolts should be greased
before fitting.
3. Fit the motor cables and the speed measuring cables.
4. Fill the drive gear with oil.
5. Lower the truck to the floor.

OH S2 2550
Transmission, Gear
Version no T-code
001 175-178
3.3. Dismantling the drive motor and the

gear:
1. Dismantle the drive wheel (1) from the gear.

2. Separate the drive motor and the gear by removing the 5
motor bolts (2).
3.4. Fitting the drive motor and the gear:

1. Fit a new O-ring (3) on the drive motor’s bearing retainer.
2. Fit together the drive motor and drive gear taking care not
to damage the O-ring.
Tighten the motor bolts (2) to a torque of 20 Nm. The bolts
should be greased before fitting.
3. Fit the drive wheel. The wheel nuts (1) should be tighte-
ned crosswise at a torque of 88 Nm.

OH S2 2550
Transmission, Gear
Version no T-code
001 175-178
4. Oil level check/replacing
4.1. Check/filling of oil
• The oil level in the gear should be checked every 250

working hours.
• Check the oil level by removing the oil filling plug on the
upper part of the gear housing.
• Fill oil up to the hole to get the correct oil level, 2,6 litre.

OH S2 2550
Transmission, Gear
Version no T-code
001 175-178
4.2. Oil replacement

The oil should be replaced after every 1000 working hours or
a minimum of once a year.
1. Drain off the old oil by removing the drainage plug (1).
2. Use a new copper seal (2) when the drainage plug is refit-
ted.
3. Fill up oil in accordance with filling instructions.
4. Check that no leakage occurs from the drainage plug.

OH S2 2550
Transmission, Gear
Version no T-code
001 175-178
5. Repairs
5.1. Exchange of drive shaft sealing ring

It is easier to replace the drive shaft sealing rings when the
drive unit is dismantled from the truck.
In the case of oil leakage from the drive shaft follow the proce-
dure below:
5.1.1. Dismantling:
1. Drain the gear of oil.

2. Dismantle the drive unit from the truck as set out in chap-
ter 3.1.
3. Remove the drive wheel from the gear.
4. Remove the lower gear cover.
5. Loosen the drive shaft nuts. Remove the nuts, locking
washers and spacer ring.
6. Knock out the drive shaft using a brass punch and a ham-
mer.
7. Pull off the bearing from the drive shaft using a bearing
puller.
NOTE!
A normal clamp puller cannot be used to pull off the bear-
ing. Use a KUKKO bearing puller.
8. Remove the seal ring from the drive shaft.

OH S2 2550
Transmission, Gear
Version no T-code
001 175-178
5.1.2. Assembly:
When assembling the gear after replacing the drive shaft seal,
follow the procedure described below.
1. Place the drive shafts outer bearing in the gear housing.

2. Press the new seal ring in place in the gear housing. Be
careful when pressing it in place so that the seal is seated
correctly in the gear housing.
3. Press the drive shaft into the gear housing.
Check that the splines on the drive shaft are aligned with
the splines on the crown wheel.
4. Place the spacer ring and locking washer onto the drive
shaft end and screw in the shaft bolts.
Always use new bolts.The drive shaft nut must be lubri-
cated prior to being fitted to the shaft.
Tighten the shaft bolts with a torque of 110 Nm.
Lock the shaft bolt by bending up the locking washer.
5. Before fitting the lower cover, change the O-ring. Fit the
cover and tighten the bolts to 25 Nm. Make sure that the
O-ring is not damaged when fitted. The bolts should be
greased prior to assembly.
6. Fill up oil in accordance with filling instructions, section
4.1.
7. Fit the drive wheel and tighten the wheel nut with a torque
of 88 Nm. The wheel nuts should be greased prior to
being fitted.
8. Fit the drive unit in the truck as set out in chapter 3.2.

OH S2 2550
Transmission, Gear
Version no T-code
001 175-178
5.2. Leakage from the top cover

When there is leakage from the gear’s top cover follow the pro-
cedure described below.
1. Dismantle the gear from the truck as described in section

3.1 and 3.3.
2. Loosen all bolts holding the top cover to the gear housing.
3. Remove the cover from the gear housing and clean the
sealing surfaces of the cover and gear housing carefully.
4. Apply sealant type Curil K2 to the surfaces.
Follow the instructions given on the container.
5. Fit the cover bolts and tighten with a torque of 25 Nm. The
bolts should be greased prior to assembly.
6. Fill up oil in accordance with filling instructions, section
4.1.
7. Fit together the drive gear and the drive motor and fit the
drive unit in the truck as described in chapter 3.4 and 3.2.

OH S2 2550
Transmission, Gear
Version no T-code
001 175-178
5.3. Leakage from the lower cover

1. Drain out the remaining oil from the drive gear.
2. Dismantle the cover from the drive gear.
3. Replace the seal on the drain plug and the O-ring on the
cover.
4. Fit the cover and tighten the bolts to a torque of 25 Nm.
Ensure the O-ring is not damaged. The bolts should be
greased before fitting.
5.4. Replacing the wheel bolt
1. Dismantle the drive gear from the truck as described in

chapter 3.1.and 3.3.
2. Dismantle the drive shaft from the gear as described in
chapter 5.1.1 (replacement of seal ring).
3. Press or knock out the damaged bolt from the drive shaft
rim.
4. Smooth away any burring around the bolt hole and press
or knock the new bolt into place.
5. Fit the drive shaft into the gear as described in chapter
5.1.2.
NOTE!
Always use a new drive shaft seal when fitting drive shaft.
6. Fit the drive gear/drive unit in the truck as described in
chapter 3.4 and 3.2.

OH S3 3370
Brake
SSD C Nylin 001 175-178
Brake

175 OP 1000SE 290610AA-
176 OP 1000HSE 290610AA-
177 OPW 1200SE 290610AA-
178 OPW 1200HSE 290610AA-
1. General
The brake is a 6-step electromagnetic brake with separate
coils for each step. The steps are connected in parallel, two
and two and are controlled by the driver with speed/brake unit.

OH S3 3370
Brake
Version no T-code
001 175-178
1.1. Function
By moving the right joystick to the right, the truck brakes. The
brake force is controlled partly by the joystick potentiometer’s
(R4) input voltage to the A2 board (neutral state = 10 V) and
partly by the truck’s current speed and fork height. The truck
computer determines the maximum brake force which can be
used at the height which the forks have when the driver
brakes. Using the joystick, the driver can determine how much
of this brake force he needs to use for the braking. There is a
maximum of three brake steps.
Every brake step gives a brake moment of 12 Nm.
Total maximal brake power for the truck = 36 Nm.
2. Maintenance
The brake is, by and large, maintenance-free under normal
working conditions. But in accordance with the preventive
maintenance chart, it is recommended that regular inspection
is made of wear of the brake disk and the gap between the
magnet terminal casing and the pressure plates.

OH S3 3370
Brake
Version no T-code
001 175-178
2.1. Adjustment
The brake drum should be adjusted to 0.30 (+0.05,-0.00) mm.
If the brake drum is greater than 0.60 mm, there is a great risk
that the brake cannot be completely freed. This means, of
course, that both the wear and the heat on the brake lining in-
creases dramatically.
Maximum permitted brake drum = 0.60 mm.
Always adjust both of the brakes if adjustment is required.
The nominal gap between the spool casing and the pressure
plates, during fit-up, must be 0.3 mm.
The maximum gap before readjustment is required is 0.6 mm.
2.1.1. Procedure for adjustment:
1. Loosen the anchor bolts a little.

2. Turn the nut anticlockwise and pull out the bolts a little. At
the same time, check the gap with a 0.3 mm thickness
gauge.
3. Pull the anchor bolts to 25 Nm and check the gap with the
thickness gauge again.
4. Repeat the procedure for every brake segment.
5. Adjust the brake on motor No. 2.

OH S3 3370
Brake
Version no T-code
001 175-178
2.2. Change of brake disk

The brake disk must be changed when its total thickness has
been reduced to 13.5 mm. Allow 2 mm thickness to wear.
2.2.1. Procedure for change:
1. Disconnect the brake’s electric cabling.

2. Loosen and remove the six allen head cap screws and lift
off the brake coil.
3. Change the brake disk on the hub and visually check the
wear on the friction plates.
Also change the friction plates if their surface is uneven.
4. Unscrew the bolts on the coil so that there is a gap
between the coil and pressure plates when the coil is
remounted.
5. Mount the coil and adjust the gap as per instructions in
section 2.1.
6. Reconnect the electric cables again.

F code Section C code
OH S4 4200
Wire guidance
Issued by Approved by Version no. T code
SSD Jan Thorstensson 001 175-178
Wire guidance
Applies to serial numbers:
T code Model Serial No. Notes

175 OP 1000SE 254019AA-
176 OP 1000HSE 254019AA-
177 OPW 1200SE 254019AA-
178 OPW 1200HSE 254019AA-
1 General
Wire guidance is used to steer the truck automatically in nar-
row aisles. A generator generates alternating current in a ca-
ble installed in the floor which the truck follows. This cable runs
in the narrow aisles in a closed loop from the generator to aisle
1, then on to aisle 2 and so on. From the last aisle, the cable
then returns to the generator. The maximum length a genera-
tor can manage to feed is approx. 750-1,000 m. If longer runs
are required, another generator must be installed on a separa-
te loop.

OH S4 4200
Wire guidance
Version no. T code
002 175-178
The current in the guide wire generates a magnetic field aro-

und the cable wire. This field is used to steer the truck. The
magnetic field is detected by way of antennas fitted under the
truck. The antennas are connected to the control unit that con-
trols steering. The entire system is monitored by the onboard
computer which will stop the truck if a malfunction is detected.
2 Generator
The generator must be connected to a power outlet with a no-
minal voltage of 220 V (LDU-22). The generator can also be
ordered for 110 V (LDU-21).
Internally, the unit consists of a voltage card that converts the
line voltage to a lower operating voltage. There is a generator
card with output stages for feeding current onto the wire.
There is also a back-up battery that supplies power in case of
a power failure. In this case a buzzer sounds.
There are two LEDs on the outside. H1 (yellow) lights to show
the guidewire loop is connected and intact. H2 (green) indica-
tes that the line voltage is alright. X1 is a connector for line vol-
tage while X2 is used for output to the wire. S1 is a push-button
for testing the buzzer and the back-up battery condition.
2.1 Technical data

Power supply Model LDU-22 Model LDU-21
220 V, 50 Hz 110 V, 50/60 Hz
Output current 75 mA ± 5%
Frequency 6.25 kHz ± 3,5%
Output voltage 7.5 Veff at no load
Battery 2 x 12 V 3 Ah
Battery back-up > 6 hours
Maximum cable approx. 750 m
length
Wire dimension > 0.75 mm2
Fuse 0.4 A (slow-blow fuse) on the vol-
tage card

OH S4 4200
Wire guidance
Version no. T code
002 175-178
3 Antennas
Two antennas are mounted under the truck. The rear-moun-
ted antenna (W2) is used only when travelling in the drive
wheel direction, while both the front (W1) and rear antennas
are used when travelling in the fork direction.
It is important that the antennas are installed along the truck
centre line (±5 mm) and point in the right direction. They should
be mounted with the arrows pointing in the fork direction (see
the picture).
Each antenna consists of three coils that detect the magnetic

field generated by the wire in the floor. Each coil has its own
function. One detects when the antenna moves in the vertical
plane and is referred to as a reference signal. The other de-
tects lateral movement of the antenna and is referred to as la-
teral signal , while the third detects the angle in relation to the
guide wire, i.e. when the antenna twists, and is referred to as
the angle signal. The coil signals are amplified in a pre-amplifier
card inside the antenna and are then processed in the control unit.
The height, at which the antennas are mounted on the truck,
depends on the depth at which the wire is installed in the floor,
the magnitude of current in the wire (magnetic field) and envi-
ronmental conditions (installation position). Refer to the chap-
ter “Troubleshooting” for verification.
OH S4 4200
Wire guidance
Version no. T code
002 175-178
3.1 Antenna cable

A shielded 5-wire cable is used for connection of the antennas.
To shut out external noise, the shield conductor should be
connected to the chassis across the control unit and antenna.
This does not apply to older types of control units with version
number -001 and older types of antennas as the shield in this
case is internally connected to signal minus.
4 Wire guidance electronic card

This card controls steering with inputs from the antenna and
certain signals from the truck computer, e.g., steering respon-
se and current travel speed. System status information is sent
to the truck computer for malfunction processing.
This is a digital card and any adjustment is done using para-
meters without the use of potentiometers. As such it is impor-
tant to keep in mind that all data is stored in RAM (operating
memory) during adjustment, and that the adjustments must be
saved to EEPROM, electrically programmable memory prior to
turning off the power. Otherwise the data will lost and the pro-
cedure must be repeated.
The card is available in four versions: -001 to -004. Unless oth-
erwise noted, all versions are indicated.
4.1 Components
F Operating voltage fuse (F 315 mA)
X20 Operating voltage connector, etc.
X22 Logic input/output connector (black)
X21 Analogue output signal connector (blue)

OH S4 4200
Wire guidance
Version no. T code
002 175-178
X23 Analogue input signal connector (yellow)

X24 Antenna 1 and 2 connector (orange)
X25 Not used
X26 Terminal connector (for PC)
X27 Shield conductor connectors
H1-H4 Display
H5 Malfunction indicator (see the Error Code table)
H6 Not used
H7 The safety relay has been switched on (OK)
H8 Internal power supply is OK
S1-S3 Pushbuttons (+) (-) (↵)
4.2 Connectors
See the Circuit Diagram under C code 5000.
Con- Type No. Active Function

nector
X20:9 Out 111 +20 V Wire guidance OK
X22:1 Out 112 +20 V Locked onto wire
X22:2 Out 113 +20 V Wire detected
X21:11 Out 122 ±7,5 V Steering set point
X21:6 Out 123 0V Steering set point,
reference
Con- Type No. Active Function

nector
X23:12 In 77 ±7,5 V Travel speed
X23:6 In 71 ±7,5 V Steering angle
X22:12 In 116 +20 V Active wire steering
X20:1 In 67 +20 V Supply voltage
X20:6 In 40 0V Supply voltage
X23:13 In 40 0V Analogue reference
X20:5 In 67 +20 V + to safety relay

OH S4 4200
Wire guidance
Version no. T code
002 175-178
4.3 Display
The built-in display has been developed for use in the field.
The configuration and all parameters have been preset at the
factory, while adjustment of the antenna and steering angle
offsets can be done at the customer’s site using the service
keys S1-S3.
There are four characters in the display, one (H1) for input sig-
nals, one (H2) for output signals/operating modes and two
(H3, H4) for error codes (in some cases, H1 and H2 are also
used to display error codes).
This applies to the normal mode and not the adjustment mode.
4.3.1 Input signals
Input signals are displayed by one segment (a-dp) in H1 cor-
responding to one signal. Several segments may be lit at the
same time.
Segment Function
a-e Not used
f The segment lights when wire guidance is active
g-dp Not used
4.3.2 Output signals / operating modes

Output signals and various operating modes are displayed by
one segment (a-dp) in H2 corresponding to one signal. Seve-
ral segments may be lit at the same time.
Segment Function
a The segment lights when an antenna malfunc-
tion has occurred
b The segment lights when a malfunction has
occurred (EMERGENCY SWITCH OFF)
c The segment is lit while travelling in the drive
wheel direction and is off when travelling in the
fork direction
d The segment lights when a malfunction in the
steering angle signal has occurred
e The segment lights when the truck is locked onto
the wire and is steered by antenna position 2

OH S4 4200
Wire guidance
Version no. T code
002 175-178
Segment Function
f The segment lights when wire guidance is in
charge of steering
g The segment lights when a malfunction in the
speed signal has occurred
dp The segment lights when the truck is not
moving
4.3.3 Error codes

The characters H3-H4 correspond to an error code. In some
cases LED H5 is used in combination with an error code. At
this time H1 and H2 are also used. When everything is alright,
error code 00 is displayed.
Code Description
Err1 The microcontroller has stopped working
H5 lit Oscillator not operating
H5 blinks at Oscillator disconnected
2 Hz
Err2 No watchdog reset
Err3 & H5 lit Incorrect watchdog reset
01 Welded relay contacts
02 Watchdog transistor not operating
03 Watchdog not operating
04 Relay contacts do not close
05 Relay contacts do not open
08 Steering angle potentiometer defective
09 Pull-up resistor for steering angle potentio-
meter defective
0A All steering potentiometers defective
0B PWM signal for analogue outputs defective
0D External steering potentiometer 1 defective
0E External steering potentiometer 2 defective
0F The difference between steering potentiome-
ters 1 or 2 is too large
OH S4 4200
Wire guidance
Version no. T code
002 175-178
Code Description
10 VCC (+5 V) defective
11 +15 V defective
12 External noise
14 EPROM checksum incorrect
15 Read/write error test in external RAM
16 Read/write error test in internal RAM
17 Parameter checksum 1 is incorrect
18 Parameter checksum 2 incorrect
19 Header checksum incorrect
1E Emergency stop bit in controller cannot be
set
21 Test programme error
28 External noise at start-up
29 External noise during operation
32 “Tracking wire” signal is lost during simula-
tion
34 The emergency switch off is defective during
simulation 1
35 The emergency switch off is defective during
simulation 2
36 The reference signal is incorrect during
simulation 1
37 The reference signal is incorrect during
simulation 2
3B-003 Reference signal too low (<100)
3C “Locked on wire” signal lost
3D “Tracking wire” signal lost
3F Emergency switch off test
41 Test of the lateral signal during travel
46 WG and MAN signals not present
47 Tachometer signal not operating

OH S4 4200
Wire guidance
Version no. T code
002 175-178
Code Description
48 Lateral signal defect in active antenna
49 Angle signal defect in active antenna
4A Reference signal defective in active antenna
67-68 Steering signal interrupted by external switch
6A-6C External steering potentiometer defective
(warning)
A1-A8 Output stages 1-8 defective
-003 )
Alteration introduced from version 138973-003.
5 Miscellaneous
There is a switch in the operator’s cabin (S120) for wire gui-
dance. This switch should be engaged when travelling in nar-
row aisles.
6 Description of function
The description follows the functional course of events. See
the Circuit Diagram under C code 5000.
6.1 Travelling in the fork direction

The operator manually steers the truck towards the wire at an
angle of maximum 20º. When antenna no. 1 approaches the
wire, the operator depresses switch S120 to request wire gui-
dance. Output X20:9 (WG OK) should then be high, since an
error code would otherwise be generated. The truck computer
signals to place the wire guidance electronic card in the auto
mode, and input X22:12 then goes high.
When antenna no. 1 detects the magnetic field, the electronic
card switches to the auto mode, and output X22:2 (Tracking
wire) goes high. The truck computer then switches from ma-
nual steering to wire guidance and controls steering with refe-
rence from the set point on the wire guidance electronic card,
outputs X21:11 and X21:6.
The truck is now steered automatically, and when the first an-
tenna is right on top of the wire, the wire guidance electronic
card switches to antenna position 2 and output X22:1 (Locked
onto wire) goes high.

OH S4 4200
Wire guidance
Version no. T code
002 175-178
6.2 Travelling in the drive wheel direction

The operator manually steers the truck towards the wire at an
angle of maximum 20°. When antenna no. 2 approaches the
wire, the operator depresses switch S120 to request wire gui-
dance. Output X20:9 (WG OK) should then be high, since an
error code would otherwise be generated. The truck computer
signals to place the wire guidance electronic card in the auto
mode, and input X22:12 then goes high.
When antenna no. 2 detects the magnetic field, the electronic
card switches to the auto mode, and output X22:2 (Tracking
wire) goes high. The truck computer then switches from manu-
al steering to wire guidance and controls steering with referen-
ce from the set point on the wire guidance electronic card,
outputs X21:11 and X21:6.
The truck is now operated automatically. When the second an-
tenna is right above the wire, X22:1 (Locked on wire) goes
high.
6.3 Control signals

In order to calculate the set point the truck computer should
use for steering, three signals are used: lateral signal (L), ang-
le signal (A) and the current steering angle (P), which cor-
respond to the sum of the signal from the potentiometer R3
and the ZERO potentiometer on the A2 card.
Control signal = (L+A) - P
The lateral and angle signals are compensated depending on
the reference signal. In case the distance to the cable in the
floor somehow varies, this will be compensated for. When tra-
velling in the fork direction, the reference signal signal from an-
tenna 1 is used, while driving in the drive wheel direction that
of antenna 2 is used.
The speed signal, input X23:12, is used to adapt the level of
amplification at different travel speeds.

OH S4 4200
Wire guidance
Version no. T code
002 175-178
Different antenna signals are used depending on the selected

operating mode of the truck. The table below shows the inter-
nal signals of the antennas that are used for the above calcu-
lation.
Operating mode L A P
When travelling in the W1 W1 Angle R3*
wire in the fork direction Lateral
Locked onto wire in the W1 W2 Lateral R3*
fork direction Lateral
When travelling on the W2 W2 Angle R3*
wire in the drive wheel Lateral
direction
Locked onto wire in the W2 W2 Angle R3*
drive wheel direction Lateral
Control signal = (L+A) - P

*) P is the total sum of R3 and the fine adjustment potentiome-
ter ZERO on the A2 electronic card.

OH S4 4200
Wire guidance
Version no. T code
002 175-178
7 Adjustments
7.1 Truck computer A2

Prior to adjustment of the wire guidance equipment, it is impe-
rative that the steering angle has been correctly set in the truck
computer.
7.1.1 Steering angle

• Park the truck with the steering wheels pointing straight
forward to the entrance of a narrow aisle, and do not
request wire guidance.
• Adjust the ZERO potentiometer (2) on the A2 box until both
the yellow LEDs (1) light simultaneously.
7.2 Wire guidance electronic card A3

When it is necessary to adjust the box, first enter the setting
mode by pressing one of the pushbuttons under the display.
To return to the normal mode, press all three pushbuttons at
the same time.
From programme version -003, the following applies:
The display is usually dimmed. To enter the setting mode,
press all three pushbuttons (S1-S3) at the same time. The dis-
play brightness then increases. To return to the normal mode,
press all three pushbuttons at the same time.
When the setting mode has been selected, the display shows
various menus; the two characters on the left, H1 and H2,
show the main menu and those on the right, H3 and H4, show
the sub-menu. The current position is displayed with a blinking
number. All main menus do not have sub-menus.
Use the S1 pushbutton to increase a value and the S2 push-
button to decrease it. Use S3 to select a menu.
To switch from a main menu to a sub-menu, press Enter. To
return to the main menu, press the S1 and S2 buttons at the
same time.

OH S4 4200
Wire guidance
Version no. T code
002 175-178
The table below shows the available menus of the unit:
Menu Description Area

1.2 Automatic offset adjustment of steering angle
1.4 Automatic reset of antenna offset
1.5 Automatic readjustment of steering angle
1.9 Angle adjustment in antenna 1 mode in the selected travel direction ± 127
1.11 Change of selected travel direction (with S1 and S2) F=Fork
direction R=Drive wheeldirection
2 Side adjustment of the truck while travelling in the fork direction ± 127
4 Angle adjustment of the truck while travelling in the fork direction ± 127
5 Side adjustment of the truck while travelling in the drive wheel ± 127
direction
6 Angle adjustment in antenna 1 mode while travelling in the drive ± 127
wheel direction (3-wheel)
7 Angle adjustment of the truck while travelling in the drive wheel ± 127
direction
8 Shows the value of the steering angle offset ± 127
9.2 Selection of basic parameters for each truck 1-21-003
1. Continue on to menu 9.2, then press S3
2. The display shows POS 0
3. Select the desired parameter set using S1 and S2
4. Confirm by pressing S3
9.3 All parameters will be stored in EEPROM
1. Continue to menu 9.3, then press S3
2. POS 0 is diplayed, press S3
3. EPcr is dispalyed
4. Store by pressing S3 for more than 2 sec
10.0 Change of selected travel direction (with S1 and S2) F=Fork
direction R=Drive wheel direction
10.1 Shows the current lateral signal for the selected travel direction ± 127
10.2 Shows the current angle signal for the selected travel direction ± 127
10.3 Shows the current reference signal for the selected travel direc- 0-519
tion
10.4 Shows the current value for the steering angle potentiometer ± 127

OH S4 4200
Wire guidance
Version no. T code
002 175-178
Menu Description Area

10.5 Shows the average value of the steering angle signal since the ± 127
last stop
10.6 Shows the average value of the lateral signal since the last stop ± 127
10.7 Shows the average value of the angle signal since the last stop ± 127
10.8 Shows the lowest value of the lateral signal since the last stop ± 127
10.9 Shows the highest value of the lateral signal since the last stop ± 127
10.10 Shows the value of the travel speed signal +/- 512
(50 units / volt)
10.12 The frequency the unit needs to detect1 5-7-003
11.0 Shows the ID number that was saved last 10-71-003
11.1 - Shows the ID number from position 1-21 in the memory (see the 10-71-003
11.21 section “Installing a new wire guidance electronic card”)
11.22 Shows the current ID number 10-71-003
11.23 Shows the serial number of the box
11.24 Shows the programme version number
-003) Alteration introduced from version 138973-003.
1)
See the section reference signal in the troubleshootingchapter.
The following applies to versions 138973-001 and 138973-

002:
11.0 Shows the ID number that was saved last 10-50

11.1 - Shows the ID number from position 1-5 in the memory (see the sec- 10-50
11.5 tion “Installing a new wire guidance electronic card”)
11.6 Shows the current ID number 10-50
11.7 Shows the serial number 1-9999
11.8 Shows the programme version 1.0.0-

OH S4 4200
Wire guidance
Version no. T code
002 175-178
Other display information:
Display Description
noSP The truck is not standing still (speed <> 0)
noFo The travel direction is not the fork direction
nobS The truck type is not steered by articulated cen-
tre (CTX)
no1S Not in the antenna 1 mode
no3W The truck type does not have 3 wheels
F The fork direction has been selected
r The drive wheel direction has been selected
7.2.1 Adjustment of the steering angle offset

• Park the truck with the steering wheels pointing straight
forward to the entrance of the narrow aisle. Check all
adjustments under the heading “Steering angle”.
• Switch on the setting mode
• Auto adjust the steering angle offset in menu 1.2
- Any possible error signal from the A2 card, will now be
eliminated through compensation. A new offset value is
saved in menu 8.
7.2.2 Fine adjustment of the steering angle offset

• Enter the narrow aisle, request the wire a couple of meters
into the aisle in the drive wheel direction and then come to
a slow stop.
• Check that the signal “Locked on wire” is high, and then
slowly drive in the drive wheel direction as far as possible
and come to a slow stop.
- During this time, the unit will log the maximum and mini-
mum values for the steering angle (P), and it will calcu-
late an average value.
• Readjust the steering angle value in menu 1.5.
- The average value is then adjusted in menu 8. This
adjustment can be verified by driving the truck for about
20 seconds and then read the average value in menu
10.5. This is the most important adjustment in the
entire procedure. The value should never exceed 0 +/-
1. If the value is higher, repeat the fine adjustment pro-
cedure.

OH S4 4200
Wire guidance
Version no. T code
002 175-178
• Drive slowly in the drive wheel direction and check that the
LEDs (1) light symmetrically. If necessary, adjust the ZERO
potentiometer (2), then readjust (menu 1.5) until the value
in menu 10.5 becomes 0 +/- 1.
- If adjustment of the ZERO potentiometer is required, the
steering angle value to the wire guidance logic card will
be affected and post-adjustment will be necessary.
7.2.3 Antenna adjustment for the drive wheel direction

• Continue to drive slowly in the drive wheel direction as far
as possible, then come to a slow stop.
mum values for the angle signal (V), and it will calculate
an average value.
• Memorize the average value in menu 10.7.
• Adjust menu 6 to this value.
7.2.4 Antenna adjustment for the fork direction

• Continue to drive slowly in the fork direction as far as pos-
sible, then come to a slow stop.
mum values for the lateral signal (L), and it will calculate
an average value.
• Memorize the average value in menu 10.6.
• Multiply this value by a truck-specific constant correspon-
ding to machine type 2.
- If the multiplied value exceeds ± 80, verify the adjust-
ment under the heading “Fine adjustment of the steering
angle offset”.
- If this does not remedy the situation, then manually
adjust the W1 antenna in the lateral direction.
• Adjust menu 4 to the calculated value
- If the test procedure is repeated several times, the value
in menu 4 will change to the new one. For example, If the
value in menu 4 is +20 and the new average value is -5,
then menu 4 must be adjusted to (-5*2=-10) +20-10=+10

OH S4 4200
Wire guidance
Version no. T code
002 175-178
7.2.5. Final adjustment

• Drive in the fork direction and drive wheel direction at diffe-
rent speeds and verify the following:
- both LEDs(1) light symmetrically
- that the value in menu 10.5 equals 0 +/-1. If not, perform
fine adjustmet in menu 8
- the value in menu 10.6 is as close to 0 as possible. Fine
adjust using menu 4.
7.2.6 Storing parameters

• Store the settings in menu 9.3 when the adjustments are
complete.
- Parameters can be stored at any time during the adjust-
ment. This prevents data loss in case power needs to be
turned off due to an error code.
7.2.7 Antenna adjustment in the antenna 1 mode

This adjustment is only necessary when the truck cannot find
the wire in the fork direction at the same angle from right and
left in relation to the wire.
• Disconnect the cables of the aisle transmitters (inputs 109
and 110 on the A2 electronic card) and the centre aisle
transmitter (111) if present.
- This should be done to prevent an error code later on in
the adjustment procedure.
• Drive slowly in the drive wheel direction on the wire and
read the value in menu 10.2 (angle signal). This value is
changing continuously. Stop the truck when the value is as
close to zero as possible.
• Switch off wire guidance using the switch in the cabin and
check that fork direction travel is engaged (menu 10.0,
r=drive wheel direction, F=fork direction); if not, change
using S1 or S2, then press S3.
• Read the value in menu 10.2.
- The value corresponds to the angle signal for the W1
antenna in the antenna 1 mode. This value is obtained
because the switch is turned off.
• Adjust menu 1.9 to this value.
• Store all parameters as explained in the section “Storing
parameters”.

OH S4 4200
Wire guidance
Version no. T code
002 175-178
8 Installing a new wire guidance

electronic card
This card is used in several truck models. The basic parame-
ters are different for different truck types. Because of this, it is
necessary to set the correct parameters for the truck when a
new electronic card is installed.
The memory area consists of 21 positions-003 of which 14 are
used to store basic parameters. These are stored at the facto-
ry and can be selected in menu 9.2. Trucks with serial number
preceding -003 only have 5 positions.
Each parameter set has an ID number which can be verified in
menus 11.0. Use this number to make sure the correct para-
meters have been selected.
The table below shows the different parameters sets and their
corresponding ID numbers:
POS Truck model ID number

1 CTX with short time constant 10
when shifting from high to low
power upon entering a narrow
aisle.
2 OP/OPW. 20
3 TRT / VR 30
4 OM / OMW 40
5 OPW SPACE (wider OPW 50
model)
6 CTX with very long time constant 60
upon entering a narrow aisle.
Recommended for machines
with long mast length and heavy
loads since the truck could be
forced across the wire and an
error code would be generated
as a result
7 CTX with a long time constant 70
upon entering a narrow aisle. A
compromise of positions 1 and 6

OH S4 4200
Wire guidance
Version no. T code
002 175-178
In position 8-14 the above parameters are used however with

two additions and new ID numbers:
• Output X22:9 turns on when the unit “tracks the wire” but
the operator has not selected wire guidance. The output
can be used to e.g. engage a buzzer. Note max. 500 mA
DC current consumption.
• Output X22:8 turns on if the lateral signal >75% of the per-
missible value. The output can be used to e.g. reduce the
maximum travel speed when the truck veers off the centre
of the wire. Note max. 10 mA DC current consumption.
POS Truck model ID number

8 CTX with short time constant 11
power upon entering a narrow
aisle.
9 OP/OPW. 21
10 TRT/VR. 31
11 OM/OMW. 41
12 OPW SPACE (wider OPW 51
model)
13 CTX with very long time constant 61
upon entering a narrow aisle.
Recommended for machines
with long mast length and heavy
loads since the truck could be
forced across the wire and an
error code would be generated
as a result
14 CTX with a long time constant 71
upon entering a narrow aisle. A
compromise of positions 8 and
13.
Positions 15-21 are not used.

OH S4 4200
Wire guidance
Version no. T code
002 175-178
9 Troubleshooting
9.1 Control signals

9.1.1 Verifying the reference signal
Drive slowly on the wire and read the reference signal in menu
10.3. The value should stay between 350 and 500 when an-
tenna height, current and cable depth are correct.
Depending on the used frequency, the current in the wire ca-
ble should match the values in the table below in order to ob-
tain the correct reference signal.
kHz mA
5.2 90
6.25 75
7.0 65
9.1.2 Verifying the lateral signal

Drive slowly on the wire and read the lateral signal in menu
10.1. The value should stay between -50 and 50 when the wire
has been set properly in the floor. Error code (3C) is triggered
when the value exceeds the absolute value of 100. The lateral
signal must also stay symmetrical. This can be verified in
menu 10.6 which is the average value since the latest stop in
the selected travel direction. The value should be 0 ±10.
9.1.3 Verifying the steering angle signal

Drive slowly on the wire and read the steering angle signal va-
lue in menu 10.4. The value should stay between -10 and 10.
The steering angle signal value must also stay symmetrical.
This can be verified in menu 10.5 which is the average value
since the latest stop in the selected travel direction. The value
should be 0 ±1.

OH S5 5000
Electric system
SSD C Nylin 001 175, 176
Electric system
T-code Model Serial No. Notes

175 OP 1000SE 290610AA-
176 OP 1000HSE 290610AA-
1. General
This document is a presentation of the electric system OP
1000/2 SE/HSE, Drawing No. E141413, program version 8.
If the truck is equipped with dual control, see document 5000
version 002.
2. List of symbols
Symbol Description Function Notes

A1 Transistor panel
A2 Electronic circuit board
A3 Steering servo
A4 Wire guidance equipment
A5 Proportional valve Forks
steering
BT Battery +48 V
E1 Light mounting Cabin lighting, left
E2 Light mounting Cabin lighting, right
E3 Head light Working light, left
E4 Head light Working light, right
F1 Fuse Drive motor 160 A
F3 Fuse Pump motor, cabin lift 250 A
F4 Fuse Pump motor, initial lift 50 A
F60 Manoeuvre fuse Steering servo 20 A

OH S5 5000
Electric system
Version no T-code
001 175, 176

F61 Manoeuvre fuse Outputs A2 7.5 A
F63 Manoeuvre fuse Cabin lighting 7.5 A
F64 Manoeuvre fuse Proportional valve steering, 7.5 A
forks
F65 Manoeuvre fuse Inputs A2 7.5 A
F66 Manoeuvre fuse Battery indicator 7.5 A
H1 Horn
H2 Buzzer Option
H64 Indication lamp Steering wheel straight
H70 Error indication lamp Instrument panel
H90 Warning lamp
H120 Indication lamp Locked on load Option
K10 Main contactor
K11 Contactor Travel forwards
K13 Contactor Travel backwards
K30 Contactor Pump motor, cabin lift
K40 Contactor Pump motor, initial lift
K60 Safety contactor Steering
M1 Drive motor
M3 Pump motor Cabin lift
M4 Pump motor Initial lift
M6 Steering motor
P1 Battery indicator
R1 Potentiometer Front/back
R2 Potentiometer Lift/lower cabin
R3 Potentiometer Steering angle
R4 Potentiometer Travel brake
R6 Protecting resistance Steering motor
S17 Microswitch Key
S18 Microswitch Horn

OH S5 5000
Electric system
Version no T-code
001 175, 176

S21 Microswitch Emergency stop, cabin
S22 Microswitch Emergency stop, chassis
S34 Microswitch Initial lift/lower
S70 Magnet switch Forks in bottom position
S74 Magnet switch Aisle-middle, front Option
S75 Magnet switch Aisle-middle, rear Option
S79 Magnet switch "In narrow aisle", front
S80 Magnet switch "In narrow aisle", rear
S81 Microswitch Slack chain guard
S87 Microswitch Gate left
S88 Microswitch Gate right
S100 Deadman’s handle Left
S101 Deadman’s handle Right
S102 Pulse transducer Drive motor, channel A
S103 Pulse transducer Drive motor, channel B
S 104 Magnet switch Cabin reference
S105 Pulse transducer Height measurement, cabin
channel A
channel B
S107 Magnet switch Max. cabin, lift height
S108 Magnet switch Lift height restriction Option
S109 Microswitch Further lift (past S108) Option
S120 Microswitch Wire following
U1 Tachometer Steering
W1 Antenna Front
W2 Antenna Back
Y1 Proportional valve Cabin lift
Y2 Proportional valve Cabin lower

OH S5 5000
Electric system
Version no T-code
001 175, 176

Y3 Magnet valve Cabin lower
Y4 Magnet valve Initial lower
Y5 Proportional valve Initial lower
Y10 Travel brake Step 1

OH S5 5000
Electric system
Version no T-code
001 175, 176
2.1. Electric chart (1/10)

OH S5 5000
Electric system
Version no T-code
001 175, 176

OH S5 5000
Electric system
Version no T-code
001 175, 176

OH S5 5000
Electric system
Version no T-code
001 175, 176

OH S5 5000
Electric system
Version no T-code
001 175, 176

OH S5 5000
Electric system
Version no T-code
001 175, 176

OH S5 5000
Electric system
Version no T-code
001 175, 176

OH S5 5000
Electric system
Version no T-code
001 175, 176

OH S5 5000
Electric system
Version no T-code
001 175, 176

OH S5 5000
Electric system
Version no T-code
001 175, 176

OH S5 5000
Electric system
Version no T-code
001 175, 176
3. Presentation of electric chart

OP 1000/2 SE/HSE
Drawing No. E 141413, program version 8
3.1. Drive motor circuit (see electric chart

1/10)
• The main contactor K10 receives its plus voltage via the
transistor panel's safety circuit, connection 7.
• One of K10's contacts connects +48 V partly to pump
motor M3 and M4 (electric chart 2) partly via F 60 to
steering servo the box A3 and via F61 to input 702 on the
electronic circuit board A2 (electric chart 7).
• K10's other contact connects +48 V to drive motor M1 via
fuse F1, 160 A.
• K11 and K13 are front and back contacts, respectively.
• A1 is the transistor regulator which checks the travel
speed.
• A2 is the electronic circuit board for the travel, steering and
cabin function.
3.2. Pump motors, cabin lift and initial lift,

and also battery indicators and hour
meters. (electric chart 2/10)
• F3 (250 A) is the fuse for pump motor M3.
• F4 (50 A) is the fuse for pump motor M4 and the cabin
electronics.
• K30 is the pump motor contactor for M3 and K40 for M4.
• F65 (7.5 A) is the manoeuvre fuse for the electronic circuit
board's +20 V and the transistor panel A1 (electric chart 1).
• F66 (7.5 A) is the manoeuvre fuse for the hour meter.
• S21 and S22 are emergency stop switches.
• S17 is the ignition lock.
• Output 610 on A2 give +48 V to the hour meter when the
right deadman's handle is activated.
• Input 701 on A2 receives +48 V from S17.

OH S5 5000
Electric system
Version no T-code
001 175, 176
• On the board, +48 V is transformed to a stable working

voltage of +20 V. This voltage is found on output 707 and is
used for the transducers and switches which give
information to A2's inputs.
• The switch in the battery guard is closed as long as the
battery capacity does not fall below 20%. If the battery
capacity falls below 20%, the switch will open and the
cabin lift will be blocked.
3.3. Steering servo (see electric chart 3/10)

• Fuse F60 (20 A) is for steering servo A3.
• U1 is the tachometer (the wheel) which gives plus or minus
voltage to A3.
• M6 is the steering motor (permanent magnetic motor).
• K60 short-circuits the armature over R6, when the truck is
without voltage. This means that the armature is locked.
• A high signal (+20 V) in on A3/5 means that the steering
angle is greater than 80°. The steering speed will then be
lowered for a gentler steering towards the end stop.
• A high signal (+20 V) in on A3/11 means that the
tachometer (the wheel) is disconnected and the truck is
steered by the rails or wire.
• A high signal (+20 V) in on A3/8 means steering is
permitted.
• A high signal (+20 V) out from A3/9 informs the A2 board
that the supervision relay on A3 is activated and that we
have +48 V out on A3/1 to K60 which has drawn.
• R3 is a potentiometer which is placed on the steering
motor M6 and gives the A2 board information about the
steering angle of the truck.
• NOTE. R3 is supplied with 7.5 V from A2, output 303 and
-7.5 V from A2, output 306. When the steering wheel is
straight, therefore, the voltage is on A2, input 304, ± 0 V.

OH S5 5000
Electric system
Version no T-code
001 175, 176
3.4. Inputs to the electronic circuit board

A2 (see electric chart 4/10)
• S105 and S106 are inducing transducers which together
give A2 information about the height position of the
operator’s cabin.
• S104 is a magnet switch and is used as reference provider
in the cabin's height measurement system.
• S107 is a magnet switch which opens when the cabin's
maximum height is reached.
• S108 is a magnet switch which is used during lift height
restriction requested by the customer (not standard).
• S79 and S80 are magnet switches which indicate if the
truck is in a narrow aisle or not. Both of the switches open
means that the truck is outside the narrow aisle. A switch
closed means that the truck is in a narrow aisle and that
the truck is rail-controlled. Both switches closed means
that the truck is in a narrow aisle and that the truck is wire-
controlled.
• S74 and S75 are magnet switches for aisle-end brake and
are available as extra equipment only. When the truck
drives in the narrow aisle, it passes the special magnets
that exist for the aisle-end brake. Switches S74 or S75
stop. When the truck drives out of the narrow aisle, it
passes a magnet again, which then causes the switch to
open, and we have an automatic brake if certain conditions
are fulfilled.

• S100 left deadman's handle. During driving outside narrow
aisles, the control is used momentarily as a check that the
driver is in the operator cabin. When driving in narrow
aisles, you must keep your hand on the control so that the
truck will function.
• S101 right deadman's handle. Must be activated for the
truck to work.
• S70 is closed when the forks are in the bottom position (25
cm).
• S87 and S88 are switches placed in the cabin gates. They
are open when the gates are open and closed when the
gates are closed.
OH S5 5000
Electric system
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001 175, 176
• S81 and S82 are slack chain guards. They are closed
when the chains are stretched but are forced to open when
the chains slacken.
• S109 is the switch for disconnection of the lift height
restriction (not standard).
• The RS 485 connection is not used at present.

• R1, R2 and R4 are the three potentiometers which are in
the right joystick.
• R1 gives information about required drive speed forward/
back. R1 has been equipped with a middle output. This
output gives information to A2/204 so that any interruption
in the cabling to R1 has been detected by the A2 board.
• R2 gives information about desired lift/lower speed for the
cabin.
• R1 gives information about desired braking force, travel
brake. The potentiometers are supplied from the stabilised
+20 V.
• S102 and S103 are inducing transducers, placed on the
travel motor, which together give A2 information about the
truck's travel speed.
3.7. Outputs from the electronic circuit

board A2 (see electric chart 7/10)
• +48 V to the outputs on A2 come from contact on K10 via
F61 (7.5 A) to A2, input 702.
• K11 travel contactor, front, receives +48 V from A2, output
503, when the truck will drive forwards.
• K13 travel contactor, back, receives +48 V from A2, output
504, when the truck will drive backwards.
• Y10 - Y12 are magnet coils in the electromechanical brake.
When the brake is disengaged, all the coils are activated,
i.e. A2, outputs 505, 506 and 507 are all +48 V.
• H90 is a warning lamp located on the rear body. The lamp
blinks when the right deadman's handle is activated.
• H64 is the indication lamp for steering wheel straight.
Placed in the operator's cabin.

OH S5 5000
Electric system
Version no T-code
001 175, 176

• Y1 is the proportional valve for cabin lift. The valve is
current controlled and supplied with pulse width modulated
current. Determines the lift speed.
• Y2 is the proportional valve for cabin lower. The valve is
current. Determines the lowering speed.
• Y3 is the on/off valve for the cabin lowering.
• K30 is the pump motor contactor, activated during cabin
lift.
• H2 is a buzzer used when the truck is equipped with aisle-
end brakes (not standard).
• H70 is the error indication lamp, placed in the operator's
cabin. When the lamp lights with fixed light, everything is
OK.
• Output A2/609 is high (+48 V) when it is permitted to use
the initial lift.
3.9. Initial lift/lower, horn and lighting

(see electric chart 9/10)
• S34 is control switch for initial lift/lower. It receives its
voltage from the A2 board's output 609. It is, therefore, the
A2 board which determines if we can use the fork unit.
• A5 is the valve control for valve Y4 and prop. valve Y5,
they are used during fork lowering.
• Y4 is an on/off valve with delay during the opening.
• K40 is the contactor for pump motor initial lift M4 (electric
chart 2).
• F64 (7.5 A) is the fuse for A5, Y4 and Y5 and also the horn
H1.
• S18 is control switch for the horn.
• F63 (7.5 A) is the fuse for the cab's roof lighting (E1 and
E2) and also for spot-lights (E3 and E4) if they are
mounted (not standard).

OH S5 5000
Electric system
Version no T-code
001 175, 176
3.10. Wire guidance

• Wire guidance has a separate description. Note that when
wire guidance is not mounted, a clamp must be attached
instead of S120. Input A2/309 must, therefore, be high
(+20 V) when we do not have wire guidance.
4. Function description electric

system OP 1000/2 SE/HSE
Drawing No. 141413
4.1. Start-up
When the ignition switch, S17, is activated and the emergency
stop switches, S21 and S22, are closed, we receive voltage
into A2/701 and to A1/1. The voltage into A2/701 is
transformed in A2 to stabilised + 20 V voltage and is fed out on
A2/707, cable 67. This stabilised +20 V tension is used as
supply for microswitches and pulse transducers on A2's
inputs.
A self-test now starts of A2's functions, at the same time a
check occurs of the transistor panel. When these tests are
ready, K10 will pull and the green lamp furthest to the right on
the operator panel is lit.
We receive +48 V in to A2/702 via F61 and K10's contact. This
+48 V is used to supply A2's outputs with voltage. If the
deadman's handle is held during start-up, an error code is
received and a slow flashing on the green lamp furthest to the
right on the operator's panel. The error code is reset with the
ignition switch (S17).
NOTE. Between opening and closing of S17, it is necessary to
wait approx. 5 seconds. An error code can be received in the
event of opening and closing too quickly (usually error code 7).

OH S5 5000
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001 175, 176
4.2. Check of the operator’s presence in

the operator cabin
When driving outside a narrow aisle, the driver must, after the
gates have closed, move the left deadman’s handle,
momentarily, for the truck to work. If the gates are opened and
closed, a new movement of the left deadman’s handle must
occur. If the truck is to be driven with the gates open, when this
is permissible, start of the working function must take place
within 5 seconds after the moving of the left deadman’s
handle. The next working function must take place within 5
seconds after the previous, otherwise a new movement of the
controls must be made.
When driving in narrow aisles, your hand must be held on the
control for the truck to function.
4.3. Deadman’s handles

For the truck to be able to be used, the right deadman’s handle
must be activated (in a narrow aisle, the left deadman’s handle
also). When the right deadman’s handle is activated, the brake
is released. The deadman’s handles are time-monitored to
prevent error function. The time is calculated when the
deadman’s handles are moved, but not when travel or
hydraulic movements are carried out. Within 3 minutes, the
deadman’s handles must be released otherwise the travel and
hydraulic functions are prevented. After "retake", the time
measurement starts again from the beginning.

OH S5 5000
Electric system
Version no T-code
001 175, 176
4.4. Driving forward-back

By moving the joystick, forward or back, the potentiometer R1
is moved (sheet 6). R1 then gives an increased voltage
(neutral position = 10 V) into A2/301 if the joystick is moved
forwards or a decreased voltage if the joystick is moved
backwards. It is, therefore, the change in voltage which
determines the travel speed while voltages under 10 V give
travel direction backwards and voltages over 10 V give travel
direction backwards.
The right deadman’s handle, S101, and joystick R1 are now
activated. The brake is released, the coils Y10, Y11 and Y12
(sheet 7) are activated.
Travel direction contactor K11 (forward) or K13 (back) pulls
(sheet 7). When K11 or K13 has pulled, the transistor panel,
A1, can begin to regulate the drive motor voltage. The drive
motor current goes from battery plus over K10’s contact
through F1, through the drive motor’s anchor, through the
series field via K11’s or K13’s contact tips, into connection A1/
M, through the transistor regulator where the motor current is
regulated and further to battery minus via A1/B-. Free wheel
diode and brake diode are built into A1.
The transistor regulator is controlled via input signals from A2.
Input A1/10 is the speed set value, 0.1 to 4.75 V. This gives
speeds from 0-100%. Input A1/6 is the common minus for the
speed set value and maximum current limit.
Input A1/11 is the maximum current limit, 0-5 V. This gives
current limits from 25-100%.
During acceleration and travel, a fixed current limit value is
given and the speed is controlled by the speed set value. The
real speed and travel direction is checked by the travel speed
transducers S102 and S103 (sheet 6). The pulse transducers
are on the propulsion motor and each give their pulse train, 90°
phase displaced, where the drive wheel is rolling.
During motor braking, a fixed speed set value is given and the
brake force is controlled by the current limit value. When the
truck motor brakes, A1/8 gives out a +48 V signal to A2. This
signal together with the signals from the travel speed
transducers S102 and S103 supervise the motor braking.
The electronic circuit board A2 determines, by the height
measurer and aisle indication, which maximum speed the
truck may be driven with.

OH S5 5000
Electric system
Version no T-code
001 175, 176
4.5. Travel speed

Open gate and fork height over 3.0 m gives maximum travel
speed = 0.
The height is programmable between 0 and 3.0 m.
See section programmable parameters.
The fork height is the initial lift height plus the cabin lift height.
The initial lift height is calculated as 0 metres if the initial lift’s
switch S70 is closed (under 0.3 m) and 1.2 m if the switch is
open (over 0.3 m).
4.5.1. Outside narrow aisle:
Fork height under 1.2 m gives maximum speed = full speed.
Fork height between 1.2 m and 3.0 m and the steering reading
less than 10° gives maximum speed = half speed.
greater than 10° gives maximum speed = creep speed.
Fork heights over 3.0 m give maximum speed = creep speed.
4.5.2. In narrow aisle:
Fork heights under 3.0 m give maximum speed = full speed.
Fork heights over 3.0 m give variable speed reduction which
is dependant on stability and brake force.
Full speed = 9 km/h
Half speed = 4 km/h
Creep speed = 2.5 km/h
Maximum current limit during acceleration is 280 A, during
motor braking 350 A.
4.6. Brake
By guiding the joystick to the right, the truck brakes. The brake
force is controlled partly by the joystick potentiometer’s (R4)
input voltage to A2/311 (neutral position = 10 V) and partly by
the truck’s current speed and lift height. The truck computer
determines the maximum brake power which may be used at
the height which the cabin has when the driver brakes. With
the joystick, the driver can determine how much of this brake
power he wants to use for the braking. There is a maximum of
three brake steps. By releasing the right "deadman’s handle"
the brake is affected so that the three brake steps are
activated in order, with a certain time delay and gives, thus, a
parking brake.

OH S5 5000
Electric system
Version no T-code
001 175, 176
4.7. Steering
The steering wheel is placed to the left on the control panel.
The steering is electromechanical. When we crank the
steering wheel, we receive a continuous voltage from the
tachometer U1. The signal is positive in one direction and
negative in the other direction. The signal goes into the
connections A3/4 and 12.
A3 controls, in turn, a permanent magnet motor which
functions as a steering motor (M6). Contactor K60 is pulled
when the steering servo is in function.
Potentiometer R3 is mounted on the steering motor M6 and
gives the A2 board information about the steering angle. With
a steering angle greater than 80° the steering speed is
reduced for a gentle stop in the steering end position (sheet 3).
The potentiometer is supplied with ± 7.5 V voltage. When the
truck's steering wheel is straight forward, we get ± 0 V into
connection A2/304.
When driving in narrow aisles, for wire guidance of the truck,
the truck must be steered so that it drives straight. The
indication lamp, "straight steering wheel", is lit.
When the truck has entered the narrow aisle, S79 or S80 is
activated. The manual steering is disconnected when the truck
is straight ahead and the steering is taken over by R3.
4.8. Cabin lift

Cabin lift takes place by lifting the joystick and moving
potentiometer R2. The lift speed depends on how high the
joystick is lifted. When lifting the joystick we receive a change
in voltage (neutral position = +10 V) into A2/302. The
computer gives voltage to contactor K30. Pump motor M3
starts. The flow to the cabin's lift cylinders is controlled by
proportional valve Y1. The proportional valve's coil is current-
controlled, A2/508, 509.
In order to be able to lift over a cabin height of 3 m, the gates
must be closed. This is supervised by the microswitches S87
and S88. (sheet 5).
Cabin height measurement takes place by two inductive
transducers and a magnet switch.
When the cabin passes 0.8 m, the magnet switch S104 opens
and +20 V disappears from A2/106. This is the cabin height
reference.

OH S5 5000
Electric system
Version no T-code
001 175, 176
The actual cabin height measurement takes place with the two
inductive transducers, S105 and S106, placed on the mast. A
rail with "flags" is placed on the guider. The transducers are
placed 90° phase displaced and each give their own pulse
train into A2/102 and A2/105 respectively.
Maximum cabin height is determined by the magnet switch
S107.
The lift height limit can be connected via S108 (not standard).
If the lift height limitation has been mounted, a micro switch
(S109) for "further lift" must be mounted (sheet 5).
4.9. Cabin lower

Cabin lower takes place by pushing the joystick down and
moving the potentiometer R2. The lower speed depends on
how much the joystick is pushed down.
When the joystick is pushed down, we receive a change in
voltage (neutral position =+10 V) into A2/302. The computer
now gives out voltage to the magnet valve Y3, A2/603. The
flow from the cabin’s lift cylinders is controlled by proportional
valve Y2. The proportional valve’s coil is current-controlled,
A2/510, 511.
In order to be able to lower at a cabin height of over 3 m, the
gates must be closed. This is monitored by the microswitches
S87 and S88.
The computer automatically reconnects to low lower speed,
before the cabin has reached its lowest position.
4.10. Slack chain guard

The slack chain guards S81 and S82 (sheet 5) monitor that
the cabin lift chains are tense. If one of the chains slackens,
one of the slack chain guards opens and breaks the cabin
lower movement. A lift movement of 200 mm or a lift time of
10 seconds is permitted.
4.11. Initial lift

During initial lift, the butterfly control switch S34 is moved and
K40 receives voltages and pulls (sheet 9).
K40 activates the pump motor M4 and the forks lift (sheet 2).
NOTE. The right deadman’s handle must be activated for
initial lift to work.

OH S5 5000
Electric system
Version no T-code
001 175, 176
4.12. Initial lower

During initial lower, the butterfly control switch S34 is moved
and Y4 opens. The proportional valve control A5 gives a
current control of Y5 so that a gentle start of fork lowering is
attained.
4.13. Other
The battery guard is connected to cable 26 and is fused by
F66. The battery minus comes directly from cable 40. The
battery guard breaks away the cabin lift function when only
20% of the battery capacity remains. The battery guard’s
contact is connected to A2/103. Plus to the battery guard’s
display comes via input 2. The battery guard measures,
therefore, the battery as soon as the battery hand rail is
connected to the battery. The instrument only shows the
results, however, when the ignition lock is on.
The hour meter, which is located in the same instrument as the
battery guard, has its minus internally connected to the battery
guard’s minus. The hour meter measures the time when input
6 is high.
Wire guidance has a separate instruction.
If the truck is not equipped with wire guidance, we must have
+20 V connected directly to A2/309.
The horn and cabin lighting as well as extra functions such as
spotlight, radio and computer receive their +48 V via F4 and
F63 or F64.

OH S5 5000
Electric system
Version no T-code
001 175, 176
4.14. Aisle-end brake (extra equipment)

When driving in narrow aisles, there must not be any
automatic speed reduction. When driving outside a narrow
aisle, at a predetermined point from the aisle-end, (approx. 7
m) the truck must stop the travel and activate the brake, if the
speed at this point is higher than creep speed.
If the travel speed is creep speed or lower, the truck passes
the "braking point" without braking.
Bistable magnet switches (S74, S75) are mounted on the
truck.
Permanent magnets are mounted in the floor of the narrow
aisle.
When the truck is in the area between the "braking point" and
the aisle-end, and the joystick for driving out of the aisle is
moved, an intermittent warning signal is activated. By
releasing the joystick to neutral position, momentarily, the
warning lamp signal is switched off.

OH S5 5000
Electric system
SSD C Nylin 002 175, 176
Electric system

175 OP 1000SE 290610AA-
176 OP 1000HSE 290610AA-
1. General
1000/2 SE/HSE, with double command, Drawing No.
E142869, program version 8.
2. List of symbols

A1 Transistor panel
A3 Steering servo
steering
BT Battery +48 V

OH S5 5000
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002 175, 176

forks
H1 Horn
H2 Buzzer Option
H70 Error indication lamp Instrument panel Instrument
panel
H90 Warning lamp
K10 Main contactor
K201 Relay Double command
M1 Drive motor
M6 Steering motor
R201 Potentiometer Forward/back double
command

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002 175, 176

R202 Potentiometer Lift/lower cabin double
command
R204 Potentiometer Travel brake double
command
S17 Microswitch Key
S105 Pulse transducer Height measurement, cabin A
S106 Pulse transducer Height measurement, cabin B
S200 Deadman’s handle Left double command
S201 Deadman’s handle Right double command

OH S5 5000
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002 175, 176

U2 Tachometer Steering double command
W1 Antenna Front
W2 Antenna Rear

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002 175, 176

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002 175, 176

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Electric system
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002 175, 176

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Electric system
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002 175, 176

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Electric system
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002 175, 176

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OH S5 5000
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OH S5 5000
Electric system
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002 175, 176
3. Description of electric system

OP1000/2 SE/HSE
with double command
3.1. Drive motor circuit

• K10's other contact connects into +48 V to drive motor M1
via fuse F1, 160 A.
• K11 and K13 are front and back contacts respectively.
speed.
cabin function.

meters (see electric chart 2/10)
electronics.
• Output 610 on A2 gives +48 V to the hour meter when the

OH S5 5000
Electric system
Version no T-code
002 175, 176


• U1 and U2 are tachometers (wheels) one on each
"instrument panel". They give plus or minus voltage to A3.
• K202 is a relay which connects U1 or U2 depending on
which deadman's handle is used. The coil is drawn on
sheet 5.
• The high signal (+20 V) in on A3/5 means that the steering
tachometers (the wheels) are disconnected and the truck is
permitted.
• NOTE. R3 is supplied with +7.5 V from A2, output 303 and

OH S5 5000
Electric system
Version no T-code
002 175, 176

operator’s cabin.
controlled.
• S74 and S75 are magnet switches for aisle-end brakes
and are are available as extra equipment only. When the
truck drives in the narrow aisle, it passes the special
magnets that exist for the aisle-end brake. Switches S74 or
S75 stop. When the truck drives out of the narrow aisle, it
are fulfilled.

• S100 and S200 are left deadman's handles, one on each
"instrument panel". During driving outside narrow aisles,
the control is used momentarily as a check that the driver
is in the operator cabin. When driving in narrow aisles,
your hand must be held on the control for the truck to
function.
• S101 and S201 are right deadman's handles, one on each
"instrument panel". Apart from plus to A2/202 via diode
202, S201 also gives plus to the relays K201 and K202.
Diode 202 blocks when S101 is activated so that the plus
from S101 does not reach K201 and K202. One of the two
must be activated for the truck to function.

OH S5 5000
Electric system
Version no T-code
002 175, 176
• K201 switches the functions: Travel, travel potentiometer

monitoring and cabin lift/lower. (electric chart 6)
• K202 switches both of the tachometers U1 and U2.
(electric chart 3) K202 also switches the travel brake
function.
cm).
gates are closed.
the chains slacken.

the right joystick. R201, R202 and R204 are corresponding
potentiometers in the double command.
• R1/R201 give information about desired drive speed
forward/back. R1/R201 have been equipped with a middle
output. This output gives information to A2/204 so that any
interruption in the cabling to R1/R201 has been detected
by the A2 board.
• R2/R202 give information about desired lift/lower speed for
the cabin.
• R4/R204 give information about desired braking force,
travel brake. The potentiometers are supplied from the
stabilised +20 V.
• K201 and K202 are relays which connect to R1, R2 and R4
or R201, R202 and R204 depending on which deadman's
handle is used. The coils are drawn on sheet 5.
drive motor, which together give A2 information about the
truck's speed.

OH S5 5000
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Version no T-code
002 175, 176

F61 (7.5 A) to A2, input 702.
• K11 travel contactor, front, receives + 48 V from A2, output
• K13 travel contactor, back, receives + 48 V from A2, output
• Y10 - Y12 are magnet coils in the electromechanical
brake. When the brake is disengaged, all the coils are
activated, i.e. A2, outputs 505, 506 and 507 are all +48 V.
• H90 is the warning light located on the rear body. The lamp
• H64 the indication lamp for steered wheel straight, placed
in the operator cabin.

current. Determines the lower speed.
lift.
• H70 is the error indication lamp. When the lamp lights with
fixed light, everything is OK.
the initial lift.

OH S5 5000
Electric system
Version no T-code
002 175, 176
3.9. Initial lift/lower, sound signals and

lighting (see electric chart 9/10)
• A5 is the proportional valve steering to the proportional
valve Y5, which is used during fork lowering.
• Y4 is an on/off valve for fork lowering with delay during the
opening.
chart 2).
H1.
• F63 (7.5 A) is the fuse for the cab's roof lighting and also
for spot-lights if they are mounted (not standard).
3.10. Wire guidance (see electric chart 10/

10)
• Wire guidance has a separate description. Notice that
when wire guidance is not mounted, a clamp must be
attached instead of S120. Input A2/309 must, therefore, be
high (+20 V) when we do not have wire guidance.

OH S5 5000
Electric system
Version no T-code
002 175, 176
4. Function description of electric

system OP 1000/2 SE/HSE with
double command
Drawing No. 142869
4.1. Start-up
into A2/701 and to A1/1.
The voltage into A2/701 is transformed in A2 to stabilised +20
V voltage and is supplied on A2/707, cable 67.
This stabilised +20 V voltage is used as supply for
microswitches and pulse transducers on A2’s inputs.
A self-test now starts of A2’s functions, at the same time a
the operator panel is lit. We receive +48 V in to A2/702 via F61
and K10’s contact. This +48 V is used to supply A2’s outputs
with voltage. If the deadman’s handle is held during start-up,
an error code is received and a slow flashing on the green
lamp furthest to the right on the operator’s panel. The error
code is reset with the ignition switch (S17).

the operator’s cabin
When driving outside the narrow aisle, the driver must, after
the gates have closed, move the left deadman’s handle,
seconds after the previous one, otherwise a new movement of
the controls must be made.
When driving in a narrow aisle, you must keep your hand on
the control so that the truck will function.

OH S5 5000
Electric system
Version no T-code
002 175, 176
4.3. Deadman’s handle

To be able to use the truck, the right deadman’s handle, S101/
S201, must be activated. Use the deadman’s handle placed on
the same side as the control to be used (in narrow aisles, the
left deadman’s handle also).
Apart from plus to A2/202 via diode 202, S201 also gives plus
to the relays K201 and K202. Diode 202 blocks when S101 is
activated so that the plus from S101 does not reach K201 and
K202.
One of the two must be activated for the truck to work.
K201 switches the functions: Travel, travel potentiometer
supervision and cabin lift/lower. (electric chart 6).
K202 switches both of the tachometers U1 and U2. (electric
chart 3) and also the travel brake function. (electric chart 6).
When the right deadman’s handle is activated, the brake is
released. The deadman’s handles are time-supervised to
deadman’s grips are moved, but not when travel or hydraulic
movements are carried out. Within 3 minutes, the deadman’s
handles must be released otherwise the travel and hydraulic
functions are prevented. After "retake", the time measurement
starts again from the beginning.

By moving the joystick, forward or back, the potentiometer R1/
R201 is moved (electric chart 6). R1/R201 then gives an
increased voltage (neutral position = 10 V) into A2/301 if the
joystick is moved forwards or a decreased voltage if the
joystick is moved in the direction of the steered wheel. It is,
therefore, the change in voltage which determines the travel
speed while voltages under 10 V give direction in the direction
of the steered wheel and voltages over 10 V give travel
direction in the fork direction.
The right deadman’s handle, S101/S201, and joystick R1/
R201 are now activated. The brake is released, the coils Y10,
Y11 and Y12 (electric chart 7) are activated. Travel direction
contactor K11 (front = fork direction) or K13 (back = steered
wheel direction) pull (electric chart 7).

OH S5 5000
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When K11 or K13 has pulled, the transistor panel, A1, can
begin to regulate the travel motor’s voltage. The travel motor
current goes from the battery plus over K10's contact through
F1, through the travel motor's anchor, through the series field
via K11's or K13's contact tips, in to connection A1/M,
through the transistor regulator where the motor current is
regulated and further to the battery minus via A1/B-. Free
wheel diode and brake diode are built into A1. The transistor
regulator is controlled via input signals from A2.
speeds from 0-100%.
Input A1/6 is the common minus for speed set value and
maximum current limit.
transducers S102 and S103 (electric chart 6). The pulse
transducers are on the travel motor and each give their pulse
train, 90 x phase displaced, where the drive wheel is rolling.
During motor braking, a fixed speed limit value is given and the
transducers S102 and S103 monitor the motor braking.
4.5. Travel speed

speed=0.
The initial lift height is calculated as 0 metres if the initial lift's
open (over 0.3 m).

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Fork heights over 3.0 m give variable speed reduction which is
dependant on stability and brake force.
Full speed = 9 km/h
Half speed = 4 km/h
4.6. Brake
force is controlled partly by the joystick potentiometer’s (R4/
R204) input voltage to A2/311, increases or decreases
(neutral position = 10 V) and partly by the truck’s current speed
and lift height. The truck computer determines the maximum
brake power which may be used at the height which the cabin
has when the driver brakes. With the joystick, the driver can
determine how much of this brake power he wants to use for
the braking.
There is a maximum of three brake steps. By releasing the
right "deadman’s handle" the brake is affected so that the
three brake steps are activated in order, with a certain time
delay and gives, in this way, a parking brake.
4.7. Steering
The steering wheel is placed to the left of the control panel.
tachometer U1 or U2. The signal is positive in one direction
and negative in the other direction. The signal goes into the
connections A3/4 and 12. A3 controls, in turn, a permanent
magnet motor which functions as a steering motor (M6).
Contactor K60 is pulled when the steering servo is in function.

OH S5 5000
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002 175, 176

reduced for a gentle stop in the steering end position (electric
chart 3). The potentiometer is supplied with a ± 7.5 V voltage.
When the truck's steering wheel is straight forward, we get ± 0
V into connection A2/304.
When driving into narrow aisles, for wire guidance of the truck,
indication lamp, "straight steering wheel", is lit. When the truck
has entered the narrow aisle, S79 or S80 is activated. The
manual steering is disconnected when the truck is straight
ahead and the steering is taken over by R3.
4.8. Cabin lift

Cabin lift takes place by lifting the joystick and the
potentiometer R2/R202 is moved. The lift speed depends on
how high the joystick is lifted. When lifting the joystick we
receive a change in voltage (neutral position = + 10 V) into A2/
302. The computer gives voltage to contactor K30. Pump
motor M3 starts. The flow to the cabin's lift cylinders is
controlled by proportional valve Y1. The proportional valve's
coil is current-controlled, A2/508, 509. In order to be able to lift
over a cabin height of 3 m, the gates must be closed. This is
monitored by the microswitches S87 and S88. (sheet 5)
transducers and a magnet switch. When the cabin passes 0.8
m, the magnet switch S104 opens and +20 V disappears from
A2/106. This is the cabin height reference. The actual cabin
height measurement takes place with the two inductive
transducers, S105 and S106, placed on the mast. A rail with
"flags" is placed on the guider. The transducers are placed 90x
phase displaced and each give their own pulse train into A2/
102 and A2/105 respectively.
S107.
The lift height limit can be connected in via S108 (not
standard).
(S109) for "further lift" must be mounted (electric chart 5).

OH S5 5000
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002 175, 176
4.9. Cabin lower

moving the potentiometer R2/R202. The lower speed
depends on how much the joystick is pushed down.
voltage (neutral position = + 10 V) into A2/302. The computer
gives out voltage to the magnet valve Y3, A2/603. The flow
from the cabin’s lift cylinders is controlled by proportional
A2/510, 511. In order to be able to lower over a cabin height
of 3 m, the gates must be closed. This is monitored by the
microswitches S87 and S88. The computer automatically
reconnects to low lower speed, before the cabin has reached
its lowest position.

The slack chain guards S81 and S82 (electric chart 5) monitor
that the cabin lift chains are tense. If any of the chains
slacken, one of the slack chain guards opens and interrupts
the cabin lower movement. A lift movement of 200 mm or an
initial lift of 10 seconds is allowed.
4.11. Initial lift

K40 receives voltages and pulls (electric chart 9). K40
activates the pump motor M4 and the forks lift (electric chart
2). NOTE. The right deadman’s handle must be activated for
4.12. Initial lower

attained.

OH S5 5000
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4.13. Other
contact is connected to A2/103.
Plus to the battery guard’s display comes via input 2. The
battery guard measures the battery, therefore, as soon as the
battery hand rail is connected to the battery. The instrument
only shows, however, the results when the ignition lock is on.
6 is high.
F63 or F64.

automatic speed reduction. When driving outside narrow
aisles, at a predetermined point from the aisle-end, (approx. 7
speed at this point is higher than creep speed. If the travel
speed is creep speed or lower, the truck passes the "braking
point" without braking. Bistable magnet switches (S74, S75)
are mounted on the truck. Permanent magnets are mounted in
the floor of the narrow aisle. When the truck is in the area
between the "braking point" and the aisle-end, and the joystick
for driving out of the aisle is moved, an intermittent warning
signal is activated. By releasing the joystick to neutral position,
momentarily, the warning lamp signal is switched off.

OH S5 5000
Electric system
SSD C Nylin 003 157,176
Electric system

175 OP 1000SE 326833AA-
176 OP 1000HSE 326833AA-
1. General
1000/2 SE/HSE, Drawing No. E141413, program version 8.
If the truck is equipped with dual control, see document 5000
version 004.
2. List of symbols

A1 Transistor panel
A3 Steering servo
steering
BT Battery +48 V
E3 Working light Working light, left
E4 Working light Working light, right

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forks
H1 Horn
H2 Buzzer Option
H90 Warning lamp
K10 Main contactor
M1 Drive motor
M6 Steering motor
S17 Microswitch Key

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S21 Microswitch Emergency switch off, cabin
S22 Microswitch Emergency switch off, chassis
S99 Microswitch Working light Option
channel A
channel B
W1 Antenna Front
W2 Antenna Back

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OH S5 5000
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2.1 Electric chart (1/10)

Pg.2
X LED 1
X LED 2
X LED 3
X LED 4
D1
D2
A1
A2
160A

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Pg.1, 3
D1/E1
A2/E2
D1
D2/E2
7.5A
7.5A
7.5A
250A
50A
Pg.1, 3
Pg. 9
Pg. 4
Pg. 1
Pg. 1

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20A
Pg.2, 7
Pg.2, 4

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Pg.2, 5
Pg.3, 5
Pg.10
Pg.10

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Pg.4, 6
Pg.4, 6

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Pg.5, 7
Pg.5

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Pg.6, 8
Pg.3

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003 157,176

OH S5 5000
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Pg.8
7.5A
7.5A
7.5A
Pg.8
Pg.2

OH S5 5000
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003 157,176

4

OH S5 5000
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3. Presentation of electric chart

OP 1000/2 SE/HSE
3.1. Drive motor circuit (see electric chart

1/10)
fuse F1, 160 A.
speed.
cabin function.

meters. (electric chart 2/10)
electronics.
• S21 and S22 are emergency switch off.
• Output 610 on A2 give +48 V to the hour meter when the

OH S5 5000
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voltage to A3.
• A high signal (+20 V) in on A3/5 means that the steering
permitted.
• NOTE. R3 is supplied with 7.5 V from A2, output 303 and

OH S5 5000
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operator’s cabin.
closed means that the truck is in a narrow aisle.
• S74 and S75 are magnet switches for aisle-end brake and
are available as extra equipment only. When the truck
are fulfilled.

• S100 left deadman's handle. During driving outside narrow
aisles, the control is used momentarily as a check that the
driver is in the operator cabin. When driving in narrow
aisles, you must keep your hand on the control so that the
truck will function.
truck to work.
cm).
gates are closed.

OH S5 5000
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003 157,176
the chains slacken.

the right joystick.
• R1 gives information about required drive speed forward/
cabin.
+20 V.
truck's travel speed.

F61 (7.5 A) to A2, input 702.
• K11 travel contactor, front, receives +48 V from A2, output
• K13 travel contactor, back, receives +48 V from A2, output
• Y10 - Y12 are magnet coils in the electromechanical brake.
When the brake is disengaged, all the coils are activated,
i.e. A2, outputs 505, 506 and 507 are all +48 V.
• H90 is a warning lamp located on the rear body. The lamp

OH S5 5000
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current. Determines the lowering speed.
lift.
OK.
the initial lift.
3.9. Initial lift/lower, horn and lighting

• A5 is the valve control for valve Y4 and prop. valve Y5,
they are used during fork lowering.
• Y4 is an on/off valve with delay during the opening.
chart 2).
H1.
• F63 (7.5 A) is the fuse for the cab's roof lighting (E1 and
E2) and also for working light (E3 and E4) if they are
mounted (not standard).
• S99 is control switch for the working light (not standard).

OH S5 5000
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3.10. Wire guidance


system OP 1000/2 SE/HSE
Drawing No. 141413
4.1. Start-up
switch off, S21 and S22, are closed, we receive voltage into
A2/701 and to A1/1. The voltage into A2/701 is transformed in
A2 to stabilised + 20 V voltage and is fed out on A2/707, cable
67. This stabilised +20 V tension is used as supply for
microswitches and pulse transducers on A2's inputs.
A self-test now starts of A2's functions, at the same time a
the operator panel is lit.
We receive +48 V in to A2/702 via F61 and K10's contact. This
+48 V is used to supply A2's outputs with voltage. If the
deadman's handle is held during start-up, an error code is
received and a slow flashing on the green lamp furthest to the
right on the operator's panel. The error code is reset with the
ignition switch (S17).

OH S5 5000
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003 157,176

the operator cabin
When driving outside a narrow aisle, the driver must, after the
gates have closed, move the left deadman’s handle,
controls must be made.
When driving in narrow aisles, your hand must be held on the
control for the truck to function.
4.3. Deadman’s handles

is released. The deadman’s handles are time-monitored to
deadman’s handles are moved, but not when travel or
hydraulic movements are carried out. Within 3 minutes, the
deadman’s handles must be released otherwise the travel and
hydraulic functions are prevented. After "retake", the time
measurement starts again from the beginning.

OH S5 5000
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003 157,176

is moved (sheet 6). R1 then gives an increased voltage
direction backwards.
The right deadman’s handle, S101, and joystick R1 are now
activated. The brake is released, the coils Y10, Y11 and Y12
(sheet 7) are activated.
Travel direction contactor K11 (forward) or K13 (back) pulls
(sheet 7). When K11 or K13 has pulled, the transistor panel,
A1, can begin to regulate the drive motor voltage. The drive
motor current goes from battery plus over K10’s contact
through F1, through the drive motor’s anchor, through the
series field via K11’s or K13’s contact tips, into connection A1/
M, through the transistor regulator where the motor current is
regulated and further to battery minus via A1/B-. Free wheel
diode and brake diode are built into A1.
speeds from 0-100%. Input A1/6 is the common minus for the
speed set value and maximum current limit.
transducers S102 and S103 (sheet 6). The pulse transducers
are on the propulsion motor and each give their pulse train, 90°
phase displaced, where the drive wheel is rolling.
transducers S102 and S103 supervise the motor braking.

OH S5 5000
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4.5. Travel speed

speed = 0.
The initial lift height is calculated as 0 metres if the initial lift’s
open (over 0.3 m).
Full speed = 9 km/h
Half speed = 4 km/h
4.6. Brake
force is controlled partly by the joystick potentiometer’s (R4)
input voltage to A2/311 (neutral position = 10 V) and partly by
the truck’s current speed and lift height. The truck computer
determines the maximum brake power which may be used at
the height which the cabin has when the driver brakes. With
the joystick, the driver can determine how much of this brake
power he wants to use for the braking. There is a maximum of
three brake steps. By releasing the right "deadman’s handle"
the brake is affected so that the three brake steps are
activated in order, with a certain time delay and gives, thus, a
parking brake.

OH S5 5000
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4.7. Steering
reduced for a gentle stop in the steering end position (sheet 3).
The potentiometer is supplied with ± 7.5 V voltage. When the
truck's steering wheel is straight forward, we get ± 0 V into
connection A2/304.
4.8. Cabin lift

joystick is lifted. When lifting the joystick we receive a change
in voltage (neutral position = +10 V) into A2/302. The
computer gives voltage to contactor K30. Pump motor M3
starts. The flow to the cabin's lift cylinders is controlled by
proportional valve Y1. The proportional valve's coil is current-
must be closed. This is supervised by the microswitches S87
and S88. (sheet 5).
transducers and a magnet switch.
When the cabin passes 0.8 m, the magnet switch S104 opens
and +20 V disappears from A2/106. This is the cabin height
reference.

OH S5 5000
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003 157,176
S107.
The lift height limit can be connected via S108 (not standard).
(S109) for "further lift" must be mounted (sheet 5).
4.9. Cabin lower

now gives out voltage to the magnet valve Y3, A2/603. The
flow from the cabin’s lift cylinders is controlled by proportional
A2/510, 511.
S87 and S88.

The slack chain guards S81 and S82 (sheet 5) monitor that
the cabin lift chains are tense. If one of the chains slackens,
one of the slack chain guards opens and breaks the cabin
lower movement. A lift movement of 200 mm or a lift time of
10 seconds is permitted.
4.11. Initial lift

K40 receives voltages and pulls (sheet 9).
K40 activates the pump motor M4 and the forks lift (sheet 2).
NOTE. The right deadman’s handle must be activated for

OH S5 5000
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4.12. Initial lower

attained.
4.13. Other
contact is connected to A2/103. Plus to the battery guard’s
display comes via input 2. The battery guard measures,
therefore, the battery as soon as the battery hand rail is
connected to the battery. The instrument only shows the
results, however, when the ignition lock is on.
6 is high.
F63 or F64.

OH S5 5000
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003 157,176

automatic speed reduction. When driving outside a narrow
aisle, at a predetermined point from the aisle-end, (approx. 7
truck.
Permanent magnets are mounted in the floor of the narrow
aisle.

OH S5 5000
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003 157,176

OH S5 5000
Electric system
SSD C Nylin 004 175,176
Electric system

175 OP 1000SE 326833AA-
176 OP 1000HSE 326833AA-
1. General
1000/2 SE/HSE, with double command, Drawing No.
E142869, program version 8.
2. List of symbols

A1 Transistor panel
A3 Steering servo
A5 Proportional valve steering Forks
BT Battery +48 V

OH S5 5000
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004 175,176

forks
H1 Horn
H2 Buzzer Option
H70 Error indication lamp Instrument panel Instrument
panel
H90 Warning lamp
K10 Main contactor
M1 Drive motor
M6 Steering motor
R201 Potentiometer Forward/back double
command

OH S5 5000
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004 175,176

R202 Potentiometer Lift/lower cabin double
command
R204 Potentiometer Travel brake double
command
S17 Microswitch Key
S22 Microswitch Emergency switch off,
chassis
S105 Pulse transducer Height measurement, cabin A
S106 Pulse transducer Height measurement, cabin B
S200 Deadman’s handle Left double command

OH S5 5000
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004 175,176

S201 Deadman’s handle Right double command
U2 Tachometer Steering double command
W1 Antenna Front
W2 Antenna Rear

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004 175,176

Pg.2
F1
160A
Pg.2
Pg.2
Pg.2

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004 175,176

Pg.1, 3
7.5A
7.5A
250A
50A
7.5A
Pg.1, 3
Pg.9
Pg.4
Pg.1
Pg.1

OH S5 5000
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004 175,176
-
+
20A
Pg.2, 7
Pg.2, 4

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004 175,176

Pg. 2, 5
Pg. 3, 5
Pg.10
Pg.10

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004 175,176

OH S5 5000
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004 175,176
Pg.5, 7
Pg.5

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Pg.6, 8
Pg.3

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Pg.7, 9
Pg.9

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004 175,176

Pg.8
Pg.8
Pg.2

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004 175,176

OH S5 5000
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004 175,176

OP1000/2 SE/HSE
with double command
3.1. Drive motor circuit

• K10's other contact connects into +48 V to drive motor M1
via fuse F1, 160 A.
• K11 and K13 are front and back contacts respectively.
speed.
cabin function.

meters (see electric chart 2/10)
electronics.

OH S5 5000
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004 175,176


• U1 and U2 are tachometers (wheels) one on each
"instrument panel". They give plus or minus voltage to A3.
• K202 is a relay which connects U1 or U2 depending on
which deadman's handle is used. The coil is drawn on
sheet 5.
tachometers (the wheels) are disconnected and the truck is
permitted.
• NOTE. R3 is supplied with +7.5 V from A2, output 303 and

OH S5 5000
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004 175,176

operator’s cabin.
and are are available as extra equipment only. When the
truck drives in the narrow aisle, it passes the special
magnets that exist for the aisle-end brake. Switches S74 or
S75 stop. When the truck drives out of the narrow aisle, it
are fulfilled.

• S100 and S200 are left deadman's handles, one on each
"instrument panel". During driving outside narrow aisles,
the control is used momentarily as a check that the driver
is in the operator cabin. When driving in narrow aisles,
your hand must be held on the control for the truck to
function.
• S101 and S201 are right deadman's handles, one on each
"instrument panel". Apart from plus to A2/202 via diode
202, S201 also gives plus to the relays K201 and K202.
Diode 202 blocks when S101 is activated so that the plus
from S101 does not reach K201 and K202. One of the two
must be activated for the truck to function.
• K201 switches the functions: Travel, travel potentiometer
monitoring and cabin lift/lower. (electric chart 6)

OH S5 5000
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• K202 switches both of the tachometers U1 and U2.

(electric chart 3) K202 also switches the travel brake
function.
cm).
gates are closed.
the chains slacken.

the right joystick. R201, R202 and R204 are corresponding
potentiometers in the double command.
• R1/R201 give information about desired drive speed
forward/back. R1/R201 have been equipped with a middle
output. This output gives information to A2/204 so that any
interruption in the cabling to R1/R201 has been detected
by the A2 board.
• R2/R202 give information about desired lift/lower speed for
the cabin.
• R4/R204 give information about desired braking force,
travel brake. The potentiometers are supplied from the
stabilised +20 V.
• K201 and K202 are relays which connect to R1, R2 and R4
or R201, R202 and R204 depending on which deadman's
handle is used. The coils are drawn on sheet 5.
drive motor, which together give A2 information about the
truck's speed.

OH S5 5000
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F61 (7.5 A) to A2, input 702.
• H64 the indication lamp for steered wheel straight, placed
in the operator cabin.

lift.
• H70 is the error indication lamp. When the lamp lights with
fixed light, everything is OK.
the initial lift.

OH S5 5000
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004 175,176
3.9. Initial lift/lower, sound signals and

lighting (see electric chart 9/10)
• A5 is the proportional valve steering to the proportional
valve Y5, which is used during fork lowering.
• Y4 is an on/off valve for fork lowering with delay during the
opening.
chart 2).
H1.
for working light if they are mounted (not standard).
3.10. Wire guidance (see electric chart 10/

10)
• Wire guidance has a separate description. Notice that
when wire guidance is not mounted, a clamp must be
attached instead of S120. Input A2/309 must, therefore, be
high (+20 V) when we do not have wire guidance.

OH S5 5000
Electric system
Version no T-code
004 175,176
4. Function description of electric

system OP 1000/2 SE/HSE with
double command
Drawing No. 142869
4.1. Start-up
A2/701 and to A1/1.
The voltage into A2/701 is transformed in A2 to stabilised +20
V voltage and is supplied on A2/707, cable 67.
This stabilised +20 V voltage is used as supply for
the operator panel is lit. We receive +48 V in to A2/702 via F61
and K10’s contact. This +48 V is used to supply A2’s outputs
with voltage. If the deadman’s handle is held during start-up,
an error code is received and a slow flashing on the green
lamp furthest to the right on the operator’s panel. The error
code is reset with the ignition switch (S17).

seconds after the previous one, otherwise a new movement of
the controls must be made.
When driving in a narrow aisle, you must keep your hand on

OH S5 5000
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Version no T-code
004 175,176

To be able to use the truck, the right deadman’s handle, S101/
S201, must be activated. Use the deadman’s handle placed on
the same side as the control to be used (in narrow aisles, the
left deadman’s handle also).
Apart from plus to A2/202 via diode 202, S201 also gives plus
to the relays K201 and K202. Diode 202 blocks when S101 is
activated so that the plus from S101 does not reach K201 and
K202.
One of the two must be activated for the truck to work.
K201 switches the functions: Travel, travel potentiometer
supervision and cabin lift/lower. (electric chart 6).
K202 switches both of the tachometers U1 and U2. (electric
chart 3) and also the travel brake function. (electric chart 6).
When the right deadman’s handle is activated, the brake is
released. The deadman’s handles are time-supervised to

By moving the joystick, forward or back, the potentiometer R1/
R201 is moved (electric chart 6). R1/R201 then gives an
increased voltage (neutral position = 10 V) into A2/301 if the
joystick is moved forwards or a decreased voltage if the
joystick is moved in the direction of the steered wheel. It is,
therefore, the change in voltage which determines the travel
speed while voltages under 10 V give direction in the direction
of the steered wheel and voltages over 10 V give travel
direction in the fork direction.
The right deadman’s handle, S101/S201, and joystick R1/
R201 are now activated. The brake is released, the coils Y10,
Y11 and Y12 (electric chart 7) are activated. Travel direction
contactor K11 (front = fork direction) or K13 (back = steered
wheel direction) pull (electric chart 7).

OH S5 5000
Electric system
Version no T-code
004 175,176
begin to regulate the travel motor’s voltage. The travel motor
current goes from the battery plus over K10's contact through
F1, through the travel motor's anchor, through the series field
via K11's or K13's contact tips, in to connection A1/M,
through the transistor regulator where the motor current is
regulated and further to the battery minus via A1/B-. Free
wheel diode and brake diode are built into A1. The transistor
regulator is controlled via input signals from A2.
speeds from 0-100%.
Input A1/6 is the common minus for speed set value and
maximum current limit.
transducers S102 and S103 (electric chart 6). The pulse
transducers are on the travel motor and each give their pulse
train, 90 x phase displaced, where the drive wheel is rolling.
During motor braking, a fixed speed limit value is given and the
4.5. Travel speed

speed=0.
The initial lift height is calculated as 0 metres if the initial lift's
open (over 0.3 m).

OH S5 5000
Electric system
Version no T-code
004 175,176


Fork heights over 3.0 m give variable speed reduction which is
dependant on stability and brake force.
Full speed = 9 km/h
Half speed = 4 km/h
4.6. Brake
force is controlled partly by the joystick potentiometer’s (R4/
R204) input voltage to A2/311, increases or decreases
(neutral position = 10 V) and partly by the truck’s current speed
and lift height. The truck computer determines the maximum
brake power which may be used at the height which the cabin
has when the driver brakes. With the joystick, the driver can
determine how much of this brake power he wants to use for
the braking.
There is a maximum of three brake steps. By releasing the
right "deadman’s handle" the brake is affected so that the
three brake steps are activated in order, with a certain time
delay and gives, in this way, a parking brake.
4.7. Steering
The steering wheel is placed to the left of the control panel.
tachometer U1 or U2. The signal is positive in one direction
and negative in the other direction. The signal goes into the
connections A3/4 and 12. A3 controls, in turn, a permanent
magnet motor which functions as a steering motor (M6).
Contactor K60 is pulled when the steering servo is in function.

OH S5 5000
Electric system
Version no T-code
004 175,176

When the truck's steering wheel is straight forward, we get ± 0
When driving into narrow aisles, for wire guidance of the truck,
indication lamp, "straight steering wheel", is lit. When the truck
has entered the narrow aisle, S79 or S80 is activated. The
manual steering is disconnected when the truck is straight
ahead and the steering is taken over by R3.
4.8. Cabin lift

Cabin lift takes place by lifting the joystick and the
potentiometer R2/R202 is moved. The lift speed depends on
how high the joystick is lifted. When lifting the joystick we
receive a change in voltage (neutral position = + 10 V) into A2/
302. The computer gives voltage to contactor K30. Pump
motor M3 starts. The flow to the cabin's lift cylinders is
controlled by proportional valve Y1. The proportional valve's
coil is current-controlled, A2/508, 509. In order to be able to lift
over a cabin height of 3 m, the gates must be closed. This is
monitored by the microswitches S87 and S88. (sheet 5)
A2/106. This is the cabin height reference. The actual cabin
height measurement takes place with the two inductive
transducers, S105 and S106, placed on the mast. A rail with
"flags" is placed on the guider. The transducers are placed 90x
phase displaced and each give their own pulse train into A2/
102 and A2/105 respectively.
S107.
The lift height limit can be connected in via S108 (not
standard).
(S109) for "further lift" must be mounted (electric chart 5).

OH S5 5000
Electric system
Version no T-code
004 175,176
4.9. Cabin lower

moving the potentiometer R2/R202. The lower speed
depends on how much the joystick is pushed down.
gives out voltage to the magnet valve Y3, A2/603. The flow
from the cabin’s lift cylinders is controlled by proportional
A2/510, 511. In order to be able to lower over a cabin height
of 3 m, the gates must be closed. This is monitored by the
microswitches S87 and S88. The computer automatically
reconnects to low lower speed, before the cabin has reached
its lowest position.

that the cabin lift chains are tense. If any of the chains
slacken, one of the slack chain guards opens and interrupts
the cabin lower movement. A lift movement of 200 mm or an
initial lift of 10 seconds is allowed.
4.11. Initial lift

K40 receives voltages and pulls (electric chart 9). K40
activates the pump motor M4 and the forks lift (electric chart
2). NOTE. The right deadman’s handle must be activated for
4.12. Initial lower

attained.

OH S5 5000
Electric system
Version no T-code
004 175,176
4.13. Other
contact is connected to A2/103.
Plus to the battery guard’s display comes via input 2. The
battery guard measures the battery, therefore, as soon as the
battery hand rail is connected to the battery. The instrument
only shows, however, the results when the ignition lock is on.
6 is high.
F63 or F64.

speed at this point is higher than creep speed. If the travel
speed is creep speed or lower, the truck passes the "braking
point" without braking. Bistable magnet switches (S74, S75)
are mounted on the truck. Permanent magnets are mounted in
the floor of the narrow aisle. When the truck is in the area
between the "braking point" and the aisle-end, and the joystick
for driving out of the aisle is moved, an intermittent warning
signal is activated. By releasing the joystick to neutral position,
momentarily, the warning lamp signal is switched off.

OH S5 5000
Electric system
Version no T-code
004 175,176

OH S5 5000
Electric system
SSD C Nylin 001 177, 178
Electric system
Valid from serial number

177 OPW 1200SE 290610AA-
178 OPW 1200HSE 290610AA-
1. General
1200/2 SE/HSE, Drawing No. E 142868, program version 8.
2. List of symbols
.

A1 Transistor panel
A3 Steering servo
BT Battery +48 V
F4 Fuse Horn, lighting 50 A
forks

OH S5 5000
Electric system
Version no T-code
001 177, 178

H1 Horn
H2 Buzzer Option
H90 Warning lamp
K10 Main contactor
M1 Drive motor
M6 Steering motor
R1 Potentiometer Forward/back
S17 Microswitch Key

OH S5 5000
Electric system
Version no T-code
001 177, 178

S84 Microswitch Pallet indication
S85 Microswitch Front gate
S 104 Magnetic switch Cabin reference
channel A
channel B
W1 Antenna Front
W2 Antenna Back

OH S5 5000
Electric system
Version no T-code
001 177, 178

OH S5 5000
Electric system
Version no T-code
001 177, 178

OH S5 5000
Electric system
Version no T-code
001 177, 178

OH S5 5000
Electric system
Version no T-code
001 177, 178

OH S5 5000
Electric system
Version no T-code
001 177, 178

OH S5 5000
Electric system
Version no T-code
001 177, 178

OH S5 5000
Electric system
Version no T-code
001 177, 178

OH S5 5000
Electric system
Version no T-code
001 177, 178

OH S5 5000
Electric system
Version no T-code
001 177, 178

OH S5 5000
Electric system
Version no T-code
001 177, 178

OH S5 5000
Electric system
Version no T-code
001 177, 178
3. DESCRIPTION OF ELECTRIC
SYSTEM OPW 1200/2 SE/HSE
3.1. Drive motor circuit (electric chart 1/10)

motor M3 (electric chart 2) partly via F 60 to steering servo
the box A3 and via F61 to input 702 on the electronic circuit
board A2 (electric chart 7).
fuse F1, 160 A.
speed.
cabin function.
3.2. Pump motor, cabin lift and also battery

indicator and hour meter
(electric chart 2/10)
• F4 (50 A) is the fuse for the cabin electronics.
• K30 is the pump motor contactor for M3.

OH S5 5000
Electric system
Version no T-code
001 177, 178

3.3. Steering servo (electric chart 3/10)

voltage to A3.
permitted.
NOTE! R3 is supplied with +7.5 V from A2, output 303 and
-7.5 V from A2, output 306.
When the steered wheel is straight, therefore, the voltage is on
A2, input 304, ± 0 V.

A2 (electric chart 4/10)
• S105 and S106 are inductive transducers which together
operator’s cabin.
OH S5 5000
Electric system
Version no T-code
001 177, 178

means that the truck is outside a narrow aisle. A switch
controlled.
and are available as extra equipment only. When the truck
are fulfilled.

• S100 left deadman’s handle. During driving outside narrow
aisles, the control is momentarily used as a check that the
driver is in the operator cabin. Is used when driving in
narrow aisle.
truck to work.
• S85, S86, S87 and S88 are switches placed in the cabin
gates. They are open when the gates are open and closed
when the gates are closed. S84 is the switch for pallet
indication and is connected in parallel with the switches for
the two front gates. This means that the front gates can be
open if a pallet is on the forks.
the chains slacken.

OH S5 5000
Electric system
Version no T-code
001 177, 178

the right joystick.
• R1 gives information about desired drive speed forward/
cabin.
+20 V.
truck's speed.
3.7. Outputs to the electronic circuit board

F61 (7.5 A) to A2, input 702.

OH S5 5000
Electric system
Version no T-code
001 177, 178

• Y3 is on/off valve for the cabin lowering.
lift.
OK.
3.9. Horn and lighting (electric chart 9/10)

• F64 (7.5 A) is the fuse for the horn H1.
for spot-lights if they are mounted (not standard).
3.10. Wire guidance (electric chart 10/10)


OH S5 5000
Electric system
Version no T-code
001 177, 178

system OPW 1200/2 SE/HSE
Drawing No. 142868
4.1. Start-up
into A2/701 and to A1/1. The voltage into A2/701 is
transformed in A2 to stabilised +20 V voltage and is fed out on
A2/707, cable 67. This stabilised +20 V voltage is used as
supply for microswitches and pulse transducers on A2’s
inputs.
check occurs of the transistor panel.
When these tests are ready, K10 will pull and the green lamp
furthest to the right on the operator’s panel is lit. We receive
+48 V in to A2/702 via F61 and K10’s contact. This +48 V is
used to supply A2’s outputs with voltage.
If the deadman’s handle is held during start-up, an error code
is received and a slow flashing on the green lamp furthest to
the right on the operator’s panel. The error code is reset with
the ignition switch.
NOTE! Between opening and closing of S17, it is necessary to

unit must be made.
When driving in narrow aisles, you must keep your hand on

OH S5 5000
Electric system
Version no T-code
001 177, 178

is released. The deadman’s handles are time-supervised to

is moved (electric chart 6). R1 then gives an increased voltage
direction backwards. The right deadman’s handle, S101, and
joystick R1 are now activated. The brake is released, the coils
Y10, Y11 and Y12 (electric chart 7) are activated. Travel
direction contactor K11 (front) or K13 (back) pull (electric chart
7).
begin to regulate the travel motor voltage. The travel motor
current goes from battery plus over K10’s contact through F1,
through the travel motor’s anchor, through the series field via
K11’s or K13’s contact tips, in on connection A1/M, through the
transistor regulator where the motor current is regulated and
further to battery minus via A1/B-. Free wheel diode and brake
diode are built into A1.
speeds from 0 - 100%.
Input A1/6 is the common minus for the speed set value and
maximum current limit. Input A1/11 is maximum current limit,
0-5 V. This gives current limits from 25-100%.
given and the speed is controlled by the speed set value.

OH S5 5000
Electric system
Version no T-code
001 177, 178
The real speed and travel direction is checked by the travel

speed transducers S102 and S103 (electric chart 6). The
pulse transducers are on the travel motor and each give their
pulse train, 90 x phase displaced, when the drive wheel is
rolling.
4.5. Travel speed

speed=0. The height is programmable between 0 and 3.0 m.


Full speed = 9 km/h
Half speed = 4 km/h

OH S5 5000
Electric system
Version no T-code
001 177, 178
4.6. Brake
By guiding the joystick to the right, the truck brakes.
The brake force is controlled partly by the joystick
potentiometer’s (R4) input voltage to A2/311, (neutral position
= 10 V) and partly by the truck’s current speed and lift height.
The truck computer determines the maximum brake power
which may be used at the height which the cabin has when the
driver brakes. With the joystick, the driver can determine how
much of this brake power he wants to use for the braking.
There is a maximum of three brake steps.
By releasing the right "deadman’s handle" the brake is
affected so that the three brake steps are activated in order,
with a certain time delay and gives, in this way, a parking
brake.
4.7. Steering
When the truck's steered wheel is straight forward, we get ± 0

OH S5 5000
Electric system
Version no T-code
001 177, 178
4.8. Cabin lift

joystick is lifted. When the joystick is lifted, we get a change of
gives voltage to contactor K30. Pump motor M3 starts. The
flow to the cabin’s lift cylinders is controlled by proportional
A2/508, 509.
must be closed. This is monitored by the microswitches S85,
S86, S87 and S88 (electric chart 5). The pallet indication
switch S84 is parallel to the gates switches S85 and S86. This
means that the front gates can be open if there is a pallet is on
the forks.
Cabin height measurement takes place by two inducting
A2/106. This is the cabin height reference.
S107. The lift height limit can be connected in via S108 (not
standard). If the lift height limitation has been mounted, a
micro switch (S109) for "further lift" must be mounted (electric
chart 5).
4.9. Cabin lower

gives out voltage to the magnet valve Y3, A2/603.
The flow to the cabin’s lift cylinders is controlled by
proportional valve Y2. The proportional valve’s coil is current-
S85, S86, S87 and S88 (electric chart 5).

OH S5 5000
Electric system
Version no T-code
001 177, 178
The pallet indication switch S84 is parallel to the gates

switches S85 and S86. This means that the front gates can be
open if there is a pallet on the forks.

that the cabin lift chains are tense. If any of the chains slacken,
one of the slack chain guards opens and interrupts the cabin
lower movement. A lift movement of 200 mm or an initial lift of
10 seconds is allowed.
4.11. Other
F66. Battery minus comes directly from cable 40.
The battery guard breaks the cabin lift function when only 20%
of the battery capacity remains. The battery guard’s contact is
connected to A2/103. Plus to the battery guard’s display
comes via input 2. The battery guard measures, therefore, the
battery as soon as the battery hand rail is connected to the
battery. The instrument only shows, however, the results when
the ignition lock is on.
6 is high.
F63 or F64.

OH S5 5000
Electric system
Version no T-code
001 177, 178

truck. Permanent magnets are mounted in the floor of the
narrow aisle.

OH S5 5000
Electric system
SSD C Nylin 002 177,178
Electric system

177 OPW 1200SE 326833AA-
178 OPW 1200HSE 326833AA-
1. General
1200/2 SE/HSE, Drawing No. E 142868, program version 8.
2. List of symbols
.

A1 Transistor panel
A3 Steering servo
BT Battery +48 V
F4 Fuse Horn, lighting 50 A
forks

OH S5 5000
Electric system
Version no T-code
002 177,178

H1 Horn
H2 Buzzer Option
H90 Warning lamp
K10 Main contactor
M1 Drive motor
M6 Steering motor
R1 Potentiometer Forward/back
S17 Microswitch Key
S22 Microswitch emergency switch off, chassis

OH S5 5000
Electric system
Version no T-code
002 177,178

S84 Microswitch Pallet indication
S 104 Magnetic switch Cabin reference
channel A
channel B
W1 Antenna Front
W2 Antenna Back

OH S5 5000
Electric system
Version no T-code
002 177,178

OH S5 5000
Electric system
Version no T-code
002 177,178

OH S5 5000
Electric system
Version no T-code
002 177,178

OH S5 5000
Electric system
Version no T-code
002 177,178

OH S5 5000
Electric system
Version no T-code
002 177,178

OH S5 5000
Electric system
Version no T-code
002 177,178

OH S5 5000
Electric system
Version no T-code
002 177,178

OH S5 5000
Electric system
Version no T-code
002 177,178

OH S5 5000
Electric system
Version no T-code
002 177,178

OH S5 5000
Electric system
Version no T-code
002 177,178

OH S5 5000
Electric system
Version no T-code
002 177,178

OPW 1200/2 SE/HSE
3.1. Drive motor circuit (electric chart 1/10)

motor M3 (electric chart 2) partly via F 60 to steering servo
the box A3 and via F61 to input 702 on the electronic circuit
board A2 (electric chart 7).
fuse F1, 160 A.
speed.
cabin function.
3.2. Pump motor, cabin lift and also battery

indicator and hour meter
(electric chart 2/10)
• F4 (50 A) is the fuse for the cabin electronics.
• K30 is the pump motor contactor for M3.

OH S5 5000
Electric system
Version no T-code
002 177,178

3.3. Steering servo (electric chart 3/10)

voltage to A3.
permitted.
NOTE! R3 is supplied with +7.5 V from A2, output 303 and
-7.5 V from A2, output 306.
When the steered wheel is straight, therefore, the voltage is on
A2, input 304, ± 0 V.

• S105 and S106 are inductive transducers which together
operator’s cabin.
OH S5 5000
Electric system
Version no T-code
002 177,178

means that the truck is outside a narrow aisle. A switch
and are available as extra equipment only. When the truck
are fulfilled.

• S100 left deadman’s handle. During driving outside narrow
aisles, the control is momentarily used as a check that the
driver is in the operator cabin. Is used when driving in
narrow aisle.
truck to work.
• S85, S86, S87 and S88 are switches placed in the cabin
gates. They are open when the gates are open and closed
when the gates are closed. S84 is the switch for pallet
indication and is connected in parallel with the switches for
the two front gates. This means that the front gates can be
open if a pallet is on the forks.
the chains slacken.

OH S5 5000
Electric system
Version no T-code
002 177,178

the right joystick.
• R1 gives information about desired drive speed forward/
cabin.
+20 V.
truck's speed.

F61 (7.5 A) to A2, input 702.

OH S5 5000
Electric system
Version no T-code
002 177,178

• Y3 is on/off valve for the cabin lowering.
lift.
OK.
3.9. Horn and lighting (electric chart 9/10)

• F64 (7.5 A) is the fuse for the horn H1.
for working light if they are mounted (not standard).
3.10. Wire guidance (electric chart 10/10)


OH S5 5000
Electric system
Version no T-code
002 177,178

system OPW 1200/2 SE/HSE
Drawing No. 142868
4.1. Start-up
A2/701 and to A1/1. The voltage into A2/701 is transformed in
A2 to stabilised +20 V voltage and is fed out on A2/707, cable
67. This stabilised +20 V voltage is used as supply for
check occurs of the transistor panel.
When these tests are ready, K10 will pull and the green lamp
furthest to the right on the operator’s panel is lit. We receive
+48 V in to A2/702 via F61 and K10’s contact. This +48 V is
used to supply A2’s outputs with voltage.
If the deadman’s handle is held during start-up, an error code
is received and a slow flashing on the green lamp furthest to
the right on the operator’s panel. The error code is reset with
the ignition switch.
NOTE! Between opening and closing of S17, it is necessary to

unit must be made.
When driving in narrow aisles, you must keep your hand on

OH S5 5000
Electric system
Version no T-code
002 177,178

is released. The deadman’s handles are time-supervised to

is moved (electric chart 6). R1 then gives an increased voltage
direction backwards. The right deadman’s handle, S101, and
joystick R1 are now activated. The brake is released, the coils
Y10, Y11 and Y12 (electric chart 7) are activated. Travel
direction contactor K11 (front) or K13 (back) pull (electric chart
7).
begin to regulate the travel motor voltage. The travel motor
current goes from battery plus over K10’s contact through F1,
through the travel motor’s anchor, through the series field via
K11’s or K13’s contact tips, in on connection A1/M, through the
transistor regulator where the motor current is regulated and
further to battery minus via A1/B-. Free wheel diode and brake
diode are built into A1.
speeds from 0 - 100%.
Input A1/6 is the common minus for the speed set value and
maximum current limit. Input A1/11 is maximum current limit,
0-5 V. This gives current limits from 25-100%.
given and the speed is controlled by the speed set value.

OH S5 5000
Electric system
Version no T-code
002 177,178
The real speed and travel direction is checked by the travel

speed transducers S102 and S103 (electric chart 6). The
pulse transducers are on the travel motor and each give their
pulse train, 90 x phase displaced, when the drive wheel is
rolling.
4.5. Travel speed

speed=0. The height is programmable between 0 and 3.0 m.


Full speed = 9 km/h
Half speed = 4 km/h

OH S5 5000
Electric system
Version no T-code
002 177,178
4.6. Brake
By guiding the joystick to the right, the truck brakes.
The brake force is controlled partly by the joystick
potentiometer’s (R4) input voltage to A2/311, (neutral position
= 10 V) and partly by the truck’s current speed and lift height.
The truck computer determines the maximum brake power
which may be used at the height which the cabin has when the
driver brakes. With the joystick, the driver can determine how
much of this brake power he wants to use for the braking.
There is a maximum of three brake steps.
By releasing the right "deadman’s handle" the brake is
affected so that the three brake steps are activated in order,
with a certain time delay and gives, in this way, a parking
brake.
4.7. Steering
When the truck's steered wheel is straight forward, we get ± 0

OH S5 5000
Electric system
Version no T-code
002 177,178
4.8. Cabin lift

joystick is lifted. When the joystick is lifted, we get a change of
gives voltage to contactor K30. Pump motor M3 starts. The
flow to the cabin’s lift cylinders is controlled by proportional
A2/508, 509.
must be closed. This is monitored by the microswitches S85,
S86, S87 and S88 (electric chart 5). The pallet indication
switch S84 is parallel to the gates switches S85 and S86. This
means that the front gates can be open if there is a pallet is on
the forks.
Cabin height measurement takes place by two inducting
A2/106. This is the cabin height reference.
S107. The lift height limit can be connected in via S108 (not
standard). If the lift height limitation has been mounted, a
micro switch (S109) for "further lift" must be mounted (electric
chart 5).
4.9. Cabin lower

gives out voltage to the magnet valve Y3, A2/603.
The flow to the cabin’s lift cylinders is controlled by
proportional valve Y2. The proportional valve’s coil is current-
S85, S86, S87 and S88 (electric chart 5).

OH S5 5000
Electric system
Version no T-code
002 177,178
The pallet indication switch S84 is parallel to the gates

switches S85 and S86. This means that the front gates can be
open if there is a pallet on the forks.

that the cabin lift chains are tense. If any of the chains slacken,
one of the slack chain guards opens and interrupts the cabin
lower movement. A lift movement of 200 mm or an initial lift of
10 seconds is allowed.
4.11. Other
F66. Battery minus comes directly from cable 40.
The battery guard breaks the cabin lift function when only 20%
of the battery capacity remains. The battery guard’s contact is
connected to A2/103. Plus to the battery guard’s display
comes via input 2. The battery guard measures, therefore, the
battery as soon as the battery hand rail is connected to the
battery. The instrument only shows, however, the results when
the ignition lock is on.
6 is high.
F63 or F64.

OH S5 5000
Electric system
Version no T-code
002 177,178

truck. Permanent magnets are mounted in the floor of the
narrow aisle.

OH S5 5000
Electric system
Version no T-code
002 177,178
4.13. Electric chart Option Service switch

OH S5 5000
Electric system
Version no T-code
002 177,178
4.14 List of symbols

A2 Electronic card
F69 Manoeuvre fuse Service switch 7.5 A
K300:1 Relay Service switch
K300:2 Relay Service switch

OH S5 5000
Electric system
Version no T-code
002 177,178

OH S5 5460
Transistor regulator
SSD C Nylin 001 175-178

175 OP 1000SE 290610AA-
176 OP 1000HSE 290610AA-
177 OPW 1200SE 290610AA-
178 OPW 1200HSE 290610AA-
Transistor regulator PUB 48 350 CD 3

OH S5 5460
Version no T-code
001 175-178
1. Motor connections
The transistor regulator has four connections for the power ca-
bles as per the table below.
.
Terminal Function
number
A Brake diode to the motor’s series field and anchor
B- Battery minus
B+ Battery plus
M Minus connection to the motor’s series field
2. Contact for control voltages

Terminal Con. Function
number
1 I Supply voltage + 48 V
LD1
LD2 2 I Safety test
LD3 M
3 Not used
LD4
4 I Joint connection B -
7 1
7 1 B+ 5 I Joint connection B -
8 2
9 3
4 6 I Minus for terminal 10 and 11
10 5
11 6
7 O Safety signal for main contactor
8 O Electric motor brake
9 O Stabilised voltage 13.5 V
10 I Set value 0 - 5 V
11 I Current limit 0 - 5 V
LED no. Colour Function

1 Green OK
2 Yellow Above/below temperature
3 Red Error in power electronics
4 Red Error in set value circuit

OH S5 5460
Version no T-code
001 175-178
3. Safety checking
3.1. Check of the transistor regulator’s

safety circuit
This check applies to all BT-trucks equipped with transistor
regulator type:
PUB 48 280 CD 3 and PUB 48 350 CD 3.
• Lift up the truck in the points marked with lifting rings.
• Place stable distances under the chassis, one on each
side of the drive wheel.
• Lower the truck down on the distances.
WARNING!
The truck can tip.
Risk of serious injury to person or property.
Ensure that the truck is stable and that the drive wheel is
not in contact with the floor.
• Open the lid over the electric panel.

• Turn the ignition key so that the electronic circuit board
obtains voltage.
• Connect a 0.7 mm2 cable between the battery minus (B-)

and the contact for the control current (pin number 2, see
illustration) on the transistor regulator. Main contactor K 10
will now fall to indicate that the transistor regulator’s safety
system is functioning. If K 10 does not fall, the entire tran-
sistor regulator must be changed.
• Place the truck back into its original position after the
check.
• Reset the safety circuit by turning the ignition key to posi-
tion 0.

OH S5 5710
Electronic circuit board
SSD C Nylin 001 175-178


175 OP 1000SE 290610AA-
176 OP 1000HSE 290610AA-
177 OPW 1200SE 290610AA-
178 OPW 1200HSE 290610AA-
1. General
This is a description of electronic circuit boards OP1000/2SE/
HSE and OPW1200/2SE/HSE.
The electronic circuit board is equipped with green light-emit-
ting diodes on the inputs from micro switches and sensors and
red light-emitting diodes on the outputs to contactors and
valves. This board is also equipped with a potentiometer for
fine adjustment of the control’s mid-position as well as three
switches for setting of the programmable parameters and dis-
play of warning/error code history.
2. Voltages on the electronic circuit

board A2
Input Cable Description Active LED

No.
101 43 Motor brake active 48 V X
102 44 Supervision steering servo 20 V
103 45 Battery guard, cabin lift OK 20 V X
104 46 Height measurement pulses cabin A 20 V X
105 47 Height measurement pulses cabin B 20 V X
106 48 Cabin in bottom position 20 V X
107 49 Cabin in top position 20 V X
108 50 Cabin not at customer-specified height 20 V X

OH S5 5710
Version no T-code
001 175-178

No.
109 51 In narrow aisle, front switch 20 V X
110 52 In narrow aisle, rear switch 20 V X
111 53 In mid-aisle (for aisle-end brake) 20 V X
201 55 Left deadman’s handle activated 20 V X
202 56 Right deadman’s handle activated 20 V X
203 Reserve X
204 57 Supervision travel potentiometer 10 V
205 Reserve (RX+, RS 422) X
206 Reserve (RX-, RS 422) X
207 61 Forks in lower position 20 V X
208 62 Gates closed 20 V X
209 64 Chain guards OK 20 V X
210 66 Lift over customer-specialisation (S109) 20 V X
211 Reserve X
301 68 Joystick voltage front/back Analogue
302 69 Joystick voltage lift/lower Analogue
303 70 Voltage to control potentiometer +7.5 V
304 71 Voltage from control potentiometer Analogue
305 71 Support from 304
306 72 Voltage to control potentiometer -7.5 V
307 75 Travel speed pulses A 20 V X
308 76 Travel speed pulses B 20 V X
309 110 Wire guided steering not desired 20 V X
310 Reserve X
311 58 Joystick voltage brake Analogue
Wire guided steering
401 111 Wire guided steering OK 20 V X
402 112 Locked on wire 20 V X
403 113 Sensing the wire 20 V X

OH S5 5710
Version no T-code
001 175-178

No.
404 Reserve (TX+)
405 Reserve (TX-)
406 Reserve
407 77 Present travel direction +/-7,5 V
408 Reserve
409 116 Active wire guided steering 20 V X
410 Reserve
411 Reserve
Outputs
501 79 Current limit travelling Analogue
502 80 Travel set value Analogue
503 81 Contactor K11, front 48 V X
504 82 Contactor K13, back 48 V X
505 83 Brake step1 free, Y10 48 V X
506 84 Brake step 2 free, Y11 48 V X
507 85 Brake step 3 free, Y12 48 V X
508 88 Proportional valve cabin lift (+), Y1 Analogue X
509 89 Proportional valve cabin lift (-), Y1 Analogue
510 90 Proportional valve cabin lower (+), Y2 Analogue X
511 91 Proportional valve cabin lower (-), Y2 Analogue
601 86 Warning light H90 48 V X
602 87 Wheel in mid-position 20 V X
603 92 Cabin lowering valve Y3 48 V X
604 93 Contractor K30, pump 48 V X
605 94 Auto steering 20 V X
606 95 Steering turning > 80° 20 V X
607 100 Buzzer aisle-end brake 20 V X
608 101 Error indication (blinks) 20 V X
609 102 Initial lift allowed 48 V X

OH S5 5710
Version no T-code
001 175-178

No.
610 103 Hour meter 48 V
611 114 On wire 20 V X
701 33 Supply 48 V (+) electronics
702 21 Supply 48 V (+) outputs
703 21 Supply reserve 48 V (+)
704 34 Control contactor K60, drawn 48 V X
705 40 Supply 0 V (-)
706 39 Supply 0 V (-), transistor regulator
707 67 Voltage stabilised +20 V
708 67 Voltage stabilised +20 V,
wire guided steering
709 67 Voltage stabilised +20 V
710 40 Supply 0 V (-), outputs
711 40 Supply 0 V (-), wire guided steering

OH S5 5710
Version no T-code
001 175-178
2.1. Functions on the display on the

electronic circuit board A2.
The number of signal combinations on the electronic circuit
board, A2, is very large. This means that, from the incoming
signals, it can be difficult to see why the truck does not carry
out the functions it has been ordered to. The display can then
give the service technician information on any drive deadlock-
ing, error codes or cab height. The display is also used during
programming of parameters. The point that blinks on the dis-
play indicates that the computer is working.
Cab height is normally shown in the number of metres begun.
This information is shown with fixed lit figure 0-9.
If the point is blinking but the display is completely blank, the
computer has been set to zero with the cab over lift height 0.8
m and thereafter not been lowered.
(Set to zero = emergency stop or the key switch on/off/on). If
the cabin is lowered, an illegal height can be indicated. This is
reset automatically when the lift height = 0.8 m.
Locking is shown when the truck refuses to obey a command
because a condition is not fulfilled, e.g. gates open at a cab lh
> 3 m. This information is shown on the display by a slowly
blinking segment (1Hz).
An error code is shown with 1-F and a quicker blinking symbol
(2Hz).
When programming parameters, the segment is used to indi-
cate the different parameters and the figures 1-8 are used to
indicate the different values.
The value 1 is equal to 1/8 of the maximum value and 8 equal
to 8/8, i.e. the maximum value.
The indication lamp in the cab lights normally with fixed light.
If an error occurs, the lamp blinks at the same speed as the
display.

OH S5 5710
Version no T-code
001 175-178
2.2. Programmable parameters

There are seven different parameters in eight different steps,
1/8 per step.
To program these parameters, there are two small buttons,
marked VALUE AND PARAMETER, and a seven-segment
display on the A2 board. The display shows the following sym-
bol for the parameters that can be programmed:
Max. acceleration
Max. motor brake
Max. full speed
Max. half speed
Max. creep speed
Max. speed during wire guided steering
Gate height. Over this height, the gates must be closed so that
the truck will function.
1 and 2 = 0 m, 3 = 0.5 m, 4 = 1.0 m, 5 = 1.5 m, 6 = 2.0 m,
7 = 2.5 m, 8 = 3.0 m.

OH S5 5710
Version no T-code
001 175-178
2.3. Programming state

1. Hold one of the buttons VALUE or PARAMETER down
when you start the truck (The key switch or emergency
stop button). Hold the button down for at least three sec-
onds.
2. When you release the button, the display shows 0 or 1. If
the display shows 0, press the button PARAMETER. If the
display shows 1, press the button VALUE. When you
release the button, the display will again show 0 or 1.
Select button as per the above. This procedure will be
repeated a number of times.
3. After you have entered the programming state, the dis-
play will light a segment and let it “rotate”. By pressing the
button PARAMETER once, the symbol for the first param-
eter is shown on the display.
2.4. Selection of parameter

When you press the PARAMETER button down, the display
will darken.
When you release the PARAMETER button, the display
shows the next parameter. The parameters are chosen ac-
cording to a rotating chart.
2.5. Selection of value

When you press the VALUE button after having selected the
parameter, the display shows the programmed value. If the
VALUE button is pressed once again, the value on the display
will increase by one. Every time the VALUE button is pressed,
the value will be changed according to a rotating chart. As long
as the new value is not programmed, the figure for the value
will blink.
If you do not wish to program a new value, press the PARAM-
ETER button. You return to choice of parameter and the value
for the parameter is not changed.

OH S5 5710
Version no T-code
001 175-178
2.6. Programming of new value

If you wish to program the new value, press the VALUE button
and at the same time hold down the PARMETER button. Re-
lease the VALUE button and the display will show the sign for
the parameter which will be programmed.
If it is the correct parameter, you release the PARAMETER
button also and you have completed the programming. If you
wish to undo, you press the VALUE button again without re-
leasing the PARAMETER button.
Release the PARAMETER button first and then the VALUE
button and you are back to selection of value.
2.7. Exiting the programming

To exit the programming state, turn off the truck and allow it to
be off for at least five seconds.
2.7.1. Deadlocking:
The display shows the deadlocking code with blinking sign
(1 Hz). The deadlocking stops the function but is reset auto-
matically when the condition has been fulfilled.
Not closed gate.
Timeout, the deadman’s handle activated too long. The left

segment for left grip and the right segment for right grip.
The left segment also blinks when you attempt to drive in nar-
row aisles and the left deadman’s handle is not activated, and
also if further lift is moved without the customer-specific switch
being opened.
The customer-specialised switch has opened.

OH S5 5710
Version no T-code
001 175-178
The maximum height switch has opened.
The battery indicator has gone out.

Badly loaded battery.
The slack chain guard has opened.

Slack chain.
Error signal from Keltronic’s wire guided steering equipment.
Attendance check, the driver is not sitting in his correct place.
2.7.2. Error codes

If there is an error code, the display blinks with 2 Hz. The error
code is reset by the ignition key or emergency stop, on/off/on.
0 Error on the electronic circuit board A2.
1 Error on the safety relay (A2), the relay does not follow the
signal from the deadman’s handle or has lost the signal "WG
OK" during wire guided steering.
2 Error signal from supervision of the travel potentiometer.
3 Error signal from the travel speed transducers.

OH S5 5710
Version no T-code
001 175-178
4 Error signal from the cabin height transducers.
5 Error signal from the aisle indicator transducers.
6 Incorrect start value from the travel potentiometer.
7 The steering servo (A3) is giving an error signal. See error

code on A3.
8 Wire guided steering error. Has lost the signal “locked on

wire” or “see wire”. Only during wire guided steering.
9 Steering angle greater than 4.5° in narrow aisle.
A Incorrect start value from the brake potentiometer.
B Incorrect start value from the lift/lower potentiometer.
H Emergency driving function.

OH S5 5710
Version no T-code
001 175-178
2.8. A2 Electronic circuit board

OH S5 5710
Version no T-code
001 175-178
3. Adjusting instruction electric

system OP/OPW
3.1. Adjustment of mid-position steered

wheel (drive wheel)
• Start and drive the truck. Steer it so that it looks like it is
driving straight (outside the narrow aisle), then brake lightly
so that the truck stops without the steering changing.
• Connect a clamp between the test point GND and input
304 on the A2 board.
• Set the potentiometer to zero, on the electronic circuit
board A2, so that LED L and LED R light at the same time.
(Resetting of the supervision circuit board).
• Remove the clamp between GND and input 304 on the A2-
board.
• Adjust pot on the control motor so that LED L and LED R,
on the electronic circuit board A2, light up at the same
time. (Resetting of the steering servo).
3.2. Adjustment (offset) cabin lift

• Move the joystick so that the pump motor M3 for lift is acti-
vated.
• Adjust potentiometer LIFT, on the electronic circuit board
A2, so that the cabin begins to lift (pull position).
3.3. Adjustment (offset) cabin lower

• Move the joystick so that the cabin lowering is activated.
• Adjust potentiometer LOWER, on the electronic circuit
board A2, so that the cabin begins to lower slowly. Also
check that the cabin’s lowering speed is correct just before
it reaches the bottom position.

OH S5 5710
Version no T-code
001 175-178
3.4. Adjustment of the drive motor’s pulse

transducer
• The transducers are adjusted so that the voltage, meas-
ured over the transducers when the trucks drive, are 10 V.
Incorrectly adjusted transducers are given error code 3.
3.5. Adjustment (offset) steering motor, the

A3 box
• When checking offset, the truck must be on “idle speed”
and the steering is not touched.
• When the offset is correctly adjusted, the voltage is over
the steering motor, the cables 15 and 16, 0 +/-0.1 V. Offset
is adjusted with P2 on the A3 box.
3.6. Adjustment of height measurement

transducer
The transducers are mounted in the block, plant with the area
of the block. The block is close to the ruler on one side. The
indication of lift height 0.8 m, and maximum lift height occurs
by magnetic switch. As an extra function, there is also lift
height limitation.

OH S5 5710
Version no T-code
001 175-178
3.7. A3 Steering servo

OH S5 5710
Version no T-code
001 175-178
3.8. A3 Steering servo

3.8.1. Indications:
LD1: Blocking signal (red light-emitting
diode)
LD2: Speed reduction (red light-emitting
diode)
LD3: Selection of set value input (green light-emitting
diode)
LD4: Internal supply voltage (green light-emitting
diode)
LD5: Error supervision steering tachometer
(red light-emitting
diode)
LD6: Error supervision regulator (red light-emitting
diode)
LD7: Error supervision motor circuit board
(red light-emitting
diode)
3.8.2. DIP switch gear:

SW1
1 ON Current limit 5 A
1+2 ON Current limit 10 A
1+3 ON Current limit 15 A
1+2+3 ON Current limit 20 A
4 ON IR compensation low
5 ON IR compensation
medium
6 ON IR compensation high
7 Not used
8 Tacho OFF=input 6
(linear) ON=input 12
(non-linear)
SW2: Test of error supervision steering tacho. Lights LED5.

SW3: Test of error supervision regulator. Lights LED6.
SW4: Test of error supervision motor circuit board. Lights
LED7.
OH S5 5710
Version no T-code
001 175-178
3.8.3. P2: Potentiometer for adjustment of the steering

motor’s offset
Terminal No. Cable No. Function

1 42 Supervision output to contactor
2 Input blocking steering servo
3 71 +/- 8 V differential input
4 74 Input steering tacho, common
5 95 Input steering turning >80°
6 -- Input steering tacho. 10 V, lineal
7 -- -12 V
8 34 Input supervision relay
9 44 Output supervision relay
10 40 0 volt differential input
11 94 Switching set value
12 73 Input steering tacho. 2 V, non-lineal
13 -- +12 V
21 20 +48 V in
22 40 0V
23 15 Steering motor
24 16 Steering motor

OH S5 5710
Version no T-code
001 175-178
3.9. A5 Logic box valve steering initial lift/

lower
P1 Ripple
P2 Lower speed
P3 Ramp time, lower
P4 Time delay Y4
1 +48 V
2 (-)
3 Input signal
4, 5 Connection from Y5
6, 7 Connection from Y4

OH S5 5710
Version no T-code
001 175-178
4. Emergency drive function

With steering errors in narrow aisles, both rail-controlled and
wire-controlled, it can be difficult to manoeuvre the truck out of
the narrow aisle.
By connecting the truck’s emergency drive function, you can
drive out of the narrow aisle, at half creep speed, regardless of
which error code has stopped the truck.
Lower the operator cabin to the lowest level.
Restrictions associated with the driver’s safety remain, none-
theless. This means, e.g. that the driver must move the left
deadman’s handle within 5 seconds before he can drive, if the
gates are open.
If the truck is in the wire-control state, the wire-control button
is reset and the truck is manually steered out of the aisle. To
be able to steer the truck, the driver does not need to hold on
to the deadman’s handle when the emergency drive function
is connected.
Error indication is shown by the indication lamp blinking on the
instrument panel at 2 second intervals.
If the truck is equipped with a buzzer, it will signal at 2 second
intervals.
The emergency drive function is connected in the following
way:
1. Immediately after the switching on with the ignition key

the joystick is moved to its front position (travel). Hold
there until the lamp has gone out momentarily or until the
buzzer has stopped.
2. Thereafter, within 2 seconds, the joy-stick is moved to its
back position (travel). Hold there until the lamp has gone
out momentarily or until the buzzer has stopped.
3. Thereafter, within 2 seconds, the joy-stick is moved to its
most right position (brake). Hold there until the lamp has
gone out momentarily or until the buzzer has stopped.
4. Move the joystick back to its neutral position and wait until
the lamp has blinked three times or the buzzer has
sounded three times (at 2 second intervals).
5. You can now drive the truck at low speed. Drive carefully,
as the truck has several of its supervision circuit boards
disconnected.
The emergency function is reset by switching off the truck.

OH S5 5750
Safety/proximity switch/sensor
SSD C Nylin 001 175-178
T-code Model Serial number Notes

175 OP 1000SE 290610AA-
176 OP 1000HSE 290610AA-
177 OPW 1200SE 290610AA-
178 OPW 1200HSE 290610AA-
1 Slack chain breaker

The slack chain breakers S81 and S82 (see Electrical
description 5000) monitor the tension of the cage lifting
chains. If slack occurs on any of the chains, one of the slack
chain breakers breaks and stops the lowering movement of
the cage (applies to duplex mast). A lifting movement of
200 mm is permitted with an actuated slack chain breaker.
2 Adjusting the slack chain breaker

• Inspect the seat and spring on the mounting. Repair any
defects.
• Adjust the distance between the proximity breaker’s break-
roller and the lever. Distance: 0–2 mm.
• The adjustment should be made during a normal service
(every third month) and when replacing the chains or when
adjusting the lifting chains.

OH S5 5750
Version no T-code
001 175-178
2.1 List of components

Pos Name Art. no.
1 Spring, new 172935
2 Flat washer, new 172929
3 Nut 20006
4 Nut 20528
5 Split pin 20312
6 Lever 118313
7 Proximity switch 26863
8 Bracket, new 172932
1
2
3
4
5
6
PIC 1
8
PIC 2

OH S6 6000
Hydraulic system
SSD C Nylin 001 175-178
Hydraulic system

175 OP 1000SE 290610AA-
176 OP 1000HSE 290610AA-
177 OPW 1200SE 290610AA-
178 OPW 1200HSE 290610AA-
1. General
The hydraulic system consists of the functions:
1. lifting/lowering of operator cabin with 2 lift cylinders.
2. lifting/lowering of fork unit (only applicable to OP).
The fork unit has a separate hydraulic system with electric mo-
tor, pump and tank, etc. The oil is only regulated during fork
lowering.
In the text, only descriptions found on the hydraulic chart and
on the valve block drawing are used.
2. Function description
2.1. Cabin lift, joystick upwards
The pump flow goes through proportional valve Y1, the rear
valve,Y3’s rear valve, the hose breaker valve Y2 up to the lift
cylinders.
When adjusting the joystick upwards, Y1 opens and the flow
goes out to the lift cylinders. The pressure in the hydraulic sys-
tem is determined by the load. The overflow valve is set at 140
bar.
2.2. Cabin lift, joystick downwards

The oil flow from the lift cylinders goes through the lower valve
Y3, the proportional valve Y2 as well as the return filter back to
the tank.
When adjusting the joystick downwards, the lower valve Y3 is
activated. The proportional valve Y2 opens and the oil can re-
turn to the tank.

OH S6 6000
Hydraulic system
Version no T-code
001 175-178
The lower speed can be regulated gently with the joystick. A

manual emergency lower valve is found in the valve block.
Each lift cylinder has a hose breaker valve in the bottom block.
2.3. Hydraulic chart, cabin lift/lower

OH S6 6000
Hydraulic system
Version no T-code
001 175-178
2.4. Fork lift

The initial lift cylinder is single-acting.
The lift movement takes place by the pump, which is started
by pushing down the butterfly control switch for the forklift. The
oil goes from the pump through the back valve to the initial lift
cylinder.
2.5. Fork lower

The lowering movement takes place by lower valve Y4 and
proportional valve Y5. They are activated by pushing down the
butterfly control switch for the fork lower.
The oil goes from the cylinder through the lowering valve Y4
and proportional valve Y5 back to the tank.
When you allow the butterfly control switch to return to neutral,
proportional valve Y5 will be closed gently, whereupon Y4 is
closed (approx. 1 sec. delay).

OH S6 6000
Hydraulic system
Version no T-code
001 175-178
2.6. Hydraulic chart, fork lift/lower

OH S7 7120
Lifting chains
SSD C Nylin 001 175-178
Lifting chains

175 OP 1000SE 290610AA-
176 OP 1000HSE 290610AA-
177 OPW 1200SE 290610AA-
178 OPW 1200HSE 290610AA-
1. General
With normal handling of the chains you can estimate a service
life of approximately 10 000-15 000 operating hours. This rep-
resents about 10 years of operations during 1 shift. Regular lu-
brication and inspection are required to ensure that the chains
last this long.
2. Identifying the chains

New chains are simply identified by finding a link bearing the
certificate number. Links with the certificate number can be
found at half metre intervals.

OH S7 7120
Lifting chains
Version no T-code
001 175-178
3. Adjusting the lifting chains

The lifting chains must be adjusted at regular intervals due to
stretch and wear. The chain tension is checked during the
maintenance service as set out in the maintenance chart.
Any adjustment is made using the chain mounting bolts.
Adjustment should be performed in two stages to obtain the
correct fork height above the floor.
NOTE! The cage’s bottom position should be adjusted
first and then the initial lift is adjusted.
3.1. Adjustment instructions

• Adjust the cage’s bottom position using the main lifting
chains on the mast (1).
• The bottom of the cage is measured from a flat floor to the
entry threshold.
Nominal distance is 320 mm.
• Check that the lifting chains in the mast have the same ten-
sion after adjustment, so that the mast and cage are lifted
straight.
• Tighten the locking nut fully and secure using a locking pin.
• Adjust the initial lift’s bottom position using the initial lift
chain (13).
• With the initial lift cylinder in its bottom position the dis-
tance between the floor and the forks should be 80 -
85 mm.
• Check the setting. When the initial lift is at the max. lifting
level, the dampers, on top of the cylinders, should only be
slightly compressed.
• Tighten the locking nuts fully and secure using locking
pins.
OH S7 7120
Lifting chains
Version no T-code
001 175-178
4. Inspection of chain wear

The chains are exposed to two kinds of wear. Partly contour
wear and partly stretching.
T = Pitch A = Nominal plate height

B = Minimum plate height
4.1. Contour wear

A new lifting chain has a specific nominal plate height, defined
as A in the figure. As the truck is used the lifting chain is worn
radially, on the side which runs over the sprocket. The mini-
mum plate height, defined as B in the figure, defines the mini-
mum permitted value for the plate height. The maximum
contour wear is 5% of the height A. If a lifting chain reaches
this maximum wear level, the chain must be replaced. The
nominal and minimal plate heights for respective lifting chains
are stated in the table below.
Type of Model Nominal Mini- Pitch T Nominal Maximum

chain plate mum (mm) chain length permitted
height A plate for 20/30/50 chain length
(mm) height B plates (mm) for 20/30/50
(mm) plates (mm)
3/4”, 2x3 Mast 18.0 17.1 19.05 381/572/953 387/583/972
3/4”, 3x4 Initial lift 18.0 17.1 19.05 381/572/953 387/583/972
4.2. Stretching
Chain stretch is measured on the part of the chain that runs
over the sprocket. The stretch may be at the most 2% on the
most worn section of chain. Measurement is made over
300-1000 mm of chain. The nominal and maximum permitted
chain lengths for respective lifting chains are stated in the ta-
ble above.

OH S7 7120
Lifting chains
Version no T-code
001 175-178
5. Lubrication
The chains are initially lubricated with a mixture of wax and lu-
bricant. The wax film provides a good protection against cor-
rosion and dirt.
Lubrication interval
• Every 250 operating hours.
The chains are either brushed or sprayed with lubricant. Un-
assembled chains are suitably dipped in the lubricant. Note
the entire chain must be lubricated even the securing bolts.
It is especially important that the part of the chain that runs
over the sprocket shall be well lubricated.
Extremely dirty chains should be cleaned before being lubri-
cated, for example, by washing in a solvent such as tri or pet-
rol.
NOTE!
Exercise care with degreasing agents as these can contain
abrasives.
NOTE!
Do not use special anti-rust agents to prevent rusting on
the lifting chains.
These agents impair the lubrication of the chains. Regular
lubrication is the best method of preventing rust.
5.1. Machines in normal operating temper-

atures.
The lubricant used is food industry approved according to
class 2.
Lubricated using chain spray 73040XX5 or 68101XX5.
5.2. Machines in freezer environments

Lubricated with chain spray 163588.

OH S7 7310
Lift cylinder
SSD C Nylin 001 175-178
Lift cylinder

175 BT OP 1000 SE 290610AA-
176 BT OP 1000 HCE 290610AA-
177 BT OPW 1200 SE 290610AA-
178 BT OPW 1200 HCE 290610AA-
1. General
The truck is equipped with three lift cylinders. Two for the cage
and one for the forks.
Each cage cylinder is fitted with a hose rupture valve to pre-
vent the cage from dropping in the event of a hose rupturing.
In the fork cylinder there is a lowering brake valve which gives
the forks a constant lowering speed in the event of a hose rup-
turing.
A list of tools required for assembly and dismantling follows.
2. Tools
Tool Notes
number
08-15364 Assembling the piston rod into the cylinder
08-15391 Hook spanner
08-15393 Pipe wrench
08-15400 Assembling the hose rupture/lowering
brake valves

OH S7 7310
Lift cylinder
Version no T-code
001 175-178
3. Lift cylinder
3.1. Dismantling the cylinder

• Remove the cylinder from the mast.
• Place the lower stop (5) in a vice, allowing the upper part to
rest against a yoke so that the cylinder is lying in a horizon-
tal position.
• Tap the top sleeve (1) carefully with a rubber hammer. Heat
may be carefully applied, if necessary.
• Unscrew the top sleeve (1) using a pipe wrench 08-15393.
• Carefully remove the piston rod from the cylinder making
sure not to damage the thread. Place the piston rod on a
clean soft surface.
• Knock out the top sleeve (1) with a rubber hammer.

OH S7 7310
Lift cylinder
Version no T-code
001 175-178
3.2. Dismantling the piston rod seal and

support ring on the lift cylinder
• Force a screw driver into the seal (4) without marking the
piston (2) in any way.
NOTE!
If the piston is scratched at all it must be replaced to avoid
leakage.
• Lift the piston rod seal (4) very carefully.
• Carefully cut away the piston rod seal (4) with a knife, mak-
ing sure not to damage the piston (2).
• Remove the support ring (3).
3.3. Assembling the piston rod seal and

support ring on the lift cylinder
• Fit the support ring (3) and the piston rod seal (4) on the
piston.
3.4 Removing the piston from the lift

cylinder
• Remove the piston rod seal (4) plus the support ring (3).
• Knock and, if necessary, heat the piston (2).
• Unscrew the piston (2) using a pipe wrench 08-15393.
• Remove the old seal.

OH S7 7310
Lift cylinder
Version no T-code
001 175-178
3.5. Fitting the piston in the lift cylinder

• Apply OMNI 230 to the thread.
• Screw the piston (2) in place using tool 08-15391.
• Be sure to wipe away all excess adhesive.
3.6 Dismantling and assembling the hose

rupture/lowering brake valve
• Dismantle the hose rupture/lowering brake valve (6) using
tool 08-15400.
• Assemble the hose rupture/lowering brake valve (6) using
tool 08-15400.
3.7. Assembling the cylinder

• Use tool 08-15364 when fitting the piston rod in the cylin-
der.
• Remove the assembly sleeve 08-15364.
• Fit the top sleeve to the piston rod using a rubber hammer.
• Screw down the top sleeve on the cylinder a few turns.
• Apply sealant FD 1042 to the thread.
• Tighten with a hook spanner 08-15391.
NOTE!
The drying time for the sealant is four hours, before which
the cylinder must not be used.

(Op 1000se Hse Opw 1200se Hse) Workshop

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Master Service Manual (MSM)

Part number: 165782-040

T-code Model Serial No Notes

© BT Industries AB Service Manual 2000-03-30 English 1 (2)

Section C-code T-code Document Issued

2 (2) Service Manual 2000-03-30 English

© BT Products AB Service Manual 1994-12-02 English 1 (2)

2 (2) Service Manual 1994-12-02 English

© BT Industries AB Service Manual 1998-03-13 English 1 (1)

T-code Model Machine N° Note

1.1. Issued operator’s manuals

T-kod Ordering no Valid for machine

In this Service Manual can be found a typical Operator´s Man-

© BT Products AB Service Manual 1998-04-28 English 1

General Product Information

T-code Model Serial No Notes

1. Presentation of the truck

BT OP/OPW is developed to meet the market’s increased demands

© BT Industries AB Service Manual 1998-03-23 English 1 (17)

BT OP/OPW is designed so that order picking can be carried out in

1.1. Intended application of the truck

1.2. Forbidden application of the truck

2 (17) Service Manual 1998-03-23 English

Model designation OP OPW

© BT Products AB Service Manual 1998-03-23 English 3 (17)

4 (17) Service Manual 1998-03-23 English

Dimensions OP 1000SE OP 1000HSE

© BT Products AB Service Manual 1998-03-23 English 5 (17)

6 (17) Service Manual 1998-03-23 English

Dimensions OPW 1200SE OPW 1200HSE

Dimensions OPW 1200SE

© BT Products AB Service Manual 1998-03-23 English 7 (17)

Item Text Unit

Item Text Unit

8 (17) Service Manual 1998-03-23 English

© BT Products AB Service Manual 1998-03-23 English 9 (17)

6. Controls and instruments

10 (17) Service Manual 1998-03-23 English

1. Adjustable writing surface

6.2.1. Right-hand deadman’s handle (2)

6.2.2. Emergency switch off (3)

6.2.3. Joystick for driving forwards/backwards, travel

6.2.4. Horn (8)

© BT Products AB Service Manual 1998-03-23 English 11 (17)

6.2.5. Left-hand deadman’s grip (10)

6.2.6. Steering wheel (11)

12 (17) Service Manual 1998-03-23 English

12. Battery controller and hour meter

6.2.7. Battery controller and hour meter (12)

6.2.8. Emergency driving function

© BT Products AB Service Manual 1998-03-23 English 13 (17)

If the operator cage is in the raised position - lower it to the lowest

1. Follow the indicating lamp’s 2 second interval, located on the

6.2.9. Emergency switch off (14)

6.2.10. Emergency lowering valve

14 (17) Service Manual 1998-03-23 English

6.2.11. Button for continued lift with lifting height limit

6.2.12. Button for wire guided operations (accessory) (16)

6.2.13. Button for working light (accessory) (17)

6.2.14. Evacuation line

© BT Products AB Service Manual 1998-03-23 English 15 (17)

6.3. Control lever OPW with lifting table

1. Indication ”truck OK”