Service Manual En: OSE120, OSE120P, OSE250, OSE250P

Service Manual en
OSE120, OSE120P, OSE250, OSE250P

Valid from serial number: 918789-
Order number: 235317-040

Issued: 2006-10-27 ITS
© BT Europe AB
Document revisions:
Issue date Order Changes

number
2004-08-01 215858-040 Completely new issue OL25, OL25P.
2005-03-14 220338-040 Completely new issue OSE120, OSE120P
2005-10-21 228589-040 OSE120, OSE120P
Updated chapters: Tools (grease guns), 1760 (new drive motor),
4300, 5000 (new softvare), 6000 (Tools), TruckCom (8700).
2005-10-21 226851-040 Update with name change to OSE250, OSE250P
Updated chapters: P4 (grease guns), 1760 (new drive motor),
4300, 5000 (new softvare), 6000 (Tools), TruckCom (8700).
2006-04-10 235317-040 Manual replaces part number: 228589 and 226851 (now combined
to one manual)
Updated chapters: Maintenance (replaces P1, P2 and P3), 4300
(correction of steeing angle response), 5000 (TLS+ ID-unit)
2006-10-27 235317-040 Updated chapters: 5000, 6000.
One section removed: TruckCom (replaced by a separate manual).
This manual covers following truck models:
T-code Model Serial number

649 OSE250 917994-
649 OSE250P 917994-
783 OSE120 918789-
783 OSE120P 918789-
© BT Europe AB Service Manual OSE120, OSE120P, OSE250, OSE250P

Table of contents
Order number Date Valid from serial number T-code
235317-040 2006-10-27 918789- 649, 783
1- Table of contents
2- Technical data ..................................................................................... 2-1
2.1 Specific tightening torques ............................................................. 2-5
2.2 General tightening torques............................................................. 2-6
3- Maintenance ........................................................................................ 3-1

3.1 Safety rules during maintenance work ........................................... 3-1
3.2 Cleaning and washing.................................................................... 3-3
3.2.1 External cleaning ............................................................. 3-3
3.2.2 Cleaning the motor compartment .................................... 3-3
3.2.3 Electric components ........................................................ 3-3
3.3 Safe lifting ...................................................................................... 3-4
3.4 Lifting the truck............................................................................... 3-5
3.5 Maintenance schedule ................................................................... 3-6
.OSE120, OSE120P ...................................................... 3-12
OSE250, OSE250P ....................................................... 3-13
3.6 Lubrication schedule .................................................................... 3-14
3.7 Oil and grease specification ......................................................... 3-16
4- Tools ..................................................................................................... 4-1

4.1 Super Seal connectors................................................................... 4-1
4.2 AMP connectors............................................................................. 4-2
4.2.1 AMP connectors, Multilock series 040 ............................. 4-3
4.3 Molex connectors........................................................................... 4-3
4.4 Other tools ..................................................................................... 4-4
5- Fork carriage – 0380 ............................................................................ 5-1

5.1 OSE120, OSE120P ....................................................................... 5-1
5.1.1 Component overview ....................................................... 5-1
5.1.2 Verifying lateral play ....................................................... 5-2
5.1.3 Disassembly of the fork carriage ..................................... 5-3
5.1.4 Roller replacement .......................................................... 5-3
5.2 OSE250, OSE250P ....................................................................... 5-4
5.2.1 Included components ...................................................... 5-4
5.2.2 Disassembly of the fork carriage ..................................... 5-6
5.2.3 Roller replacement .......................................................... 5-7
6- Electric drive motor – 1760 ................................................................. 6-1

6.1 General .......................................................................................... 6-1
6.2 Mechanical design ......................................................................... 6-1
6.3 Disassembly of the motor from the truck ........................................ 6-2
6.4 Assembly of the motor in the truck ................................................. 6-2
6.5 Service and repairs ........................................................................ 6-3
6.5.1 Disassembly of the motor ................................................ 6-3
6.5.2 Disassembly, N side ........................................................ 6-4
6.5.3 Disassembly, D side ........................................................ 6-4
6.5.4 Wearing parts .................................................................. 6-4
6.5.5 Cleaning .......................................................................... 6-5
© BT Europe AB Service Manual OSE120, OSE120P, OSE250, OSE250P 1- 1

Table of contents
T-code Valid from serial number Date Order number
649, 783 918789- 2006-10-27 235317-040
7- Drive unit/gear – 2550 ......................................................................... 7-1

7.1 Component overview ..................................................................... 7-1
7.2 Disassembly/Assembly Leakage from top cover ........................... 7-3
7.3 Replacing the drive axle jointing ring.............................................. 7-3
7.3.1 Disassembly .................................................................... 7-3
7.3.2 Assembly ......................................................................... 7-4
7.4 Replacing the wheel bolt ................................................................ 7-5
8- Electromagnetic brake – 3370 ............................................................ 8-1

8.2 Disassembly .................................................................................. 8-2
8.2.1 Inspection ........................................................................ 8-2
8.3 Assembly ....................................................................................... 8-3
8.4 Manual release of the brake........................................................... 8-3
8.5 Adjustment ..................................................................................... 8-3
8.5.1 Adjusting the play ............................................................ 8-3
9- Swivel wheel – 3540 ............................................................................ 9-1

9.1 General .......................................................................................... 9-1
9.3 Maintenance .................................................................................. 9-3
9.3.1 Swivel wheel height inspection ........................................ 9-3
9.3.2 Swivel wheel height adjustment ...................................... 9-5
Adjust the swivel wheel ................................................... 9-5
Adjustment ....................................................................... 9-5
9.3.3 Replacing the swivel wheel ............................................. 9-5
Disassembly of the swivel wheel assembly ..................... 9-5
9.3.4 Replacing the wheel ........................................................ 9-6
Disassembly .................................................................... 9-6
Assembly ......................................................................... 9-6
9.3.5 Replacing the wheel bearing ........................................... 9-6
10- Electrical steering system – 4300 .................................................. 10-1

10.1 General ........................................................................................ 10-1
10.1.1 Electrical steering servo ................................................ 10-2
10.2 Component overview ................................................................... 10-3
10.3 Adjustment ................................................................................... 10-5
10.3.1 Reference sensor .......................................................... 10-5
10.3.2 Calibration ..................................................................... 10-5
Parameter 36 ................................................................. 10-5
Parameter 37 ................................................................. 10-5
10.4 Disassembly/assembly of pushbuttons ........................................ 10-6
10.4.1 Replacing the hornbutton/switch ................................... 10-6
10.4.2 Replacing the lifting/lowering pushbutton ...................... 10-7
10.4.3 Replacing the pushbutton .............................................. 10-7
10.5 Replacing the potentiometer ........................................................ 10-8
10.6 Inspection and replacement of the lateral movement line (Ergo version) 10-11
10.7 Replacing the inductive brake sensor ........................................ 10-13
10.8 Replacing the viscous damper ................................................... 10-16
1- 2 Service Manual OSE120, OSE120P, OSE250, OSE250P © BT Europe AB

Table of contents
235317-040 2006-10-27 918789- 649, 783
11- Electrical systems – 5000 ............................................................... 11-1

11.1 General ........................................................................................ 11-1
11.1.1 Firmware/hardware order numbers .............................. 11-1
11.1.2 Nomenclature ................................................................ 11-2
11.2 Electrical equipment overview...................................................... 11-3
11.2.1 Electric component overview ......................................... 11-6
11.3 Electrical wiring diagram .............................................................. 11-9
11.3.1 Symbol list ..................................................................... 11-9
11.3.2 Overview ...................................................................... 11-10
11.3.3 Detailed wiring diagram OSE120 ................................ 11-11
11.3.4 Detailed wiring diagram OSE120P .............................. 11-18
11.3.5 Detailed wiring diagram OSE250 ................................ 11-26
11.3.6 Detailed wiring diagram OSE250P .............................. 11-32
11.4 Functional description ................................................................ 11-39
11.4.1 Description of the steering servo system .................... 11-51
11.4.2 Spider expansion unit (SEU) ....................................... 11-52
11.4.3 Speed limitation ........................................................... 11-53
11.4.4 Hour meter and battery condition ................................ 11-55
11.4.5 TLS - Truck log system (optional) ................................ 11-56
General ........................................................................ 11-56
Registration ................................................................. 11-56
Logging in/out SD16 .................................................... 11-56
Logging in/out S16 ....................................................... 11-56
Collision sensor ........................................................... 11-57
Settings ........................................................................ 11-57
11.4.6 ID unit (optional) .......................................................... 11-57
11.5 Parameters & adjustments......................................................... 11-58
11.5.1 General ........................................................................ 11-58
11.5.2 Displaying parameters - without the CAN service key . 11-58
11.5.3 Adjusting operator parameters - without the CAN service key . 11-59
11.5.4 Displaying & changing parameters - CAN service key
connected 11-60
Changing a parameter ................................................. 11-61
11.5.5 List of Operator parameters ......................................... 11-62
11.5.6 Description of operator parameters ............................. 11-63
#1 - Speed, Fork direction ........................................... 11-63
# 2 - Speed, Drive wheel direction ............................... 11-63
# 3 - Acceleration ......................................................... 11-63
# 4 - Neutral braking force ........................................... 11-63
# 5 - Travel speed, platform > 0.5 m ............................ 11-63
# 6 - Travel speed, walking at side .............................. 11-63
# 7 - Neutral braking, walking at side .......................... 11-63
11.5.7 List of Service parameters ........................................... 11-64
11.5.8 Description of Service parameter ................................ 11-65
# 10 - PIN code ............................................................ 11-65
To enter a new PIN-code: ............................................ 11-66
To remove an existing PIN-code: ................................ 11-66
# 11 - Reverse braking force ....................................... 11-67
# 14 - Creep speed ...................................................... 11-67
# 15 - Non-configurable options .................................. 11-67
Setting Non-configurable options ................................ 11-67
#16 - Configurable option #1 ....................................... 11-68
# 20 - Hour meter selection ......................................... 11-69
Table of contents
649, 783 918789- 2006-10-27 235317-040
# 21 - Battery size ........................................................ 11-70

# 22 - Machine type ..................................................... 11-71
# 23 - Function selection ............................................. 11-71
# 24 - Special request .................................................. 11-71
# 25 - Service interval .................................................. 11-71
# 28 - Button selection ................................................. 11-72
# 35 - Automatic log-off ............................................... 11-72
# 36 - Steer servo calibration ....................................... 11-72
# 37 - Steering offset ................................................... 11-73
# 39 - Log-in method & operator parameter access .... 11-73
Extended keypad - General ......................................... 11-74
Extended keypad - Programming ................................ 11-74
11.5.9 Configurable “Option” Parameters ............................... 11-77
General ........................................................................ 11-77
Parameter #16 to #19 Configurable options ................ 11-78
Setting Configurable options ....................................... 11-79
11.6 Diagnostic and troubleshooting.................................................. 11-88
11.6.1 General ........................................................................ 11-88
11.6.2 Fault code history ........................................................ 11-89
11.6.3 List of error codes ........................................................ 11-90
11.6.4 Transistor regulator troubleshooting and error codes .. 11-96
General ........................................................................ 11-96
Transistor regulator errors ........................................... 11-97
Resetting errors ........................................................... 11-98
Safety .......................................................................... 11-98
11.6.5 Built-in Test Function ................................................... 11-99
Digital inputs/outputs test mode ................................ 11-100
Transistor regulator inputs ......................................... 11-100
Transistor regulator outputs ....................................... 11-101
Digital input of logic card [A2]. ................................... 11-101
Digital input/output to expansion unit [A36] ............... 11-102
Extra functions ........................................................... 11-102
11.6.6 Display test mode ...................................................... 11-103
11.7 Technical specifications – Curtis 1243 ..................................... 11-104
12- Hydraulic system – 6000 ................................................................. 12-1

12.1 Hydraulic component overview ................................................... 12-1
12.1.1 Hydraulic diagrams ........................................................ 12-2
12.1.2 Component overview ..................................................... 12-4
12.2 Functional description .................................................................. 12-5
12.2.1 Fork lifting ...................................................................... 12-5
12.2.2 Fork lowering ................................................................. 12-5
12.2.3 Platform lifting ................................................................ 12-5
12.2.4 Platform lowering ........................................................... 12-5
12.2.5 Operating pressure ........................................................ 12-5
12.2.6 Relief valve .................................................................... 12-6
12.2.7 Platform cylinder check valve ....................................... 12-6
12.2.8 Pressure sensor ............................................................ 12-6
12.3 Adjustments ................................................................................. 12-7
12.3.1 Adjusting the pressure limiting valve ............................. 12-7
12.4 Tools ............................................................................................ 12-8

Table of contents
235317-040 2006-10-27 918789- 649, 783
13- Main lift chain system – 7120 ......................................................... 13-1

13.1 General ........................................................................................ 13-1
13.2 Checking the chain setting ........................................................... 13-1
13.3 Chain inspection .......................................................................... 13-1
13.3.1 Noise ............................................................................. 13-1
13.3.2 Surface rust ................................................................... 13-1
13.3.3 Rusty links ..................................................................... 13-1
13.3.4 Stiff links ........................................................................ 13-2
13.3.5 Bolt rotation ................................................................... 13-2
13.3.6 Loose bolts .................................................................... 13-2
13.3.7 Outline wear .................................................................. 13-3
13.3.8 Stretching ...................................................................... 13-3
13.3.9 Damage ......................................................................... 13-4
13.3.10 Damaged discs .............................................................. 13-4
13.3.11 Damaged bolts .............................................................. 13-5
13.3.12 Dirty chain ...................................................................... 13-5
13.4 Cleaning....................................................................................... 13-5
13.5 Lubrication ................................................................................... 13-5
14- Platform – 9130 ................................................................................ 14-1

14.1 General ........................................................................................ 14-1
14.2 Component overview ................................................................... 14-2
14.3 Adjustment ................................................................................... 14-4
14.3.1 Outer side guide ............................................................ 14-5
15- Destruction instructions ................................................................. 15-1

15.1 General ........................................................................................ 15-1
15.2 Procedure .................................................................................... 15-1
15.3 Abbreviations ............................................................................... 15-1
15.4 Sorting ......................................................................................... 15-2
15.5 Hoods, hatches (0340)................................................................. 15-3
15.5.1 Disassembly .................................................................. 15-3
15.5.2 Material handling ........................................................... 15-3
15.6 Battery cover (0340).................................................................... 15-4
15.6.1 Disassembly .................................................................. 15-4
15.7 Frame/chassis (0300) and fork frame (0380/7000) ...................... 15-5
15.7.1 Disassembly .................................................................. 15-5
15.8 Seat, cushions (0620) .................................................................. 15-6
15.8.1 Disassembly .................................................................. 15-6
15.9 Wall/floor covering (0670) ............................................................ 15-7
15.9.1 Disassembly .................................................................. 15-7
15.10 Internal fittings (0680) .................................................................. 15-8
15.10.1 Disassembly .................................................................. 15-8
15.11 Operator protection (0840)........................................................... 15-9
15.11.1 Disassembly .................................................................. 15-9
15.12 Electric motors (1700) ................................................................ 15-10
15.12.1 Disassembly ................................................................ 15-10

Table of contents
649, 783 918789- 2006-10-27 235317-040
15.12.2 Material handling ......................................................... 15-10

15.13 Drive assembly/gear (2550) ....................................................... 15-11
15.13.1 Disassembly ................................................................ 15-11
15.14 Wheels (3500)............................................................................ 15-12
15.14.1 Disassembly ................................................................ 15-12
15.15 Steering unit (4110) ................................................................... 15-13
15.15.1 Disassembly ................................................................ 15-13
15.16 General electronic equipment (5100)......................................... 15-14
15.16.1 Disassembly ................................................................ 15-14
15.17 Battery cut out connector/contactor (5190) ................................ 15-15
15.17.1 Disassembly ................................................................ 15-15
15.18 Extra I/O module (5730)............................................................. 15-16
15.18.1 Disassembly ................................................................ 15-16
15.19 Hydraulic unit (6100) .................................................................. 15-17
15.19.1 Disassembly ................................................................ 15-17
15.20 Hydraulic lines chassis (6230) and main lift cylinders (6610) ..... 15-18
15.20.1 Disassembly ................................................................ 15-18
15.21 Charger adaptor (9380) ............................................................. 15-19
15.21.1 Disassembly ................................................................ 15-19
15.22 Terminal on board (9410)........................................................... 15-20
15.22.1 Disassembly ................................................................ 15-20
15.23 Other extra equipment, tuck log device (9420) .......................... 15-21
15.23.1 Disassembly ................................................................ 15-21
15.24 Other extra equipment, load support (9500) .............................. 15-22
15.24.1 Disassembly ................................................................ 15-22
15.25 Other extra equipment, writing table (9500) ............................... 15-23
15.25.1 Disassembly ................................................................ 15-23
15.26 Other extra equipment, writing table (9500) ............................... 15-24
15.26.1 Disassembly ................................................................ 15-24
15.27 Other extra equipment, support (9500) ...................................... 15-25
15.27.1 Disassembly ................................................................ 15-25
15.28 Other extra equipment, collision protection (9500)..................... 15-26
15.28.1 Disassembly ................................................................ 15-26
15.29 Other extra equipment, working cage (9130) ............................. 15-27
15.29.1 Disassembly ................................................................ 15-27

Technical data
235317-040 2006-10-27 918789- 649, 783
2- Technical data
Table 1: Technical data

Drive motor
Type TSL160 A DS60
Power 2.5kW
Intermittence S2, 60min
Minimum carbon brush length 11mm
Nominal commutator diameter 71mm
Minimal commutator diameter 68mm
Resistance, shunt field winding at 0.346Ω
24°C
Resistance, armature winding at 0.0098Ω
24°C
Weight 23kg
Brake
Type 1EB46-11
Braking force 48Nm
Power 44W
Resistance, coil 12Ω
Nominal play when applied 0.25-0.38mm
Minimum thickness of brake disc 7.7mm
Thickness of new brake disc 9.7mm
Transmission/gear mechanism
Type 2-stage angle gear
Gear ratio 14.20:1
Oil volume 1.75l
Oil type Hypoid oil
at normal temperature SAE 80W/90
at temperatures < -15oC SAE 75W

Technical data
649, 783 918789- 2006-10-27 235317-040

Wheels OSE120 OSE120P OSE250 OSE250P
Drive wheel 250x75mm 250x75mm 250x75mm 250x75mm
250x105mm 250x105mm 250x105mm 250x105mm
Drive wheel load unloaded, short/ 480/500kg 480/500kg 480/500kg 480/500kg
long chassis
Drive wheel load with rated load, 833/894kg 833/894kg 802/863kg 880/920kg
short/long chassis
Wheel pressure (250x75) with 32/34kg/cm2 32/34kg/cm2 30/32kg/cm2 33/35kg/cm2
rated load
Wheel pressure (250x105) with 26/27kg/cm2 26/27kg/cm2 24/25kg/cm2 26/27kg/cm2
rated load
Wheel nut tightening torque 130Nm 130Nm 130Nm 130Nm
Bogie wheel, fork-mounted 85x75mm 85x75mm 85x75mm 85x75mm
Axle load pressure unloaded, 250/270kg 250/270kg 250/270kg 250/270kg
short/long chassis
Axle load pressure with rated 2223/2243kg 2223/2243kg 1918/1940kg 2223/2243kg
load, short/long chassis
Wheel pressure with rated load 51kg/cm2 51kg/cm2 47kg/cm2 49kg/cm2
Swivel wheel 150x76mm 150x76mm 150x76mm 150x76mm
Axle load pressure unloaded, 270/300kg 270/300kg 270/300kg 270/300kg
short/long chassis
Axle load pressure with rated 670/800kg 670/800kg 495/711kg 670/800kg
load, short/long chassis
Wheel pressure with rated load 46/51kg/cm2 46/51kg/cm2 34/42kg/cm2 36/44kg/cm2

Technical data
235317-040 2006-10-27 918789- 649, 783

Hydraulic system OSE120 OSE120P OSE250 OSE250P
Power 2.2kW 2.2kW 1.2kW 1.2kW
Intermittence 6% 6% 10% 3%
Minimum carbon brush length 7.5mm 7.5mm 7.5mm 7.5mm
Pressure at rated load 180bar 180bar 110bar 120bar
Overflow pressure 200bar 200bar 130bar 170bar
Pump flow 6.2l/min 6.2l/min 4.7l/min 4.7l/min
Tank volume 2l 2l 0.5l 0.5l
Oil type
at normal temperature ISO-L-HM32 ISO-L-HM32 ISO-L-HM32 ISO-L-HM32
at temperatures < -15oC ISO-L-HV32 ISO-L-HV32 ISO-L-HV32 ISO-L-HV32
Power steering
Model Powerstearing PST 24/10
Power 240W
Torque at rated load 0.68Nm
Max. current 60A
Resistance, phase to phase 0.075Ω
Fuses
Control circuit, F50, F51 3A, 7.5A
Drive motor, F1 160A
Pump motor, F3 125A
Power steering, F52 30A
Batteriutrymme, Batterier
Battery compartment
Dimensions (LxWxH)
Short 212x790x775mm
Long 303x790x775mm
Capacity 300-600Ah
Weight 300-490kg

Technical data
649, 783 918789- 2006-10-27 235317-040

Drive speed OSE120 OSE120P OSE250 OSE250P
Unloaded 12km/h 12km/h 12km/h 12km/h
With rated load 8km/h 8km/h 9km/h 9km/h
Lifting/lowering speed OSE120 OSE120P OSE250 OSE250P
Lift to max. height with load 0.10m/s 0.10m/s 0.049m/s 0.035m/s

Lowering with no load 0.15m/s 0.15m/s 0.043m/s 0.049m/s
Current consumption OSE120 OSE120P OSE250 OSE250P
Driving unloaded -
Driving with rated load -
Lifting with no load 65A 65A
Lifting with rated load 160A 160A
Hill climbing ability OSE120 OSE120P OSE250 OSE250P
Unloaded, short/long chassis 5/5% 5/5% 13/13% 13/13%
With rated load, short/long chas- 9/10% 9/10% 9/10% 9/10%
sis
Dimensions OSE120 OSE120P OSE250 OSE250P
Chassis
Short 1406mm 1406mm 1335mm 1335mm
Long 1492mm 1492mm 1420mm 1420mm
Wa with 1,150 mm forks and short 2271mm 2271mm 2196mm 2196mm
chassis
Wa with 2,350 mm forks and long 2472mm 2472mm 2410mm 2410mm
chassis
Lifting height 800mm 800mm 225mm 225mm
Weight excluding battery OSE120 OSE120P OSE250 OSE250P
Short chassis, 1,150 mm forks 1184kg 1184kg 765kg 765kg
Long chassis, 1,150 mm forks 1263kg 1263kg 897kg 897kg

Technical data
Specific tightening torques
235317-040 2006-10-27 918789- 649, 783
2.1 Specific tightening torques
Table 2: Specific tightening torques

Description Quantity Tightening Locking Measure
torques method
Upper locking nut - 1 130 Nm Punch mark See section
primary drive of “7.1 Component over-
driving gear view”.
Locking nut, output 1 400 Nm Punch mark See section
shaft of driving gear “7.1 Component over-
view”.
Bolt -drive gear 6 25 Nm Loctite 242 See section
cover “7.1 Component over-
view”.
Wheel bolt 5 90 Nm Loctite 270 See section
“7.1 Component over-
view”.
M8 mounting bolt - 8 27 Nm See section
driving gear “7.2 Disassembly/Assem-
bly Leakage from top
cover”.
Drive motor secur- 5 45 Nm Punch mark See section “6.4 Assembly
ing bolt of the motor in the truck”.
Locking nut - swivel 1 30-45 Nm See section
wheel shaft no. “9.3.4 Replacing the
wheel”.
OSE120, OSE120P
Mounting bolt - 3 9.5 Nm See section
Brake unit “8.5.1 Adjusting the play”.
Mounting bolt - 2 197 Nm See section
Mast “3.6 Lubrication sched-
ule”.(7100)

Technical data
General tightening torques
649, 783 918789- 2006-10-27 235317-040
2.2 General tightening torques

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

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

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

Maintenance
Safety rules during maintenance work
235317-040 2006-10-27 918789- 649, 783
3- Maintenance
To assure maximum safety and minimum downtime, all items in the
service programme should be covered. The service intervals are only
guidelines and need not be strictly followed. The operator of the truck
should adapt these to local requirements, however, it is important that
the minimum requirements as stated by BT are observed.
The service intervals are based on truck operating hours and can be
adapted to most common 8-hour shifts. When calculating the service
intervals, the following operating hours have been used:
Day time: 08.00-17.00 (20 hours/week)
Double shift: 06.00-14.00, 14.00-22.00 (40 hours/week)
Triple shift: 06.00-14.00, 14.00-22.00, 22.00-06.00
(60 hours/week)
Make sure the truck receives the necessary regular maintenance serv-
ice according to the maintenance schedule. The truck's safety, efficien-
cy and service life rely on the service and maintenance the truck
receives.
For service and repairs, only use spare parts approved by BT.
3.1 Safety rules during maintenance

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

Maintenance
Safety rules during maintenance work
649, 783 918789- 2006-10-27 235317-040
• Prior to commencing any work on the hydraulic system of the truck,

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

Maintenance
Cleaning and washing
235317-040 2006-10-27 918789- 649, 783
3.2 Cleaning and washing

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

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

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

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

Maintenance
Safe lifting
649, 783 918789- 2006-10-27 235317-040
3.3 Safe lifting

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

Maintenance
Lifting the truck
235317-040 2006-10-27 918789- 649, 783
3.4 Lifting the truck
• Only lift the truck using the indicated lifting points using a suitable lift-
ing equipment.
WARNING!
Risk of tipping.
The truck may tip over if it is lifted in the wrong places.
Always lift the truck in the indicated lifting points.
• Lift the truck at its centre of gravity using another fork lift truck.
• Fasten the truck to the forks of the lifting truck.
• Lift it very carefully
WARNING!
Risk of tipping.
The truck may tip over if it is lifted incorrectly.
Always lift the truck when it has been fastened to the forks of the lift-
ing truck and its centre of gravity between the forks.

Maintenance
Maintenance schedule
649, 783 918789- 2006-10-27 235317-040
3.5 Maintenance schedule
Table 4: Maintenance schedule

I:Inspect, rectify and change if necessary T: Tighten. C: Clean L: Lubricate.
M:Control measurement, rectify if necessary
Pos. Work to carry out

no. Interval in hours - may vary due to applica- 5 20 500 1000 3000
tion
Interval in days/weeks/months - may vary 1d 1w 6m 12m 36m
due to application
0000 Chassis
0000.1 Inspect all shafts, links and clamping pins I
0000.2 Inspect possible damage on the chassis; open the I
battery cover and use it as an aid
0000.3 Check the cover locks I
0000.4 Check finger guard I
0000.5 Check signs and stickers I
0000.6 Inspect the operator platform I
0350 Support arm
0350.1 Tightening torque inspection of the cap bolts (Note T
7)
0380 Fork carriage
0380.1 Check for crack formation and damage I
0380.2 Check clearance in bushes and links I
0380.3 Press grease into grease nipples (Note 6) I/L
0380.4 Inspect the guides for wear and lubricate them (Note I/L
6)
0380.5 Inspect the load support (Option) I
0450 Frame-mounted components
0450.0 Inspect the motor plate links and turning pipe I

Maintenance
235317-040 2006-10-27 918789- 649, 783


tion
due to application
1700 Drive motors
1700.1 Check clearance in connections I/T1 I/T
1700.2 Inspect the carbon brushes in the drive motor and lift M
motor
1700.3 Clean the drive motor and lift motor C
1700.4 Re-tighten the attachment bolts T2
1700.5 Check for abnormal noise in bearing I
2550 Drive unit
2550.1 Check for leakage I3 I
2550.2 Check the oil level I

2550.3 Check for abnormal noise I
2550.4 Check the attachment and clearance in steering I
bearing
2550.5 Change the oil in the drive gear L4 L
2550.6 Lubricate the gear rim L

3100 Brake
3100.1 Clean and verify correct operation of the service C/I
brake and parking brake
3100.2 Inspect brake disc weak and verify correct tightening M
torque (32 Nm)
3100.3 Check the clearance in disengaged position. (0,2-0,3 M
mm)

Maintenance
649, 783 918789- 2006-10-27 235317-040


tion
due to application
3500 Wheels
3500.1 Remove string and other rubbish I
3500.2 Check the drive wheel for wear and the tightening M
torque on bolts
New wheel: Tread thickness = 30 mm
Tightening torque = 65 Nm) (3500,2)
3500.3 Check whether the castor wheel rotates and swings I
freely; lubricate the horizontal bearing. Inspect the
castor wheels for wear and correct installation. New
wheel: Tread thickness = 10 mm)
4110 Tiller arm
4110.1 Check the mountings I
4110.2 Inspect the steering couplings for excessive play and I
the return spring
4110.3 Inspect the gear of the steering servo unit. (Option) I

Maintenance
235317-040 2006-10-27 918789- 649, 783


tion
due to application
5000 Electrical functions
5000.1 Inspect brake switch operation I I
5000.2 Inspect correct operation of the emergency stop switch I I
5000.3 Check the function of the collision safety switch I I
5000.4 Inspect lifting/lowering operation of the forks (and I I
support arms SPE125L/160L)
5000.5 Inspect correction operation of the platform switch I I
5000.6 Inspect the side guard switch for correct operation I I
5000.7 Check the function of the horn I I
5000.8 Check for wear on cabling I I
5000.9 Check the function of the driver’s control I I
5000.10 Inspect the error code log, operating hours and all I I
segments in the display panel
5000.11 Check the lift limit switches I
5110 Battery
5110.1 Check the electrolyte level, 10-15 mm over the cell M
plates
5110.2 Check connections to battery, truck and charge I
5110.3 Check that the cell and pole guards are undamaged I
5110.4 Check the fluid density and temperature M
5110.5 Remove overflow fluid from the battery trough C
5110.6 Check the battery locking I

Maintenance
649, 783 918789- 2006-10-27 235317-040


tion
due to application
5400 Power system
5400.1 Clean and inspect the mounting devices C/T
5400.2 Re-tighten cable connections T
5400.3 Check the contactor points on K10 I
5400.4 Check the movement of the contactors I
5400.5 Check the cable insulation I
6000 Hydraulic system
6000.1 Check hoses and connections for wear I
6000.2 Check hoses for wear and damage I
6000.3 Check the oil tank for cracks, leakage and damaged I
mountings
6000.4 Check that the oil level is correct I I
6000.5 Replace the oil and clean the reservoir L5 L
6600 Lift cylinder

6600.1 Check for leakage I
6600.2 Check the mountings I

Maintenance
235317-040 2006-10-27 918789- 649, 783


tion
due to application
7100 Mast
7100.1 Check for any cracks and other damage I
7100.2 Tighten the mast mounting bolts (tightening torque = T
197 Nm)
7100.3 Inspect the play between the mast member and the I
mast stabiliser rollers inside the mast
7100.4 Inspect lateral play in the mast stabiliser I
7100.5 Inspect the lifting chains and chain rollers for wear I
7100.6 Inspect correct adjustment of the lifting chains I
7100.7 Inspect the chain pin shafts and split cotters I
1 = Retighten all connections the first time after 500 hours, and then
every 1,000 hours.
2 = Retighten the mounting bolts after 500 hours to a torque of 45 Nm.
3 = Inspect for leakage during first oil replacement.
4 = Replace the il the first time after 500 hours/6 months and then every
3,000 hours/36 months.
5 = Replace the oil and clean the filter the first time after 500 hours/6
months and then every 1,000 hours/12 months.
6 = If the truck is used in cold stores or other severe conditions, perform
this item every 250 hours.
Unless otherwise indicated, whenever performing service according to
longer service intervals, all service items at shorter intervals should
also be carried out.

Maintenance
649, 783 918789- 2006-10-27 235317-040
. OSE120, OSE120P
.

Maintenance
235317-040 2006-10-27 918789- 649, 783
OSE250, OSE250P
.
5000
5000
5700
5000
4110
0380
5400
3500 3100
7120 6600
0000
5100
9130 6100
0450
2550
3500

Maintenance
Lubrication schedule
649, 783 918789- 2006-10-27 235317-040
3.6 Lubrication schedule
Table 5: Lubrication schedule

Pos. no. Service item Interval/Operating Lubricant
hours
500 h 1,000 h 3,000 h
0350 Lubricant nipples L A
2550 Driving gear O4 I O C
2550 Gear rim L E
3500 Swivel wheel L F
6100 Hydraulic system O5 O B
7100 Mast beam L G
7120 Lifting chain L D
7420 Guides L A
9130 Side guide L A
L= Lubricate I = Inspect O = Oil replacement
4 = Replace the oil the first time prior to 500 hours and after that every
3000 hours/36 months.
5 = Replace the oil and clean the filter the first time prior to 500 hours
and after that every 1,000 hours/12 months.

Maintenance
Lubrication schedule
235317-040 2006-10-27 918789- 649, 783
7120
0380
6100
9130 2550
3500

Maintenance
Oil and grease specification
649, 783 918789- 2006-10-27 235317-040
3.7 Oil and grease specification
Table 6: Oil and lubricant specifications

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

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

Tools
Super Seal connectors
235317-040 2006-10-27 918789- 649, 783
4- Tools
4.1 Super Seal connectors
3
3
Figure Number Application

159232 Crimping tool (pins/sleeves)
159229 Picklock (1)
159230 Tool for secondary locking, 1-2-

poles (2)
159231 Tool for secondary locking, 3-6-

poles (2)
159228 Pin/sleeve removal tool (3)

Tools
AMP connectors
649, 783 918789- 2006-10-27 235317-040
4.2 AMP connectors

PT = Power Timer (4.8. 5.8. 6.3 mm)
JPT = Junior Power Timer (2.8 mm)
MPT = Micro Power Timer (1.5 mm)

151080 (PT) Pin/sleeve removal tool
213296 (JPT) Pin/sleeve removal tool
213298 (MPT) Pin/sleeve removal tool
1=163787 (JPT) Crimping tool (sleeves only)

2=163788 (JPT)
1=213336 (MPT)
1 2=213337 (MPT)
2
1=213336 (JPT) Crimping tool (pins only)
2=213549 (JPT) For 0.5–2.5 mm2
1
2

Tools
Molex connectors
235317-040 2006-10-27 918789- 649, 783
4.2.1 AMP connectors, Multilock series 040

213130 Pin removal tool
213129 Crimping tool (pins only)
4.3 Molex connectors
16
9
8
1
156937 Crimping tool (sleeves/pins)
156936 Crimping tool (pins/sleeves)

Tools
Other tools
649, 783 918789- 2006-10-27 235317-040
4.4 Other tools

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

nection cable) gramme changes
2=163792
(Adapter for con-
nection to parallel
PC printer port)
1=155619-001 1= Service instrument for Curtis

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

Tools
Other tools
235317-040 2006-10-27 918789- 649, 783

08-13022 Driving gear puller

Tools
Other tools
649, 783 918789- 2006-10-27 235317-040
This page is intentionally left blank

Fork carriage – 0380
OSE120, OSE120P
235317-040 2006-10-27 918789- 649, 783
5- Fork carriage – 0380
5.1 OSE120, OSE120P
5.1.1 Component overview
5
4 6
7
2
3
Fig. 1 Fork carriage

OSE120, OSE120P
649, 783 918789- 2006-10-27 235317-040
Table 7: Component overview

Pos. Name Notes
2 Mast
3 Fork carriage
4 Roller Initially lubricated
5 Groove ring
6 Cup spring Reduce play using 2-4 cup springs
7 Guide
5.1.2 Verifying lateral play

• Inspect the guides Fig. 1(7) for uneven or abnormal wear.
• Inspect wear on the inside of the mast.
• Minimise play between the guide and the mast beam using 2-4 cup
springs Fig. 1 (6).
A maximum play of 2 mm is allowed Fig. 2 (A) .
A
Fig. 2 Lateral play, fork carriage

OSE120, OSE120P
235317-040 2006-10-27 918789- 649, 783
5.1.3 Disassembly of the fork carriage

• Disassemble the back rest parts according to Fig. 3.
A
Fig. 3 Back rest parts
• Disassemble the load support from the fork carriage

• By lifting the forks approx. 30-40 cm the chain mounts can be ac-
cessed from the operator side of the mast. Fig. 3 (A)
• Disassemble the lift chain.
• Unscrew the stop screws Fig. 3 (B)
• Lift out the fork carriage.
NOTE! It is safest to lift the fork carriage at its centre of gravity. The
guides and cup springs can be lost when the fork carriage is lifted
free from the mast.
Fig. 4 Lift the fork carriage
Assembly is done in reverse.
5.1.4 Roller replacement

• Remove the guide Fig. 1 (7) and the cup springs Fig. 1 (6), disas-
semble the groove ring Fig. 1 (5) and remove the roller Fig. 1 (4).

OSE250, OSE250P
649, 783 918789- 2006-10-27 235317-040
5.2 OSE250, OSE250P
5.2.1 Included components

15
16 35
17
23
22
21
20 19 18
34
33 24
25
26
32
31 27
29
30 28
14
13
12
11

OSE250, OSE250P
235317-040 2006-10-27 918789- 649, 783
Pos. Name Notes

11 Roller Initially lubricated
12 Groove ring
13 Cup spring Reduce play using 2-4 cup springs
14 Guide
15 Wheel fork
16 Bushing
17 Axle
18 Lubricant nipple
19 Tensioning pin
20 Axle
21 Lubricant nipple
22 Bushing
23 Sleeve
24 Bushing
25 Axle
26 Washer
27 Screw
28 Axle
29 Bushing
30 Axle
31 Lubricant nipple
32 Bushing
33 Lubricant nipple
34 Rotating pipe
35 Tensioning pin

OSE250, OSE250P
649, 783 918789- 2006-10-27 235317-040
5.2.2 Disassembly of the fork carriage

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

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

OSE250, OSE250P
235317-040 2006-10-27 918789- 649, 783
• Lift out the fork carriage.

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

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

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

OSE250, OSE250P
649, 783 918789- 2006-10-27 235317-040

Electric drive motor – 1760
General
235317-040 2006-10-27 918789- 649, 783
6- Electric drive motor – 1760
6.1 General
The drive motor is integrated with the brake and assembled together
with the driving gear to form a complete drive unit.
The drive motor uses an independent excitation design. It consists of a
field winding and armature winding, which are separately controlled
Armature current is transferred in the conventional manner using car-
bon brushes (8 pcs.) lying against the armature commutator.
The rotational direction of the motor can be reversed by changing the
direction of the field current.
6.2 Mechanical design

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

Disassembly of the motor from the truck
649, 783 918789- 2006-10-27 235317-040
6.3 Disassembly of the motor from the

truck
• Switch off the truck and disconnect the battery connector.
• Remover the motor compartment cover.
• Disconnect the motor cables (A).
• Disassemble the brake (B).
• Unscrew the five screws holding the motor shield against the motor
plate (C).
A B
C
• Lift out the motor and place it on a clean surface. Cover the driving gear
opening.
It is now possible to commence with the necessary service and repairs of
the motor.
6.4 Assembly of the motor in the truck

• Assembly is done in reverse.
• Place a new O-ring on the sealing flange (25) on the drive axle.
• Carefully lower the motor onto the driving gear while making sure the
seals and gear wheels are not damaged.
• Tighten the five screws holding the motor shield in place against the
motor plate to a torque of 45 Nm.
• Connect the motor cables. Verify that the polarity is correct. Connect
the brake.
• Verify brake operation.

Service and repairs
235317-040 2006-10-27 918789- 649, 783
6.5 Service and repairs
6.5.1 Disassembly of the motor

1
2 28
N side 16
18 29
15
30
3
31
4
5 32
6
33
34
17
7
8
11
10 19
13
20
22 21
12
23
24
25
26
D side
27
14

Service and repairs
649, 783 918789- 2006-10-27 235317-040
6.5.2 Disassembly, N side

• Remove the carbon brushes (8).
• Loosen the screws (1), (2).
• Disassemble the bearing plate (3).
• Disassemble the lock rings (4).
• Disassemble the washer (5).
• Disassemble the ball bearing (6).
6.5.3 Disassembly, D side

• Disassemble the lock ring (27).
• Disassemble the ball bearing (26).
• Disassemble the seal (25).
• Disassemble the ring (24).
• Disassemble the hub (23).
• Disassemble the expanding sleev (22).
• Disassemble the fan (20). If necessary, use a slide hammer.
• Disassemble the expanding sleev (22).
6.5.4 Wearing parts

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

Service and repairs
235317-040 2006-10-27 918789- 649, 783
6.5.5 Cleaning
To assure proper truck operation, it is important to keep the motor
clean. Make sure the motor and motor compartment are free from dust,
oil and other contaminants.
If the motor windings and internal compartments are dry, use a vacuum
cleaner with a suitable nozzle to clean the motor. Compressed air may
be used in combination with a vacuum cleaner, however, in this case,
the compressed air should be clean and dry.
If there are deposits on the windings, use a lint-free rag, if necessary
moistened with an organic grease solvent and a volatile cleaning agent
that do not damage the windings. However, do not use too much clean-
ing agent as it will penetrate into the motor parts.
Cleaning agent remains must be removed, using a suitable solvent, if
grease deposits are left on the surface.
If the motor components are heavily contaminated, it may be necessary
to use a solvent that is sprayed onto the parts. It is especially important
for the rotor that the cleaning agent is applied in a manner that avoids
contaminants from penetrating into the motor section.
One method to clean the rotor is to submerge it in solvent. If the rotor is
cleaned in this way, it should always be dried using warm air. While dry-
ing the rotor, make sure the work site is well ventilated. Drying should
continue until several measurements of the insulation resistance have
been made and the measurements are similar and result in passing
results.

Service and repairs
649, 783 918789- 2006-10-27 235317-040

Drive unit/gear – 2550
Component overview
235317-040 2006-10-27 918789- 649, 783
7- Drive unit/gear – 2550
7.1 Component overview
2
1 3
18
4
5
6
10
16 17 7
15 8
9
14
11
12
13

Component overview
649, 783 918789- 2006-10-27 235317-040
Pos. Name Notes

1 Motor gear
wheel
2 Locking nut Tightening torque 130 Nm
Centre punch to lock
3 Primary gear
wheel
4 Tapered roller
bearing
5 Shim
6 Shim
7 Tapered roller
bearing
8 Tapered roller
bearing
10 Cover
11 Screw Tightening torque 25 Nm
Lock using Loctite 242
12 Shim
13 Pinion/crown Gear play 0.09-0.15 mm. Pretighten
wheel the bearing by 2-5/100. The punched
measure in the pinion should be
adjusted using shims.
14 Drive axle
15 Wheel bolt Tightening torque 90 Nm
Lock using Loctite 270
16 Jointing ring Fill the jointing ring with grease
Seal using Loctite 574
17 Tapered roller
bearing

Disassembly/Assembly Leakage from top cover
235317-040 2006-10-27 918789- 649, 783
7.2 Disassembly/Assembly
Leakage from top cover
• Lift up the truck and properly secure it using trestles.
• Unscrew the drive wheel.
• Unscrew the M8 bolt securing the gear unit in the gear cover using a
6 mm Allen key. Hold the gear unit to prevent it from falling down.
• Seal the gear unit against the cover using Loctite 547.
• Tighten the M8 bolts to a torque of 27 Nm.
7.3 Replacing the drive axle jointing

ring
When replacing the drive axle jointing ring, the gear unit can remain
installed on the truck.
If the drive axle leaks oil, follow the instructions below.
7.3.1 Disassembly
7 6 5 2
4
• Remove the drive wheel from the gear unit.
• Remove the lower gear cover and drain the oil (2).
• Loosen the drive axle nut. Remove the nut and the spacer ring (3).
• Carefully knock out the drive axle using a brass mandrel and ham-
mer (4).
• Pull out the bearing from the drive axle using the bearing removal
tool 08-13022 (5).

Replacing the drive axle jointing ring
649, 783 918789- 2006-10-27 235317-040
• Verify that the bearing plates are free from damage. If the plates
have been damaged by the bearing puller, then measure the total
thickness of the spacing washers and replace them prior to assem-
bly (6).
• Remove the jointing ring from the drive axle (7).
7.3.2 Assembly
Assembly of the gear unit after replacement of the drive axle jointing
ring is done in reverse.
Pay special attention to the following during assembly:
• Fill the jointing ring with grease after setting it on the drive axle.
• Ensure that only undamaged spacing washers of equal total thick-
ness as the original spacers are set on the drive axle.
• Press on the bearing on the drive axle, making sure not to damage
the bearing spacing washers.
• During assembly of the drive axle with attached bearing, spacing
washers and jointing ring, make sure the placement of the axle
wedges coincide with the crown wheel wedges and that the bearing
and jointing ring are properly positioned on the axle prior to pressing
the axle into the final position.
• Place the spacer ring on the drive axle end and then screw on the
axle nut. Be sure always to use a new nut. Tighten the axle nut to a
torque of 400 Nm, and lock it with one centre punch in the middle.
Lubricate the drive axle nut prior to setting it on the axle.
• Replace the O-ring before mounting the lower cover. Make sure it is
not damaged. Fit the cover and tighten the bolts to a torque of 25
Nm. Lubricate the bolts prior to mounting. Fill with oil according to
the oil filling instructions.
Fit the drive wheel and tighten the wheel nut to a torque of 90 Nm.
Lubricate the wheel nut prior to mounting.

Replacing the wheel bolt
235317-040 2006-10-27 918789- 649, 783
7.4 Replacing the wheel bolt

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

• Lift the machine using a lift jack and properly secure it using trestles
and wooden blocks.
• Remove the drive wheel.
• Wheel bolts with damaged threads can be removed using the pin
bolt tool.
• Broken wheel bolts:
• Method 1: Drill a hole in the centre of the bolt and unscrew the bolt
using an M14 bolt removal tool.
• Method 2: If the bolt cannot be removed with the bolt removal tool,
the drill it out.
- Make one centre punch in the bolt centre. Pay attention to correct
centring of the punch.
- Pre-drill a hole through the bolt using a 5 mm drill steel.
Drill out the bolt using an 11.5 mm drill steel.
- Try to remove the bolt remains using pliers, etc. If this is not pos-
sible, remove the bolt remains by cleaning the thread with an
M14x1.5 thread tap.
• Apply a string of LOCTITE 270 onto the wheel bolt thread.
Fit the new wheel bolt using the pin bolt tool.
Tightening torque 90 Nm.
• Fit the drive wheel. Tighten the wheel nuts to a torque of 90 Nm.
• Remove the trestle or wooden blocks and lower the truck to the
ground.
• Reconnect the battery connector.

Replacing the wheel bolt
649, 783 918789- 2006-10-27 235317-040

Electromagnetic brake – 3370
Component overview
235317-040 2006-10-27 918789- 649, 783
8- Electromagnetic brake – 3370
1
2
12 3
11 4
5
10
9 8 7 6
13
A A
A-A

Disassembly
649, 783 918789- 2006-10-27 235317-040
Pos. Name Notes

1 Magnet housing
2 Screw 3 pcs.
3 Pressure plate
4 Sleeve
5 Shims for air gap 1 pc. = 0.5 mm
adjustment 5 pcs. = 0.13 mm in each position
6 Friction plate, brake Nom. thickness: 9.7 mm
disc Min. thickness: 7.7 mm
7 O-ring
8 Hub
9 Mounting plate
10 Screw 3 pcs.
11 Spring 8 pcs.
12 Cable with connector
13 Screw for manual Not included
release M6
8.2 Disassembly
• Loosen the screws (10).
• Lift out the brake assembly from the motor axle.
• Place the brake assembly on a clean surface.
• Gradually unscrew the adjusting screws (2) in order to release the
spring tension evenly and a little by little.
8.2.1 Inspection
Inspect all parts for damage and/or wear.
• Be sure specially examine the brake disc (6) and the wear surface of
the pressure plate (3).
• Inspect the springs (11) and spacers (4,5) for damage.
• Inspect the hub splines (8) and the friction plate splines (6) for dam-
age.
• Inspect the magnet plate (1) and pressure plate (3) for swelling/de-
formations and other damage.

Assembly
235317-040 2006-10-27 918789- 649, 783
8.3 Assembly
• Carefully clean all parts.
• Assembly of the brake assemble is done in reverse of disassembly.
• Pay attention to the following:
- The holes in the pressure plate (3) must be centred with the cor-
responding holes in the magnet housing.
- The correct number of springs is installed.
- The play of 0.25-0.38 mm is correctly set. Adjustment may be re-
quired.
NOTE!
The friction surfaces must not come into contact with oil or grease
since this will seriously impair braking performance.
13
8.4 Manual release of the brake
A A The brake can be manually released, e.g. if the brake is broken and the
truck needs to be moved to the service area or to facilitate easier cen-
tring of the brake disc during assembly. To release the brake, gradually
screw in the two screws (13) evenly.
A-A WARNING!
Lost braking function.
Braking does not work when the brake has been manually release.
Drive the truck at reduced speed and be very careful.
Do NOT forget to remove the screws after completed work.
8.5 Adjustment
8.5.1 Adjusting the play
9,5 Nm
0,25-0,38 mm 4
5
Fig. 5 Adjusting the play
• Measure the play in three different positions.

• Adjust the play by removing the shims (5).

Adjustment
649, 783 918789- 2006-10-27 235317-040

Swivel wheel – 3540
General
235317-040 2006-10-27 918789- 649, 783
9- Swivel wheel – 3540
9.1 General
The truck has an adjustable swivel wheel assembly holding a single
wheel. It is easily accessible once the front cover of the chassis has
been removed.
Correct adjustment of the swivel wheel height is very important for the
drive wheel pressure and the braking performance of the truck. This is
why the height of the swivel wheel should be regularly adjusted at inter-
vals of 500 operating hours because of the wear on the drive wheel.
The bearings in the swivel wheel assembly have been sealed and lubri-
cated at the factory. The swivel wheel bearings should be lubricated at
intervals of 500 operating hours.

Component overview
649, 783 918789- 2006-10-27 235317-040

1
2
3
7
4
8
5
9 6
10
11
12
13
14
15
16
17

Maintenance
235317-040 2006-10-27 918789- 649, 783
Pos. no. Description

1 Locking screw
2 Top plate
3 Locking screw for height adjustment
4 Height adjustment
5 Swivel arm
6 Spacing sleeve
7 Groove ring
8 Wheel fork
9 Wheel axle
10 Spacing bolt
11 Swivel wheel
12 Wheel bearing
13 Spacer
14 Guard
15 Swivel bearing lubricant nipple
16 Swivel bearing
17 Top bolt
9.3 Maintenance
The swivel wheel should be lubricated at regular intervals. As a result of
wear on the drive wheel, the height of the swivel wheel must be inspect-
ed at intervals of 5000 operating hours as a result of this wear. This is
due to the importance of the relative height of the swivel wheel in rela-
tion to the drive wheel.
9.3.1 Swivel wheel height inspection

:
• Park the truck on a level floor.

• Remove the motor cover and the two brackets that keep the cover
closed against the chassis.
• Use a water level and place it on the motor plate in the motor com-
partment.
• If the motor plate is not level, adjust the swivel wheel height as ex-
plained in the following section.

Maintenance
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Maintenance
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9.3.2 Swivel wheel height adjustment
3
4
To achieve the correct pressure on the drive wheel, the swivel wheel
should be adjusted so that the motor plate is level.
Adjust the swivel wheel

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

When replacing components in the swivel wheel assembly, it is neces-
sary to always remove the front cover of the chassis. Further, it is easier
to carry out work on the swivel wheel when the entire assembly has
been disassembled from the chassis.
Disassembly of the swivel wheel assembly

• Disassemble the swivel wheel assembly by remove the four mount-
ing bolts.

Maintenance
649, 783 918789- 2006-10-27 235317-040
9.3.4 Replacing the wheel

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

• Disassemble the wheel from the wheel fork as explained in the pre-
vious section.
• Press out the spacing sleeve and punch out the bearing race on one
of the sides.
• Turn over the wheel and punch out the other bearing race.
• Press a new bearing race into place.
• Place the spacing sleeve in the hub.
• Lubricate the wheel.
• Mount the wheel as explained in the previous section.

Electrical steering system – 4300
General
235317-040 2006-10-27 918789- 649, 783
10- Electrical steering system – 4300
10.1 General
The electrical steering system consists of the steering unit (A) and
steering servo (B). A potentiometer in the steering system sends infor-
mation to the electronic module in the steering servo system. When
starting the truck, a drive reference measurement is performed and the
drive wheel position is calibrated using the reference sensor (C)

General
649, 783 918789- 2006-10-27 235317-040
10.1.1 Electrical steering servo

The electrical steering servo consists of twin potentiometers connected
to an electronic module in the motor compartment. The electronic mod-
ule, which is also referred to as the EPS (Electrical Power Steering), is
directly mounted on a Brush-Less Permanently Magnetised servo
motor (BLPM). The motor has a power amplifier that consists of 2-stage
planetary gearing with a gear wheel mounted on a trailing journal and
locked with a nut. The gear wheel is meshed with the gear ring on the
driving wheel gear, and as such the drive unit also handles steering of
the truck.
The steering system is electric and uses a "Steer-By-Wire" design. This
means there is no mechanical contact between the steering unit and
the truck's steering wheel.
The electronic module monitors all electrically connected components.
Monitoring is continuous enabling instant detection of possible cable
interruptions. Electrical faults detected in potentiometers, cables and
the electronic module result in automatic switch-off of the truck's drive
mode and application of the electromechanical brake.
An automatic drive reference measurement is performed at each start-

up after a no-voltage state. During this calibration, the truck cannot be
driven. The drive reference mode safety-checks the system and simul-
taneously calibrates the wheel position.
Steering is progressive, implying slow-down of the travel speed at large
steering angle throws. This promotes safe and efficient truck travel. A
certain steering response in the steering unit results in an increasingly
greater steering response in the steering wheel. The steering unit is
limited to a +/- 60 degree steering response which gives the steering
wheel +/-100 degree steering response (drive wheel direction) or +/-90
degree steering response (fork direction).

Component overview
235317-040 2006-10-27 918789- 649, 783

3 2
1
8
9
10
11
10
12

Component overview
649, 783 918789- 2006-10-27 235317-040
Pos. Name
1 Screw
2 Electronic module
3 Seal
4 Motor
5 Drive
6 Washer
7 Nut
8 Screw
9 Guide
10 Nilos ring
11 Pilot bearing
12 Gear rim

Adjustment
235317-040 2006-10-27 918789- 649, 783
10.3 Adjustment
10.3.1 Reference sensor

After replacement or adjustment of the reference sensor, screw it all the
way down until it makes contact with the top of the gear ring. Then
screw it upwards two full turns and lock it with the nut. Calibrate the sys-
tem using parameters 36 and 37.
10.3.2 Calibration
Calibration and adjustment of the steering servo is accomplished using
parameters 36 and 37.
Parameter 36
Parameter 36 calibrates the potentiometer and must be adjusted when
the following components are replaced.
• complete steering servo assembly or parts of the steering servo as-
sembly
• reference sensor
• potentiometer
• following any work on the steering unit
Detailed instructions as to the function of parameter 36 are presented in
C code 5000.
Parameter 37
Parameter 37 adjusts the drive wheel centre position. The wheel can be
adjusted 30 degrees to either side. Prior to adjustment of parameter 37,
parameter 36 must be adjusted to ascertain the wheel's zero position.
Detailed instructions as to the function of parameter 37 are presented in
C code 5000.

Disassembly/assembly of pushbuttons
649, 783 918789- 2006-10-27 235317-040
10.4 Disassembly/assembly of
pushbuttons
• Disassemble the keypad.
• While taking hold of the top cover, remove the screws.
• Disconnect the cable that is connected to the logic card.
• Remove the screws.
• Carefully lift out the lower cover, while holding a finger between the
lower cover and the pushbutton in order to keep the pushbutton in
place.
NOTE!
Static electricity!
Risk of static discharge that can damage the electronic modules.
Before commencing work on the electronic modules, be sure to take
the necessary measures.
10.4.1 Replacing the hornbutton/switch

• Disassemble the pushbutton
as shown in the picture.
• Disconnect the switch connector on the logic card.

• Press out the switch from its holder.

Disassembly/assembly of pushbuttons
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10.4.2 Replacing the lifting/lowering

pushbutton
• Remove the pushbutton by
inserting a flat screwdriver
into the slot (A) as shown in
the picture below.
A A
• Unscrew the holder to loosen the arm.

10.4.3 Replacing the pushbutton

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

slot as shown in the picture
and carefully pry loose the
pushbutton.
• Unscrew the pushbutton holder and arm.


Replacing the potentiometer
649, 783 918789- 2006-10-27 235317-040
10.5 Replacing the potentiometer

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

(B) from the emergency stop
switch by depressing the
locking device on the con-
nection block.

235317-040 2006-10-27 918789- 649, 783
• Separate the switch at the

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

ers (D, E) and the keypad.
D E

649, 783 918789- 2006-10-27 235317-040
• Disassemble the top cover

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

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

bundling cords are placed at the same positions as prior to disas-
sembly. After complete assembly, calibrate the steering using pa-
rameters 36 and, if necessary, also parameter 37.

Inspection and replacement of the lateral movement line (Ergo version)
235317-040 2006-10-27 918789- 649, 783
10.6 Inspection and replacement of the

lateral movement line (Ergo version)
• Loosen the front and rear
covers. The steel line is at-
tached with a screw at each
end. Make sure the line is
not damaged.
• If the line needs replace-

ment, release the line ten-
sioner (A).

Inspection and replacement of the lateral movement line (Ergo version)
649, 783 918789- 2006-10-27 235317-040
• First loosen the screw at the

emergency stop switch (C),
where the line splits into two.
Then loosen the front screw
(B) and pull out the line.
NOTE! During later assem-
bly, it is important to use the
same type of screw and
washer. If the steering unit is
exposed to exceptional later-
al forces, the weakest link in
the design is the screw (D),
which will break. The truck
can still be steered, howev-
D B
er, the steering unit cannot
be locked in its fixed posi-
tions.
• Assemble the line and covers in reverse.

Replacing the inductive brake sensor
235317-040 2006-10-27 918789- 649, 783
10.7 Replacing the inductive brake

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

and the top cover of the
steering unit.

649, 783 918789- 2006-10-27 235317-040
• Cut off the bundling cords

and separate the switch (A).
NOTE! It is important to
place new bundling cords at
the same places where the
old ones were removed.

235317-040 2006-10-27 918789- 649, 783
• Loosen the screw that holds

the sensor in place and lift it
straight up. The sensor has
a guide pin on the rear side.
• Reassemble in reverse.

Replacing the viscous damper
649, 783 918789- 2006-10-27 235317-040
10.8 Replacing the viscous damper

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

and the pivot arm covers,
and loosen the 4 screws (B)

235317-040 2006-10-27 918789- 649, 783
• Loosen the screws that hold

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

viscous damper and the
spacer.
• Assembly is done in reverse.

649, 783 918789- 2006-10-27 235317-040

Electrical systems – 5000
General
235317-040 2006-10-27 918789- 649, 783
11- Electrical systems – 5000

Software: 203384-012 and later versions.
11.1 General
The electrical system of the truck is based on the PowerDrive platform.
• The main power source is a 24 V DC traction battery.
• The travel drive motor is a separate excitation type (SEM) . The trav-
el drive motor is operated by an enclosed transistor regulator relying
on pulse width modulation (PWM) technology. The transistor regula-
tor also controls the input and output signals for truck travel and lift-
ing operations.
• The lift unit motor is a conventional DC motor without any external
field winding connections. Switch-on of the hydraulic unit's electric
motor is achieved using a contactor.
• The truck also features electric power steering. The power steering
servo and the motor have been integrated as one unit directly onto
the driving gear mounting plate.
• All electric units communicate via a CAN bus with an IC card in the
steering unit handle. This card contains a processor and firmware
that controls and monitors truck functions. A set of parameters used
to adjust truck functions and characteristics is stored in the card. The
card also monitors error conditions that may occur.
11.1.1 Firmware/hardware order numbers

• Press and hold the horn button [S18], enter a valid PIN-code and
then press on the keypad [A17].
• Keep [S18] depressed until = the part number is

displayed.
By scrolling with L1 you can get the following information:
• Firmware part number
• Machine part number
• Machine serial number

General
649, 783 918789- 2006-10-27 235317-040
11.1.2 Nomenclature
Items shown in square brackets [ ] refer to electric component designa-
tions as stated in the electrical wiring diagrams. See “11.2.1 Electric
component overview” on page 6.
{high} refers to a voltage level that is approximately the same as the
supply voltage level.
{low} refers to a voltage level of approximately 0 Volt.

Electrical equipment overview
235317-040 2006-10-27 918789- 649, 783
11.2 Electrical equipment overview

X1
M3
Y10/Y41
Y45
Y69
B10
S19
A5 Y1
M6 M1 A36
S65 G1
R1
A1 X41
F50
K30
F51
F52
F1 K10
H1
F3

649, 783 918789- 2006-10-27 235317-040
A17
A6
S18:1 S18:2
A2
A2:S20
A2:S19
A2:S22
A2:S21
L1
S10
R2
S21

235317-040 2006-10-27 918789- 649, 783
S31
S12
S32
S107
S103 S214
S19
TRUCK WITH MAST AND WITH PLATFORM

649, 783 918789- 2006-10-27 235317-040
11.2.1 Electric component overview

The following table shows a summary of the major electric components
of this truck.
Table 8: Component designation overview

Designation Function Component type Inf.
Energy and main power isolation
G1 Main electrical power source Traction battery 24 V
X1 Battery connection / isolation Connector
K10 Main contactor Contactor
Equipment protection
F1 Drive motor protection Fuse 160 A
F3 Pump motor protection Fuse 125 A
F 50 Operating circuit protection A5, A2 Fuse 3 A
F 51 Operating circuit protection A1 Fuse 7,5 A
F 52 Steer servo motor protection Fuse 30 A
Control and Signal processing
A1 Lift, traction and peripherals power control Transistor regulator
A2 Control of truck functions Logic card 1
A5 Steering servo Logic card 2
A6 Display of truck functions Display 1
A17 PIN log-in and data entry Keypad 1
A36 "SEU" expansion unit Logic card
Safety and braking
S21 Emergency switch-off Switch
S10 Activation of mechanical brake Inductive sensor 7
Y1 Mechanical brake Electromagnetic brake 7
H1 Audible warning signal -Horn Horn
S18:1 / 2 Horn activation Switch 4
S18:2 Horn activation Switch 4

235317-040 2006-10-27 918789- 649, 783

Traction
L1 Speed control and travel direction selector Hall sensors 6, 7
(butterfly)
S19 Presence control (operator on platform) Inductive sensor 7, 8
(OSE120, OSE250)
Contact sheet (OSE120P,
OSE250P)
M1 Truck traction Motor
Guide
R2 Steering angle signal Potentiometer
S65 Drive wheel in centre reference Inductive sensor
M6 Drive wheel steering Motor 2
Lifting forks
A2:S19 Fork lifting control Hall sensors 5, 7
A2:S20 Fork lowering control Hall sensors 5, 7
Y10 Fork lowering -hydraulic control Magnetic valve
Y45 Fork lifting/lowering -hydraulic control Magnetic valve 7
S12 Forks > 500 mm Inductive sensor
S31 Fork lift limiter Inductive sensor 7
S32 Forks < 200mm Inductive sensor
B10 Fork Load supervision Pressure sensor
K30 Fork lifting (Pump motor power switching) Contactor
M3 Pump motor Motor
Platform lifting
Y69 Platform lifting/lowering - hydraulic Magnetic valve
S103 Platform >500mm Inductive sensor
S107 Platform lift limiter Inductive sensor
S214 Activation of platform lowering (via floor Contact sheet 8
contact sheet switch)
A2: S21 Activation of platform lifting (via steering unit) Hall sensors 5
A2: S22 Activation of platform lowering (via steering Hall sensors 5
unit)

649, 783 918789- 2006-10-27 235317-040

Other
R1 Power supply PTC-resistor 15 Ohm
S1-6 Options Switch 3
S215/216 Walk-mode button -left/right Switch 3
S219/220 Fork lifting from side - left/right Switch 3
S221/ 222 Fork lowering from side - left/right Switch 3
S217/ 218 Safety stop (all side-operated functions) Switch 3
X41 CAN communication (external) Connection point
X29 CAN communication (external) Connection terminal for
optional I/O units
Footnotes to the table above:

1. Situated in the tiller unit and communicates via the CAN bus
2. The steering servo controller, servo motor and mechanics are inte-
grated into one single unit.
3. Optional function
4. S18:1 represents the left side button and S18:2 represents the right
side button.
5. These input signal are controlled directly via Hall units mounted on
the A2 logic card and subsequently processed by the CAN bus.
6. Speed control signals from [L1] are processed by Hall element sen-
sors mounted on the [A2] card. Sensors [A2:S1-9] control speed control
signals for driving in fork direction. Sensors [A2:S10-18] control speed
control signals for driving in drive wheel direction.
7. Signals to/ from these elements can be checked via the Built-in Test
function. See Built-in Test Function on page 99.
8. [S19] & [S214] are integrated in the platform contact sheet on the
OSE120P & OSE250P

Electrical wiring diagram
235317-040 2006-10-27 918789- 649, 783
11.3 Electrical wiring diagram
11.3.1 Symbol list
Table 9: Symbol list

Symbol Description Symbol Description
Truck battery Horn
Fuse Emergency stop switch NC
Resistor (PTC)a Switch, weight pressure oper-

ated
DC motor b(SEM type)c Sensor, inductive NO

A1 A2
M
E1 S E2
DC motor Sensor, inductive NC
Contactor Variable resistor (potentiometer)
Brake coil (normally applied) Pressure switch NO
Coil for hydraulic magnetic valve Multi-pin connector
Analogue pressure sensor NO = Normally Open

P NC = Normally closed
a. PTC = Positive Temperature Coefficient (resistance increases as temperature increases)

b. DC = Direct Current
c. SEM = Separately Excited Motor

649, 783 918789- 2006-10-27 235317-040
11.3.2 Overview
3 2
24 (+) POWER 24VDC 6 A2
M1
A1
F1 R1
(J2-16) SUPPLY 24VDC ARMATURE (M) M
40
(-) POWER 0VDC 4 S
B10 FIELD (S1)
E2 E1
63
P (J2-10) LOAD WEIGHT F3
5 21
S19 FIELD (S2) K10
65
(J2-11) DRIVER ON PLATFORM
K10 K30
57 64 10
(J2-12) BRAKE MAIN CONTACTOR (J2-4)
S10 M3 M
24 A1 38
Y10/ Y41
LOWER VALVE (J2-2) 40
MAST MODELS Y1
S32 BRAKE; A (J2-5) 31
47
(J2-13) FORKS<0,2M
K30
45
PUMP CONTACTOR (J2-6)
H1
48 39
(J2-14) FORKS>0,5M SIGNAL HORN (J2-7)
MACHINE F51
S12 WITH MAST
FORKS LIFT/LOWER VALVE (J2-9) 88
49 S21
Y45
(J2-15) LIFT LIMIT
S31 24
(J2-1/J2-8) CAN H/L
119/120
S218 74 S217
71 S215 70
(33)AUX SW; (27/42)
S216 CAN
GO/WALK
SERVICE
S219 72
CAN CONNECTOR X1
(20)AUX SW; X41
S220 LIFT FORKS
+
G1
S221 73
-
(6)AUX SW; F50

S222 AUX
LOWER FORKS CAN CONNECTOR X1
(34)AUX SW; X29
OPTION STOP 40
40 (1)+24VDC A36 20
(29)0VDC
86
(5)PLATFORM>0,5M (X3:3/7)
S103 CAN F52
40 (X3:6) +24VDC A2:S19
STEER R2
(X3:2) 0VDC ANGLE 20 23
80 (7)FOOTSWITCH; Hall
SENSOR
S214 LOWER PLATFORM (2/10) (6) (8/16)
PLATFORM;LIFT/ 89 A2:S20 CAN H/L ENABLE +24V
Hall
91/93/92/94
S107 LOWER (16) (4/13/5/14)
85 A2 95
(19)PLATFORM
A2:S21 96
(3) +12V A5
LIFT LIMIT (11) REF.
Hall 40
Y69 (7/15) 0V (12) 0V
A2:S22 S65
97
PLATFORM SPECIFIC Hall M M6
(X1:1) HORN 2
(X4:1) HORN 1 (X11) KEYBOARD
S18:2
A2:S1-S9 A2:S10-S18 A17
Hall Hall
S18:1 (X4:2) DISPLAY
(X1:2) (X12) (X1) A6

1 2 3 4 5 6 7 8
TRANSISTOR REGULATOR
A A1 A
235317-040
3A 24V
F50 X1 G1 X1
Order number
20 + - 40
© BT Europe AB
Sh. 3 - INP. POWER SUPPLY, 0V DC
160A
R1 F1
2 3
+ INP. POWER SUPPLY +24V DC
PUMP MOTOR DRIVE MOTOR
PTC 15 OHM 125A
F3 M3 M1
2 1 9 2 1 10 A1 A2 A1 A2 6
Date
M M M OUT. ARMATURE
B B
S
1 4 3 E1 E2 4
Sh. 2 S1 OUT. FIELD
2006-10-27
7,5A
F51
21 5
Sh. 2 S2 OUT. FIELD
30A
Service Manual
F52
23
Sh. 3
C C
918789-
40
Sh. 2
Y10
24 1 2 38
Sh. 2 J2-2 OUT. LOWER VALVE
K10
A1 A2 64
J2-4 OUT. MAIN CONTACTOR
D D
Y1
Valid from serial number
1 2 31
J2-5 OUT. BRAKE; A
K30
A1 A2 45
J2-6 OUT. PUMP CONTACTOR
H1 S
39
J2-7 OUT. SIGNAL HORN
- +
E E
T-code
649, 783

11.3.3 Detailed wiring diagram OSE120
1/7 PROD B
F F
219441
1 2 3 4 5 6 7 8
11- 11
1 2 3 4 5 6 7 8
11- 12
T-code
A1 649, 783
A A
119 119 J2-1
Sh. 3 CAN HIGH
120 120 J2-8

Sh. 3 CAN LOW
EMERGENCY SWITCH OFF
X20 S21 X20 Y45
21 21 22 24 1 2 88 J2-9 OUT. FORKS LIFT/LOWER VALVE
Sh. 1
B10
B 24 24 P 63 J2-10 INP. LOAD WEIGHT B

Sh. 1 7 B C
A
S19
(1) (2) 65 J2-11 INP. DRIVER ON PLATFORM
(3)
918789-
40
Service Manual
Sh. 1 3
X22 S10 X22 X20

C 1 (1) (2) 57 C
Sh. 1 J2-12 INP. BRAKE
X20 X22 (3)

F
X31 S32 X30

(1) (2) 47
J2-13 INP. FORKS; <200MM

X31 (3)
EXTERNAL EQUIPMENT
D D
S12 X30
(1) (2) 48 J2-14 INP. FORKS; >500MM
(3)
Date
S31 X31
2006-10-27
(1) (2) 49 J2-15 INP. LIFT LIMIT

E (3) E

24 J2-16 INP. SUPPLY +24V DC
235317-040
F F
Order number
2 / 7 PROD B
219441
1 2 3 4 5 6 7 8
© BT Europe AB
1 2 3 4 5 6 7 8
ELECTRONIC ASSY; STEER SERVO
A5
A A
235317-040
40 40 7
Sh. 2 4 POWER SUPPLY OV DC
Order number
© BT Europe AB
40 15 POWER SUPPLY 0V DC
23 23 8
Sh. 1 POWER SUPPLY +24V DC
Date
B 23 16 B
POWER SUPPLY +24V DC
2006-10-27
119 119 2
Sh. 2 4 CAN HIGH
120 120 10
Sh. 2 4 CAN LOW
Service Manual
R2, STEER ANGLE SENSOR
X22 X21
91 4 OUT. SUPPLY +5V DC M6
C C
918789-
RD
X22 X21 M
R2:A 92 5 INP. A_IN0
WH
BU
BU
X22 X21
R2:B 93 13 INP. A_IN1
GN
RD
X22 X21
94 14 OUT. SUPPLY 0V DC
D D
95 3 OUT. SUPPLY +12V DC

S65
(1) (2) 96 11 INP. REFERENCE SWITCH
(3)
97 12 OUT. SUPPLY 0V DC
E 20 20 E
Sh. 1 4 6 INP. ENABLE(B+)
T-code
649, 783

F 3/7 PROD B F
219441
1 2 3 4 5 6 7 8
11- 13
11- 14
1 2 3 4 5 6 7 8 T-code
649, 783
A A
ELECTRONIC CARD STEERING UNIT

A2
X20 X22
20 20 X3:6 INP. +24V DC
Sh. 3
X20 X22
40 40 X3:2 INP. OV DC
Sh. 3 7
B B
X21 X22
119 119 X3:7
Sh. 3 7 CAN HIGH
X21 X22
120 120 X3:3
Sh. 3 7 CAN LOW
918789-
Service Manual
CAN, SERVICE CONNECTOR

X41
SPEED REF. VALUE
C 1 20 C
A2:S1-S9 A2:S10-S18
2 40
3 119
A2:S21
4 120
MAN LIFT
A2:S22
24 MAN LOWER
D Sh. 3 7 D
CAN, AUX CONNECTOR A2:S19

X29
Date
C 1 FORK LIFT
A2:S20
2 40
FORK LOWER
2006-10-27
3 119
E E
4 120

235317-040
4/7 PROD B
F F
Order number
219441
1 2 3 4 5 6 7 8
© BT Europe AB
1 2 3 4 5 6 7 8
A A
235317-040
Order number
© BT Europe AB
DISPLAY ELECTRONIC CARD STEERING UNIT
A6 A2
X1 1 X12 1 +5V DC
Date
B B
X1 2 X12 2 SI
2006-10-27
X1 3 X12 3 SCK
Service Manual
8 8 8 8
C X1 4 X12 4 ENABLE C
918789-
X1 5 X12 5 LCLK
X1 6 X12 6 0V DC
D D
S18:1
1 2
X4 1 INP. HORN 1
X4 2 OUT. OV DC HORN 1
S18:2
1 2
E X1 1 INP. HORN 2 E
T-code
649, 783

X1 2 OUT. 0V DC HORN 2
5/7 PROD B
F F
219441
1 2 3 4 5 6 7 8
11- 15
11- 16
T-code
1 2 3 4 5 6 7 8
649, 783
A A
KEY BOARD ELECTRONIC CARD STEERING UNIT
A17 A2
X11 1 1 4 7 -
X11 2 2 5 8 0
B X11 3 3 6 9 # B
X11 4 1 2 3
918789-
Service Manual
X11 5 4 5 6
X11 6 7 8 9
C C
X11 7 - 0 #
X11 8 LED_GREEN
X11 9 LED_RED
D D
X11 10 0V DC
Date
2006-10-27
E E

235317-040
6/7 PROD A
F F
Order number
219441
1 2 3 4 5 6 7 8
© BT Europe AB
1 2 3 4 5 6 7 8
ELECTRONIC ASSY; "SPIDER"

A36
235317-040
A A
X29
Order number
24
© BT Europe AB
24 1
Sh. 2 POWER SUPPLY 24VDC
X29
40 40 29
Sh. 4 POWER SUPPLY 0VDC
RIGHT; "STOP" LEFT; "STOP" LEFT; "GO/WALK"

X25 S218 X25 X24 S217 X24 S215 X24
Date
1 2 74 1 2 71 3 4 70 33
AUX SWITCH; "GO/WALK"
B B
X25 RIGHT; "GO/WALK"
2006-10-27
S216 X25
3 4
LEFT; "LIFT"
S219 X24
3 4 72 20
AUX SWITCH; "LIFT FORKS"
Service Manual
RIGHT; "LIFT"
C C
S220 X25
918789-
3 4
LEFT; "LOWER"
S221 X24
3 4 73 6
AUX SWITCH; "LOWER FORKS"
RIGHT; "LOWER"
S222 X25
3 4
D D
71 34
AUX SWITCH; "STOP"
X29
119 119 27
Sh. 4 CAN HIGH
X29
120 120 42
Sh. 4 CAN LOW
E E
T-code
649, 783

7/7 PROD B
F F
219441
1 2 3 4 5 6 7 8
11- 17
11- 18
1 2 3 4 5 6 7 8 T-code
649, 783
A A1 A
3A 24V
F50 X1 G1 X1
20 + - 40 -
Sh. 3 INP. POWER SUPPLY, 0V DC
160A
R1 F1
2 3
PTC 15 OHM 125A
F3 M3 M1
2 1 9 2 1 10 A1 A2 A1 A2 6 M
M M OUT. ARMATURE
B B
S
1 4 3 E1 E2 4 S1
Sh. 2 OUT. FIELD
7,5A
F51
21 5 S2
Sh. 2 OUT. FIELD
918789-
Service Manual
30A
F52
23
Sh. 3
C C
40
Sh. 2
Y10
24 1 2 38 J2-2 OUT. LOWER VALVE
Sh. 2
K10
A1 A2 64 J2-4 OUT. MAIN CONTACTOR
D D
Y1
1 2 31 J2-5 OUT. BRAKE; A
K30
Date
A1 A2 45 J2-6 OUT. PUMP CONTACTOR
H1 S
2006-10-27
39 J2-7 OUT. SIGNAL HORN

- +
E E

235317-040
11.3.4 Detailed wiring diagram OSE120P
F F
Order number
1/8 PROD B
219442
1 2 3 4 5 6 7 8
© BT Europe AB
1 2 3 4 5 6 7 8
A1
A A
235317-040
119 119
Sh. 3 J2-1 CAN HIGH
Order number
© BT Europe AB
120 120
Sh. 3 J2-8 CAN LOW
X20 X23 X27 S21 X27 X23 X20 Y45
21 21 22 24 1 2 88
Sh. 1 J2-9 OUT. FORKS LIFT/LOWER VALVE
B10
Date
B 24 24 P 63 B
Sh. 1 4 J2-10 INP. LOAD WEIGHT
B C
A
2006-10-27
40
Sh. 1 3 CONTACT MAT
X26 S19 X26 X23 X19

1 (YE) (BN) 65
Sh. 1 J2-11 INP. DRIVER ON PLATFORM
Service Manual
S10
F X22 X22 X27 X23 X20
C (1) (2) 57 C
J2-12 INP. BRAKE
918789-
X20 X23 X27 X22 (3)
EXTERNAL EQUIPMENT S32

X30
(1) (2) 47
J2-13 INP. FORKS; <200MM
X31 (3)
D D
S12
X30
(1) (2) 48
J2-14 INP. FORKS; >500MM
(3)
S31
X31
(1) (2) 49
J2-15 INP. LIFT LIMIT
E (3) E
T-code
24
J2-16 INP. SUPPLY +24V DC
649, 783

2 /8 PROD B
F F
219442
1 2 3 4 5 6 7 8
11- 19
1 2 3 4 5 6 7 8
11- 20
T-code
A5 649, 783
A A
40 40
Sh. 2 4 7 POWER SUPPLY OV DC
40
15 POWER SUPPLY 0V DC
23 23
Sh. 1 8 POWER SUPPLY +24V DC
B 23 B
16 POWER SUPPLY +24V DC
119 119
Sh. 2 4 2 CAN HIGH
120 120
Sh. 2 4 10 CAN LOW
918789-
Service Manual

X22 X28 X23 X21
91
4 OUT. SUPPLY +5V DC M6
C C
RD
X22 X28 X23 X21 M
92
R2:A 5 INP. A_IN0
WH
BU
BU
X22 X28 X23 X21
93
R2:B 13 INP. A_IN1
GN
RD
X22 X28 X23 X21
94
14 OUT. SUPPLY 0V DC
D D
95
3 OUT. SUPPLY +12V DC
S65
(1) (2) 96
11
Date
INP. REFERENCE SWITCH
(3)
97
2006-10-27
E 20 20 E

235317-040
3 / 8 PROD B
F F
Order number
219442
1 2 3 4 5 6 7 8
© BT Europe AB
1 2 3 4 5 6 7 8

A A36 A
235317-040
X20
24 24
1 POWER SUPPLY 24VDC
Order number
Sh. 2 8
© BT Europe AB
S103
(1) (2) 86
5 INP. PLATFORM >500mm
(3)
X20
40
Sh. 3 5 CONTACT MAT
Date
B B
X23 X26 S214 X26 X23
(YE) (GN) 80
7 INP. FOOTSWITCH, LOWER PLATFORM
2006-10-27
Y69
1 2 89
16 OUT. PLATFORM, LIFT/LOWER VALVE
S107
(1) (2) 85
19 INP. PLATFORM LIFT LIMIT
Service Manual
(3)
C C
918789-
40
X21
119 119
Sh. 3 5 27 CAN HIGH
X21
D 120 120 D
Sh. 3 5 42 CAN LOW
E E
T-code
649, 783

4 / 8 PROD B
F F
219442
1 2 3 4 5 6 7 8
11- 21
11- 22
1 2 3 4 5 6 7 8 T-code
649, 783
A A

A2
X20 X23 X27 X22

20 20
Sh. 3 X3:6 INP. +24V DC
X20 X23 X27 X22

40 40
Sh. 4 X3:2 INP. OV DC

B B
X21 X23 X28 X22

119 119
Sh. 4 X3:7 CAN HIGH
X21 X23 X28 X22

120 120
Sh. 4 X3:3 CAN LOW
918789-
Service Manual

X41
C 1 20 C
A2:S1-S9 A2:S10-S18
2 40 SPEED REF. VALUE
3 119
A2:S21
4 120
MAN LIFT
A2:S22
24 MAN LOWER
DD Sh. 3 7 D

X29
Date
C 1 FORK LIFT
A2:S20
2 40
FORK LOWER
2006-10-27
3 119
EE E
4 120

235317-040
5 /8 PROD B
F F
Order number
219442
1 2 3 4 5 6 7 8
© BT Europe AB
1 2 3 4 5 6 7 8
A A
235317-040
Order number
© BT Europe AB
A6 A2
X1 1 X12 1 +5V DC
Date
B B
X1 2 X12 2 SI
2006-10-27
X1 3 X12 3 SCK
X1 4 X12 4 ENABLE
Service Manual
X1 5 X12 5 LCLK
C C
918789-
X1 6 X12 6 0V DC
S18:1
1 2
X4 1 INP. HORN 1
D D
S18:2
1 2
X1 1 INP. HORN 2
E E
T-code
649, 783

6 /8 PROD B
F F
219442
3 4 6 7 8
1 2 5
11- 23
11- 24
1 2 3 4 5 6 7 8 T-code
649, 783
A A
KEY BOARD ELECTRONIC CARD STEERING UNIT
A17 A2
X11 1 1 4 7 -
X11 2 2 5 8 0
B X11 3 3 6 9 # B
X11 4 1 2 3
918789-
X11 5 4 5 6
Service Manual
X11 6 7 8 9
C C
X11 7 - 0 #
X11 8 LED_GREEN
X11 9 LED_RED
D D
X11 10 0V DC
Date
2006-10-27
E E

235317-040
7/8 PROD B
Order number
F F
219442
1 2 3 4 5 6 7 8
© BT Europe AB
1 2 3 4 5 6 7 8 235317-040
A OPTION A
Order number
© BT Europe AB
A36
Date
X25 S218 X25 X24 S217 X24 S215 X24

24 1 2 74 1 2 71 3 4 70 33
Sh. 4 AUX SWITCH "GO/WALK"
B B
2006-10-27
S216 X25
3 4
LEFT; "LIFT"
S219 X24
3 4 72
Service Manual
20 AUX SWITCH; "LIFT FORKS"
RIGHT; "LIFT"
C C
918789-
S220 X25
3 4
LEFT; "LOWER"
S221 X24
3 4 73 6 AUX SWITCH; "LOWER FORKS"
RIGHT; "LOWER"
S222 X25
3 4
D D
71 34 AUX SWITCH; "STOP"
E E
T-code
649, 783

8/8 PROD B
F F
219442
1 2 3 4 5 6 7 8
11- 25
11- 26
T-code
1 2 3 4 5 6 7 8 649, 783
A A1 A
24V
3A
F50 X1 G1 X1
20 + - 40
160A
R1 F1
2 3
PTC 15
125A
F3 M3 M1
2 1 9 2 1 10 A1 A2 A1 A2 6
M M M OUT. ARMATURE
B S
B
4 3 E1 E2 4
S1 OUT. FIELD
7,5A
F51
21 5
Sh. 2 S2 OUT. FIELD
918789-
Service Manual
30A
F52
23
Sh. 3
C 40 C
Sh. 2
BRAKE SWITCH
S10
X20 X22 X22 X20
24 Bn Bk 57
Sh. 2 J2-12 INP. BRAKE
Bu
X20 X22
K10
A1 A2 64
D D
Y1
1 2 31
J2-5 OUT. BRAKE; A
Date
K30
A1 A2 45
H1
2006-10-27
S
39
- +
E E
Y41

1 2 38
J2-2 OUT. FORK LOWER VALVE
11.3.5 Detailed wiring diagram OSE250
235317-040
F F
Order number
1 / 6 PROD D
200036
1 2 3 4 5 6 7 8
© BT Europe AB
1 2 3 4 5 6 7 8
A A1 A
235317-040
119 119
Order number
Sh. 3 J2-1 CAN HIGH
© BT Europe AB
120 120
Sh. 3 J2-8 CAN LOW
PRESSURE SENSOR
Date

B B10 B
X20 S21 X20
21 21 22 24 P 63
Sh. 1 J2-10 INP. LOAD WEIGHT
B C
2006-10-27
40
Sh. 1 3
Service Manual
PLATFORM SWITCH
S19
C 1(BN) 2(BK) 65 C
J2-11 INP. DRIVER ON PLATFORM
918789-
3(BU)
FORKS < 225mm
S31
1(BN) 2(BK) 49
D D
3(BU)
24 24
Sh. 1 J2-16 INP. SUPPLY +24V DC
E E
T-code
649, 783

F F
2 / 6 PROD D
200036
1 2 3 4 5 6 7 8
11- 27
11- 28
1 2 3 4 5 6 7 8 T-code
ELECTRONIC ASSY; STEER SERVO 649, 783
A5
A A
40 40
40
23 23
B 23 B
119 119
Sh. 2 4 2 CAN HIGH
120 120
Sh. 2 4 10 CAN LOW
918789-
Service Manual

X22 X21
91
C C
RD
X22 X21 M
92
R2:A 5 INP. A_IN0
WH
BU
BU
X22 X21
93
R2:B 13 INP. A_IN1
GN
RD
X22 X21
94
D D
STEER ANGLE REF. SWITCH
95
S65
BN BK 96
Date
11 INP. REFERENCE SWITH
BU
97
2006-10-27
E 20 20 E

235317-040
F F
Order number
3 / 6 PROD D
200036
1 2 3 4 5 6 7 8
© BT Europe AB
1 2 3 4 5 6 7 8 235317-040
A A
Order number
© BT Europe AB
A2
X20 X22
20 20
Sh. 3 X3:6 INP. +24V DC
X21 X22
Date
119 119
Sh. 3 X3:7 CAN HIGH
B B
X21 X22
120 120
2006-10-27
Sh. 3 X3:3 CAN LOW
X20 X22
40 40
Service Manual
X41
C 1 20 C
918789-
A2:S1-S9 A2:S10-S18
2 40 SPEED REF. VALUE
3 119
A2:S21
4 120 MAN LIFT
A2:S22
MAN LOWER
D D
24
Sh. 2
A2:S19
FORK LIFT

X29
FORK LOWER
1 24
E 2 40 E
T-code
649, 783

3 119
4 120
F F
4 / 6 PROD D
200036
1 2 3 4 5 6 7 8
11- 29
11- 30
1 2 3 4 5 6 7 8 T-code
649, 783
A A

A6 A2
X1 1 X12 1 +5V DC
B X1 2 X12 2 SI
B
X1 3 X12 3 SCK
8 8 8 8
X1 4 X12 4 ENABLE
918789-
Service Manual
X1 5 X12 5 LCLK
C C
X1 6 X12 6 0V DC
S18:1
1 2
X4 1 INP. HORN 1
D D
S18:2
1 2
X1 1 INP. HORN 2
Date
2006-10-27
E E

235317-040
F 5 / 6 PROD D F
Order number
200036
1 2 3 4 5 6 7 8
© BT Europe AB
235317-040 2006-10-27 918789- 649, 783
D
A
F
6 / 6 PROD D
8
8
200036
LED_GREEN
7
7
LED_RED
2580
369#
0V DC
147-
123
456
789
-0#
X11 10
X11 1
X11 2
X11 3
X11 4
X11 5
X11 6
X11 7
X11 8
X11 9
A2
6
6
5
5
4
4
3
6
9
I
2
5
8
0
3
3
O
1
4
7
KEY BOARD
A17
2
2
1
1
C
D
A

11- 32
T-code
1 2 3 4 5 6 7 8
649, 783
A A1 A
3A 24V
F50 X1 G1 X1
20 + - 40
160A
R1 F1
2 3
PTC 15~E
125A
F3 M3 M1
2 1 9 2 1 10 A1 A2 A1 A2 6
M M M OUT. ARMATURE
B S
B
4 3 E1 E2 4
S1 OUT. FIELD
7,5A
F51
21 5
Sh. 2 S2 OUT. FIELD
30A
918789-
Service Manual
F52
23
Sh. 3
C 40 C
Sh. 2
Y10
24 1 2 38
Sh. 2 J2-2 OUT. LOWER VALVE
K10
A1 A2 64
Y1
1 2 31
J2-5 OUT. BRAKE; A
D D
K30
A1 A2 45
Date
H1 S
39
- +
2006-10-27
E E

235317-040
11.3.6 Detailed wiring diagram OSE250P
F 1 / 7 PROD B F
Order number
214570
1 2 3 4 5 6 7 8
© BT Europe AB
1 2 3 4 5 6 7 8
A A1 A
235317-040
119 119
J2-1 CAN HIGH
Order number
Sh. 3
© BT Europe AB
120 120
Sh. 3 J2-8 CAN LOW
X20 X23 X27 S21 X27 X23 X20 Y45
21 21 22 24 1 2 88
Sh. 1 J2-9 OUT. FORKS LIFT/LOWER VALVE
Date
B B10 B
24 24 P 63
Sh. 1 4 J2-10 INP. LOAD WEIGHT
B C
A
2006-10-27
40
Sh. 1 3 CONTACT MAT
X26 S19 X26 X23 X19

(YE) (BN) 65
J2-11 INP. DRIVER ON PLATFORM
Service Manual
C C
918789-
S10
X22 X22 X27 X23 X20
(BN) (BK) 57
J2-12 INP. BRAKE
X20 X23 X27 X22
(BU)
D D
S31
(BN) (BK) 49
(BU)
E E
T-code
24
J2-16 INP. SUPPLY +24V DC
649, 783

2 / 7 PROD B F
214570
1 2 3 4 5 6 7 8
11- 33
11- 34
1 2 3 4 5 6 7 8 T-code
A5
649, 783
A A
40 40
40
23 23
B 23 B
119 119
Sh. 2 4 2 CAN HIGH
120 120
Sh. 2 4 10 CAN LOW
918789-
Service Manual

X22 X28 X23 X21
91
C C
RD
X22 X28 X23 X21 M
92
R2:A 5 INP. A_IN0
WH
BU
BU
X22 X28 X23 X21
93
R2:B 13 INP. A_IN1
GN
RD
X22 X28 X23 X21
94
D D
95
S65
(BN) (BK) 96
Date
11 INP. REFERENCE SWITH
(BU)
97
2006-10-27
E 20 20 E

235317-040
F F
Order number
3 / 7 PROD B
214570
1 2 3 4 5 6 7 8
© BT Europe AB
1 2 3 4 5 6 7 8

A A36 A
235317-040
X20
Order number
24 24
Sh. 2 5 1 POWER SUPPLY 24VDC
© BT Europe AB
S103
(BN) (BK) 86
5 INP. PLATFORM >500mm
X20
(BU)
40
Sh. 3 5 CONTACT MAT
Date
B X23 X26 S214 X26 X23

B
(YE) (GN) 80
7 INP. FOOTSWITCH, LOWER PLATFORM
2006-10-27
Y69
1 2 89
16 OUT. PLATFORM, LIFT/LOWER VALVE
S107
(BN) (BK) 85
19 INP. PLATFORM LIFT LIMIT
Service Manual
(BU)
C C
918789-
40
OPTION
X25 S218 X25 X24 S217 X24 S215 X24
1 2 74 1 2 71 3 4 70
33 AUX SWITCH; "GO/WALK"
D D

S216 X25
3 4
71
34 AUX SWITCH; "STOP"
X21
119 119
Sh. 3 5 27 CAN, HIGH
E E
T-code
X21
120 120
649, 783

Sh. 3 5 42 CAN, LOW
F 4 / 7 PROD B F
214570
1 2 3 4 5 6 7 8
11- 35
11- 36
1 2 3 4 5 6 7 8 T-code
649, 783
A A

A2
X20 X23 X27 X22

20 20
Sh. 3 X3:6 INP. +24V DC
X21 X23 X28 X22

119 119
Sh. 4 X3:7 CAN HIGH
B B
X21 X23 X28 X22
120 120
Sh. 4 X3:3 CAN LOW
X20 X23 X27 X22

40 40
918789-
Service Manual

X41
1
C 20 C
2 A2:S1-S9 A2:S10-S18
40 SPEED REF. VALUE
3
119
A2:S21
4
120 MAN LIFT
A2:S22
MAN LOWER
D D
A2:S19
Date
FORK LIFT
A2:S20
FORK LOWER
2006-10-27
E E

235317-040
F 5 / 7 PROD B F
Order number
214570
1 2 3 4 5 6 7 8
© BT Europe AB
1 2 3 4 5 6 7 8
A A
235317-040
Order number
© BT Europe AB
A6 A2
X1 1 X12 1 +5V DC
Date
B X1 2 X12 2 SI
B
2006-10-27
X1 3 X12 3 SCK
8 8 8 8
X1 4 X12 4 ENABLE
Service Manual
X1 5 X12 5 LCLK
C C
918789-
X1 6 X12 6 0V DC
S18:1
1 2
X4 1 INP. HORN 1
D D
S18:2
1 2
X1 1 INP. HORN 2
E E
T-code
649, 783

F 6 / 7 PROD B F
214570
1 2 3 4 5 6 7 8
11- 37
649, 783 918789- 2006-10-27 235317-040
D
A
F
7 / 7 PROD B
8
8
214570
LED_GREEN
7
7
LED_RED
2580
369#
0V DC
147-
123
456
789
-0#
X11 10
X11 1
X11 2
X11 3
X11 4
X11 5
X11 6
X11 7
X11 8
X11 9
A2
6
6
5
5
4
4
3
6
9
I
2
5
8
0
3
3
1
4
8
KEY BOARD
A17
2
2
1
1
C
D
A

Functional description
235317-040 2006-10-27 918789- 649, 783
11.4 Functional description
means constantly on means flashing.

This section gives basic electrical descriptions of the truck’s main func-
tions in tabular form. It describes, in simple terms, what happens when
performing any of the truck’s main operations.
• Event - The main stages in performing any of the truck’s main func-
tions are referred to as “Events”. Each event is numbered.
• Preceding event - Indicates the event number which must have tak-
en place immediately before in order for the current event to function
correctly.
• Action(s) - A required action from the operator for the event to occur
• Influencing elements - conditions which must be fulfilled in order for
the event to occur. Certain parameter settings may also affect the
outcome of the event.
• Resulting conditions - Describes key occurrences which can be
checked to confirm that a function operates correctly.
• Logic - Shows the logic relationship between inputs and outputs re-
lating to a specific event
Note that “resulting conditions” show what is expected when no error
conditions are present.
Table 10: Functional description

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

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

conditions

649, 783 918789- 2006-10-27 235317-040

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

elements Brake sensor not activated [S10]
Input [A1:INP BRAKE] is {low}
Resulting
conditions Power lamp lights. Main display shows hour meter reading
and for 4 seconds followed by battery condition as a
percentage of full charge and [A6]

Mechanical brake remains on [Y1, A1:OUT.BRAKE A high]
Logic
S10
1
A2
+ -
G1
R1
K10 No error=1 &
&
F51
PIN ok
A17
S21 =1
A1

235317-040 2006-10-27 918789- 649, 783

Event: 3. Tiller unit lowered for driving
Preceding event 2
Action(s) Lower tiller unit handle
Influencing Man-on platform switch [S19]

elements Brake sensor [S10]
Resulting Brake sensor activated [S10].

conditions Input [A1:INP BRAKE] goes {high}
Output [A1:OUT.MAIN CONTACTOR] goes {low}
Main contactor closes [K10]
Logic
A2
A1 A1
S19 P23,1/3/5/7
&
S10
>1
+ -
G1
R1
K10 &
F51 P23,0/2/4/6
S21
K10

649, 783 918789- 2006-10-27 235317-040

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

elements Presence control [S19], Load sensor [B10]
Load > 500mm [S12], Platform sensor > 500 mm [S103]
Steering angle, Parameter settings. See Speed limitation on page 53
Resulting [A1:OUT.BRAKE A] goes {low}

conditions Brake coil [Y1] energises, mechanical brake releases
Current fed to traction motor field winding (S2 +ve and S1 -ve)
Pulsed current fed to traction motor armature proportional to butterfly
deflection
Logic
F1
A2
A1 A1
M1
L1 A1
M
A2
S19 A2:S1-9
Hall
E1 S E2
S12 P1
P3
B10 P P5
P6
A36
S103 L1>0%
1 Y1

235317-040 2006-10-27 918789- 649, 783

Event: 5. Traction, drive wheel first
Preceding event 3
Action(s) Move butterfly [L1]in drive wheel drive direction.
Influencing Butterfly Hall sensors [A2:S10-18]

elements Presence control [S19], Load > 500 mm [S12]
Platform sensor > 500 mm [S103],
Load detector [B10], Steering angle, Parameter settings
See Speed limitation on page 53

conditions Brake coil [Y1] energises, mechanical brake releases
Current fed to traction motor field winding (S1 -ve and S2 +ve)
Pulsed current fed to traction motor armature proportional to butterfly
deflection
Logic
F1
A2
A1 A1
M1
L1 A1
M
A2
S19 A2:S10-S18
Hall
E1 S E2
S12 P2
P3
B10 P P5
P6
A36
S103 L1>0%
1 Y1

649, 783 918789- 2006-10-27 235317-040

Event: 6. Neutral braking
Preceding event 4 or 5
Action(s) Let butterfly [L1] return to neutral position.

elements Load detector [B10]
Parameter settings
Resulting Traction motor [M1] acts as generator and via transistor controller [A1] con-
conditions verts the trucks energy of motion into electrical energy thus reducing the
truck’s speed. The excess electrical energy is fed back to the battery help-
ing to recharge it [G1].
The mechanical brake [Y1, A1:OUT.BRAKE A] activates when the truck
comes to a complete stand still
Logic
F1 K10 G1
+ -
A2 A1
P4
A1
& M1
>1
S19 1 A1
M
A2
& S
E1 E2
P7
L1
A2:S1-S18
Hall
P
B10
L1>0%
1 Y1

235317-040 2006-10-27 918789- 649, 783

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

elements Load detector [B10]
Parameter settings
Resulting Traction motor [M1] acts as generator and via transistor controller [A1] con-
conditions verts the trucks energy of motion into electrical energy thus reducing the
truck’s speed. The excess electrical energy is fed back to the battery help-
ing to recharge it [G1]. The braking effect increases the more the butterfly
is deflected The mechanical brake [Y1, A1:OUT.BRAKE A] activates when
the truck comes to a complete stand still
Logic
F1 K10 G1
+ -
A2 A1
A1 P11 M1
& >1
S19 IBRAKE A1
M
A2
1
S
& E1 E2
L1
A2:S1-S18
Hall
850kg=2.3V IBRAKEmax=170A
P if
B10 Load < 850kg
L1>0%
1 Y1

649, 783 918789- 2006-10-27 235317-040

Event: 8. Mechanical brake operation
Action(s) Move tiller unit handle to upper position
Influencing Brake sensor deactivated [S10]

elements Input [A1:INP BRAKE] goes {low}

conditions Brake coil [Y1] deactivated, mechanical brake applied
Logic
A1 A2 A1
S10 1 Y1
Event: 9. Steering
Preceding event 2
Action(s) Steer tiller unit handle to left or right
Influencing Steering angle potentiometer [R2]

elements Steering reference switch [S65, A5:INP.REFERENCE SWITCH]
Man on platform switch [S19, A1:INP.DRIVER ON PLATFORM]
Parameter settings
Resulting Steer servo motor positions drive wheel according to tiller handle’s deflec-
conditions tion [A5, M6]
Logic
A5 A2
12V
S65
U V W + H H H - P36
0V
5V P37
R2
0V

235317-040 2006-10-27 918789- 649, 783

Event: 10. Fork lifting
Preceding event 2
Action(s) Depress the fork lift button [A2:S19]
Influencing Forks lift button [A2:S19]

elements Battery status ok (>20% charge left)
Lift height limit S31 [A1:INP.LIFT LIMIT] not activated
Resulting [A1: OUT. FORKS LIFT/LOWER VALVE] goes {low}

conditions Valve coil [Y45] activated, the valve opens
[A1:OUT.PUMP CONTACTOR] goes {low}
Pump contactor [K30] activates
Pump motor [M3] starts
Logic
A2:S19
Hall
K30
& A1
S31 >1
A1 batt.>20% Y45
=0

649, 783 918789- 2006-10-27 235317-040

Event: 11. Fork lowering
Preceding event 10
Action(s) Depress the fork lowering button [A2:S20].
Influencing Forks lower button [A2:S20]

elements Man on platform switch [S19, A1:INP.DRIVER ON PLATFORM]
Sensor - Forks <200 mm [S32,A1:INP FORKS <200MM]
Influencing Forks lower button [A2:S20]

Resulting [A1:OUT.LOWER VALVE] goes {low}

conditions Magnetic valve - fork lowering [Y10] activated
[A1:OUT FORKS LIFT/LOWER VALVE] goes {low}
Valve coil [Y45] activated
Logic
A2:S20 A2
Hall
Y10
S19 &
>1
Y45
S32 &

235317-040 2006-10-27 918789- 649, 783

Event: 12. Platform lifting (OSE120P, OSE250P)
Preceding event 2
Action(s) Depress the platform lift button [A2:S21].
Influencing Platform lift button [A2:S21]

Sensor for platform lift limiter [S107,A36:INP. PLATFORM LIFT LIMIT]
Resulting [A36:OUT.PLATFORM LIFT/LOWER VALVE] goes {low}

conditions Valve coil [Y69] activated
[A1:OUT.PUMP CONTACTOR] goes {low}
Pump contactor [K30] activates
Pump motor [M3] starts
Logic
A2:S21
Hall A2 K30
A1
&
>1
S107
A36 batt.>20% Y69
=0
S19 A36
A1

649, 783 918789- 2006-10-27 235317-040

Event: 13. Platform lowering (OSE120P, OSE250P)
Preceding event 12
Action(s) Depress the platform lowering button [A2:S22] or the foot switch [S214]
Influencing Platform lowering button [A2:S22] / foot switch [S214]

Resulting [A36:OUT.PLATFORM LIFT/LOWER VALVE] goes {low}

conditions Valve coil [Y69] activated
[A1:OUT.LOWER VALVE] goes {low}
Magnetic valve - fork lowering [Y10] activated
Logic
A2:S22
Hall
A2
S214 Y10
>1
& A1
A36
Y69
S19
A36
A1

235317-040 2006-10-27 918789- 649, 783
11.4.1 Description of the steering servo

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

649, 783 918789- 2006-10-27 235317-040
11.4.2 Spider expansion unit (SEU)

The Spider expansion unit ,referred to as the SEU, allows the main con-
trol card to handle a greater number of inputs & outputs. The SEU
allows up to 8 extra digital inputs and 4 digital outputs which can be
addressed and controlled via the CAN bus. The SEU contains firmware
but this is only for internal configuration. No truck control logic is
present in the SEU. This means a faulty SEU can be exchanged with-
out affecting the truck’s functions in any way.
There are 3 cases covering the usage of SEU:
a) The SEU can be fitted if the truck is modified according to a customer
special request. In this case, correct operation of the modification is
acheived by adjustment of service parameters 16 to 19.
b) The SEU is fitted as standard in certain truck models, to allow control
of standard features. Such trucks do not require that service parame-
ters 16 to 19 be activated. (parameters 16 to 19 shall be set to “0”.)
c) Trucks fitted with an SEU as standard can also have additional mod-
ifications using “configurable options”. These additional modifications
are controlled by the setting of service parameters 16 to 19.
Refer to section Parameter #16 to #19 Configurable options on page 78
for more detailed information.
Fig. 6 shows how the SEU is used to allow a greater number of functions
to be controlled via the CAN bus. The SEU has one 42-pin multipin con-
nector which handles all inputs, outputs, CAN and supply signals.
A2
Electronic
card
TLS
A36 Extra / Customised
A5 SEU function(s)
Steer servo
CAN bus
A3
Pump
controller
X41
CAN service
connector
A1
Traction
controller
Fig. 6 Connection architecture for SEU

235317-040 2006-10-27 918789- 649, 783
11.4.3 Speed limitation

The truck's maximum travel speed is limited depending on a combina-
tion of factors, i.e. direction of travel, load, load lift height, steering angle,
the operator's driving position and the platform height. Operator param-
eter settings also affect maximum speed. See Description of operator
parameters on page 63 for more information. The table below summa-
rises the speed limitations and assumes that all relevant operator
parameters are set to 100%. Note that the speeds given are nominal.
Table 11: Summary of speed limitations

OSE120, OSE120P
Lift height, Platform Operator posi- Steer angle Maximum speed km/h Inf
load [S12] height tion and load degrees .
In drive In forks
[S103] (kg) [S19] &
wheel di- direc-
[B10]
rection tion
< 0.5 m < 0.5 m On platform & 0 kg 0 12 10.5
load
15 12 10
25 11 9.6
60 8.7 7.6
85 7 6
On platform and >0 0 12 - 8 10.5 - 6.5
to maximum load
15 12 - 8 10 - 6.5
25 11 - 8 9.6 - 6.5
60 8-7 7.6 - 5
85 7-5 6-5
> 0.5 m 0 to max. On platform and 0 to 100 6 6
height load < 700
On platform and 6 - 2.5 6 - 2.5
load 700 kg
to maximum load
0 to max. > 0.5 m On platform and 6 6 2.3
height load < 700
On platform and 6 - 2.5 6 - 2.5
load 700 kg
to maximum load
0 to max. < 0.5 m By side of truck 0 to 10 6 6 1
height and 0 to maximum
load 20 to 30 2.5 2.5
>30 0 0

649, 783 918789- 2006-10-27 235317-040
Table 11: Summary of speed limitations

OSE250, OSE250P
Platform height Operator posi- Steer angle Maximum speed km/h Inf
tion and load degrees .
(kg) In drive In forks
wheel di- direc-
rection tion
< 0,5 m On platform & 0 kg 0 12 10.5
load
15 12 10
25 11 9.6
60 8.7 7.6
85 7 6
On platform and >0 0 12-8 10.5-6.5
to maximum load
15 12-8 10-6.5
85 7-5 6-5
0 to max. height On platform and 0 till 100 6 6 2,3
load < 500kg
On platform and 6-2.5 6-2.5
load 500kg
to maximum load
< 0,5 m By side of truck 0 till 10 6 6 1
and 0 to maximum
load 20 till 30 2.5 2.5
>30 0 0
1. In this position, is displayed.
2. In this position, is displayed.

3. If the operator is not standing on the platform in this posi-
tion, is displayed. Neither lifting nor truck travel can

be operated in this case.

235317-040 2006-10-27 918789- 649, 783
11.4.4 Hour meter and battery condition

Upon switch-on, the hour meter is displayed and the hour meter symbol
lights for 4 seconds. Fig. 7
The display will then change to show the battery’s remaining capacity
Fig. 7 expressed as a percentage of full charge and the battery symbol lights.
Fig. 8
The truck’s control system stores 5 different elapsed time values in
units of hours. The time value normally shown depends on the setting
of service parameter #20. (See # 20 - Hour meter selection on page
69). However, any of these time values can be temporarily displayed on
the hour meter. To choose which value to display carry out the following
procedure:
Fig. 8
• Ensure the battery is connected.
• Ensure the truck is switched off. Press on the keypad.

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

• Hold [S18] depressed until “H” is displayed, then release [S18]. Fig.
9
Hour meter symbol lights.

Fig. 9
The different hour meter modes are displayed by repeatedly operating
speed control [L1]. The actual time value will be displayed momentar-
ily after the mode is selected.
Table 12: Hour meter modes

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

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

(Parameter #25 controls the initial value) See # 25 - Service interval on page
71 for more information.

649, 783 918789- 2006-10-27 235317-040
11.4.5 TLS - Truck log system (optional)

General
The truck log system, which is CAN based, is either an integrated sys-
tem (SD16) or a freestanding supplementary system (S16). A collision
sensor can also be connected.
The TLS communicates wirelessly with a base station (RG3) once the
truck is within range. The base station then receives information on
what the truck has done since they last communicated with one anoth-
er.
Built-in system PC
A2 RG3
Electronic card
Add-on system
CAN bus
TLS SD16
TLS S16
CAN bus
Shock sensor
Shock sensor
A1
Traction controller I/O-unit
Registration
To register the truck with the base station, follow the instructions below:
• Position the truck close to the base station.
• Press and hold the green button for approx. 5-10 seconds until
three LEDs on the base station start flashing at the same time.
The base station can now communicate with the truck whenever it is
within range.
Logging in/out SD16

Logging in and out is performed as usual via the keyboard on the han-
dle (or by using an ID unit). The difference is that communication pass-
es through the TLS, which makes all the decisions.
Logging in/out S16

Logging in and out is performed using the keyboard on the TLS.

235317-040 2006-10-27 918789- 649, 783
Collision sensor
If there is a collision sensor installed on the CAN bus, it registers when
the truck bumps into something. If the impact exceeds a certain level, it
is classified as a collision and the truck comes to a halt. It can be reset
by entering the PIN code for “resetting the collision sensor” (see table
below).
Settings
Additional equipment (software and wiring) from Davis Derby is
required to change the TLS settings.
Table 13: Settings TLS

Function Description Default setting
PIN code PIN code for different driver pro- 00001 (profile 1)
files. 00002 (profile 2)
00003 (profile 3)
11111 (resetting the collision sensor)
Logoff time Time in minutes (1-254) that the 255 (not switched off)
truck is inactive before it is
switched off.
Impact level Determines how sensitive the 5 % (sideways)
truck is to an impact. 5 % (forwards/backwards)
Department Only applies when ID unit is 14
installed.
Type of truck Only applies when ID unit is 16
installed.
11.4.6 ID unit (optional)

See the separate manual that is included with the software.

Parameters & adjustments
649, 783 918789- 2006-10-27 235317-040
11.5 Parameters & adjustments
11.5.1 General
The truck’s control system stores a number of parameters. These
parameters are used to configure the truck for correct operation in the
particular application for which it was designed. The parameters are
divided into two groups, Operator parameters and Service parameters.
• Operator parameters (1 to 9) - These parameters are used to tailor
the driving characteristics of a truck for a specific operator or opera-
tion. A maximum of 10 operator parameter sets, so called operator
profiles, can be stored in a truck. Operator parameters can be ad-
justed directly without the requirement for a suitable CAN service
key.1
• Service parameters (10 to 40) - These parameters are used to tai-
lor the truck’s performance / operation characteristics and include all
other parameters not designated as operator parameters. Service
parameters can ONLY be adjusted when a suitable CAN service key
is plugged into the truck.2
11.5.2 Displaying parameters - without the

CAN service key
Proceed as follows to display parameters when a CAN service key is
not connected:

PIN code and then press on the keypad.

• Hold [S18] depressed until “P” is displayed, then release [S18]. Fig.
10
Parameters symbol lights.

Fig. 10
The different parameters are now displayed by repeatedly operating
speed control [L1]. Operator parameters can be both viewed and
changed.1
1.Operator parameters can only be set without a CAN key if parame-

ter #39 is set to value “1”, “3”, ”5”, “7”, “9” or “11”. See # 39 - Log-in
method & operator parameter access on page 73.
2.Service parameters can be viewed without a CAN key being
plugged in but they cannot be adjusted.

235317-040 2006-10-27 918789- 649, 783
11.5.3 Adjusting operator parameters -

without the CAN service key
NOTE!
Operator parameters can only be set without a CAN key if parameter
#39 is set to value “1”, “3”, ”5”, “7”, “9” or “11”. See # 39 - Log-in
method & operator parameter access on page 73.
To change the value of a particular operator parameter carry out the fol-
lowing:
• Switch on the truck and log in with the appropriate PIN-code. This is
important if the truck has more than one set of Operator parameters
active . Any changes made will only be in effect when that particular
“operator” is logged in.
• Select the required parameter.
• Press Horn button [S18].
Parameter symbol flashes.
• Set parameter value by repeatedly operating speed control [L1] up

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

You have now completed a parameter change and the next time you
start the truck the new parameter setting will be valid.
For detailed descriptions and effects of these parameters, see the sec-
tion Description of operator parameters on page 63

649, 783 918789- 2006-10-27 235317-040
11.5.4 Displaying & changing parameters -

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

• Press and hold horn button [S18] for at least 1 second and then
press on the keypad.

• Hold [S18] depressed until “P” is displayed, then release [S18]. Fig.
11
Fig. 11
When pressing the speed control [L1] forwards repeatedly, the first
operator profile will be displayed. Continue to press [L1] in the forward
direction and the next operator profile will be displayed (operator no. 2),
etc. until the last operator (operator no. 10). See Fig. 12
Operator parameter no.
Once the 10 operator profile have been displayed, the truck service
Profile no.
parameters will be displayed as [L1] is repeatedly pressed in the for-
Fig. 12 ward direction.

235317-040 2006-10-27 918789- 649, 783
Changing a parameter
• Select the required parameter.
• Set the parameter value by repeatedly operating speed control [L1]

up or down

You have now completed a parameter change and the next time you
start the truck the new parameter setting will be valid.
The truck’s service parameters can be displayed first by operating
speed control [L1] in the backward direction. This will cause parameter
#40 to be displayed and then parameter #39 etc.1
For detailed descriptions and effects of these parameters see the sec-
tion List of Service parameters on page 64.
NOTE!
Truck handling.
Modifying specific truck parameters will change the driving charac-
teristics of the truck.
Do not change any parameters without the necessary know how.
1.Certain parameters numbers displayed are not active in this truck

model.

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11.5.5 List of Operator parameters

NOTE!
Before changing any parameters, ensure you have read and under-
stood the procedures for viewing and setting parameters in the sec-
tions Displaying parameters - without the CAN service key on page 58
and Changing a parameter on page 61.
See also section Speed limitation on page 53 for information regarding
the maximum speeds of the truck.
Table 14: List of Operator parameters

Param Name Unit Min. Max. Step Std. Note
eter
01 Speed, Fork direc- % 30 100 5 80 30:lowest Speed
tion 100:highest Speed
02 Speed, Drive % 30 100 5 100 30:lowest Speed
wheel direction 100:highest Speed.
03 Acceleration % 10 100 5 80 10:lowest accelera-
tion
100:full accelera-
tion
04 Neutral braking % 40 100 5 80 40: lowest reduction
effect force
100: highest reduc-
tion force
05 Travel speed, plat- % 0 100 10 100 0: travel distance
form > 0.5 metre 100: 6 km/h
06 Speed -Walking at % 40 100 5 70 40:lowest Speed
side 100:highest Speed.
07 Neutral braking % 60 100 5 90 60:reduction force
effect - Walking at 100:highest reduc-
side tion force

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11.5.6 Description of operator parameters

#1 - Speed, Fork direction
Allows for adjustment of the maximum speed of the truck in the fork
direction.
# 2 - Speed, Drive wheel direction

Allows for adjustment of the maximum speed of the truck in the drive
wheel direction.
# 3 - Acceleration
The lower the value of the parameter the longer it takes to accelerate
the truck to maximum speed.
# 4 - Neutral braking force

Defines motor brake force when lever [L1] returns to the neutral posi-
tion. The lower the value of parameter the longer it takes to reduce
speed.
# 5 - Travel speed, platform > 0.5 m

Adjusts the truck's max. speed when the platform is lifted above 0.5
metre. The value 0 switches off truck travel. The value 100 allows 6 km/
h travel speed with the platform lifted above 0.5 metre.
# 6 - Travel speed, walking at side

Allows for adjustment of the maximum speed of the truck when the
operator is not standing on the platform, i.e. when the operator is walk-
ing along side the truck.
# 7 - Neutral braking, walking at side

Defines the motor brake force when lever [L1] returns to the neutral
position and the operator dismounts the truck and walks by the side of
the truck. The lower the value of parameter the longer it takes to reduce
speed.

649, 783 918789- 2006-10-27 235317-040
11.5.7 List of Service parameters

NOTE!
Before changing any parameters, ensure you have read and under-
stood the procedures for viewing and setting parameters in the sec-
tions Displaying & changing parameters - CAN service key connected
on page 60 and Changing a parameter on page 61.
The CAN service key must be connected to the external CAN connec-
tor [X41] before adjusting any Service parameters
Table 15: List of Service parameters

Parame- Name Unit Min. Max. Step Std Note
ter .
10 PIN-code - 0 9999 1 1 PIN code assignment.
NOTE! Not applicable if
Parameter #39 has been
set to the value 5, 6, 7 or 8.
11 Reversing % 50 100 5 100 50: lowest reduction force
brake force 100: highest reduction force
14 Creep % -10 10 1 0 This defines how much out-
speed put the controller gives
when you reach the first
speed sensor.
-10 : lower speed.
10:higher speed
15 Non-config- See “11.5.9 Configurable “Option” Parameters” on page 77, Service
urable Manual
options 0 to
9
16 Configura- See “11.5.9 Configurable “Option” Parameters” on page 77, Service
ble option Manual
#1
17 Configura-
ble option
#2
18 Configura-
ble option
#3
19 Configura-
ble option
#4
20 Hour meter - 1 5 1 2 Select which hour meter is
selection normally displayed
21 Battery size - 1 20 1 10 Selects the battery size
22 Machine - 0 5 1 0 Sets the machine type
type

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Table 15: List of Service parameters

Parame- Name Unit Min. Max. Step Std Note
ter .
23 Function - 0 7 1 0 Enables selection of various
selection functions
24 Special - 0 2 1 0 Special request (requires
request special identification plates)
25 Service h 0 2000 50 0 Setting of service interval
interval timer.
28 Button - 1 3 1 1 Button selection
selector
35 Automatic min 0 20 1 10 Time interval for automatic
log-out log-out 0=4h
36 Calibrate - 0 2 1 0 Performs calibration of
steer servo steer servo
37 Steering - -300 300 1 0 Fine adjustment of steering
offset (zero)
-300:30 deg. left
300:30 deg. right
39 Log-in 1 12 1 3 Defines the active log-in
method & method and whether the
operator operator has access to the
parameter operator parameter set-
access tings.
11.5.8 Description of Service parameter

# 10 - PIN code
NOTE!
The functionality of parameter #10 is ignored if the value of parameter
#39 has been set to 5, 6, 7 or 8. PIN code input is facilitated via the ex-
tended keypad. For detailed information, see the section Extended
keypad - General on page 74.
This parameter stores the active PIN-codes for the truck. The truck can
store a maximum of ten operator profiles. The operator profile is acti-
vated when the operator logs in with the assigned PIN code. Logging in
with a specific PIN code when the truck is started will activate the oper-
ator profile to which this PIN code has been assigned. This allows up to
ten operators to individually adjust the characteristics of the truck.
On delivery the truck has one default PIN-code stored which is “1“.

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To enter a new PIN-code:

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

• Press horn button [S18]
The new PIN-code has now been entered.
To remove an existing PIN-code:

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

• Press horn button [S18].
The selected PIN-code has now been removed.

To check whether a PIN-code will start the truck follow the procedure in
2. Switch on (PIN-code entry) on page 27.
Parameter #10 cannot be displayed without the CAN service key.
1.Operating L1 lightly will step the value in increments of 1.

Operating L1 fully will step the value in increments of 100
Valid values are 1 to 9999

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# 11 - Reverse braking force

Determines the amount of motor braking when the speed control [L1] is
operated opposite the travel direction. The lower the parameter value,
the longer time it will take to slow down for a given degree of actuation
of [L1].
# 14 - Creep speed
This parameter allows adjustment of the initial speed when the first Hall
sensor is activated in the speed control [L1].
# 15 - Non-configurable options
See Service Manual.
Up to 16 so called sub-parameters are stored and accessed via param-
eter #15. These options are either switched ON or switched OFF and
require no other adjustments. They are therefore called non-configura-
ble options. The number of available options is dependant on the truck
type. Consult table Parameter #15 Non-configurable options on page
68 for available options.
Setting Non-configurable options

• Ensure the truck is in the parameter mode.
The parameters symbol lights.
• Select parameter #15 using [L1].

The first sub-parameter will be displayed
Continued operation of the speed control [L1] will display the next sub-
parameter. Note also that only relevant sub-parameters will be dis-
played.
After 1 second the value of the sub-parameter will be displayed.

• Press horn button [S18].
• Set the sub-parameter value by repeatedly operating speed control

[L1] up or down. See Table 20: for details.
• Press horn button [S18] once to confirm the new setting.
The parameters symbol lights. (stops flashing).

649, 783 918789- 2006-10-27 235317-040

The non-configurable option will now be activated.
• Ensure the option operates correctly before returning the truck for
normal use.
P
Table 16: Parameter #15 Non-configurable options

Option name Value NOTE!
Sub-parameter No.
Default setting
Function OFF
Function ON
1 to 9 N/A at present - - -
#16 - Configurable option #1

See “11.5.9 Configurable “Option” Parameters” on page 77, Service
Manual.

Manual.

Manual.

Manual.

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# 20 - Hour meter selection

This parameter determines which hour meter mode to display during
normal use.
Table 17: Hour meter parameter selection

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

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

(Parameter #25 controls the initial value)
See # 25 - Service interval on page 71.

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# 21 - Battery size
Matches the discharge indication to the characteristics of the battery fit-
ted.
To adjust the disconnection point of the battery discharge indicator,
measure according to:
• Acid concentration when fully charged battery. To check quality of
battery. Shall be between 1,27-1,29.
• When you get lift cut-out (80% discharged of battery capacity) you
shall have close to 1,14 not less.
The acid concentration can vary depending on battery brand.
Table 18: Battery size parameter

Value Function Battery (Ah)
1
2
3
4
5
6
7
8
9
10
11 Less discharged 610-640

12 570-600
13 More discharged 520-560
14 470-510
15 430-460
16 370-420
17 330-360
18 300-320
19
20
WARNING!
Ensure you have set the parameter correctly.
The battery may otherwise be irreparably damaged.

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# 22 - Machine type
This parameter should be set according to the type of truck.
0 = OSE250
1 = OSE250P
2 = OSE120
3 = OSE120P
4 = OSE180X
5 = OSE180XP
# 23 - Function selection
This parameter activates a number of different travel and lift functions.
0= The truck can be driven with the operator standing next to the truck.
1= The truck CANNOT be driven with the operator standing next to the
truck.
2= Activate the “Walkie” button
3= A combination of modes 1 & 2
4= The pallet stops 100 mm above ground when lowering the forks
(“Pallet to ground” function)
7= A combination of modes 1 & 2 & 4
# 24 - Special request
The parameters for a special request are entered as follows:
0 = Not activated
1 = Speed restriction due to poor tyre pressure. Only OSE250, special
identification plates are required.
2 = Speed restriction and extra hydraulic function. Only OSE250, spe-
cial identification plates are required.
# 25 - Service interval
This parameter determines the time value in hours to the next service
from 0 to 2000 hours in steps of 50 hours. Whenever this value is
changed the timer is reset and will start counting activity time up to the
set value. On reaching the set value caution code 29 (C29) will be
shown on the display.

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# 28 - Button selection
This parameter determines which button to be used for lifting/lowering.
1 = Lower lift/lower button activated (default)
2 = Upper lift/lower button activated
3 = Both lift/lower buttons are activated
# 35 - Automatic log-off
This parameter determines the time interval, in minutes, after which
automatic log-offt takes place if the truck is not used. The value “0”
(zero) results in log-out after 4 hours.
# 36 - Steer servo calibration

Value 0 - Parameter always returns to this value after calibration
Value 1 - Calibrate steer unit (in centre position)
Value 2 - Calibrate steer arm (in end position - not used on this truck)
This parameter is used to perform a calibration of the steer servo. The
calibration establishes the steering centre position (straight ahead).
Situations which may require that this calibration be performed are:
• The truck deviates from a straight line when steering tiller is in neu-
tral position.
• Occurrences of error codes E121 or E135
Before performing this calibration, ensure the drive wheel in centre sen-
sor [S65] is functioning and correctly adjusted.
To perform calibration perform following procedure:
• Move the steering tiller to the straight ahead position and maintain
this position.
• Select parameter #36 and set its value to 1.
• Press on the keypad. “PUSH” is displayed

• Maintain steering unit in straight-ahead position and press horn but-
ton [S18]. Display now shows “End”
• Press on the keypad. Steering calibration is now complete

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# 37 - Steering offset
This parameter can be used to “trim” the actual steering position of the
drive wheel in relation to the position of the steering tiller. It should only
be adjusted after having performed a steering calibration (parameter
#36)
A situation which may require that this parameter be adjusted is if the
truck tends to drift away from a straight ahead course when driving over
longer distances Many factors can contribute to this. It is therefore
advisable to make adjustments to this parameter on a trial and error
basis.
Whenever this parameter is adjusted, it is necessary to restart the
truck. (Disconnect and reconnect battery)
# 39 - Log-in method & operator parameter access

This parameter determines which function will be used for log-in and
whether or not the operator is allowed to adjust the operator parameter
settings.
• Value 1 - Key switch installed - Operator parameters accessible
(without CAN service key).
• Value 2 - Key switch installed - Operator parameters NOT accessi-
ble (without CAN service key).
• Value 3 - Keypad (standard 10 PIN codes) - Operator parameters
accessible (without CAN service key). NOTE: This is the default set-
ting.
• Value 4 - Keypad (standard 10 PIN codes) - Operator parameters
NOT accessible (without CAN service key).
• Value 5 - Extended keypad (100 PIN codes) - Operator parameters
accessible (without CAN service key).
• Value 6 - Extended keypad (100 PIN codes) - Operator parameters
NOT accessible (without CAN service key).
• Value 7 - Extended keypad (100 PIN codes) + TLS - Operator pa-
rameters accessible (without CAN service key).
• Value 8 - Extended keypad (100 PIN codes) + TLS - Operator pa-
rameters NOT accessible (without CAN service key).
• Value 9 - ID unit - Operator parameters accessible (can be changed
without CAN service key).
• Value 10 - ID unit - Operator parameters NOT accessible (CAN serv-
ice key needed).
• Value 11 - ID unit + TLS - Operator parameters accessible (can be
changed without CAN service key).
• Value 12 - ID unit + TLS - Operator parameters NOT accessible
(CAN service key needed).

649, 783 918789- 2006-10-27 235317-040
Extended keypad - General

The truck can be programmed with a maximum of 10 operator profiles.
The extended keypad then enables a maximum of 10 PIN codes to be
assigned to each operator profile. This makes it possible to handle up
to 100 different PIN codes.
NOTE!
If the extended keypad is activated, handling of standard PIN codes
that are normally accessible via parameter #10 is ignored.
Extended keypad - Programming

A group of PIN codes can be made accessible by defining them as a
block. Block no. 0 is activated in the default setting. This means that 3
different operator profiles can be accessed from the very start. Activa-
tion of other blocks will make all the PIN codes for that block accessible
(see Table 20:). If all 10 blocks have been activated, then 10 PIN codes
will be accessible for the operator profile.
The truck software stores the standard PIN code set according to Table
20:
NOTE!
These PIN codes can be adjusted to any value, however, it is advisa-
ble to avoid identical PIN codes in different operator profiles.

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Starting programming using the extended keypad:

• Connect a suitable CAN-service key to X41.
• Enter code 341671 and depress on the keypad.

• Select a programming command from Table 19:
Table 19: Programming commands - extended keypad

Programming Function Notes
Reset to default settings Blocks 1 - 9 are dis-
Depress “1” + abled. The original
PIN codes are reset
according to Table
20:
The PIN codes in the block can B = Block no. 0 - 9
Depress “2” + B + be used
The PIN codes in the block B = Block no. 0 - 9
Depress “3” + B + cannot be used
Changing current PIN code B = Block no. 0 - 9
Depress “4” + B + F + NNNN + F = Operator profile
no. 0 - 9
NNNN = New PIN
code

Programming of the extended keypad is now complete.
Parameter #39 must be set to the value 5, 6, 7 or 8 in order for the new
PIN codes to take effect.
Perform a test by logging in with one of the new PIN codes. It is impor-
tant to verify that the correct operator profile is enabled when a specific
PIN code is entered, especially if an operator profile has been pro-
grammed for a specific application or special goods handling.

649, 783 918789- 2006-10-27 235317-040
Table 20: The table shows the standard PIN codes in the software.
These can be activated for use or changed according to the preferenc-
es of the operator.
One or more of these blocks can be activated.
When logging in normally, an operator profile is activated when any of
the PIN codes in an activated block is entered.
The truck software will deny log-in if PIN code “0000” is used.
Service technicians are requested to keep notes on activated blocks,
PIN code changes and special operator profile settings.
NOTE!
If the extended keypad is reset, this does NOT affect the operator pro-
file settings.
Table 20: Standard PIN code assignment with extended keypad

Opera- 0 1 2 3 4 5 6 7 8 9
tor pro-
file
No.
Block 0 0000 0001 0002 0003 0000 0000 0000 0000 0000 0000
Block 1 5421 7901 1437 3731 1049 9439 7265 1322 2869 1574
Block 2 1787 4854 2907 9175 5799 1490 3031 7392 5622 5023
Block 3 4659 3174 1026 3815 6703 1179 5152 7514 5668 3215
Block 4 9197 7110 5477 3846 9491 5918 8222 6923 8139 7025
Block 5 2549 6276 9879 9658 1690 4042 5201 9807 4332 9715
Block 6 7474 4142 8620 3754 8432 8788 7430 1948 2595 8527
Block 7 1930 1482 7135 2395 7365 7092 4611 2831 4185 6067
Block 8 2876 4731 1022 5377 3257 7334 9009 7881 8843 7436
Block 9 3242 3162 5878 2828 1910 6907 2136 5730 2957 7691

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11.5.9 Configurable “Option” Parameters

WARNING!
The information in this section is not intended as a programming ref-
erence and is included solely to allow the reader to gain a thorouth
understanding of parameter setting / checking.
Do not attempt to make any adjustments to these parameters unless
you have sufficient knowledge of the truck’s options/ modified func-
tions. This manual only covers the truck’s standard equipment. Spe-
cially modified trucks may require that you have access to special
service information. Improper adjustment of the option service pa-
rameters may compromise safe operation and / or result in a malfunc-
tion.
General
Parameters #16 to #19 are reserved in the truck’s control system for
extra truck options and/or special product modifications. The parame-
ters configure and control the behavior of the Spider expansion unit
(SEU) which must be fitted in the truck. See “11.4.2 Spider expansion
unit (SEU)” on page 52. This method of implementation allows the
standard software program to be used without the need for a special-
ised software. Normally, these parameters are configured by the manu-
facturer when the truck is modified or customized. It is advisable to up-
load the parameter settings from trucks which are modified. In the event
the main control card[A2] is changed, the original parameter settings
can then be transferred to the new card thus ensuring the special option
functions correctly.
Parameter Nos. #16, #17, #18 & #19 can be adjusted to allow up to a
maximum of 4 preprogrammed “base options” to be activated and con-
figured to suit a specific special option or customisation. See table
below.
Table 21: Summary of base options

Base Function Refer to..
option
no.
1 Pressing an option button controls a digital o/p table 22 on page 80
2 Activating a digital input will reduce maximum drive speed table 23 on page 81
3 Specific truck movement(s) activates a digital o/p table 24 on page 82
4 Activating a digital input causes main contactor to close table 25 on page 84
5 Activating digital inputs will operate lift /lower table 26 on page 85
6 Lift height can be restricted by activating a digital input + abil- table 27 on page 87
ity to override by pressing an option button

649, 783 918789- 2006-10-27 235317-040
Parameter #16 to #19 Configurable options

• Each parameter can be designated to hold a particular base option.
• Each designated option has up to 4 arguments associated with it.
• Each argument holds a value which configures that option.
Parameter no. (range 16-19)

Argument: #0 holds option designator (displayed for 2 s only)
Argument value (range 0 - 63)
0= no base option is activated for this parameter
1 to 6 = Base option no. See See separate tables)
16 - 0 - 1
OPTION ASSIGNATION
Argument: #1, #2, #3 & #4 hold configurable values for the option
Argument value (range depends on argument)
Value depends on option and argument selected
See separate table
16 - 1- 1
OPTION CONFIGURATION
Fig. 13 Configurable option layout

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Setting Configurable options

To activate a configurable option the base option must first be assigned
to one of the parameters #16 to #19. This is achieved by setting argu-
ment #0 to the base option number. Once it is assigned, the option’s
arguments must be configured. This is achieved by setting a value for
arguments #1, #2, #3 and #4.
• Ensure the truck is in parameter mode.
• Select parameter #16, #17, #18 or #19 using [L1].

Argument #0 will be displayed
After 1 second the argument’s value will be displayed. A value of “0”

indicates no option is assigned to this parameter, in which case contin-
ued operation of the speed control [L1] will display the next parameter
• Set argument #0 value by repeatedly operating speed control [L1]

up or down. Refer to base option list Table 21:
• Select argument #1 by operating speed control [L1].

After 1 second the value of argument #1 will be displayed.
• Set argument #1 value by repeatedly operating speed control [L1]

up or down. Refer to base option list Table 21:

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Adjust arguments #2, #3 and #4 using the same method as above.
• Switch off the truck by pressing on the keypad

The special option shall now be activated.
• Ensure the special option operates correctly before returning the
truck for normal use.
Table 22: Base option 1 - Option button controls SEU output

Argument #0 Option designator
Values Meaning
Initial display 1 Sets relevant parameter to handle base option 1
(value shown after 2s delay)

Argument #1 Selection of SEU unit 1 or 2
Values Meaning
0 option is handled by SEU unit 1(A36)
Initial display
(value shown after 2s delay) 1 option is handled by SEU unit 2 (second SEU unit)
Argument #2 Selection of SEU digital output

Values Meaning Pin no.
0 activate SEU digital o/p 1 (1,6A) 16
Initial display
(value shown after 2s delay) 1 activate SEU digital o/p 2 (1,6A) 30
Argument #3 Selection of option button
Values Meaning
1 activated by option button 1
Initial display
(value shown after 2s delay) 2 activated by option button 2
Argument #4 Type of switching
Values Meaning
0 activated when button is depressed
Initial display
(value shown after 2s delay) 1 option is toggled when button is pressed

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Table 23: Base option 2 - Reduced drive speed by SEU i/p

Initial display Values Meaning
2 Sets relevant option parameter to handle base option
2
1 option is handled by SEU unit 2 (second SEU unit)
Argument #2 Selection of SEU digital input
Initial display Values Meaning Pin no.
0 activate SEU digital i/p 1 (1mA) 5
(value shown after 2s delay) 2 activate SEU digital i/p 3 (1mA) 33
Argument #3 Speed limitation as a percentage of max. speed
0-12 Max. speed adjustable from 40-100%
formula: =40+5*Arg.3
e.g. 40+5*4=60%
Argument #4 Speed range
0 Affects only high speed range
1 Affects only low speed range
(value shown after 2s delay) 2 Affects both speed ranges

649, 783 918789- 2006-10-27 235317-040
Table 24: Base option 3 - Truck movement activates SEU O/P

Initial display (value displayed Values Meaning
after 2s) 3 Sets relevant option parameter to handle base option
3

after 2s) 0 option is handled by SEU unit 1(A36)
Argument #2 Selection of SEU digital output

Initial display (value displayed Values Meaning Pin no.
after 2s) 0 activate SEU digital o/p 1 (1,6A) 16
...table continued on next page

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...continued from previous page
Argument #3 Selection of activating movement
Initial display (value displayed Values Drive Drive Lift Lower Any
forward back- forks forks other
ward movement
after 2s) 1 X
2 X
3 X X
4 X
5 X X
6 X X
7 X X X
8 X
9 X X
10 X X
11 X X X
12 X X
13 X X X
14 X X X
15 X X X X
16 X
17 X X
18 X X
19 X X X
20 X X
21 X X X
22 X X X
23 X X X X
24 X X
25 X X X
26 X X X
27 X X X X
28 X X X
29 X X X X
30 X X X X
31 X X X X X

649, 783 918789- 2006-10-27 235317-040

Argument #4 Output switching mode
after 2s) 0 Output continuously on
1 Output switches at 1 Hz
2 Output switches at 2 Hz
Table 25: Base option 4 - Activate main contactor by SEU i/p

4 Sets relevant option parameter to handle base option 4

Argument #2 Selection of SEU digital input
0 activated by SEU digital i/p 1 (1mA) 5
(value shown after 2s delay) 2 activated by SEU digital i/p 3 (1mA) 33
Argument #3 Hold time in minutes
0-30 Contactor is held on from 0 to 30 minutes after digital i/p
is activated
Argument #4 Not used

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Table 26: Base option 5 - Activate lift/lower by SEU i/p


5 Sets relevant option parameter to handle base
option 5

Argument #2 Selection of SEU digital inputs

0 Lift - SEU digital i/p 1 5
Lower - SEU digital i/p 2 19
Lower inhibit - SEU digital i/p 3 33

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Table 26: Base option 5 - Activate lift/lower by SEU i/p

Argument #3 Enable / Idisable lower inhibit

0 Lower inhibit disabled
1 Lower inhibit enabled
Argument #4 Selection of fork / support arm

0 Selects fork lift / Lower
1 Selects support arm lift / lower

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Table 27: Base option 6 - Lift height restriction by SEU i/p &
override

6 Sets relevant option parameter to handle base option 6

Argument #2 Selection of SEU digital input for restriction switch

Argument #3 Selection of option button to override

Argument #4 Not used

Diagnostic and troubleshooting
649, 783 918789- 2006-10-27 235317-040
11.6 Diagnostic and troubleshooting
11.6.1 General
means always on. means blinking.

The trucks’s electronic control system incorporates built-in fault code
display and logging. This capability works as a powerful complement in
assessing the cause of eventual truck malfunctions. When a fault code
occurs the code number is displayed and the fault condition LED flash-
es. Fig. 14.
Fig. 14
The codes can be broadly divided into two groups:
• Caution codes - denoted by prefix “C”. These codes alert the opera-
tor to the presence of a caution condition. Caution codes in the
range C50 to C99 will limit the truck’s maximum speed to creep
speed. The conditions which cause such codes can usually be easi-
ly remedied without further attention. Caution codes C1 to C49 are
not stored in the code history log.
• Error codes - denoted by prefix “E”. These codes alert the operator
to the presence of a fault condition in the truck. Error codes E100
and higher will stop all truck driving functions until the error code is
cleared.
The first time any fault code is displayed it is advisable to check if the
condition persists by switching the truck off completely. i.e. disconnect
the battery and then switch back on. Check to see if the fault code is
again displayed.

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11.6.2 Fault code history

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

PIN-code and then press on the keypad.

• Hold [S18] depressed until “E” is displayed, then release [S18]. Fig.
15
Fig. 15 Fault symbol lights.
The most recently occurred error will be displayed. The display will
alternate between the fault code and the hour meter reading when the
fault occurred. If the fault code log contains more than one fault code,
these can be displayed by repeatedly operating the speed control [L1].

649, 783 918789- 2006-10-27 235317-040
11.6.3 List of error codes

NOTE!
The text “Restart the truck!” in the subsequent tables always indicate
that the trucks must be completely switched off by disconnecting the
battery connector [X1], then reconnecting it and starting the truck.
Table 28: List of error codes

Code Description Possible cause / Hint or Solution
C3 TLS impact warning The impact sensor of the TLS system has triggered and
all truck modes have been locked. / Reset the TLS unit.
C4 TLS “deactivated” warning The TLS system is not in the standard travel mode and
all truck modes have been locked. / Switch the TLS unit
to the standard mode.
C19 Default parameter warning One or more parameter values may be outside the nor-
mal max./min. limits. These parameter values will be
reset to the default values. / If this code is displayed, it
may become necessary to verify all parameter settings.
C20 Butterfly warning Problem with butterfly sensor [L1].
The speed control may have been actuated during start-
up.
Faulty sensor(s) [A2] / Verify operation of the speed con-
trol.
C22 “Walkie” button warning One of the “Walkie” buttons is depressed during start-up.
/ Restart the truck!
C26 Steer servo start up error The steering servo does not respond during initialisation.
[A5] / Inspect the connections to the steering servo. [A5]
C28 Emergency switch warning Emergency switch activated [S21]
No voltage supply to transistor regulator [A1].
Harness problem. / Check emergency switch is not
depressed. Check wiring.
C29 Service time warning Time for next service. / Verify the service parameter.
The parameter may not have been reset during the most
recent service intervention. / See # 25 - Service interval
on page 71 for setting of parameter #25
C31 Pressure sensor warning Problem with the pressure sensor or the cabling [B10]. /
Verify that the voltage is 24 V between cable 24 and 40
on the pressure sensor.
Check voltage between cable 40 and 63 connected to
the pressure sensor. The output voltage should be 0.5
Volt (unloaded machine) to 4,5 Volt (max. load)
C35 Steer servo - Internal temper- Servo internal temperature has exceeded +68 °C /
ature warning Steering activity too intensive.See also code E127

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C41 Battery undervoltage warning Battery voltage < 17 volt
Battery parameter not correctly adjusted. / See # 21 -
Battery size on page 70 for setting of parameter #21
Battery due for charging
C42 Battery overvoltage warning Battery voltage > 33 volt
Fully charged battery and energy regeneration during
hard reversing braking.
C43 Transistor regulator thermal Driving may be too intensive
cutback Defective transistor regulator [A1]
C50 Platform sensor active > 5 Sensor is continuously actuated. The sensor output has
minutes with no truck activity short-circuited or faulty sensor. / Inspect sensor opera-
[S19] tion.
C51 Logical fault in mast sensors One of the signals from the fork height detection sensors
is incorrect. / Verify correct operation of all fork height
sensors, [S31], [S32] & [S12]
C52 Wrong truck type Wrong truck type selected / # 22 is probably entered
incorrectly / Check # 22.
C80 Steer servo - Home reference Reference sensor receives incorrect signal. [S65]
error Faulty reference sensor [S65] / Inspect the sensor
cabling.
C81 Steer servo - Home reference Defective home reference sensor [S65] /
error Low voltage feed to reference sensor. 12 V between
cables 95-97 / Inspect the cabling to the reference sen-
sor [S65]
Check condition of [F50]
C82 Steer servo - drive current Steer servo drive current is exceeding 80% of maximum.
warning Steering activity may be too intensive
See also code E132
C90 Communication problem with Verify the voltage supplied to the unit (A36: POWER
the expansion unit (Expan- SUPPLY 24VDC) and check that the CAN cabling is OK.
sion unit 1)
C91 Communication problem with Verify the voltage supplied to the other expansion unit
the expansion unit (Expan- and check that the CAN cabling is OK.
sion unit 2)
C92 Programming warning Incorrect programming of I/O expansion unit 1 [A36].
(Expansion unit 1) The truck travels at creep speed. / May have been
caused by incorrect allocation of an output during adjust-
ment of the option parameters (16 to 19). Verify all set-
tings of any option parameters.

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C93 Programming warning Incorrect programming of I/O expansion unit 2. The truck
(Expansion unit 2) travels at creep speed. / May have been caused by
incorrect allocation of an output during adjustment of the
option parameters (16 to 19). Verify all settings of any
option parameters.
E101 Transistor regulator [A1] An incorrect transistor regulator type has been installed.
incompatible with the type of / Verify that the correct transistor regulator type has
truck been installed.
E104 Brake switch transistor output Defective transistor regulator [A1] / Check cables and
in transistor regulator [A1] magnetic coil to the brake [Y1]
shorted
E106 Digital output fault or field Attempting to drive more current than specified from out-
current limit puts.
OR problem regulating field current.
Internal transistor regulator fault. [A1]
E107 Main contactor not activated Problem with main contactor tips or cabling (open cir-
[K10] cuit).
Contactor control wire not connected.
Incorrect contactor output from the transistor regulator
(switched off). / Inspect the main contactor tips. Check
control wires to main contactor. Check contactor drive
output goes {low}. [A1]
E108 Main contactor tips welded or Main contactor tips welded.
open circuit in coil.[K10] Contactor drive output in controller faulty (on) / Check
main contactor tips Check contactor drive output goes
{high}. [A1]
E110 Incorrect rotor current value. Defective transistor regulator [A1].
[M1, A1] Can be caused by excessive moisture inside regulator. /
Restart the truck
E113 Unspecified steer servo fault Control system has detected a fault condition but is una-
ble to ascertain the exact cause. / Restart the truck
E114 Steer servo phase error [A5, Loss of motor phase to steer servo motor. / Check inter-
M6] nal motor cable connections in steer servo
E115 Steer servo start up error [A5] Faulty Servo
Internal logical fault
Incorrect parameter settings. / Restart the truck
E116 Steer servo checksum error Can occur after new firmware has been loaded into truck
[A5] / / Restart the truck
E117 Steer servo communication Not used
error

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E118 Command mode error Not used
E119 Steer servo error during hom- Home position (steering straight) not achieved within
ing operation (Time out) preset time.
Home reference sensor [S65] not adjusted correctly
Faulty reference sensor / Check reference sensor gap is
adjusted correctly, check wiring to sensor
E120 Error in steer servo potenti- Not used
ometer
E121 Steer servo error -steering Defective steering signal potentiometer [R2] or cabling /
angle value check Restart the truck! The sum of the voltages between
cables 92-94 and 93-94 =5 V Recalibrate steering. See#
36 - Steer servo calibration on page 72
E122 Steer servo -reference supply Defective steer servo [A5] / Check voltage between wire
out of range nos. 91-94 = 4,5 to 5,5 V
E123 Steer servo - Hall sensor fault Intermittent contacts inside steer servo
Defective steer servo [A5] / Check internal contacts in
steer servo [A5]
E124 Steer servo - overvoltage Fully charged battery and energy regeneration during
[A5] hard reversing braking. / Restart the truck
E125 Steer servo - internal short Defective steer servo [A5,M6] / Restart the truck
circuit [A5, M6]
E126 Steer servo - current offset Defective steer servo [A5,M6] / Restart the truck
error [A5, M6]
E127 Steer servo - temperature too Steering activity too intensive
high [A5, M6] (>85º C) Defective steer servo [A5,M6] / Restart the truck
E128 Not applicable at present -
E129 Steer servo - supply under- Battery charge too low
voltage Intermittent connection in servo supply circuit [A5]
Steer servo fuse [F52] faulty or blown. / Check condition
of Fuse [F52] Charge battery
E130 Steer servo - analogue steer Faulty steer angle potentiometer. [R2]
signal input fault [R2] Intermittent connection in potentiometer circuit [R2,A5] /
Check wiring to potentiometer [R2]
Move tiller unit handle in all directions to ensure no wir-
ing problems exist.

649, 783 918789- 2006-10-27 235317-040

signal input fault Intermittent connection in potentiometer circuit
[R2,A5:INP.A_IN0] / Check 0,4 to 4.8V between wires
94-92, check wiring to potentiometer [R2]
Move tiller unit handle in all directions to ensure no wir-
ing problems exist.
E132 Steer servo - current limit Steered portion of drive unit not moving freely./ Check
reached for free movement of drive wheel on floor.
Check steering drive train is free of dirt or other foreign
objects. See also code C82.
signal input fault Intermittent connection in potentiometer circuit
[R2,A5:INP.A_IN1] / Check 0,4 to 4.8V between wires
94-93 , check wiring to potentiometer [R2] Move tiller
unit handle in all directions to ensure no wiring problems
exist.
E134 Steer servo - analogue steer Faulty steer angle potentiometer. [R2] or wiring Short cir-
signal input short circuit cuit between [A5:INP.A_IN1 and INP.A_IN0] / Check
wiring to potentiometer. [R2]. Move tiller unit handle in all
directions to ensure no wiring problems exist.
E135 Steer servo - offset value Requires recalibration / Recalibrate steering (parameter
error #36) See # 36 - Steer servo calibration on page 72
E136 Steer servo - steer angle Defective potentiometer [R2] / Ensure potentiometer is
potentiometer error fitted correctly.
Recalibrate steering. See # 36 - Steer servo calibration
on page 72
E137 Steer servo - checksum error Faulty wiring. / Check CAN bus signal cables and con-
on received data nections.[A5, A2] Restart the truck
E138 Steer servo - data not Faulty wiring. / Check CAN bus signal cables and con-
received nections.[A5, A2] Restart the truck
E139 Steer servo - data transmis- Faulty wiring. / Check CAN bus signal cables and con-
sion to servo failed nections.[A5, A2] Restart the truck
E140 Checksum error Faulty internal micro controller [A2], faulty software
E141 Software problem Faulty internal micro controller [A2], faulty software / It
may be necessary to download new software via the
CAN
E150 Drive communication error CAN cabling interruption.
Defective transistor regulator [A1]
E151 Drive communication trans- The transistor regulator [A1] does not respond, poor
mit error connections or defective transistor regulator [A1].

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E157 Bus off error CAN-bus problem, wiring harness or hardware prob-
lem.[A2] / Check wiring
E159 Over-run error CAN-bus problem, wiring harness or hardware prob-
lem.[A2] / Check wiring
E160 Not applicable for this truck -
E200 Drive motor field circuit open Shunt field open [M1], harness broken, transistor regula-
tor defective [A1]. / Check wiring and connections to
shunt field [M1]
E201 Minus error Problem with switch transistor in armature circuit inside
transistor regulator [A1]
Defective transistor regulator [A1].
E202 Power amplifier sensor error Armature current sensor fault in transistor regulator [A1].
Defective transistor regulator [A1].
E214 Power amplifier CAN timeout Transistor regulator reports unexpected loss of data flow
from tiller head [A2].

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11.6.4 Transistor regulator troubleshooting

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

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Transistor regulator errors

I
The table below depicts the error codes that may be shown by the sta-
tus LED or read using the hand-held terminal.
STATUS
MODEL VOLTAGE
SERIAL CURRENT
Table 29: Transistor regulator error codes

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

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Resetting errors
An error condition can be reset by disconnecting the battery connector
[X1], then reconnecting it and starting the truck.
Error Reset when

OVERVOLTAGE Battery voltage falls below 33 V
THERMAL CUTBACK The temperature is within allowed
range
THROTTLE FAULT 1, 2 Error has been fixed
LOW BATTERY VOLT- When battery voltage exceeds 16 V
AGE
Safety
The regulator is a high-power component. When working on a battery
operated vehicle, necessary precautions should be taken. This
includes, but is not limited to, correct training, use of eye protectors,
avoiding use of lose-fitting clothes, removal of watches and jewellery,
and use of insulated tools only.
WARNING!
Remove all watches, jewellery and always use insulated tools only.

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11.6.5 Built-in Test Function

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

NOTE!
All truck functions operate as normal in this mode. Care should be
taken when operating the truck and reading the display at the same
time!
Table 30: Built-in test modes

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

Table 31:, Table 32: & Table 33:for more
information.
3 Battery voltage (V)
4 Armature current (A)
5 Field current (A)
6 PWM Armature in %
7 Status Curtis
8 Signal from pressure sensor [B10]

(Hydraulic pressure in lift circuit) (V)
9 Digital inputs/outputs of expansion unit

[A36]. Seetable 34 on page 102

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Digital inputs/outputs test mode

In the digital inputs/outputs mode, the operation of both inputs and out-
puts can be checked by checking the individual segments of the main
display as given in the following tables.
Transistor regulator inputs
Table 31: Transistor regulator inputs check

Segment Function
Forks < 200 mm [S32], input A1.INP FORKS <
200MM (OSE120, OSE120P)
Forks < 500 mm [S12], input A1.INP FORKS <

500MM (OSE120, OSE120P)
Lift height limit [S31], input A1:INP.LIFT LIMIT
Watchdog [Y1], A1:OUT. BRAKE, A (Senses

whether Y1 is drawing current correctly - should
normally show the inverse of output signal)
Man on platform [S19], input A1:INP.DRIVER
ON PLATFORM
Mechanical brake [S10], input A1:INP.BRAKE

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Transistor regulator outputs
Table 32: Transistor regulator outputs

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

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

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

CONTACTOR
Fork lift/lowering valve [Y45], output A1:OUT

FORKS LIFT/LOWER VALVE (OSE120,
OSE120P)
Digital input of logic card [A2].
Table 33: Digital input of logic card [A2]

check
Segment Function
Forks up [A2:S19]
Fork down [A2:S20]
Platform up [A2:S21]
Platform down [A2:S22]

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Digital input/output to expansion unit [A36]
Table 34: Digital input/output to expansion

unit check
Segment Function
Platform > 500 mm [S103], input
A36:INP.PLATFORM > 500MM
Platform lift limiter [S107], input A36:INP.PLAT-

FORM LIFT LIMIT
Platform lowering switch (in contact sheet)

[S214], input A36.INP.FOOTSWITCH LOWER
PLATFORM
Platform lift/lowering valve [Y69], output
A36:OUT.PLATFORM LIFT/LOWER VALVE
Extra functions
Table 35: Extra functions check

Segment Function
Extra function 6
Extra function 5
Extra function 4
Extra function 3
Extra function 2
Extra function 1

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11.6.6 Display test mode

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

Fig. 16
PIN code and then press on the keypad.
• Hold [S18] depressed until “d” is displayed, then release [S18]. Fig.
16
All number segments on the display and symbol lamps should flash
sequentially. Fig. 17
Fig. 17

Technical specifications – Curtis 1243
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11.7 Technical specifications – Curtis

1243
Table 36: Technical specification -Curtis 1243

Item Trac- Lift Unit Explanation
tion
Rated operating voltage 24 24 Volts
Overvoltage limit 33 33 Volts
Undervoltage limit 16 16 Volts Minimum operating volt-
age
Electrical insulation towards cold 500 500 V AC Minimum
body
PWM frequency 16 16 kHz
Max. current of armature wind- 200 300 Amps for 2 minutes
ing *
100 100 Amps For 1 hour
Max. current of field winding 25 35 Amps For 2 minutes
20 20 For 1 hour
Contactor voltage 24 24 Volts Same as battery voltage
Contactor current 2 2 Amps Max (current limit at 2.5
amps)
KSI input voltage, Min. 16.8 16.8 Volts
KSI input current 50 50 mA
Logic input voltage >7.5; High >7.5; High Volts
<1; Low <1; Low
Logic input current 15 15 mA
Operating temperature -40 to +50 -40 to +50 °C
Overtemperature, reduction 85 85 °C
Undertemperature, reduction -25 -25 °C
* During specific test conditions.

Hydraulic system – 6000
Hydraulic component overview
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12- Hydraulic system – 6000
12.1 Hydraulic component overview

TRUCK WITHOUT MAST AND
WITHOUT PLATFORM
15
3
5
1
10
6
11
8
(12,13)
7
14 9

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12.1.1 Hydraulic diagrams
8
7
16
B10
Y45 Y69
12
Y10
14 13
P M3
11
TRUCK WITH MAST AND WITHOUT PLATFORM
8 10
7 9
16 17
P I B10
Y45 Y69
12
Y10
14
13
P M3
11
6
TRUCK WITH MAST AND WITH PLATFORM

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8
7
B10
Y41
12
14 13
P M3
TRUCK WITHOUT MAST AND WITHOUT PLATFORM
8 10
7 9
B10
Y45 Y69
12
Y10
14 13
P M3
11
TRUCK WITHOUT MAST WITH PLATFORM

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12.1.2 Component overview
Table 37: Hydraulic component overview

Pos. Des- Function Component type Notes
igna
tion
1 Y45 Fork lifting Valve Gentle-closing electro-
magnetic valve for the
forks
2 Y69 Platform lifting Valve Gentle-closing electro-
magnetic valve for the
platform
3 B10 Load monitoring Analogue pressure sen-
sor
4 Y10 Lowering of forks/platform Valve
Y41 Lowering of forks Valve Only OSE250
5 P Hydraulic pressure Hydraulic pump
6 Tank
7 Hydraulic hose
8 Fork lifting Lift cylinder
9 Hydraulic hose Only OSE120P,
OSE250P
10 Platform lifting Lift cylinder Only OSE120P,
OSE250P
11 Oil filtering Filter Rough filtering of oil
received by the pump
12 Non-return valve
13 Flow regulating valve
14 Limiting of max. hydraulic Pressure limiting valve
oil pressure
15 M3 Hydraulic oil pump drive Electric pump motor
16 Hose rupture valve Valve Only OSE120P
17 Hose rupture valve Valve Only OSE120P

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12.2 Functional description
12.2.1 Fork lifting

When the fork lifting control is actuated, the pump contactor closes and
the pump motor starts operating. At the same time, the Y45 valve
opens and oils flows through the non-return valve and Y45 to the lift cyl-
inders.
If the lifting movement is interrupted, Y45 closes gently.
12.2.2 Fork lowering

When the fork lowering control is actuated, the electromagnetic valves
Y10/Y41 and Y45 open completely to allow the oil in the pressure lines
to flow back into the oil reservoir.
If the lowering movement is interrupted, first Y45 closes slowly and
then Y10/Y41 closes. To ensure Y45 is completely closed before Y10/
Y41 closes, Y10/Y41 receives a retarded holding voltage from the
truck's logic card.
The lowering speed cannot be adjusted, and is instead determined by
the brake valve for the lowering action in the hydraulic unit valve plate.
12.2.3 Platform lifting

When the platform lifting control is actuated, the pump contactor closes
and the pump motor starts operating. At the same time, the Y69 valve
opens and oil flows through Y69 to the lift cylinder.
If the lifting movement is interrupted, Y69 closes gently.
12.2.4 Platform lowering

When the platform lowering control (pushbutton or foot pedal) is actuat-
ed, the magnetic valves Y10 and Y69 opens completely to allow the oil
in the pressure line to return to the oil reservoir.
If the lowering movement is interrupted, first Y69 closes slowly and
then Y10 closes. To ensure Y69 is completely closed before Y10 clos-
es, Y10 receives a retarded holding voltage from the truck's logic card.
12.2.5 Operating pressure

The operating pressure at rated load is:
- 180 bar (OSE120, OSE120P)
- 110 bar (OSE250)
- 120 bar (OSE250P)

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12.2.6 Relief valve

Relief valve opening pressure:
- 200 bar (OSE120, OSE120P)
- 130 bar (OSE250)
- 170 bar (OSE250P)
12.2.7 Platform cylinder check valve

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

The purpose of the pressure sensor is to provide the truck controller
with a pulse signal to reduce the speed when carrying loads that
exceed 700 kg (OSE120, OSE120P) /500 kg (OSE250. OSE250P).

Adjustments
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12.3 Adjustments
12.3.1 Adjusting the pressure limiting valve

The pressure limiting valve has been correctly set at the factory, howev-
er, adjustment may be required if the valve or the entire hydraulic unit is
replaced.
The truck must handle lifts between 1250-1300 kg (OSE120,
OSE120P) / 2250-2600 kg (OSE250, OSE250P).
2
1
Fig. 18 Pressure limiting valve
1. Locking nut. Use a special tool. See the picture in the ”Tools”
section.
2. Adjusting screw, pressure limitation.
When turned clockwise, the pressure increases.
When turned counterclockwise, the pressure decreases.
Pressure limiting valve. Use a special tool.
• Loosen the locking nut using a special tool. Place a load of 1200/
2500 kg on the forks and verify that the truck is able to lift this load.
• If the truck can lift 1200/2500 kg, place an additional 100 kg on the
forks. Verify that the truck is able to lift the load.
• If the truck can manage to lift more than 1300/2600 kg, adjust the
pressure limiting valve using the adjusting screw Fig. 18(2) by turn-
ing it clockwise with a 4 mm Allen key until the truck cannot lift the
load.

Tools
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12.4 Tools
Two special tools are required to adjust the pressure limit valve of the
hydraulic system.
A B
12
8
26,5 13,5
• A – Socket for loosening or tightening the adjuster screw for pres-

sure limitation (part number 08-16530).
• B – Socket for loosening or tightening the lock nut (part number 08-
16530/1).

Main lift chain system – 7120
General
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13- Main lift chain system – 7120
13.1 General
Applies to all machines with a mast.
13.2 Checking the chain setting

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

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

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

Fretting corrosion results in a reddish brown powder being visible by
the outer discs. It can also appear as if the chain is bleeding when lubri-
cated.

Chain inspection
649, 783 918789- 2006-10-27 235317-040
13.3.4 Stiff links

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

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

If a bolt is loose it will protrude from the side of the chain, which is due
to a stiff link or bolt rotation.

Chain inspection
235317-040 2006-10-27 918789- 649, 783
13.3.7 Outline wear
H2 H3
P = Pitch
H2 = Nominal disc height.
H3 = Minimum disc height.
A new lift chain has a specific nominal disc height, defined as H2 in the
figure. As the truck is used the lift chain wears radically, on the side that
runs over the chain sprocket. The minimum disc height is define as H3
in the figure and denotes the minimum permitted value of the disc
height.
Maximal permitted outline wear is 5% of the height H2. If a lift chain
reaches the maximum level of wear, the chain should be replaced.
The nominal and minimum disc heights for respective lift chains are
stated in the table in the chapter “Stretching”.
13.3.8 Stretching
The amount of stretch on a lift chain is measured on the part of the
chain that runs over the chain sprocket. The amount of stretch may, at
the most, be 2% on the most worn section of the chain.
Measurement is suitably made over 300-1000 mm of the chain.
The nominal and maximum permitted chain lengths for lift chains are
stated in the table below.

Chain inspection
649, 783 918789- 2006-10-27 235317-040
Table 38: Stretching

Type of Nominal Minimum Pitch P Nominal chain Maximum permit-
chain disc disc (mm) length for 20/30/ ted chain length
height H2 height H3 50 discs (mm) for 20/30/50 discs
( mm) (mm) (mm)
3/4”, 2x3 17.8 16.9 19.05 381/572/953 389/583/972
3/4”, 3x4 17.8 16.9 19.05 381/572/953 389/583/972
3/4”, 4x6 17.8 16.9 19.05 381/572/953 389/583/972
1”, 4x4 23.6 22.4 25.4 508/762/1270 518/777/1295
1”, 6x6 23.6 22.4 25.4 508/762/1270 518/777/1295
Wear to the bolts and around the holes on the discs are a reason why
the chain stretches. The chain should be replaced if stretching is
more than 2%.
13.3.9 Damage
The chain should be replaced if damaged in any way.
13.3.10 Damaged discs

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

Cleaning
235317-040 2006-10-27 918789- 649, 783
13.3.11 Damaged bolts

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

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

Lubrication
649, 783 918789- 2006-10-27 235317-040
The lubricate must comply with the viscosity demands at respective

temperatures as set out in the table below. The following lubricants are
recommended:
Table 39: Recommended Product

Environmen- Viscosity Recommended products*
tal tempera- class
ture
> - 40°C VG 15 Klüberoil 4UH 1-15, Klüber Lubri-
cation
< - 30°C
> - 30°C VG 68 Klüberoil 4UH 1-68N, Klüber Lubri-
cation
< + 5°C
Anticorit LBO 160 TT, Fuchs DEA
> + 5°C VG 150 Klüberoil 4UH 1-150N, Klüber
Lubrication
< +45°C
Anticorit LBO 160, Fuchs DEA
Rexoil, Rexnord Kette
>+ 45°C VG 220 Klüberoil 4UH 1-220N, Klüber
Lubrication
<+ 80°C
* Similar products from other manufacturers may be used.
NOTE!
Do not use a special rust protective agent to prevent
rust on the lift chains.
These agents impair the lubrication of the chains. Regular lubrication
is the best method to prevent rust attack.

Platform – 9130
General
235317-040 2006-10-27 918789- 649, 783
14- Platform – 9130
14.1 General
With the standard chassis, cabin lifting can be considered as an add-
on. Apart from cabin lifting, also the steering controller's hydraulic unit
and lift buttons are different.
NOTE! The operator's cabin must always be suspended by the lifting
chain when the cabin is in the bottom position; it must not rest against
the chassis.

Platform – 9130
Component overview
649, 783 918789- 2006-10-27 235317-040
12
13
49 15
14
48
47
46
45
44
20
42 43
41
40
39
50
37
21
38
36
6610
23
24
35
34 33 32
30
31
25
28
26
27
29

Platform – 9130
Component overview
235317-040 2006-10-27 918789- 649, 783
Pos. Description Notes

12 Axle See the subsequent illus-
tration
13 Cotter pin
14 Bushing
15 Chain wheel
16 Lifting chain
17 Axle
18 Cotter pin
19 Anchor bolt
20 Screw
21 Wiring harness complete(With chain)
23 Nut
24 Nut
25 Platform
26 Bracket
27 Screw
28 Screw
29 Rivet
30 Bracket
31 Sensing device
32 Mast frame
33 Screw
34 Nut
35 Sensing device
36 Rivet
37 Bracket
38 Screw
39 Screw
40 Nut
41 Bracket
42 Plate
43 Block
44 Guide
45 Screw
46 Groove ring
47 Ball bearing
48 Guide
49 Screw
50 Screw
51 Washer
52 Screw

Platform – 9130
Adjustment
649, 783 918789- 2006-10-27 235317-040
14.3 Adjustment
The cabin lift uses 8 adjustable side guides Fig. 19 (A and B). When lift-
ed to the highest position, it is possible to adjust the operator cabin side
guides by inserting an Allen key Fig. 19 (45) through the holes in the
side member C. Be sure to lubricate the side member according to the
lubrication interval (500 hours) indicated in the lubrication chart.
Removal of components is not required in order to access the adjus-
tors.
NOTE! It is important that the operator's cabin is raised to the topmost
position before adjustment is made.
C
A
47
46
45
44 C
Fig. 19 Adjusting the operator lift

Platform – 9130
Adjustment
235317-040 2006-10-27 918789- 649, 783
14.3.1 Outer side guide

The outer side guides Fig. 20 (A) can be accessed from the outside
once the operator's cabin has been lifted to the topmost position. Adjust
the side guards Fig. 20 (43) using the adjusting screws Fig. 20 (39) until
any play has been eliminated. The operator's cabin must be lifted to its
topmost position prior to performing this adjustment.
A
42 43
41
40
39
38
Fig. 20 Adjusting the side guides

Platform – 9130
Adjustment
649, 783 918789- 2006-10-27 235317-040

Destruction instructions
General
235317-040 2006-10-27 918789- 649, 783
15- Destruction instructions
15.1 General
These instructions have been drawn up as part of BT's environmental
management program. An important motive is, by taking nature into
consideration, to economise with resources. In other words, you should
try to recycle material as far as possible. This is to minimise the dis-
charge of environmentally-hazardous substances.
The dismantling instructions are designed for an F-code (truck family)
and then divided into different C-codes (parts and functions on the
truck.) These C-codes are:
• 0000 Chassis
• 1000 Motors
• 2000 Transmission/drive transmission
• 3000 Brakes/belt/wheel system
• 4000 Steering system
• 5000 Electrical system
• 6000 Hydraulics/pneumatics
• 7000 Working function - lift frame
• 8000 Auxiliary/installation equipment
• 9000 Accessories/extra equipment
The instructions do not tell you the type of material the parts are made
of, but refer you to different material containers where the parts should
be collected. Some plastics are marked, which means some instruc-
tions refer to the marking to determine the collection container to use.
15.2 Procedure
When sorting a component part you must know what plastic parts, liq-
uids, environmentally hazardous substances and metals it incorpo-
rates.
15.3 Abbreviations
Abbreviations for Service Manuals and plastic materials are used in the
dismantling instructions. The abbreviations used are:
ABS = Acrylonitrile-butadiene-styrene
PMMA = Plexiglas
PP = Polypropylene
SM = Service Manual

Sorting
649, 783 918789- 2006-10-27 235317-040
15.4 Sorting
The sorting method for component parts is based on how you can recy-
cle them and whether they must be handled in a special way.
• Plastics must first and foremost be sorted into recyclable and non
recyclable plastics. Plastics that can be recycled must be subdivided
to differentiate between the different types of plastic. Instructions ei-
ther indicate in which container the plastic should be placed or there
is a reference to the material marking on the plastic component. In
those cases where the container is indicated, the type of plastic is
shown by an abbreviation.
Sorting is not necessary for non-recyclable plastics. These are
placed in the container intended for combustible material.
• Small plastic and rubber items are placed in the container intended
for combustible material.
• Iron and steel scrap are sorted separately.
• Composite scrap that is difficult to dismantle and which contains dif-
ferent metals such as steel, aluminium, copper and other materials,
for example, plastics, should be sorted separately.
• Oil is collected in the intended container.
• Oil filters are collected in the intended container.
• Parts contaminated by oil, such as hydraulic hoses, should be sort-
ed separately.
• Batteries should be returned to the manufacturer, either directly to
the manufacturer or through BT.
• Electronic scrap should be sorted from other scrap.
• Cables should be removed and collected separately.
• Small parts, such as screw, bolts, nuts, washers, etc. are not includ-
ed in the dismantling instructions. These are placed in the container
intended for iron and steel scrap.

Hoods, hatches (0340)
235317-040 2006-10-27 918789- 649, 783
15.5 Hoods, hatches (0340)
3
Fig. 21 Hoods, covers
15.5.1 Disassembly
• Remove the hood Fig. 21 (1).
• Remove the plastic handles Fig. 21 (2).
• Remove the hatch Fig. 21 (3).
15.5.2 Material handling

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

Battery cover (0340)
649, 783 918789- 2006-10-27 235317-040
15.6 Battery cover (0340)
Fig. 22 Battery cover
15.6.1 Disassembly
• Remove the skidding protection Fig. 22 (1).
• Remove the battery panel Fig. 22 (2).

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

Frame/chassis (0300) and fork frame (0380/7000)
235317-040 2006-10-27 918789- 649, 783
15.7 Frame/chassis (0300) and

fork frame (0380/7000)
Fig. 23 Fork body
15.7.1 Disassembly
• For dismantling see SM.
• Dismantling of wheel see 3500.

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

Seat, cushions (0620)
649, 783 918789- 2006-10-27 235317-040
15.8 Seat, cushions (0620)

1
2
Fig. 24 Operator's seat
15.8.1 Disassembly
• Remove the cushion Fig. 24(1 alt. 2).

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

Wall/floor covering (0670)
235317-040 2006-10-27 918789- 649, 783
15.9 Wall/floor covering (0670)
1
2
Fig. 25 Wall/floor covering
15.9.1 Disassembly
• Remove the carpet Fig. 25 (1).
• Remove the plate Fig. 25 (2).

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

Internal fittings (0680)
649, 783 918789- 2006-10-27 235317-040
15.10 Internal fittings (0680)
1
1
Fig. 26 Interior components

3
15.10.1 Disassembly
• Remove the panels Fig. 26 (1).
• Remove the carpet Fig. 26 (2).
• Remove the skidding protection Fig. 26 (3).
• Remove the foot step Fig. 26 (4).

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

Operator protection (0840)
235317-040 2006-10-27 918789- 649, 783
15.11 Operator protection (0840)
Fig. 27 Operator protection device
15.11.1 Disassembly
• Remove the operator protection device.

The operator protection device should be placed in a container intend-
ed for iron and steel scrap.

Electric motors (1700)
649, 783 918789- 2006-10-27 235317-040
15.12 Electric motors (1700)
1
3
Fig. 28 Electric motors
15.12.1 Disassembly
• Remove the cables.
• Remove the steering motor Fig. 28 (1).
• Remove the pump motor including pump Fig. 28 (2) (see 6100).
• Remove the drive motor including the electric parking brake from the
gearbox Fig. 28 (3).

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

Drive assembly/gear (2550)
235317-040 2006-10-27 918789- 649, 783
15.13 Drive assembly/gear (2550)
Fig. 29 Driving gear
15.13.1 Disassembly
• Empty the oil from the gearbox.
• Remove the gearbox from the drive motor (se SM).
• Remove the drive wheel.

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

Wheels (3500)
649, 783 918789- 2006-10-27 235317-040
15.14 Wheels (3500)
Fig. 30 Wheels
15.14.1 Disassembly
• Remove the drive wheel, support arm wheel, fork wheel and climber
wheel.

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

Steering unit (4110)
235317-040 2006-10-27 918789- 649, 783
15.15 Steering unit (4110)
1
Fig. 31 Steering unit
15.15.1 Disassembly
• Remove the steering unit from the cover Fig. 31(1).
• Remove the cable.

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

General electronic equipment (5100)
649, 783 918789- 2006-10-27 235317-040
15.16 General electronic equipment

(5100)
Fig. 32 General electronic equipment
15.16.1 Disassembly
• Remove the cables.
• Remove the battery.

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

Battery cut out connector/contactor (5190)
235317-040 2006-10-27 918789- 649, 783
15.17 Battery cut out connector/

contactor (5190)
Fig. 33 Main contactor
15.17.1 Disassembly
• Remove the electric panel with battery cut out connector/ contactor
and transistor panel.

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

Extra I/O module (5730)
649, 783 918789- 2006-10-27 235317-040
15.18 Extra I/O module (5730)
Fig. 34 Extra I/O module
15.18.1 Disassembly
• Remove extra I/O module

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

Hydraulic unit (6100)
235317-040 2006-10-27 918789- 649, 783
15.19 Hydraulic unit (6100)

1710
1
2
Fig. 35 Hydraulic unit
15.19.1 Disassembly
• Empty the oil from the hydraulics.
• Remove oil-filter from tank Fig. 35 (1).
• Remove the hydraulic cables (see 6230).
• Remove the oil tank Fig. 35 (2).
• Remove the hydraulic unit (motor + pump) (see 1710).

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

Hydraulic lines chassis (6230) and main lift cylinders (6610)
649, 783 918789- 2006-10-27 235317-040
15.20 Hydraulic lines chassis (6230)

and main lift cylinders (6610)
6610
6100
Fig. 36 Hydraulic oil lines
15.20.1 Disassembly
• Remove the cylinder.
• Empty the oil from the cylinders
• Remove hydraulic cables

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

Charger adaptor (9380)
235317-040 2006-10-27 918789- 649, 783
15.21 Charger adaptor (9380)

2
1
Fig. 37 Charger adapter
15.21.1 Disassembly
• Charger adaptor Fig. 37 (1) comes with the battery.
• Remove the charger adaptor Fig. 37 (2).

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

Terminal on board (9410)
649, 783 918789- 2006-10-27 235317-040
15.22 Terminal on board (9410)

1
Fig. 38 Terminal on board
15.22.1 Disassembly
• Remove housing (1).
• Remove the terminal (2).
• Remove the bracket (3).
• Remove the hose (4).
• Remove the spiral spring from the hose.

The terminal should be placed in a container for dangerous waste
The housing should be placed in a container for ABS.
The bracket and the spiral spring should be placed in a container
intended for iron and steel scrap.
The hose should be placed in a container intended for combustible
material.
Other extra equipment, tuck log device (9420)
235317-040 2006-10-27 918789- 649, 783
15.23 Other extra equipment, tuck log

device (9420)
Fig. 39 Truck log device
15.23.1 Disassembly
• Remove the truck log device.
• Remove wiring harness.

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

Other extra equipment, load support (9500)
649, 783 918789- 2006-10-27 235317-040
15.24 Other extra equipment, load

support (9500)
Fig. 40 Load support
15.24.1 Disassembly
• Remove the load support.
• Remove the finger cover.

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

Other extra equipment, writing table (9500)
235317-040 2006-10-27 918789- 649, 783
15.25 Other extra equipment, writing

table (9500)
1
Fig. 41 Writing table
15.25.1 Disassembly
• Remove the writing table Fig. 41 (1).
• Remove the clamp Fig. 41 (2).
• Remove the support Fig. 41 (3).

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

Other extra equipment, writing table (9500)
649, 783 918789- 2006-10-27 235317-040
15.26 Other extra equipment, writing

table (9500)
1
Fig. 42 Writing table
15.26.1 Disassembly
• Remove the writing table (1).

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

Other extra equipment, support (9500)
235317-040 2006-10-27 918789- 649, 783
15.27 Other extra equipment, support

(9500)
Fig. 43 Holder
15.27.1 Disassembly
• Remove the support.

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

Other extra equipment, collision protection (9500)
649, 783 918789- 2006-10-27 235317-040
15.28 Other extra equipment, collision

protection (9500)
Fig. 44 Collision protection
15.28.1 Disassembly
• Remove the collision protection.

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

Other extra equipment, working cage (9130)
235317-040 2006-10-27 918789- 649, 783
15.29 Other extra equipment, working

cage (9130)
Fig. 45 Working cage 1
2
3
6
5 4
15.29.1 Disassembly
• Remove the 4 screws Fig. 45 (6) that holds the working cage.
• Remove the hydraulic hose Fig. 45 (7) from the lift cylinder.
• The working cage can now be lifted straight up.

The working cage Fig. 45 (1) should be placed in a container intended
for iron and steel scrap.
The wiring harness with chain is dismounted and placed in a container
intended for ABS.
The wiring harness Fig. 45 (3) should be placed in a container intended
for cables
The carpet Fig. 45 (4) should be placed in a container for dangerous
waste.
The sensing device Fig. 45 (5) should be placed in a container intended
for electronic scrap.

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

Service Manual En: OSE120, OSE120P, OSE250, OSE250P

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Service Manual en

OSE120, OSE120P, OSE250, OSE250P

Order number: 235317-040

Issue date Order Changes

This manual covers following truck models:

T-code Model Serial number

© BT Europe AB Service Manual OSE120, OSE120P, OSE250, OSE250P

3- Maintenance ........................................................................................ 3-1

4- Tools ..................................................................................................... 4-1

5- Fork carriage – 0380 ............................................................................ 5-1

6- Electric drive motor – 1760 ................................................................. 6-1

© BT Europe AB Service Manual OSE120, OSE120P, OSE250, OSE250P 1- 1

7- Drive unit/gear – 2550 ......................................................................... 7-1

8- Electromagnetic brake – 3370 ............................................................ 8-1

9- Swivel wheel – 3540 ............................................................................ 9-1

10- Electrical steering system – 4300 .................................................. 10-1

1- 2 Service Manual OSE120, OSE120P, OSE250, OSE250P © BT Europe AB

11- Electrical systems – 5000 ............................................................... 11-1

# 21 - Battery size ........................................................ 11-70

12- Hydraulic system – 6000 ................................................................. 12-1

1- 4 Service Manual OSE120, OSE120P, OSE250, OSE250P © BT Europe AB

13- Main lift chain system – 7120 ......................................................... 13-1

14- Platform – 9130 ................................................................................ 14-1

15- Destruction instructions ................................................................. 15-1

© BT Europe AB Service Manual OSE120, OSE120P, OSE250, OSE250P 1- 5

15.12.2 Material handling ......................................................... 15-10

1- 6 Service Manual OSE120, OSE120P, OSE250, OSE250P © BT Europe AB

Table 1: Technical data

© BT Europe AB Service Manual OSE120, OSE120P, OSE250, OSE250P 2- 1

Table 1: Technical data

2- 2 Service Manual OSE120, OSE120P, OSE250, OSE250P © BT Europe AB

Table 1: Technical data

© BT Europe AB Service Manual OSE120, OSE120P, OSE250, OSE250P 2- 3

Table 1: Technical data

Lift to max. height with load 0.10m/s 0.10m/s 0.049m/s 0.035m/s

2- 4 Service Manual OSE120, OSE120P, OSE250, OSE250P © BT Europe AB

2.1 Specific tightening torques

Table 2: Specific tightening torques

© BT Europe AB Service Manual OSE120, OSE120P, OSE250, OSE250P 2- 5

2.2 General tightening torques

Table 3: General tightening torques

M12 M14 M16 M20 M24

2- 6 Service Manual OSE120, OSE120P, OSE250, OSE250P © BT Europe AB

3.1 Safety rules during maintenance

© BT Europe AB Service Manual OSE120, OSE120P, OSE250, OSE250P 3- 1

• Prior to commencing any work on the hydraulic system of the truck,

3- 2 Service Manual OSE120, OSE120P, OSE250, OSE250P © BT Europe AB

3.2 Cleaning and washing

3.2.1 External cleaning

3.2.2 Cleaning the motor compartment

3.2.3 Electric components

© BT Europe AB Service Manual OSE120, OSE120P, OSE250, OSE250P 3- 3

3.3 Safe lifting

3- 4 Service Manual OSE120, OSE120P, OSE250, OSE250P © BT Europe AB

3.4 Lifting the truck

© BT Europe AB Service Manual OSE120, OSE120P, OSE250, OSE250P 3- 5

3.5 Maintenance schedule

Table 4: Maintenance schedule

Pos. Work to carry out

3- 6 Service Manual OSE120, OSE120P, OSE250, OSE250P © BT Europe AB

Table 4: Maintenance schedule

Pos. Work to carry out