Master Service Manual Product Family OL

Master Service Manual
Product family OL
BT PPO 1500 MX
BT OS 1.0
BT OS 1.0 W
BT OS 1.0 HW
BT OS 1.0 WL
BT OS 1.2 CB
BT OS 1.8 X
BT OS 2.0
BT OS 3.0
Ring binder number: Part number: 147638-040

© BT Industries AB Issued: 1994-12-01 SSD
F-code Section C-code
OL
Introduction to BT’s Service Manual
IIssued by Approved by Version no T-code
SSD 001
Introduction to BT’s
Service Manual
This Service manual contains product information regarding
the current trucks including the technical data and instructions
for maintenance and service. It includes the operator’s
Instruction Manual, Spare Part Handbook and oil and grease
specifications:
M Machine information
P Preventive maintenance
S Service instructions
O Options
At the top of each page you can find information on which
section the page belongs: Section M 4 means that it is Tech-
nical Data; F-code means it deals with this specific truck fam-
ily; T-code means specific products; Date and Version
number give information on when the page was issued and
which version.
It is our ambition to send modification notifications concerning
improvements to you as soon as possible. It’s stated on the
notifications which section/s in the binder should be replaced.
Notifications should be inserted immediately so that the
binder always contains current service information.
When contacting BT’s technical support always have the
actual Service Manual close at hand. If you have any views
regarding the Service Manual, please contact your training
officer at BT who will forward your views to the technical doc-
umentation department.
This document can be available on different media and will
have different part numbers. Please see the following exam-
ple:
XXXXXX-040= An English document on paper
XXXXXX-04C= The same document but on CD-ROM
© BT Industries AB Service Manual 1998-11-04 English 1 (2)

OL
Introduction to BT’s Service Manual
Version no T-code
001
2 (2) Service Manual 1998-11-04 English

2/
&RQWHQWV0DVWHU6HUYLFH0DQXDO060
66' 8*UHQEODG ±±
&RQWHQWV
0DVWHU6HUYLFH0DQXDO060
3DUWQXPEHU
,VVXHG
Valid from serial number:
7FRGH 0RGHO 6HULDO1R 1RWHV

342 OS 1.8X 305487AA-
345 OS 2.0 256600AA-
346 OS 3.0 256600AA-
347 OS 1.0W 256600AA-
348 OS 1.0 256600AA-
423 OS 1.2CB 306381AA-
424 OS 1.0HW 317556AA-
425 OS 1.0WL 295610AA-
'RFXPHQWOLVW
6HFWLRQ &FRGH 7FRGH 'RFXPHQW ,VVXHG
203 Contens Master Service 1998-11-04
Manual (MSM)
M Contents, M 1998-11-04
M1 203 Operator’s manual 1998-11-09
M2 345 General product information 1994-12-23
M4 203 Technical service data 1998-06-02
M6 Ordering Spare Parts 1998-11-04
M7 203 Quality Parts 1998-11-10
M8 203 Recommended Spare Parts 1999-09-01
(RSP)

2/
Version no T-code
±±

P Contents P 1998-11-04
P1 Introduction, maintenance 1998-11-04
P2 203 Preventive maintenance 1998-01-09
P2 342 Preventive maintenance 1999-05-27
P3 203 Oil and grease specification 1998-01-09
P3 342 Oil and grease specification 1995-03-15
S Contents S 1998-11-04
S0 0380 345 Fork unit 1995-03-15
S2 2550 203 Driving gear 1995-08-29
S2 2550 342 Driving gear 1995-01-03
S3 3360 203 Mechanical brakes 1998-01-09
S3 3370.1 345 Electro magnetic brake 1996-10-22
S3 3370.2 342 Electro magnetic brake 1999-03-23
S3 3540.1 345 Castor wheel 1995-03-09
S3 3540.2 342 Castor wheel 1999-05-12
S3 3540 347 Castor wheel 1998-01-09
S4 4100.1 345 Electrical steering wheel 1995-01-04
S4 4100.2 342 Electrical steering wheel 1999-03-23
S5 5000.1 203 Electrical system 1995-03-28

2/
Version no T-code
±±

S5 5460 203 Transistor Controller, Curtis 1999-01-02
1207
S5 5460.1 345 Transistor Controller, PUB 1995-12-29
24220 CD2
S5 5460.2 345 Transistor Controller, PUB 1996-01-25
24220 CD2
S5 5460 346 Transistor Controller, PUB 1995-01-05
24350 CD1
S5 5710 203 Connection Card, 1996-01-02
Transistor Control
S5 5710.1 345 Electronic card 1996-01-02
S5 5710.2 345 Electronic card 1995-12-29
S5 5710 346 Electronic card 1996-01-09
S6 6000.2 342 Hydraulic system, 1999-03-01
pneumatic system
S6 6000.1 345 Hydraulic system 1996-02-12
S6 6000 347 Hydraulic system 1998-05-08
S6 6000 425 Hydraulic system 1998-11-18

2/
Version no T-code
±±

OL M
Contents, M
SSD U Grenblad
Contents, M
1 Truck information
M1 Operator’s Manual
M2 General product information
M3 Product sheet
M4 Technical data
M5 Product improvements
M6 Spare Part ordering
M7 Quality Parts
M8 Recommended Spare Parts

OL M
Contents, M
Version no T-code

OL M1
Operator’s manual
SSD U Grenblad 001 203, 345–348, 425
Operator’s manual
T-code Model Serial No Notes

203 PPO 1500MX 249329AA-
342 OS 1.8X 305487AA-
345 OS 2.0 256600AA-
346 OS 3.0 262700AA-
347 OS 1.0W 295607GA-
348 OS 1.0 262700AA-
425 OS 1.0WL 295607AA-
1 General
An Operator´s Manual is supplied with every truck. If, for any
reason, the customer does not obtain an Operator´s Manual,
they can be ordered from BT. In the table below, you can see
which Operator´s Manuals are available for this machine
series.
1.1 Issued operator’s manuals
T-code Model Serial number Order Issued

number
203 PPO1500MX 277313AA-293314AA 147350 1996-04-10
203 PPO1500MX 293315AA-298799AA 156054 1996-10-16
203 PPO1500MX 298800AA-306954AA 157359 1997-04-08
203 PPO1500MX 306955AA-324213AA 161282 1998-02-06
203 PPO1500MX 324214AA- 166154 1998-08-11
342 OS1.0 1.8X 305140AA-317174AA 160410 1997-08-22
342 OS1.0 1.8X. 317175AA- 164455 1998-03-17
345 OS2.0 277116AA-282236AA 150209 1995-08-25
345 OS2.0 282237AA-289678AA 153224 1996-03-20
345 OS2.0 289679AA-295606AA 154800 1996-08-19

OL M1
Operator’s manual
Version no T-code
001 203, 345–348, 425
T-code Model Serial number Order Issued

number
345 OS2.0 295607AA-305139AA 157329 1997-01-15
345 346 OS2.0 OS3.0 305140AA-317174AA 160409 1997-08-21
305140AA-317174AA 160409 1997-08-21
345 346 OS2.0 OS3.0 317175AA- 164456 1998-03-10
317175AA- 164456 1998-03-10
346 OS3.0 277116AA-282236AA 150210 1995-08-24
346 OS3.0 282237AA-289678AA 153225 1996-03-20
346 OS3.0 289679AA-295606AA 154801 1996-08-20
346 OS3.0 295607AA-305139AA 157329 1997-01-15
347 OS1.0W 295607GA- 845107 1997-04-23
348 OS1.0 277116AA-282236AA 150208 1995-08-23
348 OS1.0 282237AA-289678AA 153223 1996-03-20
348 OS1.0 289679AA-295606AA 154799 1996-08-20
348 OS1.0 295607AA-305139AA 157328 1997-01-17
425 OS1.0WL 295607AA- 845118 1997-05-05

OL M2
General product information
SSD K. Hallman 001 345,346


345 OS 2.0 256600AA-
346 OS 3.0 256600AA-
1 General description
BT OS 2.0/OS 3.0 is an order picking truck for picking goods
or products from floor level. In it’s basic design is the truck
equipped with a tiller arm for being alternatively operated
standing in the drivers compartment or walking at the side of
the truck. The speed is reduced to a suitable walking speed
when the truck is operated walking at side. In it’s basic design
the truck is only meant to be used for picking from the floor or
the 1:st level.
BT OS 2.0/OS 3.0 can be equipped with different options
such as foot step, anti-slip carpet and hand rail for picking
from the 2:nd level, and electrical steering wheel.
BT OS 2.0 has a maximum lifting capacity of 2000kg and OS
3.0 3000 kg.
The truck has a 24V electrical system and the speed is regu-
lated by means of a transistor controller to provide gentle con-
trol of acceleration and the speed while driving.
For stability and safety reasons is the speed in the fork direc-
tion lower than the speed forward.
The forks are lifted by using a powerful and compact hydraulic
unit that is automatically shut-off when the forks reach their
highest lifting position. The automatic shut-off is used to
increase the service life of the hydraulic components and
reduce the power consumption from the battery.

OL M2
Version no T-code
001 345,346
1.1 Intended application of OS 2.0/OS 3.0

BT OS 2.0/OS 3.0 is designed and manufactured purely to be
your tool to carry out order picking inside the warehouse. The
truck shall be adapted to the application by using the appro-
priate available options.
1.2 Forbidden application of OS 2.0/OS 3.0

As BT OS 2.0/OS 3.0 is designed for indoor order picking, it is
forbidden to use to the truck for other purposes including the
following:
• In areas that contain gases which can cause fires or explo-
sions.
• As a tow truck for trailers.
• For towing other trucks.
• For transporting or lifting passengers.
• Driving on grass or gravel.

OL M2
Version no T-code
001 345,346
2 Truck data
The table provides information regarding some technical
data, which is of value with daily use of the truck.
Model designation OS 2.0 OS 3.0

Lifting capacity 2000 3000
classified load, kg
Lifting height, mm 205 205
Platform height, mm 125 125
Operating speed forward 12.0 12.0
without load, km/h
Operating speed forward 9.3 8.0
with load, km/h
Operating speed in fork direc- 9.0 9.0
tion without load, km/h
Operating speed in fork direc- 7.0 7.0
tion with load, km/h
Hill climbing capacity 5 5
with load,%
Service weight without 700 -870 770 -950
battery kg
Service weight with 1050 (320) 1070 (360)
battery, kg (Ah) 1270 (600) 1450 (600)
Turning radius with raised 2230 - 3140 2370 - 3140
forks. Wa, mm (depending on
fork length and battery size)
Continuous noise level. dB < 70 < 70
(A))
Vibration level. < 2,5 < 2,5
m/s2
For further dimensions refer to the diagram in section Truck

dimensions.

OL M2
Version no T-code
001 345,346
3 Truck dimensions
The diagram shows external dimensions for the truck in its
standard design.
OS2.0 OS3.0
A 660 800
B 1305 1445

OL M2
Version no T-code
001 345,346
4 Presentation of main components

The truck’s main components are presented in the diagram
and description here below.
1. Tiller arm;
The truck can be manoeuvred by the operator standing in
the drivers compartment or walking by the side of the
truck. When walking alongside the truch the speed is
reduced to 5.0 km/h. The brake is applied in the upper
and lower position of the arm. The upper stop position of
the arm is adjustable.
2. Type plate;
With type designation, manufacturer, serial number, year
of manufacture, service weight, battery weight, classified
lifting capacity and battery voltage.
3. Removable cover;
Provide good accessibility when servicing.
4. Castor wheel;
One adjustable castor wheel to ensure stability.
5. Electrical panel;
Electrical components fitted to one panel. 24 volt electri-
cal system. Speed control; Variable transistor regulator.
6. Drive unit with brakes;
Drive motor, gears and drive wheel combined into a com-
pact unit. Steering bearings between the motor and
gears.
7. Electrical steering motor;
For steering wheel.
8. Hydraulic unit;
Pump motor, pump, valves and oil tank integrated in a
compact unit.
9. Serial number;
Punched machine serial number plate fitted to the chas-
sis.
10. Control circuit fuse:
10A, BT part no. 122308-100.
11. Fuse for electrical steering wheel:
20A, BT part no. 122308-200.
12. Pump motor fuse:
100A, BT part no. 29228.
13. Drive motor fuse:
125A, BT part no. 29584.
14. Lifting points;
For the machine weight, see the type plate.

OL M2
Version no T-code
001 345,346
15. Battery/Recharging connector;

The battery is recharged via the battery connector
mounted on the battery.
16. Battery:
24 Volt.
17. Fork carriage;
The forks are held horizontal by a link system. The fork
carriage requires no lubrication.
18. Push buttons for driving from the side (Option):
Two push buttons allows driving walking alongside the
truck. Driving can only be manitained as long as the drive
wheel is straight. The speed is reduced to 5.0 km/h when
driving from the side.
19. Emergency switch off:
Two emergency switch off buttons placed on the top of
the backrest.
20. Cushion:
Adjustable in four positions.
21. Steering wheel:
The truck is operated standing in the drivers compart-
ment. Adjustable steering wheel height and angle. For
2:nd level picking can the steering wheel be folded up
completely.

OL M2
Version no T-code
001 345,346

OL M2
Version no T-code
001 345,346
5 Signs on the truck

The figure shows the placement and significance of all signs
located on the truck.
.
M-PLATE A
TYPE B
S/NO C D
CODE NO DATE
E F G
1. Signal/Horn
2. Hydraulic control: Lift
3. Hydraulic control: Lower
4. Brake
5. Travel direction
6. Hydraulic control: Lifting/Lowering
7. Travel direction
8. Signal/Horn
9. Identification plate
10. Lifting points
11. Modification plate
OL M4
Technical service data
SSD L-G Andersson 001 203


203 PPO 1500 MX 249329AA-
MODELL PPO 1500MX

Drive motor
Type TTL 140S-M2
Power, kW 1,2
Intermittens, % 60
Min carbon brush length, mm 12
Min commutator diameter, mm 47
Transmission/gear
Type 2-step angular
Gear ratio 19.14:1
Oil volume, liter 1,0
Oil type Hypoid oil
Normal temperature SAE 80W/90
< -15oC SAE 75W
Wheels
Drive wheel, mm Dia 215x70
Axle pressure without load, kg 355
Axle pressure with rated load, kg 415
Torque wheel screws, Nm 65 Nm
Fork wheel, mm Dia 85
Axle pressure without load, kg 180
Axle pressure with rated load, kg 1620
Support wheel, mm Dia 125x40
Axle pressure without load, kg 2x95
Axle pressure with rated load, kg 2x95

OL M4
Version no T-code
001 203
MODELL PPO 1500MX

Hydraulic unit
Power, kW 2
Revolutions/min at work pressure 3000
Intermittens, % 10
Min carbon brush length, mm 12
Min commutator diameter, mm 4.75
Pressure at rated load,bar 150
Relief pressure, bar 175
Pump flow, litre/min 5
Tankvolume, litre 1,0
Oil type Hypoid oil
Normal temperature ISO-L-HM32
< -15oC ISO-L-HV32
Fuses
Motor circuits, A 100
Control circuit, A 7,5
Batteries
Dimension WxLxH, mm 196x645x570/
245x645x570
Capacity, Ah 240/320
Weight, kg 200/250
Driving speeds
Without load, km/h 5,9 alt. 7,9
Without load, m/s 1,65 alt. 2,2
With rated load, km/h 5,0 alt. 6,5
With rated load, m/s 1,40 alt. 1,8

OL M4
Version no T-code
001 203
MODELL PPO 1500MX

Lifting/lowering time
Lift without load, s 1,7
Lift with rated load, s 2,3
Lower without load, s 2,2
Lower with rated load, s 1,9
Current consumption
Driving without load, A 35
Driving with rated load, A 46
Lifting without load, A 55
Lifting with rated load, A 104

OL M4
Version no T-code
001 203

OL M4
SSD P-Å Gustafsson 001 342, 347, 425


342 OS1.8X 305487AA-
347 OS1,0W 256600AA-
425 OS1,0WL 295610AA-
MODEL OS 1.8X OS 1,0W OS 1,0WL

DRIVE MOTOR
Type TTL 140BB-D2 TTL 140BB-D2 TTL 140BB-D2
Power, kW 1,8 1,8 1,8
Intermittens, % 60 60 60
Min carbon brush length, 12 12 12
mm
Min commutator diameter, 60 60 60
mm
Part no 160606 160606 160606
TRANSMISSION/GEAR
Type 2-step angular 2-step angular 2-step angular
Gear ratio 12.48:1 12.48:1 12.48:1
Oil volume, liter 1,75 1,75 1,75
Oil type Hypoid oil Hypoid oil Hypoid oil
Normal SAE 80W/90 SAE 80W/90 SAE 80W/90
temperature
< -15o C SAE 75W SAE 75W SAE 75W

OL M4
Version no T-code
001 342, 347, 425

WHEELS
Drive wheel, mm Dia 250x75 Dia 250x105 Dia 250x105
Wheel pressure without 560 kg (±100) 883 kg (±50) 932kg (±50)
load
Wheel pressure with rated 690 kg (±100) 393 kg (±50) 445kg (±50)
load
Torque wheel bolts, Nm 90 90 90
Fork wheel, mm Dia 85x75 Dia 140x60 Dia 140x60
Axle pressure with rated 2030 (±300) 2300 (±100) 2298 (±100)
load, kg
Torque axle bolts, Nm 60 60 60
Support wheel, mm 2x Dia 150x50 1x Dia 150x75 1x Dia 150x75
Axle pressure, kg 360 (±100) 50 (-10) 50 (-10)
HYDRAULIC UNIT
Power, kW 2,0 2,0 2,0
Revolutions/min at work 2400 2400 2400
pressure
Intermittens, % 11 11 11
Min carbon brush length, 8 8 8
mm
Min commutator diameter, 43 43 43
mm
Pressure at rated load, bar 165 160 165
Relief pressure, bar 175 170 175
Pump flow, l/min 6 l at 165 bar 6 l at 160 bar 6 l at 165 bar
Tank volume, l 2 1,5 1,5
Oil type Hydraulic oil Hydraulic oil Hydraulic oil
Normal ISO-L-HM32 ISO-L-HM32 ISO-L-HM32
temperature
< -15 oC ISO-L-HV32 ISO-L-HV32 ISO-L-HV32

OL M4
Version no T-code
001 342, 347, 425

FUSES
Drive motor circuit P/N 29584 P/N 29584 P/N 29223
Amperage, A 125 125 125
Pump motor circuit P/N 29228 P/N 29228 P/N 29228
Amperage, A 100 100 100
Control circuit P/N 122308-100 P/N 122308-100 P/N 122308-100
Amperage, A 10 10 10
BATTERIES ALL MODELS
Dimension WxLxH, mm 212 x 584 x 600 353 x 621 x 630
353 x 621 x 775
Capacity, Ah 220/600 360/480
Weight, kg 210/500
Part No. 143048-203 /
143047-201
DRIVING SPEEDS
Without load, direction of 12,0 km/h, 3,3 m/s 10 km/h, 2,8 m/s 10 km/h, 2,8 m/s
the steering wheel
Without load, direction of 10,5 km/h, 2,9 m/s 10 km/h, 2,8 m/s 10 km/h, 2,8 m/s
forks
With classified load, direc- 9,5 km/h, 2,6 m/s
tion of the steering wheel,
forks raised < 500 mm
With classified load, direc- 4 km/h, 1,1 m/s
tion of the steering wheel,
forks raised > 500 mm
With classified load, direc- 8,1 km/h, 2,2 m/s
tion of forks, forks raised <
500 mm
With classified load, direc- 4km/h, 1,1 m/s
tion of forks, forks raised >
500 mm
With load >750 kg in both 6 km/h, 1,7m/s 6 km/h, 1,7m/s
directionse

OL M4
Version no T-code
001 342, 347, 425

LIFTING/LOWERING TIME
Lift without load, m/s 0,094 0,15 0,15
Lift with rated load, m/s 0,062 0,10 0,10
Lower without load, m/s 0,086 0,09 0,09
Lower with rated load, m/s 0,076 0,11 0,11
CURRENT CONSUMPTION
Driving without load
Driving with rated load
Värden för strömför-
Lifting without load
brukning kommer enl
Pågen 99-04-27.
Lifting with rated load

OL M4
SSD K Hallman 345, 346, 348


345 OS2.0 256600AA-
346 OS3.0 256600AA-
348 OS1.0 256600AA
MODEL OS 1.0 OS 2.0 OS 3.0
DRIVE MOTOR
Type TTL 140BB-D2 TTL 140BB-D2 TTL 160-D35
Power 1.8 kW 1.8 kW 2.7 kW
Intermittens 60% 60% 60%
Min carbon brush 12 mm 12 mm 12 mm
length
Min commutator 60 mm 60 mm 68 mm
diameter
Part no 140324 140324 140326
TRANSMISSION/GEAR
Type 2-step angular 2-step angular 2-step angular
Gear ratio 12.48:1 12.48:1 12.48:1
Oil volume 1.75 liter 1.75 liter 1.75 liter
Oil type Hypoid oil Hypoid oil Hypoid oil
Normal temperature SAE 80W/90 SAE 80W/90 SAE 80W/90
< -15o C SAE 75W SAE 75W SAE 75W

OL M4
Version no T-code
345, 346, 348
WHEELS
Drive wheel Dia 250x75 mm Dia 250x75 mm Dia 250x75 mm
Wheel pressure with- 700 kg (+-100) 510 kg (+-90) 550 kg (+-100)
out load
Wheel pressure with 750 kg (+-100) 730 kg (+-100) 750 kg (+-100)
rated load
Torque wheel bolts 90 Nm 90 Nm 90 Nm
Fork wheel Dia 85x75 mm Dia 85x75 mm Dia 85x75 mm
Axle pressure with 1550 kg (+-150) 2000 kg (+-200) 2900 kg (+-300)
rated load
Torque axle bolts 60 Nm 60 Nm 60 Nm
Support wheel 2x Dia 150x50 mm 2x Dia 150x50 mm 2x Dia 150x40 mm
Axle pressure 550 kg (+-75) 400 kg (+- 100) 450 kg (+- 150)
HYDRAULIC UNIT
Power 2.0 kW 2.0 kW 2.0 kW
Revolutions/min at 2400 2900 2600
work pressure
Intermittens 12% 20% 14%
Min carbon brush 8 mm 8 mm 8 mm
length
Min commutator 43 mm 43 mm 43 mm
diameter
Pressure at rated 145 bar 85 bar 125 bar
load
Relief pressure 150 bar 95 bar 135 bar
Pump flow 6.5 l at 146 bar 7.5 l at 85 bar 6.9 l at 125 bar
Tank volume 1.5 liter 1.5 liter 1.5 liter
Oil type Hydraulic oil Hydraulic oil Hydraulic oil
Normal ISO-L-HM32 ISO-L-HM32 ISO-L-HM32
temperature
< -15 oC ISO-L-HV32 ISO-L-HV32 ISO-L-HV32

OL M4
Version no T-code
345, 346, 348
FUSES
Drive motor circuit P/N 29584 P/N 29584 P/N 29223
Amperage 125 A 125 A 160 A
Pump motor circuit P/N 29228 P/N 29228 P/N 29228
Control circuit P/N 122308-100 P/N 122308-100 P/N 122308-100
BATTERIES ALL MODELS
Dimension WxLxH 212 x 584 x 600 mm / 353 x 621 x 775 mm
Capacity 220 Ah / 600 Ah
Weight 210 kg / 500 kg
Part No 143048-203 / 143047-201
DRIVING SPEEDS
Without load, for- 12.0 km/h, 3.33 m/s 12.0 km/h, 3.33 m/s 12.0 km/h, 3.33 m/s
ward, OS 1.0 forks
lifted <500 mm
Without load, for- 10.5 km/h, 2.91 m/s
ward, OS 1.0 forks
lifted >500 mm
Without load, fork 8.4 km/h, 2.33 m/s 8.4 km/h, 2.33 m/s 8.4 km/h, 2.33 m/s
direction, OS 1.0
forks lifted <500 mm
Without load, fork 8.4 km/h, 2.33 m/s
direction, OS 1.0
forks lifted >500 mm
With rated load, for- 7.9 km/h, 2.19 m/s 9.3 km/h, 2.58 m/s 8.0 km/h, 2.22 m/s
ward, OS 1.0 forks
lifted <500 mm
With rated load, for- 3.5 km/h, 0.97 m/s
ward, OS 1.0 forks
lifted >500 mm

OL M4
Version no T-code
345, 346, 348
With rated load, fork 7.4 km/h, 2.05 m/s 6.5 km/h, 1.80 m/s 6.5 km/h, 1.80 m/s
direction, OS 1.0
forks lifted <500 mm
With rated load, fork 3.5 km/h, 0.97 m/s
direction, OS 1.0
forks lifted >500 mm
LIFTING/LOWERING TIME
Lift without load, m/s 0.18 0.034 0.034
Lift with rated load, 0.10 0.03 0.03
m/s
Lower without load, 0.18 0.024 0.024
m/s
Lower with rated 0.15 0.03 0.03
load, m/s
CURRENT CONSUMPTION
Driving without load 53 A 61 A
Driving with rated 72 A 95 A
load
Lifting without load 32 A 32 A
Lifting with rated load 75 A 95 A

OL M6
Ordering Spare Parts
SSD Morgan Käll 001

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

OL M6
Version no T-code
001

OL M7
Quality Parts
SSD Iréne Karlsson 001 203,342,345,346,348
Quality Parts

203 PPO1500MX 247364AA-
342 OS1.8X 305139AA-
345 OS2.0 256600AA-
346 OS3.0 262700AA-
348 OS1.0 262700AA-
382 OS 2.0 TT 295607-
423 OS1.0 CB 306381-
424 OS1.0 HW 317556-
425 OS1.0 WL 289679-
1 Issued Quality Parts
T-code Model Serial No Order number Issued

203 PPO 1500MX 247364AA-247369AA 138891 1993-06
203 PPO 1500MX 247370AA255244AA 140955 1994-02
203 PPO 1500MX 255245AA-268676AA 143017 1994-05
203 PPO 1500MX 268677AA-284058AA 148186 1995-05
203 PPO 1500MX 284059AA-293314AA 152382 1996-04
203 PPO 1500MX 293315AA- 154668 1996-12
203 PPO 1500MX 306955AA- 161051 1997-10-31
203 PPO 1500MX 316740AA- 163644 1998-03-31
342 OS 1.8X 305139AA-315965AA 160742 1997-09-02
342 OS 1.8X 315966AA-325961AA 164458 1998-03-21
342 OS 1.8X 335962AA- 165547 1998-09-23
345 OS 2.0 256600AA-268926AA 143027 1994-11-14
345 OS 2.0 268927AA-271425AA 147898 1995-05-05

OL M7
Quality Parts
Version no T-code
001 203,342,345,346,348

345 OS 2.0 271426AA-275188AA 149589 1995-06-20
345 OS 2.0 275189AA-282236AA 149604 1995-10-04
345 OS 2.0 282237AA-289678AA 152104 1996-02-21
345 OS 2.0 289679AA-295606AA 154797 1996-09-10
345 OS 2.0 295607AA-305138AA 156816 1997-01-24
345 OS 2.0 305139AA-305965AA 160406 1997-09-03
345 OS 2.0 315966AA-325961AA 164459 1998-03-24
345 OS 2.0 325962AA- 165543 1998-09-23
346 OS 3.0 262700AA-268926AA 145513 1994-11-18
346 OS 3.0 268927AA-271425AA 147899 1995-05-04
346 OS 3.0 271426AA-275188AA 149590 1995-06-20
346 OS 3.0 275189AA-282236AA 149605 1995-10-04
346 OS 3.0 282237AA-289678AA 152105 1996-02-26
346 OS 3.0 289679AA-295606AA 154798 1996-09-11
346 OS 3.0 295607AA-305138AA 156817 1997-03-20
346 OS 3.0 305139AA-315965AA 160407 1997-09-03
346 OS 3.0 315966AA-325961AA 164460 1998-03-24
346 OS 3.0 325962AA- 165545 1998-09-23
348 OS 1.0 262700AA-268926AA 145514 1995-03-23
348 OS 1.0 268927AA-271425AA 147897 1995-05-03
348 OS 1.0 271426AA-275188AA 149588 1995-06-20
348 OS 1.0 275189AA-282236AA 149603 1995-10-04
348 OS 1.0 282237AA-289678AA 152103 1996-02-26
348 OS 1.0 289679AA-295606AA 154796 1996-09-11
348 OS 1.0 295607AA-305138AA 156815 1997-01-23
348 OS 1.0 305139AA-315965AA 160408 1997-09-02
348 OS 1.0 315966AA-325961AA 164457 1998-03-23
348 OS 1.0 325962AA- 165546 1998-09-23
382 OS 2.0 TT 295607- 845170 1997-12-08

OL M7
Quality Parts
Version no T-code
001 203,342,345,346,348

423 OS 1.2 CB 306381- 845225 1998-10-28
424 OS1.0 HW 371556- 845218 1998-05-08
425 OS 1.0WL 289679 845065 1997-02-03
425 OS 1.0WL 295607- 854119 1997-05-05
425 OS 1.0WL 336630- 845119 1999-04-08
425 OS 1.0WL 339900- 845119 1999-07-16

OL M7
Quality Parts
Version no T-code
001 203,342,345,346,348

OL M8
Recommended Spare Parts (RSP)
SSD U Grenblad 001 203,342,345–348


203 PPO 1500MX 255245AA-
342 OS 1.8X 305487AA-
345 OS 2.0 256600AA-
346 OS 3.0 256600AA-
347 OS 1.0W 256600AA-
348 OS 1.0 256600AA-
1 Issued RSP
T-code Model Serial No Issued

203 PPO 1500 MX 257919–293314 1996-12-17
203 PPO 1500 MX 335439– 1998-05-20
203 PPO 1500 MX 293315–306954 1998-09-01
203 PPO 1500 MX 306955–316739 1998-09-02
203 PPO 1500 MX 316740–324213 1998-09-02
203 PPO 1500 MX 324214–335438 1998-11-05
342 OS 1.8 X 305139AA–315995AA 1997-09-02
342 OS 1.8 X 315996AA–325962AA 1998-05-04
342 OS 1.8 X 325962AA–336995AA 1998-10-16
342 OS 1.8 X 336996AA– 1999-05-31
345 OS 2.0 256600– 1994-07-01
345 OS 2.0 256600–268926 1995-05-31
345 OS 2.0 268927–275188 1995-10-20
345 OS 2.0 275189–289678 1996-03-05
345 OS 2.0 289679–295606 1996-08-15
345 OS 2.0 295607AA– 1997-01-30

OL M8
Version no T-code
001 203,342,345–348
T-code Model Serial No Issued

345 OS 2.0 305139AA–315995AA 1997-09-02
345 OS 2.0 315996AA–325961AA 1998-04-30
345 OS 2.0 325962AA–336995AA 1998-10-06
345 OS 2.0 336996AA– 1999-05-27
346 OS 3.0 262700– 1994-12-21
346 OS 3.0 262700–268926 1995-06-01
346 OS 3.0 268927–275188 1995-06-01
346 OS 3.0 275189–289678 1996-03-05
346 OS 3.0 289679–295606 1996-08-15
346 OS 3.0 295607AA– 1997-01-30
346 OS 3.0 305139AA–315995AA 1997-09-02
346 OS 3.0 315966AA–325961AA 1998-05-04
346 OS 3.0 325962AA–336995AA 1998-10-26
346 OS 3.0 336996AA– 1999-05-31
347 OS 1.0 W 256600– 1995-02-06
348 OS 1.0 256600– 1995-02-14
348 OS 1.0 256600–268926 1995-06-01
348 OS 1.0 268927–275188 1995-10-20
348 OS 1.0 275189–289678 1996-03-05
348 OS 1.0 289679–295606 1996-08-15
348 OS 1.0 295607AA– 1997-01-30
348 OS 1.0 315996AA–325961AA 1998-04-29
348 OS 1.0 325962AA–336995AA 1998-10-28
348 OS 1.0 336996AA– 1999-05-31

OL P
Contents, P
SSD Irené Karlsson 001
Contents, P
1 Preventive Maintenance
P1 Introduction
P2 Preventive Maintenance
P3 Oil and grease specification
P4 Tools

OL P
Contents, P
Version no T-code
001

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

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

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

OL P1
Version no T-code
001
2 Cleaning and washing

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

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

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

OL P1
Version no T-code
001
2.3 Electrical components

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

OL P2
Preventive maintenance

203 PPO 1500MX 249329AA-
1 Maintenance schedule
Item Work required

Interval in hours 5 20 80 160 500 1000 3000
Interval in Days/Weeks/Months 1d 1v 1m 2m 6m 12 m 36 m
0000 Chassis
0000.1 Check all links and roll pins X
0000.2 Check the battery securing blocks X
for wear
0000.3 Check for cracks and damage X
0000.4 Check the lift cylinder brackets for X
wear or damage
0000.5 Check the cover lockings X
0000.6 Check for damage on the backrest X
0380 Fork Carriage
0380.1 Check for cracks and damage X
0380.2 Check bushings for excess play X
0380.3 Check that push rods are not bent X
or damaged
1700 Drive Motor
1700.1 Check for arcing due to poor con- X
nections
1700.2 Check of carbon brushes X
1700.3 Clean motor of dirt and dust X
1700.4 Check tightening of motor bolts X

OL P2
Version no T-code
001 203
Item Work required

1700.5 Check for abnormal noise in motor X
bearings
2550 Drive Gear
2550.1 Check for oil leakage X
2550.2 Check oil level X
2550.3 Check for abnormal noise X
2550.4 Change the gear oil X
3100 Brake
3100.1 Cleaning from dust and debris X
3100.2 Check brake disc for wear X
3100.3 Check correct clearence of brake X
disc
3500 Wheels
3500.1 Remove all string, wrapping and X
debris
3500.2 Check drive wheel for wear and bolt X
torque
3500.3 Check castor wheel free to rotate X
and swivel
3500.4 Check castor wheel for wear X
3500.5 Dismount and grease fork wheel X
bearings
4100 Tiller arm
4100.1 Check the function of the micro- X
switches
4100.2 Check fastening X
4100.3 Check return of tiller arm to upper X
position
4100.4 Check steering force X

OL P2
Version no T-code
001 203
Item Work required

4100.5 Check the force of the gas suspen- X
sion
5110 Battery
5110.1 Electrolyte level, 10 - 15 mm above X
cell plates
5110.2 All connections: battery, battery and X
charger plugs
5110.3 All cell and link covers intact X
5110.4 Check of battery specific gravity X
and battery temperature
5400 Electrical Panel
5400.1 Cleaning and fixation to chassis X
5400.2 Tightening of connections X
5400.3 Check contactor contacts, clean X
and unburnt
5400.4 Check contactor contacts for free X
movements
5400.5 Check all cable insulations for X
damage
6000 Hydraulic System
6000.1 Check hoses and connections for X
leakage
6000.2 Check hoses for wear and damage X
6000.3 Check oil tank for cracks, leaks and X
mounting
6000.4 Change oil X
7310 Lift Cylinder
7310.1 Check for leakage X
7310.2 Check mounting X

OL P2
Version no T-code
001 203
4100
7000
0380
3100
1700
6000
3500
0000
2550
5110
5400
3500

OL P2
Version no T-code
001 203
2 Lubrication chart
Item Service point Interval/Running hours Lubricant

250 h 1000 h 3000 h
1 Rollers in the fork carriage L A
2 Hydraulic system C O B
3 Drive gear C O C
L = Lubrication C = Check O = Oil change

OL P2
Version no T-code
001 203

OL P2
SSD P-Å Gustafsson 001 342, 345-348, 423-425
T code Model Machine no. Note

342 OS 1.8 X 305487AA-
345 OS 2.0 256600AA-
346 OS 3.0 256600AA-
347 OS 1.0 W 256600AA-
348 OS 1.0 256600AA-
423 OS 1.2 CB 306381AA-
424 OS 1.0 HW 317556AA-
425 OS 1.0 WL 295610AA-
1 Maintenance schedule
No. Work to be carried out
Interval in days/weeks/months 1d 1w 1m 2m 3m 6m 12m
0000 Chassis
0000.1 Check that the identification plate of X
the truck is clearly readable.
0000.2 Check all links and pins X
0000.3 Check for wear on the door locks and X
cover of the battery compartment
0000.4 Check for any cracks or other damage X
0000.5 Check the attachments for the lifting X
cylinder
0000.6 Check the cover locks X
0000.7 Check for any damage to the back-rest X

OL P2
Version no T-code
001 342, 345-348, 423-425

0380 Fork lift truck
0380.2 Check for excess play in the bushes X
0380.3 Check for wear and play in the rollers X
0380.4 Check that the plunger rods are not X
warped or damaged
0380.5 Check the limit switch for lifting X
0380.6 Lubricate the rollers X
0640 Control system
0640.1 Check that the operating regulator/ X
speed selector do not jam
0640.2 Check that the signal horn button oper- X
ates
0640.3 Check that the lift/lower buttons oper- X
ate
0640.4 Check that the brake lever does not X
jam
0800 Operator safety
0800.1 Check that the emergency brake oper- X
ates
0800.2 Check the attachments for the protec- X
tive hoop at 2nd level
0800.3 Check that non-slip mats are not worn X
1700 Drive motor
1700.1 Check for any sparks due to poor con- X
tacts
1700.2 Check all connections for proper con- X
tact
1700.3 Check carbon brushes X
1700.4 Clean dust and dirt from motor X
1700.5 Check that the motor bolts are tight X
1700.6 Check for any abnormal noise from the X
motor bearings

OL P2
Version no T-code
001 342, 345-348, 423-425

2550 Drive gearing
2550.1 Check for any oil leaks X
2550.2 Check oil level X
2550.3 Check for any abnormal noise X
3370 Brake
3370.1 Clean away dust and foreign matter X
3370.2 Check for wear on brake disks X
3370.3 Check the play of the brake disk X
3500 Wheels
3500.1 Remove any objects stuck to the wheel X
3500.2 Check for wear on the drive wheel and X
check the torque of the wheel bolts
3500.3 Check that the link wheel rotates and X
swivels freely
3500.4 Check for wear on link wheel X
3500.5 Check the height adjustment of the link X
wheel, 4 mm above the drive wheel
with chassis level
3500.6 Lubricate the wheel axle NOTE 1 X
3500.7 Lubricate the link wheel bearing NOTE X
1
3500.8 Remove and lubricate fork wheel bear- X
ing
4100 Steering arm
4100.1 Check attachment X
4100.2 Check steering force X
4100.3 Check that the steering arm returns to X
upper position
4100.4 Check adjustment of steering chains X

OL P2
Version no T-code
001 342, 345-348, 423-425

4100. Electric wheel steering
4100.1 Check the installation and locking of X
the wheel
4100.2 Check the force of the gas stay and its X
locking function
4100.3 Check adjustment of steering chains X
4100.4 Lubricating the steering chains X
5110 Battery
5110.1 Check electrolyte level, 10 - 15 mm X
above cell plates
5110.2 All connections: battery and battery X
and charger contacts
5110.3 Check that all cell and link covers are X
intact
5110.4 Check the battery density and temper- X
ature
5200 Instrument panel
5200.1 Check the function of the battery indi- X
cator and timer
5300 Electrical control system
5300.1 Check the function of the ignition key X
5300.2 Check the function of “brake micros- X
witch” S10
5300.3 Check the function of microswitches for X
direction, speed
5300.4 Check for wear in control system X
cabling
5300. Side operation
(Additional equipment)
5300.1 Check the function of the micros- X
witches
5300.2 Check the speed - 5 km/h X
5300.3 Check the straight-ahead sensor for X
the drive wheel

OL P2
Version no T-code
001 342, 345-348, 423-425

5400 Electrical panel
5400.1 Check for dirt and check attachment to X
chassis
5400.2 Tighten connections X
5400.3 Check contactor pins, clean and X
remove scorch marks
5400.4 Make sure the contactors have free- X
dom of movement.
5400.5 Check for damage to cable insulation X
5710 Electronics board
5710.1 Clean the electronics board, blow with X
pressurised air and allow to dry
5710.2 Check for any poor connections in the X
cable connector
5710.3 Check LED indications X
7100 Mast
7100.2 Tighten the fastening bolts of the mast X
7100.3 Check the play between the mast X
beam and the rollers of the inner guide
7100.4 Check the side play of the inner guides X
7100.5 Check for wear on the lifting chains and X
chain rollers
7100.6 Check the adjustment of the lifting X
chains

OL P2
Version no T-code
001 342, 345-348, 423-425

6000 Hydraulic system
6000.1 Check the hoses and the connections X
for any leaks
6000.2 Check the hoses for any wear or dam- X
age
6000.3 Check for any cracks or leaks in the X
fluid reservoir
6000.4 Check fluid level X
6000.5 Change fluid X
7310. Lifting cylinder
7310.1 Check for any leaks X
7310.2 Check attachment X
NOTE 1. Applies from machine number: 337280AA-

OL P2
Version no T-code
001 342, 345-348, 423-425
0800 4100
5300
0640
5300
4100
5200
0000
0380
3500 0000
5110 7310
5710
5400
3370
6000
1700
4100
2550
3500

OL P2
Version no T-code
001 342, 345-348, 423-425
2 Lubrication table for OPUS
Number Service item Interval/Hours service Lubricant Volume

250 h 1000 h 3000 h
0380 Rollers in fork L A
lift truck
2550 Drive gearing C O C 1.75 L
3500 Wheel bearing L A
4100 Steering chain L D
6000 Hydraulic system C O B 1.5 L
L = Lubricate C = Check O = Change oil
0380
3500
6000
4100
3500 2550

OL P3
Oil and grease specification


203 PPO 1500MX 249329AA
1 Approved oil’s and grease for

PPO 1500MX
Type of lubricant Specification To be used for

> -15o C < -15o C
A Grease BT 26777 BT 26777 Bearings and Bushings
(Spray) (Spray)
B Hydraulic Oil ISO-L-HM32 ISO-L-HV32 Hydraulic Systems
C Transmission Oil Hypoid Oil Hypoid Oil Gears
SAE 80W/90 SAE 75W

OL P3
Version no T-code
001 203

OL P3
SSD K. Hallman 001 342, 345–348, 423–425


342 OS 1.8X 305487AA-
345 OS 2.0 256600AA-
346 OS 3.0 256600AA-
347 OS 1.0W 256600AA-
348 OS 1.0 256600AA-
423 OS 1.2CB 306381AA-
424 OS 1.0HW 317556AA-
425 OS 1.0WL 295610AA-
1 Approved oil’s and grease for OPUS
TYPE OF LUBRICANT SPECIFICATION TO BE USED

FOR
> - 15°C < -15o C
A Grease BT 26777 BT 26777 Bearings and Bush-
(Spray) (Spray) ings
B Hydraulic Oil ISO-L-HM32 ISO-L-HV32 Hydraulic Systems
C Transmission Hypoid Oil Hypoid Oil Gears
Oil SAE 80W/90 SAE 75W
D Grease BT 26778 BT 26778 Chains and Wires
(Spray) (Spray)

OL P3
Version no T-code
001 342, 345–348, 423–425

OL S
Contents, S
SSD U Grenblad
Contents, S
1 Service instructions
C-code
S0 Chassis 0000
S1 Primary motor 1000
S2 Transmission/Drive gear 2000
S3 Brake/Wheel/Caterpillar system 3000
S4 Steering system 4000
S5 Electrical system 5000
S6 Hydraulic/pneumatic system 6000
S7 Working functions, lift mast/cylinders 7000
S8 Peripheral/installation equipment 8000
S9 Options, attatchments 9000

OL S
Contents, S
Version no T-code

OL S0 0380
Fork unit
SSD K. Hallman 001 345,346
Fork unit
Valid from machine number:

345 OS 2.0 256600AA-
346 OS 3.0 256600AA-
The fork unit is mounted in a small single mast in the chassis
making the movement of the fork unit, when lifting, to be
straight in the vertical plane. The lift cylinders operates
directly at the top of the fork unit to create the lift. The torsion
link and push rod system of the fork unit transform the lift
movement from the cylinders to raise the fork wheel assembly
to get a parallel lift of the forks.

OL S0 0380
Fork unit
Version no T-code
001 345,346
2 Main components of the fork unit
POS NO DESCRIPTION
1 Lift cylinder support
2 Fork unit rollers
3 Wheel fork axle
4 Torsion link roller
5 Torsion links
6 Push rod
7 Wheel fork
8 Fork wheel assembly
9 Load support/Cover plate

OL S0 0380
Fork unit
Version no T-code
001 345,346
3 Dismantling/fitting the fork unit

from/to the chassis
In almost all cases of repair, or lubrication of the rollers, it is
necessary to dismantle the fork unit from the chassis (fork
wheel assembly not included). To make the dismantling/fitting
easier there are cut-outs in the mast beams to reduce the
hight necessary to lift.

OL S0 0380
Fork unit
Version no T-code
001 345,346
3.1 Dismantling
• Remove the backrest cover plate.
• Lift off the seat cusion and lift out both pocket compart-
ments from the backrest.
• Disconnect both emergency stop switches inside the back-
rest.
If the truck is equipped with side buttons for driving or inching
speed buttons diconnect also these switches inside the back-
rest.
• Remove the three backrest mounting bolts and lift off the
backrest straight up.
• Remove the backrest mounting bracket and the lift limit
switch.
• Jack up both chassis corners to a height allowing the fork
wheel assembly to swing down without touching the
ground.
• Block the chassis.
Warning!
Falling truck.
Working on a truck only jacked up might cause it to fall
down on you.
Always secure the truck with blocks.
• Push both fork wheel assemblies in the forward direction

until they reaches their mechanical stop. This makes the
torsion links swing downwards enough to make clearence
between the chassis and the torsion link rollers.
• Lift the fork unit til the lower rollers have reached the cut-
outs in the beams and the upper rollers are above the edge
of the beams.
• Pull out the fork unit from the chassis.
3.2 Fitting
• Fitting the fork unit to the chassis is done in the reverse
order from dismantling it.
Note: When fitting the lift limit switch, adjust the limit point
corresponding to a lift height of 205 mm with a few hundred
kilogram load on the forks.

OL S0 0380
Fork unit
Version no T-code
001 345,346
4 Maintenance
The fork unit needs to be checked and maintained according
to the preventive maintenance schedule on a 250 and 500
hours basis.
The only parts of the fork unit that needs to be lubricated are
the fork rollers. They shall be lubricated every 1000 working
hours. To lubricate the rollers it is necessary to dimantle the
fork unit from the chassis according to chapter “Dismantling/
fitting the fork unit from/to the chassis”.
.
• Dismantle the fork unit from the chassis according to chap-

ter “Dismantling/fitting the fork unit from/to the chassis”.
• Remove the guide pins and spring washers from the trun-
nion.
• Remove the roller locking ring.
• Remove the protection washer from the roller.
• Pull off the roller from the trunnion.
• Grease the roller bearing from both sides.
4.0.1 Re-assemble
• Fit the greased rollers to the fork unit.
• Fit the protection washer and the locking ring.
• Fit the guide pin with its spring washers.
• Put the fork unit back on to the chassis according to chap-
OL S0 0380
Fork unit
Version no T-code
001 345,346
5 Exchange of push rods and bush-

ings
5.1 Dismantling
• Dismantle the fork unit from the chassis according to chap-
Alternatively jack up the truck to have enough work space
beneath the fork unit. Then see to that there is no pressure
in the hydraulic system.
Warning!
Falling truck.
Working on a truck only jacked up might cause it to fall
down on you.
Always secure the truck with blocks.
• Knock out the locking pin of the wheel fork axle from
above.
• Knock out the wheel fork axle.
• Remove the locking bolt of the torsion link axle.
• Remove the torsion link axle.
• Remove the locking pin and remove the push rod axle.

OL S0 0380
Fork unit
Version no T-code
001 345,346
• Remove the locking bolt and the torsion link roller axle to
free the roller.
• Press out the worn bushings necessary to change.
• Mount the new bushings carefully. Make sure the align-
ment of the new bushing is correct whilst pressing it in
place.
Note!
The bushings will be damaged if a hammer is used to insert
them. All bushings in the fork unit are lubrication free.
5.2 Re-assemble
• Re-assemble the fork unit in the reverse order from the dis-
mantling procedure.

OL S0 0380
Fork unit
Version no T-code
001 345,346

OL S2 2550
Driving gear
SSD K Hallman 001 203
Driving gear

203 PPO 1500MX 255245AA-
1 General technical desciption

OL S2 2550
Driving gear
Version no T-code
001 203
1.1 Technical data
Data Description
Type 2-step angular
Upper gear wheels Cylindrical with helical gear
Lower gear wheels Angle gear 90 degrees
Gear ratio, overall 19.43:1
Gear ratio, upper gear 4:1
Gear ratio, lower gear 4.86:1
Oil volume 1.0 litre
Oil type, normal temperature Hypoid oil SAE 80W/90
Oil type, < -15oC Hypoid oil SAE 75
Oil change First time: 250 hours
Regular change: 3000 hours

OL S2 2550
Driving gear
Version no T-code
001 203
1.2 Gear components
3
4
5
A
12
11
10 6
9 7
8

OL S2 2550
Driving gear
Version no T-code
001 203
Pos No Component
1 Primary gear wheels
2 Upper pinion bearing L2
3 Bearing shim S2
4 Bearing shim S1
5 Lower pinion bearing L1
6 Set of pinion and crown wheel
7 Inner drive shaft bearing L3
8 Bearing shim S3
9 Outer drive shaft bearing L4
10 Bearing shim S4
11 Drive shaft
12 Drive shaft seal
A Built-in measure, pinion height 65 mm

OL S2 2550
Driving gear
Version no T-code
001 203
1.3 Special tools
Pos No Tool
1 Bearing withdrawer: part no = 08-13022
2 Dial indicator with magnetic bracket
3 Thickness gauge
4 Micrometer 0-25 mm (0-1 inch)
5 Spring balance 0-10 kg (0-22 lb)
6 Measuring gauge: part no = 06-13020
7 Assembly axle: part no 08-13021

OL S2 2550
Driving gear
Version no T-code
001 203
2 Removing the gear from the truck

• Lift the machine that high so the bolts for the driving gear
are easy accessible from beneath.
The truck can also be laid on the side after removal of the
battery and sealing off the hydraulic system.
• Remove the drive wheel (17 mm spanner)
• Drain the gear from oil by removing the lower gear cover
( 6 mm allen key).
• Remove the nuts (13 mm spanner) holding the gear and
motor together.
• Take the driving gear out of the machine.
• Reassemblying the driving gear into the truck is made in

the reversed order.

OL S2 2550
Driving gear
Version no T-code
001 203
3 Change of seal on the drive shaft

• Remove the gear from the truck as shown in chapter
“Removing the gear from the truck”.
• Remove the upper gear cover (6 mm allen key).
• Knock out the locking on the drive shaft nut.
• Remove the drive shaft nut (36 mm spanner).
• Knock the drive shaft out with a plastic club or press it out.
• Remove the crown wheel and bearing L3.
• Remove the old seal ring and place the new.

OL S2 2550
Driving gear
Version no T-code
001 203
• Put the drive shaft in place and place the inner ring of the
bearing L3 in the gear housing.
• Put the crown wheel onto the splines of the drive shaft and
fit a new washer and nut.
Tighten the drive shaft nut 300 Nm (217 ft-lb) with a torque
wrench.
• Lock the shaft nut with a punch into the groove in the shaft.
• Fit the covers to the gear with new gaskets.

Tightening torque: 26,6 Nm (19,5 ft-lb).
• Fit the driving gear into the truck.
Fill up with new oil.
• Fit the drive wheel
Tightening torque: 65Nm (47,7 ft-lb).

OL S2 2550
Driving gear
Version no T-code
001 203
4 Reconditioning of the gear

• Remove the gear from the truck as shown in chapter 2.
• Remove the gear covers (6 mm allen key).
• Knock out the locking on the drive shaft nut.
• Remove the drive shaft nut (36 mm spanner).
• Knock the drive shaft out with a plastic club or press it out.
• Remove the crown wheel and bearing L3.
• Remove the old seal ring.

• Press or knock out the bearing cups for bearing L3 and L4
and remove the shim-pack S3 from the gear housing.
• Remove the bearing L4 from the drive shaft by using the
withdrawer, part no 08-13022. Remove the shim S4 from
the shaft.
• Knock out the locking on the pinion nut. Remove the nut
(22 mm spanner) and the primary gear wheel.

OL S2 2550
Driving gear
Version no T-code
001 203
• Knock out the pinion with a plastic club or press it out.

Remove the bearing L2 and shim S2.
• Remove the bearing L1 from the pinion with the with-

drawer, part no 08-13022.
• Press or knock the cups for the bearingsL1 and L2 out and
remove the shim-pack S1 from the housing. Remove the
old seal ring.
• Clean the covers, gear housing and drive shaft with a suita-
ble dissolvent.
• Fit new races for the bearings L1 and L2 into the gear
housing with 0,5 mm shim S1.
• Fit the new bearing L1 on the new pinion.
• Assemble the pinion, bearing L2 and primary gear wheel.

Assemble with enough thickness of shim S2 so that there
is no axial play. Tighten the nut 30 Nm (22,5 ft-lb), using the
old nut.

OL S2 2550
Driving gear
Version no T-code
001 203
• Fit the new races for the bearings L3 and L4 into the gear
housing without shim S3.
• Fit the assembly axle 08-13021 with the bearing L4 into the
gear housing. Place the bearing L3 and the crown wheel
onto the axle. Make sure that there is enough shim S4 for
the bearing L4 that there is no axial play on tool 08-13021.
Tighten the axle nut 100 Nm (72 ft-lb), using the old nut.
• Measure the pinion height with the measuring gauge, part

no 08-13020, between the surface of bearing L1 and the
pin on tool 08-13021. Use shims or feeler gauge together
with the measuring gauge to get the correct thickness of
shim S1. Built-in measure pinion height = 65 mm, measur-
ing gauge length 59 mm + the radius of the pin 5 mm + 1
mm shim or feeler gauge thickness. The difference from
65 mm gives you the thickness of shim S1.
• Fit the measured shim thickness under bearing L1.

OL S2 2550
Driving gear
Version no T-code
001 203
• Assemble the pinion, bearings and primary gear wheel with

shim thickness S2 so that there is no axial play on the pin-
ion,Zero-play, when having tightened the pinion nut 70 Nm
(50,5 ft-lb). When needed adjust S2 so that the play is
zero.
• Fit the assembly axle with bearings, crown wheel and shim
as previously. Tighten the nut 300 Nm (217 ft-lb)
• Measure the flank clearence with the crowh wheel in three
different positions. Carefully point the dial indicator 90
degrees to the gear tooth surface.
• Shim (S3) bearing L3 so that a flank clearence of 0,10-0,15

mm is attained. Remove the same shim thickness from S4
that is fitted on S3, before the tool with bearings and crown
wheel is reassembled.
• Check the flank clearence and measure the axial play on
the tool 08-13021.
• Adjust the axial play to Zero-play by adjusting shim S4.

OL S2 2550
Driving gear
Version no T-code
001 203
• Check the gear tooth impression with engineer’s blue.

Adjust shim S1 when needed. S2 is to be adjusted,
reduced if S1 is increased and increased if S1 is reduced,
correspondingly to the change on S1. Check the axial play
on the pinion.
• Fit the tool 08-13021 with bearings and crown wheel.

Check the flank clearence. Adjust shim S3 when needed.
S4 is to be adjusted, reduced if S3 is increased and
increased if S3 is reduced, correspondingly to the change
on S3. Check the axial play on tool 08-13021.
• Check the gear tooth impression. ´When the impression is
correct fit a new washer and pinion nut. Tighten the nut 70
Nm (50,5 ft-lb) and lock it with a punch in the keygroove.
• When the gear tooth impression and the axial play is cor-
rectly adjusted, remove tool 08-13021. Shim-pack S4 is
shifted over to the drive shaft and bearing L4 is placed on
the shaft.
• Fit the new seal ring in the gear housing.

• Put the drive shaft into the housing and put bearing L3 in
place.

OL S2 2550
Driving gear
Version no T-code
001 203
• Put the crown wheel onto the splines of the drive shaft and
fit a new washer and nut.
Tighten the drive shaft nut 300 Nm (217 ft-lb) with a torque
wrench. Check the axial play on the drive shaft, shall be
Zero. Lock the nut with a punch in the groove on the shaft.
• Check the force needed to rotate the gear with the spring
balance.
Maximum value: 6-6,5 kg
• Fit the covers onto the gear with new gaskets.

• Fit the driving gear into the truck.
Fill up with new oil.
• Fit the drive wheel.
Tightening torque: 65 Nm (47,7 ft-lb)

OL S2 2550
Transmission, Gear
SSD K Hallman 001 345,346,347,348
Transmission, Gear

342 OS 1.8X 305487AA-
345 OS 2.0 256600AA-
346 OS 3.0 256600AA-
347 OS 1.0W 256600AA-
348 OS 1.0 256600AA-
423 OS 1.2CB 306381AA-
424 OS 1.0HW 317556AA-
425 OS 1.0WL 295610AA-
The gear and radial steering ball bearing is assembled
together as one unit mounted under the motor plate in the
chassis. The main components of the assembly are shown in
the picture below.

OL S2 2550
Transmission, Gear
Version no T-code
001 345,346,347,348
1.1 Gear components
2
3
4
15 14
13
6
12
11 8
10 9

OL S2 2550
Transmission, Gear
Version no T-code
001 345,346,347,348
Pos No Component Part No

1 Radial Bearing 139711
2 Upper Cover 139707
3 Primary Gears 139709/139710
4 Pinion Bearings 28343/29569
5 Pinion Set 142932
6 Lower Cover 139705
7 Crown Wheel Set 142932
8 O-ring 23620
9 Drive Shaft Bearings 29570/26312
10 Seal Protection 140099
11 Drive Shaft Sealing 139712
12 Drive Shaft 139702
13 Shims, Drive Shaft Bearings 140101/140103
14 Shims, Pinion Bearings 140100/140102
15 Gear Housing 139700
1.2 Gear data
Truck type OS 1.0 OS 2.0 OS 3.0

Gear Type 2-step angular 2-step angular 2-step angular
Gear Ratio 12.48:1 12.48:1 12.48:1
Oil Volume 1.75 liter 1.75 liter 1.75 liter
Oil Type Hypoid oil Hypoid oil Hypoid oil
Normal SAE 80W/90 SAE 80W/90 SAE 80W/90
Temperature
< -15oC SAE 75W SAE 75W SAE 75W
Part No 139715 139715 139715

OL S2 2550
Transmission, Gear
Version no T-code
001 345,346,347,348
2 Dismantling/fitting of gear from/in

truck
2.1 Dismantling
• Remove the front bumper of the chassis.
• Jack up the truck in a safe manner.
• Remove the steering chain from the gear by removing the
chain locks.
• Loosen and remove the six M12 bolts holding the gear to
the motor plate.
• Lower the gear to the floor.
• To remove the radial bearing from the gear there is eight
M8 bolts to remove from the bearing side and three from
the under side of the upper cover.

OL S2 2550
Transmission, Gear
Version no T-code
001 345,346,347,348
2.2 Fitting
• To fit the radial bearing to the gear tighten all bolts symetric
with a torque of 25 Nm. The bolts shall be lubricated prior
to assembly.
• Put the gear in position and make sure that the lower motor
bearing and gear wheel is in its correct position.
• Fit the M12 bolts through the motor plate and tighten them
50 Nm. The bolts shall be lubricated prior to assembly.
• Mount the steering chain and adjust the play according to
the picture.
• Lower the truck to the ground and fit the front bumper.
3 Filling of oil
• The filling point of oil is located at the front of the upper part
of the gear housing.
• Fill oil up to the hole to get the correct oil level.

OL S2 2550
Transmission, Gear
Version no T-code
001 345,346,347,348
4 Exchange of oil
Exchange of oil in the gear shall be done after every 3000
working hours.
• Draining the old oil out of the gear is done by removing the
lower gear cover completely.
• Change the O-ring seal at every oil change. Make sure that
the O-ring isn’t damaged when fitted.
• Fit the cover and tighten the bolts 25 Nm. The bolts shall
be lubricated prior to assembly.
• Fill up oil in accordance with filling instructions.

OL S2 2550
Transmission, Gear
Version no T-code
001 345,346,347,348
5 Exchange of drive shaft seal ring

Exchange of the drive shaft sealing can be done while the
gear still is fitted to the truck. In the case of oil leakage from
the drive shaft follow the procedure below:
5.1 Dismantling
• Remove the drive wheel from the gear.
• Remove the lower gear cover and drain the gear from oil.
• Loosen the drive shaft nut. Remove the nut and spacer
ring.
• Nock the drive shaft out. Gently with a brass drifter and a
hammer.
• Pull the bearing off the drive shaft with tool 08-13022
• Check the bearing shims for damage. If they are damaged
by the bearing tool measure the total shim thickness and
replace them with new shims before assembly.
• Remove the seal ring from the drive shaft.
7 6 5 2

OL S2 2550
Transmission, Gear
Version no T-code
001 345,346,347,348
5.2 Assembly
Assemblying the gear after changing the drive shaft seal ring
is done in the reverse order.
When assemblying take notice of the following.
• Fill the seal ring with grease after fitting it on to the drive
shaft.
• Make sure that only undamaged shims of a total thickness
as the original is placed on the drive shaft.
• Press the bearing on to the drive shaft and make sure not
to damage the bearing shims.
• When placing the drive shaft with the bearing, shims and
sealing fitted ensure yourself, that the splines of the shaft
corresponds with the splines of the crown wheel and that
the bearing and sealing is in a good position for their seat-
ings in the gear housing before pressing the shaft com-
pletely in.
• Place the spacer ring on to the drive shaft end and fit the
shaft nut. Thighten the shaft nut with a torque of 500 Nm
and lock it with a centre punch mark. The drive shaft nut
shall be lubricated prior to being fitted to the shaft.
• Before fitting the lower cover, change the O-ring. Make
sure that it not is damaged when fitted. Fit the cover and
tighten the bolts 25 Nm. The bolts shall be lubricated prior
to assembly. Fill up oil in accordance with filling instruc-
tions, section 3.
• Fit the drive wheel and tighten the wheel nut with a torque
of 90 Nm. The wheel nuts shall be lubricated prior to being
fitted.

OL S2 2550
Transmission, Gear
Version no T-code
001 345,346,347,348
6 Leakage from the top cover

When having a leakage at the gear top cover follow the pro-
cedure described below:
• Dismantle the gear and radial steering ball bearing from
the truck as described in chapter “Dismantling/fitting of
gear from/in truck”.
• After removing the radial bearing loosen all eleven bolts
holding the top cover to the gear housing.
• Remove the cover from the gear and clean the surface of
the cover and housing carefully.
• Apply liquid sealant type Loc-Tite 574 to the surfaces. Fol-
low the instructions given on the container.
• Fit the cover bolts and tighten with a torqe of 25 Nm.The
bolts shall be lubricated prior to assembly.
• Fill up oil in accordance with filling instructions, section 3.
• Fit the gear and radial bearing to the truck as described in
chapter “Dismantling/fitting of gear from/in truck”.
2, 5
3, 4

OL S2 2550
Transmission, Gear
Version no T-code
001 345,346,347,348

OL S3 3360
Mechanical brakes
Mechanical brakes

203 PPO 1500 MX 249329AA-
1 General
The brake is a mechanical spring-loaded brake. The brake
construction is as shown in the component list below.
4
3
5
Position Description
1 Brake disk
2 Adjustment screws for braking force
3 Collar
4 Adjustment screws for clearance in off
position
5 Pressure plate

OL S3 3360
Mechanical brakes
Version no T-code
001 203
2 Function
The mechanical brake provides both the driving and parking
brakes for the truck.
2.1 Releasing the brakes

The brakes are released when the tiller arm is in the driving
position.
2.2 Braking
The truck is braked when the tiller arm is moved into one of
the two braking positions.

OL S3 3360
Mechanical brakes
Version no T-code
001 203
3 Maintenance
The brakes require virtually no maintenance in normal work-
ing environments. It is, however, recommended that regular
cleaning, inspection of wear in brake disk and pressure plate
plus the clearance between these is carried out in accord-
ance with the schedule for preventative maintenance. Check
also the brake force adjustment.
16 mm
1 mm
Position Adjustment measurement

1 Clearance in un-braked position
2 Adjustment of brake force. Clearance in
braked position

OL S3 3360
Mechanical brakes
Version no T-code
001 203

OL S3 3370
Electro magnetic brake
SSD P-Å Gustafsson 001 342,345–348, 423–425


342 OS 1.8X 305487AA-337279AA
345 OS 2.0 256600AA-337279AA
346 OS 3.0 256600AA-337279AA
347 OS 1.0W 256600AA-337279AA
348 OS 1.0 256600AA-337279AA
423 OS 1.2CB 306381AA-337279AA
424 OS 1.0HW 317556AA-337279AA
425 OS 1.0WL 295610AA-337279AA
The brake is a two stage electro magnetic brake with sepa-
rate coils for each of the stages. The stages are controlled
individually by the logic card of the electrical system which
controls the operation depending on the weight of the load on
the forks.
The first stage is in operation at all times. The second stage
becomes operative at loads of 550 kg or more supervised by
a pressure sensor (S61) in the hydraulic system, input 504 on
the logic card.
2 Main components of the brake
Pos No Description
1 Electrical wire, first stage
2 Coil winding, first stage
3 Electrical wire, second stage
4 Coil winding, second stage
5 Pressure spring, second stage

OL S3 3370
Version no T-code
001 342,345–348, 423–425
3
4 5 6 7
2
1
8
12
9
11
10
Pos No Description
6 Pressure springs, first stage
7 Mounting bolts
8 Adjustment locking nut
9 Hub
10 Friction plate
11 Brake disc
12 Pressure plate

OL S3 3370
Version no T-code
001 342,345–348, 423–425
3 Maintenance
Basically the brake is maintenance free in normal work envi-
ronments. However it is recommended according to the pre-
ventive maintenance schedule to check the brake disc for
wear and the gap between the magnetic coil housing and the
pressure plate on a regular basis.
4 Basic Adjustment of gap
3
1
The nominal gap between the coil housing and the pressure
plate, in applied position, shall be 0.3 mm. The maximum
gap before readjustment is necessary is 0.8 mm.
Adjustment procedure:
Loosen the tension of the three mounting bolts (1).
Turn the lock nuts (2) anti-clockwise and tighten the bolts
slightly while checking the gap on three points with a 0.3
mm feeler gauge (3).
Tighten the mounting bolts 25 Nm and recheck the gap with
the feeler gauge.

OL S3 3370
Version no T-code
001 342,345–348, 423–425
5 Optimising the brake system

To be able to obtain optimal brake effect on OPUS-trucks and
above all to avoid locking up the drive wheel during braking,
some adjustment can be made. The brake force for the two
brake stages can be individualy adjusted as well as the point
where the second brake stage activate.
The factors to be considered when adjusting the brake are:
• Avoiding lock up of the drive wheel. (The biggest risk for
that is when the minimum of load is lifted for respective
brake stage).
• To meet the brake norm. (This is always hardest with maxi-
mum of load and speed).
5.1 Adjusting the change between the

brake stages
When the first brake stage is active the LED 504 comes on
and when the second brake stage is active the LED 504 goes
out. Switching usually takes place at a load of approx. 500 kg.
If switching at a higher load is required proceed as follows:
• Lift a load at a weight for which the change is desired.
• Adjust the pressure switch so that LED 504 goes out.
• Lower the load and reduce it with 50-100 kg.
• Lift the new weight and check that LED 504 is ON.
If switching at a lower load is required proceed as follows:

• Lift a load at a weight for which the change is desired.
• Adjust the pressure switch so that LED 504 goes on.
• Lower the load and reduce it with 50-100 kg.
• Lift the new weight and check that LED 504 is out.

OL S3 3370
Version no T-code
001 342,345–348, 423–425
5.2 Adjusting of the first brake stage

To reduce the braking force for the first brake stage turn the
screws (6) counterclockwise on the brake. To increase the
braking force, turn the screws clockwise.
To avoid locking up the drive wheel while braking, proceed as
follows:
• Turn screw counter clockwise, so that braking without load
and with max speed is done without the drive wheel lock-
ing up.
• Check that the brake norm is met, for the first brake stage.
This is done with max load for the first brake stage (check
that input 504 is ON), drive at full speed and brake. Meas-
ure the stoptime, it must under all conditions be below
1,5s.
5.3 Adjusting of the second brake stage

To reduce the braking force for the second brakestage, turn
the screw in the middle (5) counterclockwise. To increase the
braking force, turn it clockwise.
To avoid locking up the drive wheel while braking, proceed as
follows:
• Turn screw counterclockwise, so that braking with the min-
imum of load that activate the second brake stage (input
504 OFF). and max speed does not lock up the drive
wheel.
• Check that the brake standard is obtained, for the second
brake stage. This is done with max load, drive at full speed
and brake. Measure the stoptime, it must under all condi-
tions be below 1,5s.
If the max. load never amounts to 2000 kg it can be limited by
adjusting the pressure limiting valve. This means that the
force required for the second brake stage can be reduced
while the braking standard is still maintained. This gives the
possibility of smoother braking during the second stage.

OL S3 3370
Version no T-code
001 342,345–348, 423–425
6 Exchange of brake disc

The brake disc shall be exchanged when its total thickness
has been reduced to 6 mm.
• Disconnect the electrical wires of the brake.
• Loosen and remove the three mounting bolts and remove
the brake coil.
• Replace the brake disc on the hub and make a visual
inspection of the wear of the friction plate. Replace the fric-
tion plate if the surface is worn uneven.
• Unwind the lock nuts on the coil at least 6 mm to make
sure there is a gap between the coil and the pressure plate
when the coil is refitted.
• Mount the coil on the motor end and carry out adjustment
of the gap according to chapter “Basic Adjustment of gap”.
• Reconnect the electrical wiring.

OL S3 3370
Electromagnetic brake
SSD P-Å Gustafsson 002 342, 345-348, 423-425

342 OS 1.8 X 337280AA-
345 OS 2.0 337280AA-
346 OS 3.0 337280AA-
347 OS 1.0 W 337280AA-
348 OS 1.0 337280AA-
423 OS 1.2 CB 337280AA-
424 OS 1.0 HW 337280AA-
425 OS 1.0 WL 337280AA-
The brake is a two-stage electromagnetic brake with separate
coils for each stage. The stages are individually controlled by
the logic card of the electrical system, according to the weight
of the load on the forks.
1.1 Function OS 2.0 and OS 3.0

The first stage is always in operation. The second stage
comes into operation when the weight of the load is 550 kg or
more and is monitored by a pressure sensor in the hydraulic
system.
1.2 Function OS 1.X

The first stage is always in operation. The second stage
comes into operation 1.5 s after the braking circuit is broken.

OL S3 3370
Version no T-code
002 342, 345-348, 423-425
2 Main brake components

3
4 5 6 7
2
1
8
12
9
11
10
Number Description
1 Electrical cable, first stage
2 Coil winding, first stage
3 Electrical cable, second stage
4 Coil winding, second stage
5 Pressure spring, second stage
6 Pressure spring, first stage
7 Mounting bolts
8 Adjustment lockin nuts
9 Hub
10 Friction plate
11 Brake disc
12 Pressure plate

OL S3 3370
Version no T-code
002 342, 345-348, 423-425
3 Maintenance
The brake is essentially maintenance-free under normal oper-
ating conditions. According to the preventive maintenance
schedule, however, the brakes should be regularly inspected
for wear on the brake disc and to check the gap between the
magnetic coil housing and the pressure plate.
4 Adjusting the gap
3
1
The nominal gap between the coil housing and the pressure
plate, on contact, is 0.3 mm.
The maximum gap, when adjustment becomes necessary, is
0.8 mm.
Adjustment procedure:
• Slightly undo the mounting bolts (1).
• Turn the lock nuts (2) anti-clockwise and tighten the
mounting bolts slightly. Check the gap using a 0.3 mm
feeler gauge (3).
• Tighten the mounting bolts to a torque of 25 Nm and check
the gap again with the feeler gauge.

OL S3 3370
Version no T-code
002 342, 345-348, 423-425
5 Adjusting the brake force

When the brake is replaced, the new brake is supplied ready-
adjusted for OS 2.0.
This means that after replacing the brake or changing to logic
card (149149-006 tiller arm steering or 153984-005 wheel
steering module), the brake must be adjusted in accordance
with the table below. It is important to set the correct brake
pressure, because the second brake stage does not come
into operation in OS 1.0.
To obtain optimum braking force in other trucks, the first
brake stage must be adjusted according to the truck type.
The adjustment is done using the four screws, number 6 in
section 2 above.
NB!
THE ADJUSTMENT MUST BE DONE WHEN REPLACING
THE BRAKE ON TRUCKS FROM THE MACHINE NUMBER
ABOVE.
Truck type Adjustment

OS 1.0 0.5 turns clockwise
OS 1.0 W 1.0 turns anticlockwise
OS 1.0 WL 1.0 turns anticlockwise
OS 1.0 HW 1.0 turns clockwise
OS 1.2 CB 1.0 turns clockwise
OS 1.8 X 1.0 turns clockwise
OS 2.0 NONE
OS 3.0 1.25 turns clockwise

OL S3 3370
Version no T-code
002 342, 345-348, 423-425
6 Replacing the brake disc

The brake disc must be replaced when its overall thickness is
reduced to 6 mm.
• Disconnect the electric cables to the brake.
• Undo and remove the three mounting bolts and remove
the brake coil.
• Replace the brake disc on the hub and check the friction
plate for visible signs of wear. If the surface of the friction
plate is uneven, replace this too.
• Undo the lock nuts on the coil at least 6 mm to ensure that
there is a gap between the coil and the pressure plate
when the coil is refitted.
• Install the coil and adjust the gap according to the instruc-
tions in the “Adjusting the gap” section.
• Reconnect the electrical cables.

OL S3 3370
Version no T-code
002 342, 345-348, 423-425

OL S3 3540
Castor wheel
SSD K. Hallman 001 345,346,348
Castor wheel
Valid for machine number:

345 OS 2.0 256600AA-337279AA
346 OS 3.0 256600AA-337279AA
348 OS 1.0 256600AA-337279AA
The truck is equipped with an adjustable twin castor wheel
assembly, easy accessible after removal of the chassis front
cover.
The adjustment of the castor wheel height is of outmost
importance for the drive wheel pressure and the braking abil-
ity of the truck. Therefore the castor wheel height needs to be
adjusted on a regular 500 working hours basis due to its wear
relative to the wear of the drive wheel.
The bearings in the castor wheel assembly are sealed and
greased from factory and need no lubrication.
The bearings in the wheel are also sealed and lubrication
free.

OL S3 3540
Castor wheel
Version no T-code
001 345,346,348
2 Main components of the castor

wheel
Pos No Description
1 Mounting bracket
2 Locking bolt
3 Locking bolt (for adjustment procedure only)
4 Locking ring
5 Locking ring
6 Hub cap (bearing protection)
7 Wheel bearing
8 Wheel axle
9 Axle nut
10 Wheel bearing spacer ring
11 Spacer ring
12 Wheel
13 Wheel fork
14 Swivel bearing
15 Trunnion

OL S3 3540
Castor wheel
Version no T-code
001 345,346,348
3 Maintenance
Basically the castor wheels are maintenance free in normal
work environments. However, according to the preventive
maintenance schedule it is necessary to check the castor
wheels for wear on a 500 hours basis. This due to the
importance of the castor wheel’s relative height to the drive
wheel.
3.1 Check procedure, castor wheel height

:
• Place the truck on a flat floor.

• Jack up the truck chassis to be parallel to the floor, meas-
urement A shall be equal on both sides.
• Use a 4 mm thick steel plate, or similar, to check the
clearence under the castor wheel.
• If the clearence is less than 4 mm re-check with a 2 mm
plate.
• If the clearence is less than 2 mm re-adjust the castor
wheel height according to next paragraph.

OL S3 3540
Castor wheel
Version no T-code
001 345,346,348
3.2 Adjustment of castor wheel height
To have a correct pressure on the drive wheel, the castor

wheel contact surface must be adjusted to a nominal height 4
mm higher than the drive wheel contact surface when the
chassis is parallel to the ground.
3.2.1 Adjustment of the castor wheel must be done:

• Every time that a new castor wheel is placed to the truck.
• When the routine maintenance check shows less height
difference than 2 mm.
3.2.2 Adjustment procedure:

• Place the truck on a flat floor.
• Remove the front cover of the chassis to get access to the
castor wheel assembly.
• Jack up the truck chassis to be parallel to the floor. Meas-
ure distance A to be equal on both sides of the chassis.
Block the truck to prevent it from falling.
Warning!
Risk of crushing.
A badly supported truck can fall.
Never work under a truck that is not supported on trestle-
blocks and secured by a jack device.

OL S3 3540
Castor wheel
Version no T-code
001 345,346,348
• Turn the castor wheel around to get access to the loocking

bolts. Tighten the lower bolt (1) to block the swivel bearing
and loosen the upper locking bolt (2).
• Turn the castor wheel assembly to acceive a clearence to
the floor that is greater than 4 mm.
• Put a 4 mm steel plate, or similar, on the floor and adjust
the castor wheel assembly down until the wheel touches
the plate.
• Lock the trunnion in the mounting bracket with the upper
locking bolt (2) in the nearest grove in the trunnion.
• Free the swivel bearing by unwinding the lower locking bolt
(1). Leave the bolt in place in the wheel fork til next adjust-
ment.
3.3 Exchange of castor wheel

In all cases when changing components of the castor wheel
assembly it is necessary to remove the chassis front bumper.
It is the easiest way to do all the job on the castor wheel after
removing the complete assembly from the chassis.
3.3.1 Removal of the complete castor wheel assembly
• Remove the castor wheel assembly by removing the four

mounting bolts.

OL S3 3540
Castor wheel
Version no T-code
001 345,346,348
3.4 Exchange of wheel
3.4.1 Removal:
• Loosen one wheel axle nut and knock the axle half way
out.
• Remove the wheel with the hub cap and the out side
spacer ring.
• Remove the centre spacer ring.
• Remove the second wheel with its spacer ring and hub
cap.
3.4.2 Mounting:
• Place the first hub cap and spacer ring on the wheel axle
before fitting the first wheel.
• Place the centre spacer ring on the wheel axle.
• Put the second wheel, the out side spacer ring and the hub
cap in position in the wheel fork and push the wheel axle
trough.
• Fit the wheel axle lock nut and tighten it to a torque of 60 -
80 Nm.

OL S3 3540
Castor wheel
Version no T-code
001 345,346,348
3.5 Exchange of wheel bearing

• Remove the wheel from the wheel fork according to the
previous paragraph.
• Move the bearing spacer to the side and knock the bearing
on one side out.
• Turn the wheel around and knock the other bearing out.
• Press a new bearing into the hub.
• Place the bearing spacer in the hub before pressing in the
second bearing.
• Mount the wheel according to the previous paragraph.

OL S3 3540
Castor wheel
Version no T-code
001 345,346,348

OL S3 3540
Castor wheel
SSD P-Å Gustafsson 002 342, 345, 346, 348
Castor wheel

342 OS 1.8 X 337280AA-
345 OS 2.0 337280AA-
346 OS 3.0 337280AA-
348 OS 1.0 337280AA-
1 General
The truck is equipped with an adjustable castor wheel assem-
bly with a single wheel, easily accessible with the front chas-
sis panel removed.
The adjustment of the castor wheel height is crucial to the
drive wheel pressure and braking performance. It is neces-
sary to adjust the height of the castor wheel every 500 hours
of service because of wear on the drive wheel.
The bearings of the castor wheel assembly are sealed and
pre-lubricated at the factory, while the wheel bearings must
be lubricated once a month, and the link bearings once every
six months.

OL S3 3540
Castor wheel
Version no T-code
002 342, 345, 346, 348
2 Main castor wheel components
1
2
3
4
12
9
11
10
Number Description
1 Mounting bracket
2 O ring
3 Link bearing
4 Grease nipple for link bearing
5 Locking screw for height adjustment
6 Height adjustment
7 Wheel bearing, hub cap, bearing cover
8 Grease nipple for wheel axle
9 Wheel axle
10 Wheel
11 Wheel bearing
12 Axle nut

OL S3 3540
Castor wheel
Version no T-code
002 342, 345, 346, 348
3 Maintenance
The castor wheel must be lubricated at regular intervals.
Wear and tear on the drive wheel means that the height of
the castor wheel must be checked for wear every 500
hours of service. This is because the height of the castor
wheel in relation to the drive wheel is of crucial importance.
3.1 Checking the height of the castor

wheel
:
A 4 A
• Position the truck on a level surface.
• Raise the truck chassis so that it remains parallel with the
ground - measurement A must be the same on both sides.
• Use a steel plate 4 mm thick, or a similar item, to check
the distance under the castor wheel.
• If the distance is less than 4 mm, check again, this time
using a 2 mm plate.
• If the distance is less than 2 mm, adjust the castor wheel
according to the instructions in the next section.

OL S3 3540
Castor wheel
Version no T-code
002 342, 345, 346, 348
3.2 Adjusting the castor wheel height
The correct pressure on the drive wheel is obtained when the

contacting surface of the castor wheel is adjusted to a nomi-
nal height of 4 mm above the contacting surface of the drive
wheel, with the chassis parallel with the ground.
3.2.1 The castor wheel must be adjusted in the following

circumstances:
• Whenever a new castor wheel is installed in the truck.
• When the routine maintenance check shows a height dif-
ference of less than 2 mm.
3.2.2 Adjustment procedure

• Remove the front chassis panel to gain access to the cas-
tor wheel assembly.
• Raise the truck chassis, keeping it parallel with the ground.
Check measurement A to make sure it is the same on both
sides of the chassis. Place blocks under the truck to pre-
vent it falling.
WARNING!
Danger of crushing.
The truck can fall if it is not adequately blocked.
Never work underneath a truck which is not supported by
blocks and secured with jacks.
• Rotate the castor wheel to gain access to the locking

screw. Undo the locking screw (1) to release the adjusting
screw (2).
• Turn the adjusting screw (2) until there is a distance of at
least 4 mm from the ground.

OL S3 3540
Castor wheel
Version no T-code
002 342, 345, 346, 348
• Place a 4 mm steel plate, or similar item, on the floor and

adjust the castor wheel assembly down until the wheel
comes into contact with the plate.
• Lock the adjusting screw (2) with the locking screw (1).
3.3 Replacing the castor wheel

The front chassis panel always has to be removed when
replacing components in the castor wheel assembly. Any
work on the castor wheel is easiest with the entire assembly
removed from the chassis.
3.3.1 Removing the castor wheel assembly

• To remove the castor wheel assembly, take out the three
mounting bolts.
3.4 Changing the wheel

3.4.1 Removal
• Undo the wheel axle nut and tap out the axle.
• Remove the wheel with its hub cap and bearing.
3.4.2 Assembly
• Place the hub cap and bearing on the wheel axle before fit-
ting them.
• Push the wheel axle into place.
• Fit the locking nut of the wheel axle and tighten it to a
torque of 30-45 Nm.
• Always use split washers when replacing the wheel.
NB! Always make sure the wheel is not seized - it must be

possible to turn it by hand.

OL S3 3540
Castor wheel
Version no T-code
002 342, 345, 346, 348
3.5 Changing the wheel bearing

• Remove the wheel from the wheel fork as described in the
previous section.
• Push out the wheel bearing’s spacer and tap out the bear-
ing track on one side.
• Turn the wheel and tap out the other bearing track.
• Push in new bearing tracks.
• Place the bearing’s spacer in the hub.
• Regrease the wheel.
• Install the wheel as described in the previous section.

OL S3 3540
Castor wheel
SSD E.De Smedt 001 347, 423, 424, 425
Castor wheel
Applies from machine number:

347 OS 1.0 W 256600GA-
423 OS 1.2 CB 306381GA-
424 OS 1.0 HW 317556GA-
425 OS 1.0 WL 295610GA-
1 General
The truck is equipped with an adjustable spring-loaded castor
wheel assembly, easily accessible with the front chassis
cover removed.
It is vitally important to set the castor wheel pressure in order
to maintain the braking performance of the truck and to
ensure that the drive wheel obtains the correct driving force. It
is therefore necessary to adjust the castor wheel pressure
every 500 hours of service. The adjustment is based on the
wear on the castor wheel in relation to the wear on the drive
wheel.
The bearings in the castor wheel are pre-lubricated and
sealed at the factory. They must not be re-lubricated.
The pivot bearing is equipped with a grease nipple, and must
be lubricated every 500 hours.

OL S3 3540
Castor wheel
Version no T-code
001 347, 423, 424, 425

OL S3 3540
Castor wheel
Version no T-code
001 347, 423, 424, 425
2 Main components
Number Description
1 Adjusting nut
2 Grease nipple
3 Mounting frame
4 Wheel fork
5 Adjustment nut
6 Complete wheel
7 Wheel axle
8 Axle nut
9 Split washer
10 Screw
11 Bearing

OL S3 3540
Castor wheel
Version no T-code
001 347, 423, 424, 425
3 Maintenance
The castor wheel is essentially maintenance-free, except for
the pivot bearing, under normal operating conditions.
According to the preventive maintenance schedule, however,
the castor wheel should be inspected for wear every 500
hours. This is because it is crucial that the height of the castor
wheel is correct in relation to the drive wheel.
3.1 Inspection procedure, castor wheel

pressure

• Use a jack to raise the truck chassis, keeping it parallel
with the ground. Measurement A must be the same on
both sides.

OL S3 3540
Castor wheel
Version no T-code
001 347, 423, 424, 425
3.2 Adjusting the castor wheel pressure
The castor wheel pressure must be adjusted to make sure

the pressure to the drive wheel is correct. See the table.
T code Machine Min. Max.

pressure pressure
347 OS 1.0 W 0 50
424 OS 1.0 HW 0 50
423 OS 1.2 CB -30 0
382 OS 2.0 TT -30 0

OL S3 3540
Castor wheel
Version no T-code
001 347, 423, 424, 425
3.2.1 The castor wheel must be adjusted in the following

circumstances:
• Whenever a new castor wheel is installed in the truck.
• When a routine check shows that the maximum pressure is
greater than the pressure indicated in the table.
3.2.2 Adjustment procedure

• Remove the front chassis cover to gain access to the cas-
tor wheel.
• Use a jack to raise the truck chassis, keeping it parallel
with the ground. Measurement A must be the same on
both sides. Block the truck so that it cannot fall over.
WARNING!
Danger of crushing.
The truck can fall if it is not adequately blocked.
Never work underneath a truck which is not supported by
blocks and secured with jacks.
• Turn the castor wheel to gain access to the locking nuts
(1).
• Undo the nuts (1).
• Adjust the spring pressure (see the table) using the nuts
(1).
• Tighten the nuts (1).
3.3 Replacing the castor wheel

The front chassis bumper always has to be removed when
replacing the castor wheel or its components.
Any work on the castor wheel is easiest with the entire castor
wheel assembly removed from the chassis.

OL S3 3540
Castor wheel
Version no T-code
001 347, 423, 424, 425
3.3.1 Removing the entire castor wheel unit
• To remove the castor wheel unit, take out the four fixing
bolts (2).
3.4 Changing the wheel

• Undo the nut (1) and tap out the axle (3).
• Remove the wheel (4).

OL S3 3540
Castor wheel
Version no T-code
001 347, 423, 424, 425
3.5 Lubricating the pivot bearing

• Use the nipple to lubricate the pivot bearing (5).
3.6 Adjusting the play of the pivot bearing

• Undo the nut (6).
• Adjust the play.
• Tighten the nut (6).

2/ 6
(OHFWULFDOVWHHULQJZKHHO
66' .+DOOPDQ
7FRGH 0RGHO 6HULDO1R 1RWHV

345 OS 2.0 256600-295609AA
346 OS 3.0 256600-295609AA
347 OS 1.0W 256600-295609AA
348 OS 1.0 262700-295609AA
*HQHUDOGHVFULSWLRQ
The electrical steering wheel system cosists of a tachometer
at the steering wheel, a fly by wire controller and a DC-motor
for the motion of the steering drive wheel. The system is a
fully electric power steering system without any mechanical
connection between the steering wheel and the steering drive
wheel.
The controller continously monitors the entire steering sys-
tem. At every start up of the electrical system of the truck the
safety system of the electrical steering is checked by an error
simulation before allowing any driving to take place. Any
faults or problems in the tachometer, the cables, the controller
itself or the DC-motor will result in an automatic stop of the
drive function of the truck and the electro magnetic brake will
be applied.

2/ 6
Version no T-code

&RQWUROOHUOD\RXW
1 2 3 4
3RVLWLRQ )XQFWLRQ
1 Power connector
2 Control connector
3 Dipswitches
4 LED indicators

2/ 6
Version no T-code

&DUGFRQQHFWRUV
&RQQHFWRU.
7HUPLQDO &RQQHFW 9ROWDJH9 )XQFWLRQ

1R
1 I 24 Start/stop internal supply
2 Not connected
3 O max 24 Error indication no1
4 I 0 Tachometer
5 I 24 Negative direction blocking
6 I +- (1.4-1.9) Referance value from tachometer
7 O -12
8 O 24 Safety circuit relay
9 O Common error indication
10 I Not connected
11 I 24 Positive direction blocking
12 O max 24 Error indication no2
13 O 12
I = Input O = Output

2/ 6
Version no T-code

&RQQHFWRU.
7HUPLQDO1R &RQQHFW 9ROWDJH9 )XQFWLRQ

+ I 24 Battery voltage
- I 0 Battery voltage
M1 O Motor connection
M2 O Motor connection

2/ 6
Version no T-code

/('LQGLFDWLRQVDQGGLDJQRVWLFV
The LED’s on the controller gives a good help in the diagnos-

tics of faults to the electrical steering system. In the table
below you find possible causes of the different LED indica-
tions.
/('GLDJQRVWLF
/(' /(' /(' /(' /(' (;3/$1$7,21 $&7,21

JUHHQ UHG UHG UHG UHG
21 - - - - OK None
21 21 - - - Negative direction None
blocking active
21 - 21 - - Positive direction None
blocking active
21 - - 21 - Fault in tachometer Check cables and con-
circuit. nections. If OK: replace
Disconnection, short tachometer. If still faulty:
circuit or wrong type check for correct type of
of tachometer tachometer
21 - - - 21 Fault in controller or Check cables, connec-
motor circuit. Can tions and motor
be disconnection or brushes. If OK: replace
short circuit. DC-motor or controller.
21 - - 21 21 Fault in controller. Replace controller.

2/ 6
Version no T-code

'LSVZLWFKDGMXVWPHQW
The Dipswitches of the controller is used for adjustment of the

current limit, IR-compensation and sensitivity of the electrical
steering system. Here below you find an explanation and the
value of the different switch settings.
&XUUHQWOLPLW
The current limit, limits the motor current and by that the
torque of the DC-motor. The current limit can be set to 4 dif-
ferent levels by the Dipswitches no. 1 and 2. If the torque is
too low, the steering will be weak and slow and it will lag at
quick speed changes of the steering wheel.
6ZLWFK 6ZLWFK &XUUHQW

1R 1R $
- - 20
- 21 28
21 - 36
21 21 42

2/ 6
Version no T-code

,5FRPSHQVDWLRQ
The IR-compensation affects the ability of the DC-motor to
follow the motion of the steering wheel. The compensation
can be set to 4 different levels by Dipswitches no. 3 and 4. If it
is too low, the DC-motor will not move at slow motion of the
steering wheel. If it is too high, the DC-motor will oscillate and
cause excessive amplifier/motor heating.
6ZLWFK 6ZLWFK ,5&RPSHQVDWLRQ

1R 1R
- - No compensation
- 21 1/3 compensation
21 - 2/3 compensation
21 21 Max compensation
6HQVLWLYLW\
The sensitivity of the tachometer sensor input affects the ratio
between the speed of the steering wheel and the DC-motor
and by that the number of revolutions between the end posi-
tions of the steering. The sensitivity can be set to 8 different
levels by Dipswitches no 5, 6, 7 and 8.
If the sensitivity is too high the steering will be too quick (nerv-
ous) for full speed driving.
If the sesitivity is too low the steering will be too slow. To give
the best sensitivity at high and low truck speeds, the control-
ler has a progressive steering. This means the sensitivity will
automatically increase when the steering wheel is rotated
faster.

2/ 6
Version no T-code

In the table below is shown the recommended settings for this

particular truck type. Other sensitivities can be received by
different settings but is then out of our recommendation.
$SSUR[ 7DFKR 6ZLWFK 6ZLWFK 6ZLWFK 6ZLWFK

6WHHULQJ
ZKHHOUHYROX YROWDJH 1R 1R 1R 1R
WLRQV
3.5 1.3V 21 21 21 21
4.5 1.6V - 21 21 21
6 2.1V 21 - 21 21
7.5 2.6V - - ON ON
8.5 2.9V 21 21 - 21
10 3.3V - 21 - 21
11 3.7V 21 - - 21
12.5 4.1V - - - 21
** At this tachometer voltage the DC-motor gets full speed.

2/ 6
Version no T-code

&LUFXLWGLDJUDPRIWKHHOHFWULFDO
VWHHULQJ

2/ 6
Version no T-code

/LVWRIV\PEROV
6\PERO 'HVFLSWLRQ )XQFWLRQ 5HPDUN

A2 Logic Card Electrical System Of complete truck
A3 Controller Power Steering
F64 Fuse Power Steering 20A
K60 Relay Main Switch For Power

Steering
M6 DC-Motor Steering Motor
U1 Tachometer Steering Wheel Tachometer
$GMXVWPHQWRIVWHHULQJFKDLQ
The slack of the steering chain shall be checked and adjusted
at the 500 hours preventive maintenance service.
Adjust the chain to a maximum play of +- 5 mm by tightening
the adjustment bolt (A). Lock the bolt with the locking nut.
B B
2/ 6
Version no T-code

5HPRYDOPRXQWLQJRIWKHVWHHULQJ
PRWRU
5HPRYDO
• Remove the front bumper of the chassis.
• Disconnect the elevtrical wires to the steering motor.
• Remove one of the chain locks (B) to get one end of the
chain free and pull it out through the steering motor drive
end.
• Loosen the four motor M8 mounting bolts (C) and remove
the motor.
0RXQWLQJ
• Fit the steering motor into its hole in the motor plate.
Tighteh the bolts 25 Nm. The bolts shall be lubricated prior
to assembly.
• Pull the steering chain through the motor drive end and fit it
to the gear box cover with the chain lock. The clips of the
chain lock shall be on the chain lower side.
• Adjust the play of the steering chain.
• Connect the moter wiring.
• Fit the chassis front bumper.

2/ 6
Version no T-code


2/ 6
66' 3HUcNH*XVWDIVVRQ
7FRGH 0RGHO 0DFKLQHQR 1RWH

342 OS 1.8 X 295610AA-
345 OS 2.0 295610AA-
346 OS 3.0 295610AA-
347 OS 1.0 W 295610AA-
348 OS 1.0 295610AA-
423 OS 1.2 CB 295610AA-
424 OS 1.0 HW 295610AA-
425 OS 1.0 WL 295610AA-
*HQHUDO
The electric steering servo consists of a tachometer, fixed
under the steering wheel, and a permanently magnetised
steering motor. The actual steering regulator is integrated on
the logic card. The system is fully electrical, with no mechani-
cal links between the steer wheel and the steering wheel.
The logic card constantly monitors the entire steering system.
Every time the electrical system of the truck is started, the
safety system of the electrical system is checked with a simu-
lated fault before the truck can be operated.
If any faults or problems occur in the tachometer, cables, the
regulator itself or the DC motor, the drive function of the truck
is automatically stopped and the electromagnetic brake is
applied.
Steering is progressive, which means that the faster the
steering wheel is turned, the faster the steer wheel turns.
The speed of the truck does not affect steering.
$GMXVWPHQWV
The ratio between the steering wheel and the steer wheel can
be adjusted using a parameter. See section S5 C code 5710.

2/ 6
Version no T-code

(OHFWULFDOGLDJUDP

OL S5 5000
Electrical system
Electrical system

203 PPO 1500MX 249329AA-
1 General
The description is only valid for trucks with maximum speed
6 km/h.
2 Electrical panel, components

OL S5 5000
Electrical system
3 List of symbols
Sym- Description Function Remark

bol
A1 Transistor controller
A2 Electronic card
BT Battery
F10 Fuse Motor circuit 100 A

F50 Fuse Control circuit 7,5 A
H1 Horn
K11 Contactor Drive direction Fork direction

K13 Contactor Drive direction Steer wheel direction
K30 Contactor Pump motor
M1 Motor Driving
M3 Motor Pump
P1 Indicator Hour meter

P3 Indicator Batteryindicator/Hour
meter
R1 Potentiometer Speed 5 - 0 kOhm

RV1 Potentiometer Speed reduction
S10 Switch ”Brake”

S15 Switch Drive direction Steer wheel direction
S16 Switch Drive direction Fork direction

OL S5 5000
Electrical system

bol
S17 Switch Key
S18 Switch Horn
S21 Switch Emergency switch of
S41 Switch Fork lower
S52 Switch Fork lift
Y41 Magnetic valve Lowering

OL S5 5000
Electrical system
3.1 Circuit diagram 1(3)

OL S5 5000
Electrical system

OL S5 5000
Electrical system

OL S5 5000
Electrical system
4 Description of function
4.1 General
The Transistor controller (A1) regulates the speed step less
up to maximum speed. When starting the truck, does the con-
troller check the closing sequency of the micro switches in the
circuit. The controller is equipped with a lightdiode (LED)
showing system status and potentiometers for adjusting the
current limit and acceleration, placed under a sliding cover.
The electrical system have a connection card (A2) to group all

connections of the control circuits for input respectively output
signals to the transistor controller. The connection card is
equipped with LED’s for indication of incomming or outgoing
signals and a potentiometer for adjustment of the maximum
speed.
4.2 Adjustable settings
Setting Std. Min. Max.

value value value
Current limit 150A 100A 150A
Acceleration 0.8 s 0.1 s 3s
Maximum speed, 5.8 km/h 3.0 km/h 5.8 km/h
without load 1.61 m/s 0.83 m/s 1.61 m/s
4.3 References
For more information about: adjustment of the speed potenti-
ometer, the transistor controller and the connection card, see
C-code 5330, 5460 resp. 5710.
The description is devided into different phases which corre-
spond to the operational sequense steps. For each sequense
step the correct LED-pattern is shown below. A filled circle
denotes a LED emitting light.

OL S5 5000
Electrical system
4.4 Ignition lock S17 in the ON position
When S17 closes, the transistor controller will check that S10
is not closed. If this is the case, operation is not permitted.
Battery voltage on A2-terminal 202, LED 202 lights up. A2 (-)
return terminal 409. Battery voltage to A1.16 via A2-terminal
410, LED-status starts to flash.
4.5 The operating arm in drive position,

S10
When the opersting arm is pushed down to the driving posi-

tion, S10 is activated and closes and at the same time the
brake is mechanically released. Voltage obtained via terminal
109 and 408 to A1.15, LED 109 lights up, on the hour meter
terminal 206 and the shunt field terminal 301.
The transistor controller now regulates the current through the
shunt field, 1,2 A, (-) return via terminal 302, 417 and A1.1.

OL S5 5000
Electrical system
4.6 Driving, steer wheel direction
When the butterfly is activated for driving in the fork direction,

S15 will close. The transistor controller checks that S10 is
closed before S15 closes, if not driving is not permitted.
Battery voltage obtained via terminal 102 and 412 to A1.12,
LED 102 lights up. Battery voltage to K13 via terminal 403.
A1.3 now gives (-) return to K13, (-)input on terminal 402,
LED 402 lights up.
Depending on the position of the speed control(R1) and
adjustment of potentiometer RV1 will A1.8 obtaine a voltage
between 4.8-0.25 V.
The motor current now passes through F10, the series field
D2-D1, K13, the armature A1-A2 and K13 to battery negative
via A1.
4.7 Driving, fork direction

LED 401 lights up.

OL S5 5000
Electrical system

between 4.8-0.25 V.
via A1.
4.8 Reversing/motor brake steer wheel

direction to fork direction
S15 returns to neutral position while S16 closes. The current
in the series fiels causes the motor to work as a generator
since the drive wheel rotates in the ”wrong direction”.
The transistor controller detects the generated current at con-
nection A2, and reduces the series field current to 60A.
When the drive wheel rotates in the ”right direction” and the
potential at connection A2 becomes positive, acceleration is
done according to adjusted values of current limit and accel-
eration.
During braking sequence, the armature current passes in the
circuit A2-A1, K13, A2, the brake diode of the transistor con-
troller, M- and K13.
4.9 Reversing/motor brake fork direction

to steer wheel direction
eration.

OL S5 5000
Electrical system
4.10 Lifting the forks
The micro switch S52 closes. K30 receives (+)voltage via ter-
minal 105, 203, battery controller or the jumper, terminal 201
and 405, LED 105 and 405 lights up. (-)return via wire 40. K30
closes and the pump motor M3 starts.
4.11 Driving and simultaneously lifting the

forks
A1 detects the activation of K30, (+) at terminal 404 and

A1.14. A1 then reduces the speed to 70% and the motor cur-
rent to 100A.

OL S5 5000
Electrical system
4.12 Lowering the forks
When lowering the forks S41 is activated. The magnetic

valve, Y41, receives (+)voltage via terminal 106 and 204, LED
106 lights up. (-)return via wire 40.
4.13 Horn
Micro switch S18 is activated. The horn, H1, receives (+)volt-

age via terminal 107 and 406, LED 107 lights up. (-)return via
wire 40.
4.14 Emergency switch of

When the emergency switch of button is pushed opens micro
switch S21. All voltage supply in the truck is cut out.

OL S5 5000
Electrical system
SSD K. Hallman 002 203
Electrical system

203 PPO 1500MX 255245AA-
1 General
The description is only valid for trucks with maximum speed 8
km/h.

OL S5 5000
Electrical system
3 List of symbols

bol
A1 Transistor controller
A2 Connection card
BT Battery
F10 Fuse Motor circuit 100A

F50 Fuse Control circuit 7,5A
H1 Horn

M1 Motor Drive
M3 Motor Pump
P1 Indicator Hour meter

meter

RV1 Potentiometer Speed reduction
S10 Switch ”Brake”


OL S5 5000
Electrical system

bol
S17 Switch Key
S18 Switch Horn
S19 Switch Walking speed Platform switch
Y41 Magnetic valve Lowering

OL S5 5000
Electrical system

OL S5 5000
Electrical system

OL S5 5000
Electrical system

OL S5 5000
Electrical system
4.1 General
up to maximum speed. When starting the truck, does the con-
troller check the closing sequency of the micro switches in the
circuit. The controller is equipped with a lightdiode (LED)
showing system status and potentiometers for adjusting the
current limit and acceleration, placed under a sliding cover.
The electrical system have a connection card (A2) to group all

connections of the control circuits for input respectively output
signals to the transistor controller. The connection card is
equipped with LED’s for indication of incomming or outgoing
signals and a potentiometer for adjustment of the maximum
speed.
106 111 205 409 417

105 110 204 408 416
208
104
103
203
207
407
406
415
414
206
102 108 201 413
404
101 412
403
301 302 411
410
Setting Std. Min. Max.
value value value
Current limit 150A 100A 150A
Acceleration 0.8 s 0.1 s 3s
Walking speed, 5.8 km/h 3.0 km/h 5.8 km/h
Driving speed 8.0 km/h 4.1 km/h 8.0 km/h
4.3 References
ometer, the transistor controller and the connection card, see
C-code 5330, 5460 resp. 5710.
step the correct LED-pattern is shown below. A filled circle
denotes a LED emitting light.

OL S5 5000
Electrical system
106 111 205 409 417

105 110 204 408 416
208
104 203 407 415
207
103 406 414
206
102 108 201 413
404
101 412
403
301 302 411
410
When S17 closes, the transistor controller will check that S10
is not closed. If this is the case, operation is not permitted.
Battery voltage on A2-terminal 202, LED 202 lights up. A2 (-)
return terminal 409. Battery voltage to A1.16 via A2-terminal
410, LED-status starts to flash.

S10
106 111 205 409 417

105 110 204 408 416
208
104 203 407 415
207
103 406 414
206
102 108 201 413
404
101 412
403
301 302 411
410
When the opersting arm is pushed down to the driving posi-

tion, S10 is activated and closes and at the same time the
brake is mechanically released. Voltage obtained via terminal
109 and 408 to A1.15, LED 109 lights up, on the hour meter
terminal 206 and the shunt field terminal 301.
The transistor controller now regulates the current through the
shunt field, 1,2 A, (-) return via terminal 302, 209, S19, 205,
417 and A1.1, LED 209 lights up.

OL S5 5000
Electrical system
4.6 Driving, steer wheel direction
106 111 205 409 417

105 110 204 408 416
208
104 203 407 415
207
103 406 414
206
102 108 201 413
101 404
412
403
302 411
301
410

LED 402 lights up.
between 4.8-0.25 V.
via A1.
106 111 205 409 417

105 110 204 408 416
208
104 203 407 415
207
103 406 414
206
102 108 201 413
404
101 412
403
302 411
301
410

LED 401 lights up.

OL S5 5000
Electrical system

between 4.8-0.25 V.
via A1.
4.8 Walking speed
106 111 205 409 417

105 110 204 408 416
208
104 203 407 415
207
103 406 414
206
102 108 201 413
404
101 412
403
302 411
301
410
The operator walks alongside the truck. The platform switch

S19 is closed, indicated by LED 209. The speed is reduced to
75%. The picture shows driving in the fork direction.
4.9 Reversing/motor brake steer wheel

eration.

OL S5 5000
Electrical system

to steer wheel direction
eration.
106 111 205 409 417

105 110 204 408 416
208
104 203 407 415
207
103 406 414
206
102 108 201 413
404
101 412
403
302 411
301
410
The micro switch S52 closes. K30 receives (+)voltage via ter-
minal 105, 203, battery controller or the jumper, terminal 201
and 405, LED 105 and 405 lights up.
(-)return via wire 40. K30 closes and the pump motor M3
starts.

OL S5 5000
Electrical system
4.12 Driving and simultaneously lifting the

forks
106 111 205 409 417

105 110 204 408 416
208
104 203 407 415
207
103 406 414
206
102 108 201 413
404
101 412
403
302 411
301
410
A1 detects the activation of K30, (+) at terminal 404 and

A1.14. A1 then reduces the speed to 70% and the motor cur-
rent to 100A.
106 111 205 409 417

105 110 204 408 416
208
104 203 407 415
207
103 406 414
206
102 108 201 413
404
101 412
403
302 411
301
410

4.14 Horn
106 111 205 409 417

105 110 204 408 416
208
104 203 407 415
207
103 406 414
206
102 108 201 413
404
101 412
403
302 411
301
410

wire 40.
OL S5 5000
Electrical system
4.15 Emergency switch of

When the emergency switch of button is pushed opens micro
switch S21. All voltage supply in the truck is cut out.

OL S5 5000
Electrical system
Version no T-code
002 203

OL S5 5000
Electrical system
Electrical system
Valid from serial number: 256600-275189

345 OS 2.0 256600AA-275189AA With tillerarm
A2
A1
K11 K10
K13 K30
F10 F1
H1
F50

OL S5 5000
Electrical system
Version no T-code
001 345
2 List of symbols
Symbol Description Function Remark

A1 Transistor controller PUB 24220 CD2
A2 Electronic card 142485
BT Battery
F1 Fuse Main, Motor circuit 125A

F10 Fuse Pump motor circuit 100A
F50 Fuse Control circuit 10A
H1 Horn
K10 Contactor Main

M1 Motor Drive
M3 Motor Pump
P3 Indicator Batteryindicator/Hour meter
S9 Switch Brake Lower switch

S10 Switch Brake Upper switch
S17 Switch Key

OL S5 5000
Electrical system
Version no T-code
001 345

S18 Switch Horn
S19 Switch Platform
S21 Switch Emergency switch of Left side
S22 Switch Emergency switch of Right side
S24 Switch Side button Option, Left side
S25 Switch Side button Option, Right side
S26 Switch Low speed button Option, Steer wheel direc-
tion
S27 Switch Low speed button Option, Fork direction
S31 Switch Lift limit
S61 Switch Pressure switch for brake
S64 Inductive switch Steer wheel middle position With the side button option
Y10 Brake Step 1

Y11 Brake Step 2
Y41 Magnetic valve Fork lower

OL S5 5000
Electrical system
Version no T-code
001 345

OL S5 5000
Electrical system
Version no T-code
001 345

OL S5 5000
Electrical system
Version no T-code
001 345

OL S5 5000
Electrical system
Version no T-code
001 345

OL S5 5000
Electrical system
Version no T-code
001 345

OL S5 5000
Electrical system
Version no T-code
001 345
3.1 General
A
LD1
LD2
M B-
LD3
LD4
up to maximum speed. When starting the truck, the controller
71
B+
checks the speed potentiometer circuit before opening the
safety circuit. The controller is equipped with four lightdiodes
(LED’s) showing controller status and fault indication.
The electrical system have a logic card (A2) to group all con-
nections of the control circuits for input respectively output
signals to the transistor controller. The logic card is equipped
with LED’s for indication of incomming or outgoing signals, a
jumper for two different acceleration ramps and a potentiome-
ter for adjustment of the maximum speed.
3.2 Adjustable settings:
Setting Min. value Max. value

Acceleration 1.0 s 2.5 s
Maximum speed, with- 7.0 km/h 12.0 km/h
out load 1.94 m/s 3.33 m/s
3.3 References:
ometer, the transistor controller and the logic card, see C-
code 5330, 5460 resp. 5710.
In the electrical system is as standard a combined hour meter
and battery controller (P3) that cuts the voltage to the lift func-
tion when the battery capacity has reached 20%. The hour
meter registers the time whenever driving and lifting or lower-
ing of the forks occurs.
The operation of the instrument is indicated by LED 308 in the
sequense LED pattern.

OL S5 5000
Electrical system
Version no T-code
001 345

When S17 closes, the transistor controller (A1) will check the
speed potentiometer circuit. If the reference value is 0.8V or
less the safety circuit feeds voltage to the mani contactor K10.
If the reference value is more than 0.8V, operation is not per-
mitted.
Battery voltage on A2-terminals 101, 401, 403, 408 and 504,
corresponding LED’s will light up. A2 (-) return terminal 505.
Battery voltage to A1.1 from S17, LED1 lights up.

S10
3.5.1 First start after closing S17 or releasing the emer-
gency switch of (S21, S22)
When the operating arm is pushed down to the driving posi-
tion, S10 is activated and closes, LED 209 lights up, but the
brake stays on. To release the brake, first a selection of drive
direction must be made.
3.5.2 Normal start with S17 closed

tion, S10 is activated and closes, LED 209 lights up, A2 termi-
nals 303 and 304 becomes positive to supply voltage to Y10
and Y11, LED’s 303 and 304 lights up, and the brake is
released.
3.6 Driving, steering wheel direction

When the speed control is activated for driving in the steering
wheel direction, S15 will close. Terminal 207 becomes posi-
tive, LED 207 lights up. Voltage to K11 from A2 via terminal
301, LED 301 lights up. A1.3 receives the output signal to
K11 to determine maximum speed limitation in the steering
wheel direction.
Depending of if S19 is closed, LED’s 407 and 507 lit, (driver
on the platform) 100% modulation, or S19 open, LED’s 407
and 507 off, (driver walking) 45% modulation.
adjustment of potentiometer RV1 will A1.10 obtain a voltage
between 0 - 5V.
The motor current now passes through F1, the armature A2-
A1, K11, the series field D1-D2, and K11 to battery negative
via A1-M.
OL S5 5000
Electrical system
Version no T-code
001 345

S16 will close. Terminal 208 becomes positive, LED 208
lights up. Voltage to K13 from A2 via terminal 302, LED 302
lights up. A1.4 receives the output signal to K13 to determine
maximum speed limitation in the fork direction.
Depending of if S19 is closed, LED’s 407 and 507 lit, (driver
on the platform) 70% modulation, or S19 open, LED’s 407
and 507 off, (driver walking) 45% modulation.
between 0 - 5V.
via A1-M.
3.8 Reversing/motor brake steering wheel

During motor braking the transistor controller regulates the
series field current between 100A-330A depending on the
position of the speed potentiometer R1.
potential at connection A becomes positive, acceleration is
done according to adjusted value.
circuit A, the brake diode of A1 and M.

OL S5 5000
Electrical system
Version no T-code
001 345

to steering wheel direction
3.10 Brake
The brake operates in two steps dependant of the pressure in
the hydraulic system (i.e. load weight on the forks). Below a
pressure corresponding to a load of approx. 550 kg only the
first step is in operation, pressure switch S61 is closed. Indi-
cated by LED 504. When braking the truck within this load
range the second step is applied after some seconds.
At loads above 550 kg both steps are applied at the same
time, pressure switch S61 is open and LED 504 off.

The micro switchS51 closes. K30 receives (+)voltage via ter-
minal 210, 305, lift limit switch S31 and the battery controller
P3, LED 210 and 309 lights up. When lifting less than the
opening point of S31 this is indicated by the LED 310 at termi-
nal 310.
starts.


OL S5 5000
Electrical system
Version no T-code
001 345
3.13 Horn
wire 40.
4 Options
As an optional equipment it is possible to fit a drive function
by means of push button monuted on both sides of the back-
rest. This function can be operated by the driver by pushing
either of the buttons without holding the operating arm.
The optional drive function is only operational in the steering
wheel direction and when the steering drive wheel is in a
straight position.
It is inoperational as soon as any person steps onto the plat-
form.
4.1 Function:
By closing either S24 (left side) or S25 (right side), LED 406
lights up. Providing the steering drive wheel is in a straight
position, supervised by inductive switch S64 who supplies
voltage to terminal 503, A1 will supply voltage to the brake
coils Y10 and Y11 via terminal 303 and 304, LED 303 and
304 lights up.
K11 receives voltage from terminal 301, LED 301, and A1
determines the maximum speed limitation to low speed
range, 45% modulation.

OL S5 5000
Electrical system
Version no T-code
001 345

OL S5 5000
Electrical system
Electrical system

345 OS 2.0 256600AA-275189AA With steering
wheel
A2
A1
K11 K10
K13 K30
F10 F1
K60
A3
H1
F64 F50

OL S5 5000
Electrical system
Version no T-code
002 345
2 List of symbols

A3 Electronic card Electrical steering
BT Battery
F1 Fuse Main, motor circuit 125A

F64 Fuse Electrical steering 20A
H1 Horn
K10 Contactor Main

K60 Relay Electrical steering
M1 Motor Drive
M3 Motor Pump
M6 Motor Electrical steering
S10 Switch Brake Brake lever

OL S5 5000
Electrical system
Version no T-code
002 345

S17 Switch Key
S18 Switch Horn
S19 Switch Brake Platform
tion
S41 Switch Fork lower Left side
S42 Switch Fork lower Right side
S51 Switch Fork lift Left side
S52 Switch Fork lift Right side
U1 Tachometer Steering wheel
Y10 Brake Step 1

Y11 Brake Step 2

OL S5 5000
Electrical system
Version no T-code
002 345

OL S5 5000
Electrical system
Version no T-code
002 345

OL S5 5000
Electrical system
Version no T-code
002 345

OL S5 5000
Electrical system
Version no T-code
002 345

OL S5 5000
Electrical system
Version no T-code
002 345

OL S5 5000
Electrical system
Version no T-code
002 345

OL S5 5000
Electrical system
Version no T-code
002 345
3.1 General
A up to maximum speed. When starting the truck, the controller
LD1
checks the speed potentiometer circuit before opening the
LD2
LD3 M B- safety circuit. The controller is equipped with four lightdiodes
LD4 (LED’s) showing controller status and fault indication.
71
B+
As components of the electrical system are also the compo-
nents for the electrical steering wheel included in the circuit
diagram. The electrical steering wheel system will not be
described in detail here as its function is steering system (C-
code 4100).
3.2 Adjustable settings:

3.3 References:
For more information about: adjustment of the electrical steer-
ing wheel, the speed potentiometer, the transistor controller
and the logic card, see C-code 4100, 5330, 5460 resp. 5710.
ing of the forks occurs.
The operation of the instrument is indicated by LED 308 in the
sequense LED pattern.

OL S5 5000
Electrical system
Version no T-code
002 345

less the safety circuit feeds voltage to the mani contactor K10.
If the reference value is more than 0.8V, operation is not per-
mitted.
Also the controller (A3) of the electrical steering wheel system
will make a check of its circuits. If everything is in order the
controller closes the safety relay providing voltage to K60
making the steering system operational.
Battery voltage on A2-terminals 101, 401 and 504, corre-
sponding LED’s will light up. A2 (-) return terminal 505. K60
will provide voltage to terminal 403 and S19, LED 403 lights
up.
Battery voltage to A1.1 from S17, LED1 lights up.
3.5 Brake
3.5.1 Release of parking brake.
When the driver steps onto the down platform S19 is acti-
vated and closes, LED 408 and 209 lights up, but the brake
stays on. The parking brake is released at first when a selec-
tion of drive direction is done.
3.5.2 Braking during driving.

When the brake lever on the steering wheel module is pulled
S10 is activated and closes, interrupting the voltage to termi-
nal 209 and the drive direction switches, LED 209 off, A2 ter-
minals 303 and 304 looses positive the voltage supply to Y10
and Y11, LED’s 303 and 304 off, and the brake is applied.

OL S5 5000
Electrical system
Version no T-code
002 345
301, LED 301 lights up. A1.3 receives the output signal to
K11 to determine maximum speed limitation in the steering
wheel direction.
As the S19 is closed, LED’s 407 and 507 lit, (driver on the
platform) the output from the controller is at 100% modulation.
between 0 - 5V.
via A1-M.

lights up. A1.4 receives the output signal to K13 to determine
maximum speed limitation in the fork direction.
As the S19 is closed, LED’s 407 and 507 lit, (driver on the
platform) the output from the controller is at 70% modulation.
between 0 - 5V.
via A1-M.

OL S5 5000
Electrical system
Version no T-code
002 345


The micro switchS51 closes. K30 receives (+)voltage via ter-
minal 210, 305, lift limit switch S31 and the battery controller
P3, LED 210 and 309 lights up. When lifting less than the
nal 310.
starts.

3.12 Horn
wire 40.

OL S5 5000
Electrical system
Version no T-code
002 345
4 Options
4.1 Driving walking at the side of the truck

by means of push buttons monuted on both sides of the back-
either of the buttons walking at the side of the truck, without
touching the speed control of the steering wheel module.
straight position.
form.
4.1.1 Function:
304 lights up.
K11 receives voltage from terminal 301, LED 301, and A1
determines the maximum speed limitation to low speed
range, 45% modulation.
4.2 Inching speed

As an optional equipment it is possible to fit a inching speed
function by means of push buttons monuted on the backrest.
This function can only be operated when the driver is standing
on the platform.
The optional drive function is operational in both directions
regardless of the position of the steering drive wheel.
It becomes inoperational as soon as the driver leaves the
platfom.
4.2.1 Function:
By closing either S26 (steering wheel direction), LED 409
lights up, K11 receives voltage from terminal 301, LED 301,
and A1 determines the maximum speed limitation to low
speed range.
Closing S27 (fork direction), LED 410 lights up, K13 receives

OL S5 5000
Electrical system
Version no T-code
002 345
voltage from terminal 302, LED 302, and A1 determines the

maximum speed limitation to low speed range. The output
from the controller in the low speed range is at 45% modula-
tion.

OL S5 5000
Electrical system
Version no T-code
002 345

OL S5 5000
Electrical system
Electrical system
Valid from machine no:

345 OS 2.0 275190AA- With tiller arm

OL S5 5000
Electrical system
Version no T-code
003 345
2 List of symbols

bol
A2 Electronic card
BT Battery

H1 Horn
I64 Indicator lamp Indication of the drive Optional equipment for

wheel straight position push buttons for driving
from the side
K10 Contactor Main

M1 Motor Drive
M3 Motor Pump
meter

OL S5 5000
Electrical system
Version no T-code
003 345

bol
Re19 Relay Main relay for driving Optional equipment,
from the side in the fork push button for driving in
direction the fork direction
Re64 Relay Control relay for wheel Optional equipment
position indication
Re101 Relay Relay for direction con- Optional equipment,
tactors push button for driving in
the fork direction

S17 Switch Key
S18 Switch Horn
S19 Switch Platform
S22A Switch Emergency switch of Optional equipment on
the back rest, left side
S22B Switch Emergency switch of Optional equipment on
the back rest, right side
S24 Switch Push button, driving for- Optional equipment, left
ward from the side side
S25 Switch Push button, driving for- Optional equipment, right
S28 Switch Push button, driving in Optional equipment, left
the fork direction from the side
side
S29 Switch Push button, driving in Optional equipment, right
side

OL S5 5000
Electrical system
Version no T-code
003 345

bol
S64 Inductive switch Steer wheel middle posi- With the side button
tion option
S69 Switch Platform lift
S70 Switch Platform lower
S105 Switch Platform limit 0.5 m
S107 Switch Platform lift limit Max
Y10 Brake Step 1

Y11 Brake Step 2
Y45 Magnetic valve Fork lift/lower Extra valve at lifting plat-
form
Y69 Magnetic valve Platform lift/lower

OL S5 5000
Electrical system
Version no T-code
003 345

OL S5 5000
Electrical system
Version no T-code
003 345

OL S5 5000
Electrical system
Version no T-code
003 345

OL S5 5000
Electrical system
Version no T-code
003 345

OL S5 5000
Electrical system
Version no T-code
003 345

OL S5 5000
Electrical system
Version no T-code
003 345

OL S5 5000
Electrical system
Version no T-code
003 345
A 3.1 General
LD1
LD2
M B-
LD3
LD4 up to maximum speed. When starting the truck, the controller
71 checks the speed potentiometer circuit before opening the
B+
with LED’s for indication of incomming or outgoing signals,
potentiometer’s for adjustment of maximum speed and auto
plug brake force, and a dip switch for setting the acceleration
ramp.
Setting Min. Max.

value value
Auto-plug brake current 30 % 90 %
Maximum speed, without load 7.0 km/h 12.0 km/h
1.94 m/s 3.33 m/s

OL S5 5000
Electrical system
Version no T-code
003 345
3.3 References
code 5330, 5460 resp. 5710.
ing of the forks occurs. The operation of the instrument is indi-
cated by LED 308 in the sequense LED pattern.

less the safety circuit feeds voltage to the main contactor
K10. If the reference value is more than 1.5V, operation is not
permitted.
Battery voltage on A2-terminals 101, 309, 310, 401, 403, 408
and 504, corresponding LED’s will light up. A2 (-) return termi-
nal 505.Battery voltage to A1.1 from S17, LED1 lights up.

S10
gency switch of (S21, S22).

released.
OL S5 5000
Electrical system
Version no T-code
003 345

301, LED 301 lights up. Depending of if S19 is closed, LED
407 is lit, (driver on the platform) 100% speed, or S19 open,
LED 407 off, (driver walking) 47% speed.
between 0 - 5V.
via A1-M.

lights up. Depending of if S19 is closed, LED 407 is lit, (driver
on the platform) 100% speed, or S19 open, LED 407 off,
(driver walking) 47% speed.
between 0 - 5V.
via A1-M.

series field current between 100-330A depending on the posi-
tion of the speed potentiometer R1.
OL S5 5000
Electrical system
Version no T-code
003 345

3.10 Auto-plugbraking
By setting the dip-switch no 2 on the electronic card in the on-
position the auto-plug braking function is enabled. When the
speed control is released to neutral a generated signal from
the transistor controller is detected by the electronic card on
terminal 508, LED 508 lights up. The electronic card micro
processor then supply voltage to the opposite direction con-
tactor (picture showing travelling forward in auto-plug mode).
The braking force during auto-plug braking is determined by
the current reference value set by the electronic card at termi-
nal A1-11. The braking force is adjustable up to 70% of the
maximum brake current by adjusting the potentiometer
marked brake on the electronic card. The auto-plug mode
stays on until the generated signal disappears from terminal
508 or til the operator applies the speed control.
3.11 Brake
The brake is applied by either moving the tiller arm to its
upper position, opening S10, or to its lower position, opening
S9. The brake operates in two steps dependant of the pres-
sure in the hydraulic system (i.e. load weight on the forks).
Below a pressure corresponding to a load of approx. 550 kg
only the first step is in operation, pressure switch S61 is
closed. Indicated by LED 504. When braking the truck within
this load range the second step is applied after some sec-
onds.

OL S5 5000
Electrical system
Version no T-code
003 345

The micro switch S51 closes, positive input on terminal 210,
LED 210 lights up. K30 receives (+)voltage from terminal 305,
LED 305 lights up. When lifting less than the opening point of
S31 this is indicated by the LED 310 at terminal 310. (-)return
via wire 40. K30 closes and the pump motor M3 starts.
If the load weight exceeds approx. 550 kg the pressure switch
S61 opens and LED 504 is off.

When lowering the forks S41 is activated, positive input on
terminal 211, LED 211 lights up. The magnetic valve, Y41,
receives (+)voltage from terminal 306, LED 211 lights up. (-
)return via wire 40.
As the forks are lowered the lift limit switch S31 closes, LED
310 lights up, and when the forks are completely lowered the
hydraulic pressure disappears and S61 closes, LED 504
lights up.
3.14 Horn
wire 40.

OL S5 5000
Electrical system
Version no T-code
003 345
4 Options
4.1 Extra emergency switch of (circuit dia-

gram 2)
Extra emergency switch of buttons, S22A and S22B, mounted
on the back rest.
4.2 Inching speed push button

This driving function only works when driving straight.
form.
4.2.1 Function: (circuit diagram 1-3)

Forward:
304 lights up.
K11 receives voltage from terminal 301, LED 301, and relay
Re101 in neutral position. The electronic card determines the
maximum speed limitation to low speed range, 47% speed.
Fork direction:
By closing either S28 (left side) or S29 (right side) 24 V is fed
via diode D1 or D5 to terminal 406, LED 406 lights up. Provi-
ding the steering drive wheel is in a straight position, supervi-
sed by inductive switch S64 who supplies voltage to terminal
503, A2 will supply voltage to the brake coils Y10 and Y11 via
terminal 303 and 304, LED 303 and 304 lights up.
When the switch is closed voltage is supplied to relay Re101,
via diode D2 and Re19, which closes. Re19 opens as soon as
anybody steps onto the platform.

OL S5 5000
Electrical system
Version no T-code
003 345
4.3 Operator lift platform, circuit diagram 6

The truck can be equipped with an optional operator lifting
platform. Below is described step by step the functions of the
lifting platform.
4.3.1 Lifting the platform

Closing switch S69 to lift the platform, LED 605, provides volt-
age on terminal 611, LED 611, for Y69 and terminal 305, LED
305, for K30. (-)return via wire 40. K30 closes and the pump
motor M3 starts.
4.3.2 Speed reduction at platform height 500 mm above

the floor
When the operator platform have reached a height that
exceeds 500 mm above the floor micro switch S105 opens.
The the speed is automatically reduced to 47% by a limitation
of the speed reference value on terminal 510.
4.3.3 Platform lift limit switch

When the operator platform have reached its top position,
955 mm above the floor, the lift limit switch S107 opens.
Thereby is the voltage supply to K30, terminal 305, and Y69,
terminal 611, interrupted.
4.3.4 Lowering the platform

Closing switch S70 to lower the platform, LED 606, provides
voltage to both lowering magnetic valves Y69, LED 611, and
Y41, LED211, which opens.
As the operator platform is lowered the lift limit switch S107
closes, LED 607, and below a platform height of 500 mm limit
switch S105 closes and the speed reduction is removed (nor-
mal speed range obtained).

OL S5 5000
Electrical system
Version no T-code
003 345
4.4 Lifting and lowering of the forks

As a truck equipped with operator platform lift have got extra
magnetic valves for the platform lift, they influence the normal
lift and lower function of the forks.
4.4.1 Lifting the forks

LED 210. K30 receives (+)voltage from terminal 305, LED
305. At the same time the micro processor supply voltage to
Y45, terminal 610 and LED 610. When lifting less than the
nal 310. (-)return via wire 40. K30 closes and the pump motor
M3 starts.
4.4.2 Lowering the forks

terminal 211, LED 211. The magnetic valve, Y41, receives
(+)voltage from terminal 306, LED 211. At the same time the
micro processor supply voltage to Y45, terminal 610 and LED
610. (-)return via wire 40.
lights up.

OL S5 5000
Electrical system
Electrical system

345 OS 2.0 275190AA-289678AA
A2
A1
K11 K10
K13 K30
F10 F1
K60
A3
H1
F64 F50

OL S5 5000
Electrical system
Version no T-code
004 345
2 List of symbols

bol
A2 Electronic card
BT Battery

H1 Horn

from the side
K10 Contactor Main

M1 Motor Drive
M3 Motor Pump

OL S5 5000
Electrical system
Version no T-code
004 345

bol
meter

position indication
the fork direction

S17 Switch Key
S18 Switch Horn
S26 Switch Inching speed button, for- Optional equipment
ward/fork direction

OL S5 5000
Electrical system
Version no T-code
004 345

bol
side
side
tion option
Y10 Brake Step 1

Y11 Brake Step 2
form

OL S5 5000
Electrical system
Version no T-code
004 345

OL S5 5000
Electrical system
Version no T-code
004 345

OL S5 5000
Electrical system
Version no T-code
004 345

OL S5 5000
Electrical system
Version no T-code
004 345

OL S5 5000
Electrical system
Version no T-code
004 345

OL S5 5000
Electrical system
Version no T-code
004 345

OL S5 5000
Electrical system
Version no T-code
004 345

OL S5 5000
Electrical system
Version no T-code
004 345
A 3.1 General
LD1
LD2
M B-
LD3
71
B+ checks the speed potentiometer circuit before opening the
ramp.

code 4100).


OL S5 5000
Electrical system
Version no T-code
004 345
3.3 References
code 4100, 5330, 5460 resp. 5710.

permitted.
Battery voltage on A2-terminals 101, 309, 310, 401 and 504 ,
K60 will provide voltage to terminal 403 and S19, LED 403
lights up.Battery voltage to A1.1 from S17, LED1 lights up.

OL S5 5000
Electrical system
Version no T-code
004 345
3.5 Brake

cated by LED 504.
When braking the truck within this load range the second step
is applied after some seconds.

tive, LED 207 lights up.Voltage to K11 from A2 via terminal
301, LED 301 lights up.
As the S19 is closed, LED 407, (driver on the platform) the
output from the controller is at 100% modulation.
between 0 - 5V.
via A1-M.

OL S5 5000
Electrical system
Version no T-code
004 345

lights up.Voltage to K13 from A2 via terminal 302, LED 302
lights up.
between 0 - 5V.
via A1-M.


OL S5 5000
Electrical system
Version no T-code
004 345

The micro switch S51(S52) closes, positive input on terminal
210, LED 210 lights up. K30 receives (+)voltage from terminal
305, LED 305 lights up. When lifting less than the opening
point of S31 this is indicated by the LED 310 at terminal 310.(-
)return via wire 40. K30 closes and the pump motor M3 starts.

When lowering the forks S41(S42) is activated, positive input
on terminal 211, LED 211 lights up. The magnetic valve, Y41,
lights up.
3.13 Horn
wire 40.

OL S5 5000
Electrical system
Version no T-code
004 345
4 Options
gram 2)
on the back rest.

form.

Forward:
position, supervised by inductive switch S64 which supplies
304 lights up.
K11 receives voltage from terminal 301, via relay Re101 con-
tacts 1 and 4, LED 301 lights. The electronic card determines
the maximum speed limitation to low speed range, 47%
speed.
Fork direction:
sed by inductive switch S64 which supplies voltage to terminal
When either S28 or S29 closes a voltage is supplied to relay
coil of Re101, via diode D2 and Re19.
The forward drive output signal from terminal 301 is now diver-
ted via Re101 and feeds voltage to the reverse contactor K13.
The electronic card determines the maximum speed limitation
to low speed range, 47% speed.

OL S5 5000
Electrical system
Version no T-code
004 345
4.3 Inching speed

As an optional equipmwent it is possible to fit an inching speed
function by means of a rocker switch (S26) mounted on the
back rest. This function can only be operated when the driver
is standing on the platform. The optional drive function is ope-
rational in both directions regardless of the position of the ste-
ering drive wheel. It becomes in-operative as soon as the
driver leaves the platform.
4.3.1 Function: (circuit diagram 3)

By pushing the lower part of the rocker switch, voltage is supp-
lied to terminal 409 for driving forward, LED 409 lights up.
K11 receives voltage from terminal 301, LED 301, and A2 de-
termines the maximum speed limitation to low speed range.
By pushing the upper part of the rocker switch, voltage is supp-
lied to terminal 410 for driving in the fork direction, LED 410
lights up.
The output from the controller in the low speed range is at 47%
modulation.

lifting platform.

motor M3 starts.

the floor

OL S5 5000
Electrical system
Version no T-code
004 345




210, LED 210. K30 receives (+)voltage from terminal 305,
LED 305. At the same time the micro processor supply volt-
age to Y45, terminal 610 and LED 610. When lifting less than
the opening point of S31 this is indicated by the LED 310 at
terminal 310. (-)return via wire 40. K30 closes and the pump
motor M3 starts.

on terminal 211, LED 211. The magnetic valve, Y41, receives
lights up.

OL S5 5000
Electrical system
Version no T-code
004 345

OL S5 5000
Electrical system
Version no T-code
004 345

OL S5 5000
Electrical system
Version no T-code
004 345

OL S5 5000
Electrical system
Electrical system

346 OS 3.0 262700AA-275189AA- With tiller arm
2 List of symbols

bol
A2 Electronic card
BT Battery

OL S5 5000
Electrical system
Version no T-code
001 346

bol
H1 Horn
K10 Contactor Main

M1 Motor Drive
M3 Motor Pump
meter

S17 Switch Key
S18 Switch Horn
S19 Switch Platform

OL S5 5000
Electrical system
Version no T-code
001 346

bol
tion option
Y10 Brake Step 1

Y11 Brake Step 2
form

OL S5 5000
Electrical system
Version no T-code
001 346

OL S5 5000
Electrical system
Version no T-code
001 346

OL S5 5000
Electrical system
Version no T-code
001 346

OL S5 5000
Electrical system
Version no T-code
001 346

OL S5 5000
Electrical system
Version no T-code
001 346

OL S5 5000
Electrical system
Version no T-code
001 346

OL S5 5000
Electrical system
Version no T-code
001 346
A 3.1 General
LD1
LD2
M B-
LD3
71
ramp.
Setting Min. Max.

value value
Maximum speed, without 7.0 km/h 12.0 km/h
load 1.94 m/s 3.33 m/s
3.3 References
code 5330, 5460 resp. 5710.

OL S5 5000
Electrical system
Version no T-code
001 346

permitted.
and 504, corresponding LED’s will light up. A2 (-) return ter-
minal 505.Battery voltage to A1.1 from S17, LED1 lights up.

S10
gency switch of (S21, S22)

released.

between 0 - 5V.
via A1-M.

OL S5 5000
Electrical system
Version no T-code
001 346

between 0 - 5V.
via A1-M.


OL S5 5000
Electrical system
Version no T-code
001 346
3.11 Brake
onds.


OL S5 5000
Electrical system
Version no T-code
001 346

lights up.
3.14 Horn
wire 40.
4 Options

straight position.
form.
4.1.1 Function
304 lights up.
K11 receives voltage from terminal 301, LED 301, and the
electronic card micro processor determines the maximum
speed limitation to low speed range, 45% speed.

OL S5 5000
Electrical system
Version no T-code
001 346
4.2 Operator lift platform

lifting platform.

motor M3 starts.

the floor
The the speed is automatically reduced to approx 5 km/h by a
limitation of the speed reference value on terminal 510.



OL S5 5000
Electrical system
Version no T-code
001 346


M3 starts.

lights up.

OL S5 5000
Electrical system
Electrical system

346 OS 3.0 262700AA-275189AA- With steering wheel
A2
A1
K11 K10
K13 K30
F10 F1
K60
A3
H1
F64 F50
2 List of symbols

bol
A2 Electronic card
BT Battery

OL S5 5000
Electrical system
Version no T-code
002 346

bol
H1 Horn
K10 Contactor Main

M1 Motor Drive
M3 Motor Pump
meter

S17 Switch Key
S18 Switch Horn

OL S5 5000
Electrical system
Version no T-code
002 346

bol
S26 Switch Low speed button Option, Steer wheel
direction
tion option
Y10 Brake Step 1

Y11 Brake Step 2
form

OL S5 5000
Electrical system
Version no T-code
002 346

OL S5 5000
Electrical system
Version no T-code
002 346

OL S5 5000
Electrical system
Version no T-code
002 346

OL S5 5000
Electrical system
Version no T-code
002 346

OL S5 5000
Electrical system
Version no T-code
002 346

OL S5 5000
Electrical system
Version no T-code
002 346

OL S5 5000
Electrical system
Version no T-code
002 346

OL S5 5000
Electrical system
Version no T-code
002 346
A 3.1 General
LD1
LD2
M B-
LD3
B+
ramp.

code 4100).

load 1.94 m/s 3.33 m/s
3.3 References
code 4100, 5330, 5460 resp. 5710.
OL S5 5000
Electrical system
Version no T-code
002 346

permitted.
corresponding LED’s will light up.
A2 (-) return terminal 505. K60 will provide voltage to terminal
403 and S19, LED 403 lights up.Battery voltage to A1.1 from
S17, LED1 lights up.
3.5 Brake


OL S5 5000
Electrical system
Version no T-code
002 346

between 0 - 5V.
via A1-M.

lights up.
between 0 - 5V.
via A1-M.

OL S5 5000
Electrical system
Version no T-code
002 346


point of S31 this is indicated by the LED 310 at terminal 310.(-
)return via wire 40. K30 closes and the pump motor M3 starts.

OL S5 5000
Electrical system
Version no T-code
002 346

lights up.
3.13 Horn
wire 40.
4 Options

straight position.
form.
4.1.1 Function
304 lights up.

OL S5 5000
Electrical system
Version no T-code
002 346
4.2 Inching speed

This function can only be operated when the driver is stand-
ing on the platform.The optional drive function is operational
in both directions regardless of the position of the steering
drive wheel. It becomes inoperational as soon as the driver
leaves the platfom.
4.2.1 Function
speed range.
tion.

lifting platform.

motor M3 starts.

the floor


OL S5 5000
Electrical system
Version no T-code
002 346



motor M3 starts.

lights up.

OL S5 5000
Electrical system
Version no T-code
002 346

OL S5 5000
Electrical system
Electrical system

346 OS 3.0 275190AA-289678AA With tiller arm
2 List of symbols

bol
A2 Electronic card
BT Battery

OL S5 5000
Electrical system
Version no T-code
003 346

bol
H1 Horn

from the side
K10 Contactor Main

M1 Motor Drive
M3 Motor Pump
meter

position indication
the fork direction

OL S5 5000
Electrical system
Version no T-code
003 346

bol
S17 Switch Key
S18 Switch Horn
S19 Switch Platform
side
side
tion option

OL S5 5000
Electrical system
Version no T-code
003 346

bol
Y10 Brake Step 1

Y11 Brake Step 2
form

OL S5 5000
Electrical system
Version no T-code
003 346

OL S5 5000
Electrical system
Version no T-code
003 346

OL S5 5000
Electrical system
Version no T-code
003 346

OL S5 5000
Electrical system
Version no T-code
003 346

OL S5 5000
Electrical system
Version no T-code
003 346

OL S5 5000
Electrical system
Version no T-code
003 346

OL S5 5000
Electrical system
Version no T-code
003 346
A 3.1 General
LD1
LD2
M B-
LD3
B+
ramp.

load 1.94 m/s 3.33 m/s
3.3 References
code 5330, 5460 resp. 5710.

OL S5 5000
Electrical system
Version no T-code
003 346

permitted.
and 504, corresponding LED’s will light up. A2 (-) return termi-
nal 505.Battery voltage to A1.1 from S17, LED1 lights up.
3.5 The tiller arm in drive position, S10

gency switch of (S21, S22).
When the tiller arm is pushed down to the driving position,
S10 is activated and closes, LED 209 lights up, but the brake
stays on. To release the brake, first a selection of drive direc-
tion must be made.

When the tiller arm is pushed down to the driving position,
S10 is activated and closes, LED 209 lights up, A2 terminals
303 and 304 becomes positive to supply voltage to Y10 and
Y11, LED’s 303 and 304 lights up, and the brake is released.

between 0 - 5V.
via A1-M.


OL S5 5000
Electrical system
Version no T-code
003 346

between 0 - 5V.
via A1-M.



OL S5 5000
Electrical system
Version no T-code
003 346
3.11 Brake
onds.


OL S5 5000
Electrical system
Version no T-code
003 346

lights up.
3.14 Horn
wire 40.
4 Options
4.1 Extra emergency stops (circuit dia-

gram 2)
Extra emergency stop buttons, S22A and S22B, mounted on
the back rest.

either of the buttons without holding the tiller arm.
form.

Forward
304 lights up.

OL S5 5000
Electrical system
Version no T-code
003 346
Fork direction:

lifting platform.

motor M3 starts.

the floor


OL S5 5000
Electrical system
Version no T-code
003 346



M3 starts.

lights up.

OL S5 5000
Electrical system
Version no T-code
003 346

OL S5 5000
Electrical system
Electrical system

346 OS 3.0 275190AA-289678AA
A2
A1
K11 K10
K13 K30
F10 F1
K60
A3
H1
F64 F50
2 List of symbols

bol
A2 Electronic card
BT Battery

OL S5 5000
Electrical system
Version no T-code
004 346

bol
H1 Horn

from the side
K10 Contactor Main

M1 Motor Drive
M3 Motor Pump
meter

position indication

OL S5 5000
Electrical system
Version no T-code
004 346

bol
the fork direction

S17 Switch Key
S18 Switch Horn
ward/fork direction
side
side

OL S5 5000
Electrical system
Version no T-code
004 346

bol
tion option
Y10 Brake Step 1

Y11 Brake Step 2
form

OL S5 5000
Electrical system
Version no T-code
004 346

OL S5 5000
Electrical system
Version no T-code
004 346

OL S5 5000
Electrical system
Version no T-code
004 346

OL S5 5000
Electrical system
Version no T-code
004 346

OL S5 5000
Electrical system
Version no T-code
004 346

OL S5 5000
Electrical system
Version no T-code
004 346

OL S5 5000
Electrical system
Version no T-code
004 346

OL S5 5000
Electrical system
Version no T-code
004 346
A 3.1 General
LD1
LD2
M B-
LD3
71
ramp.

code 4100).

load 1.94 m/s 3.33 m/s
3.3 References
code 4100, 5330, 5460 resp. 5710.

OL S5 5000
Electrical system
Version no T-code
004 346

permitted.
K60 will provide voltage to terminal 403 and S19, LED 403
lights up.Battery voltage to A1.1 from S17, LED1 lights up.
3.5 Brake


OL S5 5000
Electrical system
Version no T-code
004 346

between 0 - 5V.
via A1-M.

lights up.
between 0 - 5V.
via A1-M.


OL S5 5000
Electrical system
Version no T-code
004 346


OL S5 5000
Electrical system
Version no T-code
004 346

point of S31 this is indicated by the LED 310 at terminal 310.
starts.

receives (+)voltage from terminal 306, LED 211 lights up.
(-)return via wire 40.
lights up.
3.13 Horn
wire 40.
4 Options

gram 2)
on the back rest.


OL S5 5000
Electrical system
Version no T-code
004 346

form.

Forward:
304 lights up.
Fork direction:
4.3 Inching speed


OL S5 5000
Electrical system
Version no T-code
004 346

lights up.
modulation.

lifting platform.

motor M3 starts.

the floor



OL S5 5000
Electrical system
Version no T-code
004 346


motor M3 starts.

lights up.

OL S5 5000
Electrical system
Version no T-code
004 346

OL S5 5000
Electrical system
Electrical system

348 OS 1.0 262700AA-
275189AA-

OL S5 5000
Electrical system
Version no T-code
001 348
2 List of symbols

bol
BT Battery

H1 Horn
K10 Contactor Main

M1 Motor Drive
M3 Motor Pump


OL S5 5000
Electrical system
Version no T-code
001 348

bol
S17 Switch Key
S18 Switch Horn
S19 Switch Platform
S21 Switch Emergency switch off Left side
S22 Switch Emergency switch off Right side
S32 Switch Lowering limit 0.1 m
S33 Switch Lift limit 0.5 m
S43 Switch Lowering from the side Left side
S44 Switch Lowering from the side Right side
S62 Switch Pressure switch for forks
Y10 Brake Step 1

Y11 Brake Step 2
Y45 Magnetic valve Fork lift/lower Extra valve at lifting platform

OL S5 5000
Electrical system
Version no T-code
001 348

OL S5 5000
Electrical system
Version no T-code
001 348

OL S5 5000
Electrical system
Version no T-code
001 348

OL S5 5000
Electrical system
Version no T-code
001 348

OL S5 5000
Electrical system
Version no T-code
001 348

OL S5 5000
Electrical system
Version no T-code
001 348

OL S5 5000
Electrical system
Version no T-code
001 348

OL S5 5000
Electrical system
Version no T-code
001 348
A 3.1 General
LD1
LD2
M B-
LD3
71
ramp.
Setting Min. Max.

value value
Maximum speed, without load 7.0 km/h 12.0 km/h
1.94 m/s 3.33 m/s
3.3 References
code 5330, 5460 resp. 5710.

OL S5 5000
Electrical system
Version no T-code
001 348

step the correct LED-pattern is shown. A filled circle denotes
a LED emitting light.

permitted.
Battery voltage on A2-terminals 101, 309, 310, 401, 403, 408,
504, 506, 507, 603 and 609, corresponding LED’s will light
up. A2 (-) return terminal 505.
Battery voltage to A1.1 and A1.11 from S17, LED1 lights up.

S10
gency switch off (S21, S22)

released.

Depending of if S19 is closed, LED 407 is lit, (driver on the
platform) 100% speed, or S19 open, LED 407 off, (driver
walking) 45% speed.

OL S5 5000
Electrical system
Version no T-code
001 348

between 0 - 5V.
via A1-M.

lights up.
platform) 75% speed, or S19 open, LED 407 off, (driver walk-
ing) 45% speed.
between 0 - 5V.
via A1-M.


OL S5 5000
Electrical system
Version no T-code
001 348

3.11 Brake
onds.

OL S5 5000
Electrical system
Version no T-code
001 348

LED 305 lights up. At the same time the micro processor sup-
ply voltage to Y45, teminal 610 and LED 610. (-)return via
wire 40. K30 closes and the pump motor M3 starts.
If the load weight exceeds approx. 550 kg the pressure
switches S61 and S62 opens and LED 504 and 506 is off.
When the forks are raised 0.1 meter from the bottom position
the switch S32 closes, this is indicated by LED 602 lightning
up.
When the forks have reached a lift height of 0.5 meter the
switch S33 opens, this is indicated by LED 603 and 310 going
off. When having lifted the forks 0.5 meter or more and having
a load weight that exceeds 550 kg, S62 open and LED 506
off, the maximum speed of the truck is reduced to 43%.
3.13 Lowering the forks from the drivers

compartment
terminal 211, LED 211 lights up. The magnetic valve, Y41
receives (+)voltage from terminal 306, LED 306 lights up. At
the same time the micro processor supply voltage to Y45,
teminal 610 and LED 610. (-)return via wire 40.
As the forks are lowered the limit switch S33 closes, LED 603
and 310 lights up, and S32 opens, LED 602 going off, and the
limitation of the maximum speed is removed. When the forks
are completely lowered the hydraulic pressure disappears
and S61and S62 closes, LED 504 and 506 lights up.
3.14 Lowering from the side of the truck

When lowering the forks from the side S43 or S44 is acti-
vated, positive input on terminal 601, LED 601. The magnetic
valve, Y41 receives (+)voltage from terminal 306, LED 306
lights up. At the same time the micro processor supply volt-
age to Y45, teminal 610 and LED 610. (-)return via wire 40.
and 310 lights up, and the limitation of the maximum speed is
removed.
When reaching the lift height of 0.1 meter the limit switch S32
opens and the lowering is stopped.

OL S5 5000
Electrical system
Version no T-code
001 348
To lower the forks completely this must be done by activating

the lowering switch S41 in the drivers compartment. When
the forks are completely lowered the hydraulic pressure dis-
appears and S61and S62 closes, LED 504 and 506 lights up.
3.15 Horn
wire 40.
4 Options

straight position.
form.
4.1.1 Function
304 lights up.

lifting platform.

OL S5 5000
Electrical system
Version no T-code
001 348

305, for K30. (-)return via wire 40.
K30 closes and the pump motor M3 starts.

the floor



magnetic valve for the platform lift, they influence the normal

Y45, terminal 610 and LED 610. In the same way as for a
truck without platform lift the LED’s 602 lights up at 0.1 meter
lift height, and LED 603 and 310 goes off at 0.5 meter lift
height. (-)return via wire 40. K30 closes and the pump motor
M3 starts.
S61 and S62 opens , LED 504 and 506 is off, and the plat-
form is lifted 500 mm or more (S105 open) the maximum
speed is reduced to 32%.
OL S5 5000
Electrical system
Version no T-code
001 348
4.3.2 Lowering the forks from the drivers compartment

4.3.3 Lowering from the side of the truck

valves, Y41 receives (+)voltage from terminal 306 and Y45
from terminal 610, LED 306 and 610 lights up. (-)return via
wire 40.
removed.

OL S5 5000
Electrical system
Electrical system

348 OS 1.0 262700AA-
275189AA
A2
A1
K11 K10
K13 K30
F10 F1
K60
A3
H1
F64 F50
2 List of symbols

bol
BT Battery

OL S5 5000
Electrical system
Version no T-code
002 348

bol

H1 Horn
K10 Contactor Main

M1 Motor Drive
M3 Motor Pump

S17 Switch Key
S18 Switch Horn
S21 Switch Emergency switch off Left side

OL S5 5000
Electrical system
Version no T-code
002 348

bol
S22 Switch Emergency switch off Right side
tion
Y10 Brake Step 1

Y11 Brake Step 2

OL S5 5000
Electrical system
Version no T-code
002 348

OL S5 5000
Electrical system
Version no T-code
002 348

OL S5 5000
Electrical system
Version no T-code
002 348

OL S5 5000
Electrical system
Version no T-code
002 348

OL S5 5000
Electrical system
Version no T-code
002 348

OL S5 5000
Electrical system
Version no T-code
002 348

OL S5 5000
Electrical system
Version no T-code
002 348
KEY

OL S5 5000
Electrical system
Version no T-code
002 348

OL S5 5000
Electrical system
Version no T-code
002 348
A 3.1 General
LD1
LD2
M B-
LD3
71

code 4100).

Auto-plug brake current 30% 90%
Maximum speed, 7.0 km/h 12.0 km/h
without load 1.94 m/s 3.33 m/s
3.3 References

OL S5 5000
Electrical system
Version no T-code
002 348


permitted.
506, 507, 603 and 609, corresponding LED’s will light up. A2
(-) return terminal 505.
Battery voltage to A1.1and A1.11 from S17, LED1 lights up.
3.5 Brake
3.5.1 Release of parking brake
vated and closes, LED 407, 408 and 209 lights up, but the
brake stays on. The parking brake is released at first when a
selection of drive direction is done.
3.5.2 Braking during driving


OL S5 5000
Electrical system
Version no T-code
002 348

tive, LED 207 lights up.
Voltage to K11 from A2 via terminal 301, LED 301 lights up.
between 0 - 5V.
via A1-M.

lights up.
between 0 - 5V.
via A1-M.


OL S5 5000
Electrical system
Version no T-code
002 348


position the auto-plug braking function is enabled.
When the speed control is released to neutral a generated
signal from the transistor controller is detected by the elec-
tronic card on terminal 508, LED 508 lights up.
The electronic card micro processor then supply voltage to
the opposite direction contactor (picture showing travelling
forward in auto-plug mode).
nal A1-11.
The braking force is adjustable up to 70% of the maximum
brake current by adjusting the potentiometer marked brake on
the electronic card.
The auto-plug mode stays on until the generated signal dis-
appears from terminal 508 or til the operator applies the
speed control.

OL S5 5000
Electrical system
Version no T-code
002 348

305, LED 305 lights up. At the same time the micro processor
supply voltage to Y45, teminal 610 and LED 610. (-)return via
up.
switch S33 opens, this is indicated by LED 603 going off.
When having lifted the forks 0.5 meter or more and having a
load weight that exceeds 550 kg, S62 open and LED 506 off,
the maximum speed of the truck is reduced to 43%.

compartment

lights up, and the limitation of the maximum speed is
removed.

OL S5 5000
Electrical system
Version no T-code
002 348

3.14 Horn
wire 40.
4 Options

straight position.
form.
4.1.1 Function
304 lights up.
4.2 Inching speed

This function can only be operated when the driver is stand-
ing on the platform.

OL S5 5000
Electrical system
Version no T-code
002 348
The optional drive function is operational in both directions

regardless of the position of the steering drive wheel.
IIt becomes inoperational as soon as the driver leaves the
platfom.
4.2.1 Function
speed range.
tion.

lifting platform.


the floor



OL S5 5000
Electrical system
Version no T-code
002 348



truck without platform lift the LED’s 602 and 603 goes off at
0.1 resp. 0.5 meter lift height. (-)return via wire 40. K30 closes
and the pump motor M3 starts.

As the forks are lowered the lift limit switch S33 and S32
closes, LED 603 and 602 lights up, and when the forks are
completely lowered the hydraulic pressure disappears and
S61 and S62 closes, LED 504 and 506 lights up.

wire 40.
removed. When the forks are completely lowered the hydrau-
lic pressure disappears and S61and S62 closes, LED 504
and 506 lights up.
OL S5 5000
Electrical system
Version no T-code
002 348

OL S5 5000
Electrical system
Electrical system

348 OS 1.0 275190AA-
289678AA
2 List of symbols

bol
A2 Electronic card
BT Battery

OL S5 5000
Electrical system
Version no T-code
003 348

bol
H1 Horn
I64 Indicator lamp Indication of the drive wheel Optional equipment for push
straight position buttons for driving from the
side
K10 Contactor Main

M1 Motor Drive
M3 Motor Pump
Re19 Relay Main relay for driving from Optional equipment, push
the side in the fork direction button for driving in the fork
direction
Re64 Relay Control relay for wheel posi- Optional equipment
tion indication
Re101 Relay Relay for direction contac- Optional equipment, push
tors button for driving in the fork
direction

OL S5 5000
Electrical system
Version no T-code
003 348

bol
S17 Switch Key
S18 Switch Horn
S19 Switch Platform
S21 Switch Emergency switch off
S22A Switch Emergency switch off Optional equipment on the
back rest, left side
S22B Switch Emergency switch off Optional equipment on the
back rest, right side
S24 Switch Push button, driving for- Optional equipment, left side
ward from the side
S28 Switch Push button, driving in the Optional equipment, left side
fork direction from the side
S29 Switch Push button, driving in the Optional equipment, right
fork direction from the side side
OL S5 5000
Electrical system
Version no T-code
003 348

bol
Y10 Brake Step 1

Y11 Brake Step 2

OL S5 5000
Electrical system
Version no T-code
003 348

OL S5 5000
Electrical system
Version no T-code
003 348

OL S5 5000
Electrical system
Version no T-code
003 348

OL S5 5000
Electrical system
Version no T-code
003 348

OL S5 5000
Electrical system
Version no T-code
003 348

OL S5 5000
Electrical system
Version no T-code
003 348

OL S5 5000
Electrical system
Version no T-code
003 348

OL S5 5000
Electrical system
Version no T-code
003 348
A 3.1 General
LD1
LD2
M B-
LD3
71
ramp.

3.3 References
code 5330, 5460 resp. 5710.

OL S5 5000
Electrical system
Version no T-code
003 348


speed potentiometer circuit. If the reference value is 1,5V or
K10. If the reference value is more than 1,5V, operation is not
permitted.
504, 506, 507, 603 and 609, corresponding LED’s will light
up. A2 (-) return terminal 505.
Battery voltage to A1.1 and A1.11 from S17, LED1 lights up.

S10
gency switch off (S21, S22)

released.

platform) 100% speed, or S19 open, LED 407 off, (driver
walking) 47% speed.

OL S5 5000
Electrical system
Version no T-code
003 348

between 0 - 5V.
via A1-M.

lights up.
platform) 79% speed, or S19 open, LED 407 off, (driver walk-
ing) 47% speed.
between 0 - 5V.
via A1-M.


OL S5 5000
Electrical system
Version no T-code
003 348

3.11 Brake
onds.

OL S5 5000
Electrical system
Version no T-code
003 348

LED 305 lights up. At the same time the micro processor sup-
ply voltage to Y45, teminal 610 and LED 610. (-)return via
up.
switch S33 opens, this is indicated by LED 603 and 310 going
off. When having lifted the forks 0.5 meter or more and having
a load weight that exceeds 550 kg, S62 open and LED 506
off, the maximum speed of the truck is reduced to 39%.

compartment

removed.

OL S5 5000
Electrical system
Version no T-code
003 348

3.15 Horn
wire 40.
4 Options
4.1 Extra emergency switch off (circuit

diagram 2)
Extra emergency switch off buttons, S22A and S22B, mounted
on the back rest.

form.

Forward:
304 lights up.

OL S5 5000
Electrical system
Version no T-code
003 348
Fork direction:

lifting platform.


the floor


OL S5 5000
Electrical system
Version no T-code
003 348



truck without platform lift the LED’s 602 lights up at 0.1 meter
lift height, and LED 603 and 310 goes off at 0.5 meter lift
height. (-)return via wire 40. K30 closes and the pump motor
M3 starts.


wire 40.
removed.

OL S5 5000
Electrical system
Version no T-code
003 348

OL S5 5000
Electrical system
Electrical system

348 OS 1.0 275190AA-289678AA Steering wheel
A2
A1
K11 K10
K13 K30
F10 F1
K60
A3
H1
F64 F50
2 List of symbols

bol
A2 Electronic card
BT Battery

OL S5 5000
Electrical system
Version no T-code
004 348

bol
H1 Horn
I64 Indicator lamp Indication of the drive wheel Optional equipment for push
straight position buttons for driving from the
side
K10 Contactor Main

M1 Motor Drive
M3 Motor Pump
Re19 Relay Main relay for driving from Optional equipment, push
the side in the fork direction button for driving in the fork
direction
Re64 Relay Control relay for wheel posi- Optional equipment
tion indication

OL S5 5000
Electrical system
Version no T-code
004 348

bol
Re101 Relay Relay for direction contac- Optional equipment, push
tors button for driving in the fork
direction

S17 Switch Key
S18 Switch Horn
S21 Switch Emergency switch off
S22A Switch Emergency switch off Optional equipment on the
back rest, left side
S22B Switch Emergency switch off Optional equipment on the
back rest, right side
ward/fork direction
S28 Switch Push button, driving in the Optional equipment, left
S29 Switch Push button, driving in the Optional equipment, right
OL S5 5000
Electrical system
Version no T-code
004 348

bol
Y10 Brake Step 1

Y11 Brake Step 2

OL S5 5000
Electrical system
Version no T-code
004 348

OL S5 5000
Electrical system
Version no T-code
004 348

OL S5 5000
Electrical system
Version no T-code
004 348

OL S5 5000
Electrical system
Version no T-code
004 348

OL S5 5000
Electrical system
Version no T-code
004 348

OL S5 5000
Electrical system
Version no T-code
004 348

OL S5 5000
Electrical system
Version no T-code
004 348

OL S5 5000
Electrical system
Version no T-code
004 348

OL S5 5000
Electrical system
Version no T-code
004 348
A 3.1 General
LD1
LD2
M B-
LD3
71

code 4100).

Auto-plug brake current 30% 90%
3.3 References

OL S5 5000
Electrical system
Version no T-code
004 348


speed potentiometer circuit. If the reference value is 1,5V or
K10. If the reference value is more than 1,5V, operation is not
permitted.
506, 507, 603 and 609, corresponding LED’s will light up. A2
(-) return terminal 505.
Battery voltage to A1.1and A1.11 from S17, LED1 lights up.
3.5 Brake
vated and closes, LED 407, 408 and 209 lights up, but the
brake stays on. The parking brake is released at first when a
selection of drive direction is done.


OL S5 5000
Electrical system
Version no T-code
004 348

tive, LED 207 lights up.
between 0 - 5V.
via A1-M.

lights up.
between 0 - 5V.
via A1-M.

OL S5 5000
Electrical system
Version no T-code
004 348


position the auto-plug braking function is enabled.
When the speed control is released to neutral a generated
signal from the transistor controller is detected by the elec-
tronic card on terminal 508, LED 508 lights up.
The electronic card micro processor then supply voltage to
the opposite direction contactor (picture showing travelling
forward in auto-plug mode).
nal A1-11.
The braking force is adjustable up to 70% of the maximum
brake current by adjusting the potentiometer marked brake on
the electronic card.
The auto-plug mode stays on until the generated signal dis-
appears from terminal 508 or til the operator applies the
speed control.

OL S5 5000
Electrical system
Version no T-code
004 348
305, LED 305 lights up. At the same time the micro processor
supply voltage to Y45, teminal 610 and LED 610. (-)return via
up.
switch S33 opens, this is indicated by LED 603 going off.
When having lifted the forks 0.5 meter or more and having a
load weight that exceeds 550 kg, S62 open and LED 506 off,
the maximum speed of the truck is reduced to 39%.

compartment

removed.
OL S5 5000
Electrical system
Version no T-code
004 348
3.14 Horn
wire 40.
4 Options
4.1 Extra emergency switch off (circuit

diagram 2)
Extra emergency switch off buttons, S22A and S22B, mounted
on the back rest.

form.

Forward:
304 lights up.
Fork direction:
OL S5 5000
Electrical system
Version no T-code
004 348

4.3 Inching speed


lights up.
modulation.

lifting platform.


OL S5 5000
Electrical system
Version no T-code
004 348

the floor




truck without platform lift the LED’s 602 and 603 goes off at
0.1 resp. 0.5 meter lift height. (-)return via wire 40. K30 closes
and the pump motor M3 starts.

OL S5 5000
Electrical system
Version no T-code
004 348
As the forks are lowered the lift limit switch S33 and S32
closes, LED 603 and 602 lights up, and when the forks are
completely lowered the hydraulic pressure disappears and
S61 and S62 closes, LED 504 and 506 lights up.

wire 40.
removed. When the forks are completely lowered the hydrau-
lic pressure disappears and S61and S62 closes, LED 504
and 506 lights up.

OL S5 5000
Electrical system
Version no T-code
004 348

OL S5 5460
Transistor Controller, Curtis 1207


203 PPO 1500 MX 249329AA-
M- B- B+ A2
1 Motor circuit
The transistor controller have four terminals for the high cur-
rent circuits according to the table 1 below.
Termi- Connecting
nal
M- Output to motor armature
B- Negative connection to battery
B+ Positive connection to battery/series field
A2 Plug diode to motor armature

OL S5 5460
Version no T-code
001 203
2 Control circuit
The transistor controller have an integrated 16-pin connector
to provide the low power logic control connections. The desig-
nation of the pins are according to table 2 below.
Pin No Connecting
Contactor Drivers
P1 Shunt field driver output
P2 Fork direction contactor driver output
P3 Steer wheel direction contactor driver output
P4 Not connected
Throttle Connections
P5 Not connected
P6 Not connected
P7 Throttle: pot low
P8 Throttle: 2-wire 5 kOhm-0 input
Basic Control Signals
P9 Not connected
P10 Emergency reverse check output
P11 Drive fork direction input
P12 Drive steer wheel direction input
P13 Emergency reverse input
P14 Speed range selection input
P15 Brake switch input
P16 Key switch input (KSI)

OL S5 5460
Version no T-code
001 203
3 Technical specification
The technical specification for the BT-version of the Curtis
1207 transistor controller is according to table 3 below.
Parameter Range STD set- Units Description

ting
Operating voltage 24 24 Volt
Maximum voltage 45 Volt Overvoltage point
Minimum operating 16 Volt Undervoltage point
voltage
Electrical isolation to 500 Volt ac Minimum
heatsink
Frequency 15 kHz
Contactor voltage 24 Volt
Contactor current 1 Amp Maximum(current limit at 2 amp)
Shunt driver current 2 1.2 Amp
KSI input current 80 mA
Logic input current 10 mA At 24 Volt
Logic input threshold 8 Volt
Ambient operating -40 - +50 oC
temperature
Heatsink overtem- 85 oC
perature cutback
Heatsink undertem- -25 o
C
perature cutback
Plug Braking Variable Variable Plug current dependant upon
throttle position
Current Limit, Main 100-150 150 Amp

Current Limit, Low 100 Amp Maximum current in low speed
Speed, Main mode
Current Limit, Plug 60 Amp Maximum plug current in the
series field
Current Limit, Low 60 Amp Maximum plug current in the
Speed, Plug series field in low speed mode
OL S5 5460
Version no T-code
001 203
Parameter Range STD set- Units Description

ting
Current Limit, 150 Amp Maximum field current in
Emergency Reverse emergency reverse
Current Limit, Low 150 Amp Max. field current when in low
speed, Emr. Reverse speed for emergency reverse
Throttle Type 5k-0 Ohm
Min. Duty Cycle 0 % Speed (duty factor) at minimum
throttle setting
Low Speed 70 % Maximum speed (duty factor) in
low speed mode
Emergency Reverse 50 % Speed during emergency
Speed reverse
Acceleration Rate 0.1 - 3 0.8 Sec Time to reach full output from
zero output
4 Adjustment panel
The adjustment panel is located on top of the controller, under

a sliding protective cover. The panel provides access to a set
of adjustable potentiometers, a connector for a handheld ter-
minal and the STATUS LED.
4.1 Adjustable Potentiometers

MAIN and ACCEL potentiometers can be adjusted with a
screwdriver within the range given in the technical specifica-
tion.
NOTE: In the BT-version of the Curtis 1207 are only two of
the potentiometers in operation, MAIN and ACCEL. The other
three potentiometers are disabled from factory.

OL S5 5460
Version no T-code
001 203
4.2 Connection of handheld terminal

To adjust the parameters with the handheld terminal the cor-
responding potentiometer must be set to ”off”.
4.3 Status LED

The LED displays flashing codes to indicate controller status.
The codes are listed with explanations in section 6.
5 Maintenance
There are no user-servicable parts inside the transistor con-
troller.
NOTE!
No attempt should be made to open the controller. OPEN-
ING THE CONTROLLER WILL VOID THE WARRANTY!
It is however recommended that the controller exterior be
cleaned periodically. When cleaning the controller gives a
good opportunity to check the controller’s diagnostic history
file with the handheld terminal, if available.
5.1 Safety
The controller is inherently a high power device. When work-
ing around any battery powered vehicle, proper safety pre-
cautions should be taken. These include, but are not limited
to: proper training, wearing eye protection, avoiding loose
clothing, removing watches and jewelry, and using insulated
wrenches.
WARNING
Risk of short circuits.
Remove all watches and jewelry and always use insulated
tools.
5.2 Cleaning
Although the controller requires virtually no maintenance if
properly installed, the following minor maintenance is recom-
mended on a regular 250 hours basis.
• Remove power by disconnecting the battery.

OL S5 5460
Version no T-code
001 203
• Discharge the capacitors in the controller, by connecting a

load (such as a contactor coil or the horn) across the con-
troller’s B+ and B- terminals, before doing any work on the
controller.
• Remove all dirt or corrosion from the bus bar area. The
controller should be wiped clean with a moist rag. Allow it
to dry before reconnecting the battery.
• Make sure the connections to the bus bars are tight. Use
two well insulated wrenches for this task in order to avoid
stressing the bus bars.
6 Diagnostics and troubleshooting
During normal operation, with no faults present, the Status

LED flashes a single flash at approximately 1 flash/second. If
the controller detects a fault, a 2-digit code is flashed conti-
nously until the fault is corrected, see table 4.
If using a handheld terninal for the diagnostics, switched over
to diagnostic mode, the diagnostic information can be read in
the terminal display, see table 4.
LED code Terminal LCD dis- Explanation Possible cause

play
1,2 ¤ ¤¤ HW FAILSAFE Hardware fail-safe 1. Controller defective
error
1,3 ¤ ¤¤¤ M- FAULT M- output shorted 1. M- output shorted to
ground.
2. Direction contactor not
closing.
3. Direction contactor not
closing fast enough.
4. Internal motor short to
ground.
1,4 ¤ ¤¤¤¤ SRO SRO fault 1. Improper sequence of KSI,
brake and direction inputs.
2. Brake or direction switch
circuit open.

OL S5 5460
Version no T-code
001 203

play
2,1 ¤¤ ¤ THROTTLE FAULT 1 5kOhm-0 or wiper 1. Throttle input wire open.
fault 2. Throttle input wire shorted
to ground or B+.
3. Throttle pot defective.
4. Wrong throttle type.
2,2 ¤¤ ¤¤ BB WIRING CHECK Emerg. reverse wir- 1. BB wire open.
ing fault 2. BB check wire open.
2,3 ¤¤ ¤¤¤ HPD HPD sequencing 1. Improper sequence of KSI,
fault brake, throttle inputs.
2. Misadjusted throttle.
2,4 ¤¤ ¤¤¤¤ THROTTLE FAULT 2 Pot Low broken or 1. Pot low wire open.
shorted 2. Pot low wire shorted.
3. Wrong throttle type.
3,1 ¤¤¤ ¤ CONT DRVR OC Driver output over- 1. Direction contactor coil
current shorted.
2. Shunt field shorted.
3,2 ¤¤¤ ¤¤ DIR CONT Welded direction 1. Direction contactor stuck
WELDED contactor closed.
3,4 ¤¤¤ ¤¤¤¤ MISSING CONTAC- Missing contactor 1. Direction contactor open
TOR or shunt coil.
2. Direction contactor miss-
ing.
3. Shunt field open.
4. Wire to shunt or direction
contactor open.
4,1 ¤¤¤¤ ¤ LOW BATTERY Low battery voltage 1. Battery voltage <16 volts.
VOLTAGE 2. Corroded battery terminal.
3. Loose battery or controller
terminal.
4,2 ¤¤¤¤ ¤¤ OVERVOLTAGE Overvoltage 1. Battery voltage > 45 volts.
2. Vehicle operating with
charger attached.

OL S5 5460
Version no T-code
001 203

play
4,3 ¤¤¤¤ ¤¤¤ THERMAL Over-/under-tem- 1. Temperature >85oC or
CUTBACK perature cutback < 25 oC.
2. Excessive load on vehicle.
3. Improper mounting of con-
troller.
4. Operation in extreme
environments.

OL S5 5460
Transistor controller
SSD K Hallman 001 345, 347, 348

345 OS 2.0 256600AA–275189AA
347 OS 1.0W 256600AA–275189AA
348 OS 1.0 256600AA–275189AA
1 Transistor controller, PUB 24220

CD2
LD1
LD2
LD3 M B-
LD4
71
B+

OL S5 5460
Version no T-code
001 345, 347, 348
2 Motor circuit
Termi- Connecting
nal
M Negative return from motor series field
B- Negative connection to battery
B+ Positive connection to battery
A Plug diode to motor armature
3 Control Circuit
1 2 3 4 5 6
7 8 9 10 11
Pin No Connecting
1 Controller supply 24V
2 Safety circuit test, see section 6
3 Input forward contactor
4 Input backward contactor
5 Output potentiometer, low side, 0V
6 Input acceleration ramp
7 Output safety circuit, to main contactor
8 Autoplug brake, Not connected OS 2.0 std
9 Output potentiometer, high side, 5.5V con-
nected in truck, 13.5V on separate controller

OL S5 5460
Version no T-code
001 345, 347, 348
Pin No Connecting
10 Input speed limit reference value, 0 - 5.3 V
11 Input speed range, high=24V, low=0V
The technical specification for the BT-version of the Atlas-
Copco PUB 24220 CD2 transistor controller is according to
table 3 below.
Parameter Setting Units Description

Operating voltage 24 Volt
voltage
Frequency 16 kHz
temperature
oC
Heatsink overtem- 85 0A at 125oC
perature cutback
Heatsink undertem- -20 oC 50% current limit at start
perature cutback
Current Limit, Main 220 Amp
Current Limit, Plug 100-330 Amp Maximum plug current in the
armature. Depending on throttle
position.
throttle setting
Speed forward 100 % Modulation, Steer wheel direc-
tion
Speed backward 70 % Modulation, Fork direction
Low Speed 45 % Modulation in low speed mode
Acceleration Rate 1.0 or 2.5 Sec Time to reach full output from
zero output

OL S5 5460
Version no T-code
001 345, 347, 348
5 LED indications
LD1
LD2
LD3 M B-
LD4
71
B+
The controller have got four LED’s to indicate the operation

and diagnostic of faults.
LED No Colour Indicates Diagnosis

1 Green Voltage level Is lit at >14VDC.
”OFF” means voltage level < 14VDC
2 Yellow Overtemperature/ Temperature limitation activated. Liniar
Undertemperature decreasing current from maximum to 0A
between 85-125oC internal temperature. At
temperatures < -20oC, start current reduced to
50%. LED turned off at normal operating tem-
perature conditions
3 Red Electronic power Cut the operation at faults in the electronic
components power components.
Deactivates the safety circuit output to main
contactor.
LED indication remains.
4 Red Potentiometer circuit 1. Reference value above 0.8V at initial voltage
feed. No output from safety circuit. If the refer-
ence value then drops below 0.8V is output
from safety circuit received. LED indication
remains.
2. Reference value raises above 6V during
operation. Safety circuit cut-out. If the refer-
ence value then drops below 0.8V is output
from safety circuit received. LED indication
remains.
3. Interruption or intermittent contact of the
potentiometer wiper. LED indication but no acti-
vation of the safety circuit.

OL S5 5460
Version no T-code
001 345, 347, 348
6 Maintenance
troller. No attempt should be made to open the controller.
OPENING THE CONTROLLER WILL VOID THE WAR-
RANTY!
cleaned periodically.
6.1 Safety
wrenches.
WARNING!
Remove all watches and jewelry
and always use insulated tools.
6.2 Cleaning
controller.

OL S5 5460
Version no T-code
001 345, 347, 348
7 Test of transistor unit safety circuit

This test method is valid for all BT trucks fitted with transistor-
panels of type: PUB 24220 CD2
Before testing the truck it is necessery to lift the truck´s drive
wheel clear of the floor. Lift the truck using the marked lifting
points and place it on stable chassis supports. Under no cir-
cumstance allow the drive wheel to touch the floor.
Test method.
• Place the truck on suitable support as described.
• Start the truck in the normal way by turning on the key-
switch (S17). Connect a cable (0,75 mm2) between the
battery negative (B-) and the control current conector pin
nr 2 on the transistor panel. The contactorpanels main con-
tactor (K10) should open which indicates that the safety cir-
cuit on the transistor panel is working. If the contactor does
not open, that is an indication of error in the safety circuit,
and the transistor panel should be changed.
• After completing the test return the truck to its original
state. The safety circuit can, if necessary, be reset by
switching off key-switch (S17) for a short time.

OL S5 5460
Transistor Controller, PUB 24220 CD3
SSD K Hallman 002 345, 347, 348
Transistor Controller, PUB 24220

CD3

345 OS 2.0 275190AA-
347 OS 1.0W 275190AA-
348 OS 1.0 275190AA-
1 Transistor controller
LD1
LD2
LD3 M B-
LD4
71
B+

OL S5 5460
Version no T-code
002 345, 347, 348
2 Motor circuit
Termi- Connecting
nal
B- Negative connection to battery, 0 Volt
B+ Positive connection to battery, 24 Volt
3 Control circuit
1 2 3 4 5 6
7 8 9 10 11
Pin No Connecting
3 Not connected
4 0V
5 0V
6 0 Volt, common for speed control and current
limit circuit
8 Autoplug brake, 24 V = active
9 Not connected

OL S5 5460
Version no T-code
002 345, 347, 348
Pin No Connecting
10 Input speed limit reference value, 0 - 5 V (+-
7%)
11 Input current limit reference value, 0 - 5 V
table 3 below.

voltage
Frequency 16 kHz
temperature
o
Heatsink overtem- 85 C 0A at 125oC
perature cutback
perature cutback
position.
throttle setting
Speed 100 % Modulation

OL S5 5460
Version no T-code
002 345, 347, 348
5 LED indications
LD1
LD2
LD3 M B-
LD4
71
B+


1 Green Voltage level Is lit at >14VDC. ”OFF” means voltage
level < 14VDC
2 Yellow Overtemperature/Under- Temperature limitation activated. Liniar
temperature decreasing current from maximum to 0A
between 85-125oC internal temperature.
At temperatures < -20oC, start current
reduced to 50%. LED turned off at normal
operating temperature conditions
3 Red Electronic power compo- Cut the operation at faults in the electro-
nents nic power components. Deactivates the
safety circuit output to main contactor.
4 Red Potentiometer circuit 1. Reference value above 1.5V at initial
voltage feed. No output from safety cir-
cuit. If the reference value then drops
below 1.5V is output from safety circuit
received. LED indication remains.
2. Reference value raises above 6V
during operation. Safety circuit cut-out. If
the reference value then drops below
1.5V is output from safety circuit received.

OL S5 5460
Version no T-code
002 345, 347, 348
6 Maintenance
RANTY!
6.1 Safety
wrenches.
WARNING!
tools.
6.2 Cleaning
controller.

OL S5 5460
Version no T-code
002 345, 347, 348
7 Test of transistor unit safety circuit

panels of type: PUB 24220 CD3.
Test method.

OL S5 5460
Transistor Controller, PUB 24350

CD1

346 OS 3.0 262700AA-
1 Transistor controller
LD1
LD2
LD3 M B-
LD4
71
B+

OL S5 5460
Version no T-code
001 346
2 Motor Circuit
Termi- Connecting
nal
B- Negative connection to battery, 0 Volt
B+ Positive connection to battery, 24 Volt
3 Control circuit
1 2 3 4 5 6
7 8 9 10 11
Pin No Connecting
3 Not connected
4 Not connected
5 Not connected
6 0 Volt, common for speed control and current
limit circuit
8 Autoplug brake, 24 V = active
9 Not connected

OL S5 5460
Version no T-code
001 346
Pin No Connecting
10 Input speed limit reference value, 0 - 5 V (+-
7%)
11 Input current limit reference value, 0 - 5 V
table 3 below.

voltage
Frequency 16 kHz
temperature
o
Heatsink overtem- 85 C 0A at 125oC
perature cutback
perature cutback
position.
throttle setting
Speed 100 % Modulation

OL S5 5460
Version no T-code
001 346
5 LED indications
LD1
LD2
LD3 M B-
LD4
71
B+


1 Green Voltage level Is lit at >14VDC. ”OFF” means voltage
level < 14VDC
2 Yellow Overtemperature/Under- Temperature limitation activated. Liniar
temperature decreasing current from maximum to 0A
between 85-125oC internal temperature.
At temperatures < -20oC, start current
reduced to 50%. LED turned off at normal
operating temperature conditions
3 Red Electronic power compo- Cut the operation at faults in the electro-
nents nic power components. Deactivates the
safety circuit output to main contactor.
4 Red Potentiometer circuit 1. Reference value above 1.5V at initial
voltage feed. No output from safety cir-
cuit. If the reference value then drops
below 1.5V is output from safety circuit
received. LED indication remains.
2. Reference value raises above 6V
during operation. Safety circuit cut-out. If
the reference value then drops below
1.5V is output from safety circuit received.

OL S5 5460
Version no T-code
001 346
6 Maintenance
RANTY!
6.1 Safety
wrenches.
WARNING!
tools.
6.2 Cleaning
controller.

OL S5 5460
Version no T-code
001 346
7 Test of transistor unit safety circuit.

panels of type: PUB 24350 CD1
Test method.

OL S5 5710
Connection Card, Transistor Control
Connection Card,
Transistor Control

203 PPO 1500 MX 249329AA-
1 Connection card
The connection card is equipped with green LED’s on the
inputs from micro switches and red LED’s on the outputs to
the contactors. The card is also equipped with a potentiome-

OL S5 5710
Version no T-code
001 203
2 Connections/Adjustments
1
106 111 204 207 409 417
5 105 110
203
408 416
407 415
104 206
202 414 2
406
103 109 201 205
405
102 108
404 413
101 107 301 302
403 412
402 411
4
410
401
3
Position Connection/Adjustment
1 Key switch(S17), battery -, instrument, magnetic valve (Y41)
2 Battery +, armature voltage, contactors, horn
3 Shunt field
4 RV1, adjustment of maximum speed
5 Micro switches

OL S5 5710
Version no T-code
001 203
3 Card pin connections and LED’s
Terminal LED No Connec- Function

No tion
101 101 I Driving, fork direction
102 102 I Driving, steer wheel direction
103 O Speed control
104 I Referens value, speed
105 105 I Fork lift
106 106 I Fork lower
107 107 I Horn
108 O 24 V (+)
109 109 I Brake
110 O
111 I
201 I Battery controller

202 202 I 24 V (+)
203 O Battery controller

OL S5 5710
Version no T-code
001 203

No tion
204 O Magnetic valve
205 O 24 V (+)
206 O Hour meter
301 O Shunt field(+)

302 O Shunt field(-)
401 401 I Contactor (-), fork direction

402 402 I Contactor (-), steer wheel direction
403 O Contactor drive direction, common (+)
404 O Input signal, pump contactor closed
405 405 O Contactor, pump motor
406 O Horn
407 I 24 V (+)
408 O Input signal, brake released
409 I (-)
410 O 24 V (+), to transistor controller
411 O Driving, fork direction
412 O Driving, steer wheel direction
413 I Speed control
414 O Referens value, speed
415 I
416 O
417 I Shunt field(-)
I = Input, green LED

O = Output, red LED

OL S5 5710
Electronic card
SSD K Hallman 001 345, 347
Electronic card
Valid from serial number: 256600-275189

345 OS 2.0 256600AA- –275189AA-
347 OS 1.0W 256600AA- –275189AA-
The electronic card is equipped with green LED’s on the
the contactors. The card is also equipped with a potentiome-
ter for adjustment of the maximum speed and a jumper for
two settings of acceleration.

OL S5 5710
Electronic card
Version no T-code
001 345, 347
2 Connections/Adjustments
Position Connection/Adjustment Marking

1 Key switch(S17), Brake supply
2 Horn, Steer tacho, R1, Drive direction switches, Brake
switch, Lift and lower switches
3 Drive contactors, Brake, Magnetic valve, Horn, Hour meter, Green
Lift limit switch
4 Emergency stop, Steering supervision, Inching speed, Red
Brake supply and switch
5 Steer tacho, steering wheel position, Pressure switch, Mani Blue
contactor, High speed, Acceleration ramp, Potentiometer
R1, Speed limit ref value
6 Jumper, Adjustment of acceleration ramp L= slow , R= fast
7 Potentiometer for adjustment of maximum speed Speed

OL S5 5710
Electronic card
Version no T-code
001 345, 347
3 Card pin connections and LED’s

No tion
101 101 I Key switch
102 O Key switch
103 O 24V brake supply
104 O Cold store heater
201 201 I Horn

202 O Steer tacho, U1 +
203 O Steer tacho, U1 -
204 O Speed potentiometer, 5.5V
205 I Speed potentiometer, ref value
206 I Speed potentiometer, 0V
207 207 I Driving steering wheel direction
208 208 I Driving fork direction
209 209 I Brake switch

OL S5 5710
Electronic card
Version no T-code
001 345, 347

No tion
210 210 I Fork lifting
211 211 I Fork lowering
301 301 O Contactor, steering wheel direction

302 302 O Contactor, fork direction
303 303 O Brake, step 1
305 O Lift limit
306 306 O Magnetic valve
307 O Horn
308 308 O Hour meter
309 309 I Battery contoller
310 310 I Lift limit
311 311 I Lowering from the side
401 401 I Emergency switch off

402 I Key switch
403 403 I Steering supervision, OK
404 I Steering supervision, OK
405 I Supervision inching speed
406 406 I Inching speed
407 407 I Platform switch
408 408 I Brake supply, 24V
409 409 I Inching, steering wheel direction (from
platform)
410 410 I Inching, fork direction (from platform)
411 O Brake switch signal
501 I Steer tacho, U1 -

OL S5 5710
Electronic card
Version no T-code
001 345, 347

No tion
502 I Steer tacho, U1 +
503 503 I Steering wheel middle position
504 504 I Pressure switch
505 I Battery (-)
506 Not connected
507 507 O High speed
508 508 O Acceleration ramp
509 I 5.5V supply for speed potentiometer
510 O Speed limit reference value
511 O Speed potentiometer, 0V

O = Output, red LED

OL S5 5710
Electronic card
Version no T-code
001 345, 347

OL S5 5710
Electronic card
Electronic card

345 OS 2.0 275190AA- – 289678AA-
the contactors. The card is also equipped with potentiome-
ter’s for adjustment of maximum speed and auto plug brake
force, and a dip switch for setting the acceleration ramp.
The electronic card micro processor determins the rate of
acceleration depending of the dip-switch position, the for-
ward, backward and walking speeds depending on the inputs
from the direction and platform micro switches, the auto-plug
brake current and the maximum speed depending of the
potentio-meter adjustments.

OL S5 5710
Electronic card
Version no T-code
002 345
2 Connections and adjustments

6 5 4 3 2 1

1 Key switch(S17), Brake supply, Coldstore heater, Electric
steering man up
3 Drive contactors, Brake, Pump contactor, Magnetic valve, Green
Horn, Hour meter, Lift limit switch
4 Emergency stop, Steering supervision, Inching speed, Plat- Red
form switch, Brake supply
5 Steer tacho, steering wheel position, Pressure switch, Blue
Speed limit ref value, Current limit ref value, Plug brake, 2-
ton version
6 Lowering from side, Lowering limit 0.1m, Lift limit 0.5m,
Platform lift, Platform lower, Platform lift limit, Platform limit
0.5m, Fork high lift,
7 Adjustable Dip-switches On, 1 - 8
9 Potentiometer for adjusting of auto-plug braking force Brake

OL S5 5710
Electronic card
Version no T-code
002 345
3 DIP-switch adjustments/settings
1
2
3
4
5
6
7
8
Switch Function On =
No
1 Acceleration ramp Fast acceleration
2 Auto-plug brake enable Enabled
3 Man-lift footpedal Pedals
4 Man-lift version Man-lift version
5 Man-lift with fork lift buttons Enabled
6 Spare
7 Spare
8 Test mode Test mode, factory use

OL S5 5710
Electronic card
Version no T-code
002 345
4 Card pin connections and led’s

No tion
PWR/ Power supply, Error indication
ERROR
102 O Key switch
103 I 24V brake supply
105 105 I Electric steering man-up
201 201 I Horn

204 O Speed potentiometer, +5V

OL S5 5710
Electronic card
Version no T-code
002 345

No tion

305 305 O Pump contactor
306 306 O Magnetic valve Y41
307 O Horn
311 311 Not connected
401 401 I Emergency stop

402 I Key switch
platform)
411 O Inching speed (from platform)

OL S5 5710
Electronic card
Version no T-code
002 345

No tion
504 504 I Pressure switch 1
505 I Battery (-)
507 507 I Connected for 2-ton version only
508 508 I Plug brake
509 O Curren limit reference value
601 601 I Lowering forks from side of truck

602 602 I Lowering fork limit 0.1 m
603 603 I Speed reduction fork height 0.5 m
604 I + 24V
605 605 I Platform lift
606 606 I Platform lowering
607 607 I Platform lift limit
608 608 I Speed reuction platform height 0.5 m
609 609 I High fork lift
610 610 O Valve high fork lift/lower
611 611 O Valve platform lift/lower

O = Output, red LED

OL S5 5710
Electronic card
Version no T-code
002 345
5 Fault/error indications
The PWR/ERROR LED flashes in codes up to seven times.
The table shows you the meaning of the codes and possible
reasons.
Signal Cause Result

state
On continu- All OK
ously
Off Hardware fault Not possible to drive (brake applied)
1 Flash Internal program fault Continuously indicated, not possible to drive
2 Flashes Output shorted to negative Continuously indicated, depending on which
output is shorted
3 Flashes Output shorted to positive, Continuously indicated, depending on which
alternatively interruption to output is shorted
contactor
4 Flashes Fault on speed potentiome- Continuously indicated, hydraulics functioning
ter or connections
5 Flashes Fault on the walkie speed Continuously indicated, all except walkie speed
buttons functioning
6 Flashes Too high initial voltage value Continuously indicated, hydraulics functioning
on speed potentiometer
when the key is switched on
7 Flashes Fault on pressure switch Continuously indicated, reacts as for heavy
load otherwise functioning as normal

OL S5 5710
Electronic card
Version no T-code
002 345

OL S5 5710
Electronic card
SSD K Hallman 001 345, 346, 348
Electronic card
Valid from serial number: 262700-

345 OS 2.0 256600AA-275189AA Man-lift
262700AA-299678AA
346 OS 3.0 256600AA-275189AA Man-lift
262700AA-299678AA
348 OS 1.0 256600AA-275189AA Man-lift
262700AA-299678AA
the contactors. The card is also equipped with potentiome-
ter’s for adjustment of maximum speed and auto plug brake
force, and a dip switch for setting the acceleration ramp. The
electronic card micro processor determins the rate of acceler-
ation depending of the dip-switch position, the forward, back-
ward and walking speeds depending on the inputs from the
direction and platform micro switches, the auto-plug brake
current and the maximum speed depending of the potentio-
meter adjustments.

OL S5 5710
Electronic card
Version no T-code
001 345, 346, 348
2 Connections and adjustments

6 5 4 3 2 1

1 Key switch(S17), Brake supply, Coldstore heater, Electric
steering man up
3 Drive contactors, Brake, Pump contactor, Magnetic valve, Green
Horn, Hour meter, Lift limit switch
4 Emergency stop, Steering supervision, Inching speed, Plat- Red
form switch, Brake supply
5 Steer tacho, steering wheel position, Pressure switch, Blue
Speed limit ref value, Current limit ref value, Plug brake, 2-
ton version
6 Lowering from side, Lowering limit 0.1m, Lift limit 0.5m,
Platform lift, Platform lower, Platform lift limit, Platform limit
0.5m, Fork high lift,
7 Adjustable Dip-switches On, 1 - 8
9 Potentiometer for adjusting of auto-plug braking force Brake

OL S5 5710
Electronic card
Version no T-code
001 345, 346, 348
3 DIP-switch adjustments/settings
1
2
3
4
5
6
7
8
Switch Function On =
No
1 Acceleration ramp Fast acceleration
2 Auto-plug brake enable Enabled
3 Man-lift footpedal Pedals
4 Man-lift version Man-lift version
5 Man-lift with fork lift buttons Enabled
6 Spare
7 Spare
8 Test mode Test mode, factory use

OL S5 5710
Electronic card
Version no T-code
001 345, 346, 348
4 Card pin connections and led’s

No tion
PWR/ Power supply, Error indication
ERROR
102 O Key switch
103 I 24V brake supply
105 105 I Electric steering man-up
201 201 I Horn

204 O Speed potentiometer, +5V

OL S5 5710
Electronic card
Version no T-code
001 345, 346, 348

No tion

305 305 O Pump contactor
306 306 O Magnetic valve Y41
307 O Horn
311 311 Not connected
401 401 I Emergency stop

402 I Key switch
platform)
411 O Inching speed (from platform)

OL S5 5710
Electronic card
Version no T-code
001 345, 346, 348

No tion
505 I Battery (-)
507 507 I Connected for 2-ton version only
508 508 I Plug brake
509 O Curren limit reference value
601 601 I Lowering forks from side of truck

602 602 I Lowering fork limit 0.1 m
603 603 I Speed reduction fork height 0.5 m
604 I + 24V
605 605 I Platform lift
606 606 I Platform lowering
607 607 I Platform lift limit
608 608 I Speed reuction platform height 0.5 m
609 609 I High fork lift
610 610 O Valve high fork lift/lower
611 611 O Valve platform lift/lower

O = Output, red LED

OL S5 5710
Electronic card
Version no T-code
001 345, 346, 348
5 Fault/error indications
The PWR/ERROR LED flashes in codes up to seven times.
The table shows you the meaning of the codes and possible
reasons.
Signal Cause Result

state
On continu- All OK
ously
Off Hardware fault Not possible to drive (brake applied)
1 Flash Internal program fault Continuously indicated, not possible to drive
2 Flashes Output shorted to negative Continuously indicated, depending on which
output is shorted
3 Flashes Output shorted to positive, Continuously indicated, depending on which
alternatively interruption to output is shorted
contactor
4 Flashes Fault on speed potentiome- Continuously indicated, hydraulics functioning
ter or connections
5 Flashes Fault on the walkie speed Continuously indicated, all except walkie speed
buttons functioning
6 Flashes Too high initial voltage value Continuously indicated, hydraulics functioning
on speed potentiometer
when the key is switched on
7 Flashes Fault on pressure switch Continuously indicated, reacts as for heavy
load otherwise functioning as normal

OL S5 5710
Electronic card
Version no T-code
001 345, 346, 348

OL S6 6000
Hydraulic system, pneumatic system
SSD P-Å Gustafsson 002 342
Hydraulic system,
pneumatic system

342 OS 1.8 X 305487AA- Trucks equipped
with platform lift
1 General
The hydraulic system consists of a compact hydraulic unit,
including a solenoid valve for lowering the forks and a
pressure control valve. It also includes a valve block with slow-
closing electromagnetic valves for lifting the platform and
forks. The hydraulic system also includes two pressure
monitors and one cylinder for platform lift and two cylinders for
fork lift.

OL S6 6000
Version no T-code
002 342
2 Functional description
2.1 Diagram of hydraulic system and com-

ponents

OL S6 6000
Version no T-code
002 342
2.2 Main components
Number Description Note

1 Lifting cylinder Fork lift
2 Lifting cylinder Platform
3 Hydraulic unit M3 = Pump motor
Y41 = Lowering valve, electromagnetic
4 Valve block S61 = Pressure switch, brake
S62 = Pressure switch, speed
Y45 =Slow-closing electromagnetic valve
for forks
Y69 =Slow-closing electromagnetic valve
for platform
2.3 Description
2.3.1 Fork lift
When the fork lift control is activated, the pump contactor
closes and the pump motor starts. At the same time, valve
Y45 opens and fluid passes through the non-return valve and
Y45 to the lifting cylinders.
If the lifting operation is stopped, Y45 closes slowly.
2.3.2 Fork lower

When the fork lower control is activated, solenoid valves Y41
and Y45 are fully opened so that the fluid in the delivery pipes
can flow back to the fluid reservoir.
If the lowering operation is stopped, first Y45 and then Y41
close slowly. Y41 receives a delaying holding voltage from
the logic card to ensure that Y45 is fully closed before Y41
closes.
The lowering speed cannot be adjusted - it is determined by
the flow valve in the valve block of the hydraulic system.
2.3.3 Platform lift

When the platform lift control (button or foot pedal) is acti-
vated, the pump contactor closes and the pump motor starts.
At the same time, valve Y69 opens and fluid passes through
the non-return valve and Y69 to the lifting cylinder.

OL S6 6000
Version no T-code
002 342
2.3.4 Platform lower

When the platform lower control is activated, solenoid valves
Y41 and Y69 are fully opened so that the fluid in the delivery
pipe can flow back to the fluid reservoir.
close slowly. Y41 receives a delaying withstand voltage from
closes.
2.3.5 Operating pressure

The operating pressure with the specified load is: 165 bar
2.3.6 Safety valve

The safety valve opens when the pressure reaches: 175 bar
2.3.7 Flow restrictor valve for platform cylinder (3)

The purpose of the flow restrictor valve is to ensure that in the
event of a hose rupture, the lowering speed does not exceed
0.6 m/s. It is shaped like a washer, and is fitted into the hose
connector.
Check that the washer is in place when re-attaching the hose
to the cylinder after removal.
2.3.8 Pressure monitor, S61

The function of the pressure monitor is to adjust the braking
force of the electromagnetic brake depending on the weight
of the load.
The pressure monitor opens when the pressure in the
hydraulic system corresponds to an approximate load of
800 kg on the forks.
2.3.9 Pressure monitor, S62

The function of this pressure monitor is to send a signal to the
control electronics to reduce speed if the load exceeds a pre-
defined weight.
The pressure monitor opens when the pressure in the
hydraulic system corresponds to an approximate load of
800 kg on the forks.

OL S6 6000
Version no T-code
002 342
3 Adjustments
3.1 Adjusting the pressure control valve

The pressure control valve is set to the correct value at the
factory, but it needs to be adjusted when a valve or the entire
hydraulic system is changed.
The machine must be able to lift a load of between
1,850-1,900 kg.
Cap nut

1 Cap nut
2 Adjusting screw, pressure Turn clockwise to increase
control pressure
Turn anti-clockwise to reduce
pressure.
• Unscrew the cap nut (1) using a non-adjustable spanner,

13 mm.
• Place a load of 1,800 kg on the forks and check that the
machine can lift it.
• If the machine can lift 1,800 kg, place an additional 100 kg
on the forks. Check whether the machine can lift the load.
• If the machine can lift 1900 kg, adjust the pressure control
valve by turning the adjusting screw (2) anti-clockwise
using a 4 mm Allen key until the machine can no longer lift
the load.

OL S6 6000
Version no T-code
002 342

OL S6 6000
Hydraulic system
SSD K. Hallman 001 345, 346
Hydraulic system

345 OS 2.0 256600AA- Trucks without platform lift
346 OS 3.0 256600 AA- Trucks without platform lift
1 General
including a magnetic lowering valve, pressure relief valve and
a pressure switch, and two cylinders for th fork lift.
2.1 Hydraulic diagram and components

OL S6 6000
Hydraulic system
Version no T-code
001 345, 346
2.2 Main components
Pos No Description Remark

1 Lift Cylinders Fork lift
2 Hydraulic Unit Y41 = Lowering valve
M3 = Pump motor
S61 = Pressure switch
2.3 Description
2.3.1 Lift
When the pump motor starts, the oil flows through the non
return valve to the lift cylinders.
2.3.2 Lower
When the magnetic valve is affected electrically, it opens fully
to let the oil in the pressure lines return to the oil tank.

The operating pressures at rated load are:
1. OS 2.0: 85 bar
2. OS 3.0: 125 bar
2.3.4 Relief valve

The relief valve opens at the following pressures:
1. OS 2.0: 95 bar
2. OS 3.0: 135 bar
2.3.5 Pressure switch

The purpose of the pressure switch is to be able to adjust the
braking force of the electromagnetic brake.
The switch opens at a pressure in the hydraulic system that
corresponds to an approximate load on the forks of 550 kg
(approx. 40 bar hydraulic pressure).

OL S6 6000
Hydraulic system
SSD K. Hallman 002 345, 346
Hydraulic system

345 OS 2.0 256600AA- Trucks equipped with
platform lift
platform lift
1 General
including an electromagnetic valve (on-off) for the lowering
and a pressure relief valve, a valve block with soft closing
electromagnetic valves for the platform and fork lift and a
pressure switch, and one telescopic cylinder for the platform
lift and two telescopic cylinders for the fork lift.

OL S6 6000
Hydraulic system
Version no T-code
002 345, 346

OL S6 6000
Hydraulic system
Version no T-code
002 345, 346
2.2 Main components

1 Lift cylinders Fork lift
2 Lift cylinder Platform
3 Flow restrictor For the platform cylinder
Y41 = Lowering valve, electro magnetic
5 Valve block S61 = Pressure switch
Y45 = Soft closing electro magnetic valve
for the forks
Y69 = Soft closing electromagnetic valve
for the platform
2.3 Description
When the control for the lifting of the forks is activated the
pump contactor closes and starts the pump motor,at the
same time the valve Y45 is opened, the oil flows through the
non return valve and Y45 to the lift cylinders.
If the lift is interrupted, Y45 closes slowly.

When control for lowering of the forks is activated the mag-
netic valves Y41 and Y45 is opened fully to let the oil in the
pressure lines return to the oil tank.
If the lowering is interrupted, is first Y45 closing slowly before
Y41 is closed. Y41 receives a delaying holding voltage from
the truck logic card to make sure that Y45 is completely
closed before Y41 closes.
The lowering speed cannot be adjusted. It is fixed by the flow
restriction valve in the valve block of the hydraulic unit.

OL S6 6000
Hydraulic system
Version no T-code
002 345, 346

When the control (push button or floor pedal) for the lifting of
the platformis activated the pump contactor closes and starts
the pump motor,at the same time the valve Y69 is opened,
the oil flows through the non return valve to the lift cylinders.

When control for lowering of the platform is activated the
magnetic valves Y41 and Y69 is opened fully to let the oil in
the pressure lines return to the oil tank.
the truck logic card to make sure that Y69 is completely

The operating pressures at rated load are:
1. OS 2.0: 85 bar
2. OS 3.0: 125 bar
2.3.6 Relief valve

The relief valve opens at the following pressures:
1. OS 2.0: 95 bar
2. OS 3.0: 135 bar
2.3.7 Flow restrictor for the platform cylinder

The function of the flow restrictor is to make sure that the low-
ering speed does not exceed 0,6 m/s in the case of a bursting
hose. The restrictor is in the shape of a washer mounted
inside the hose connection.
When the hose is re-fitted after removal, check that the
washer is in place.
2.3.8 Pressure switch, S61

braking force of the electromagnetic brake depending of the
load weight.
(approx. 40 bar hydraulic pressure).

OL S6 6000
Hydraulic system
SSD E. De Smedt 001 347
Hydraulic system

347 OS1.0 W 256600GA-
1 General
including a solenoid valve for lowering, a pressure relief valve
and a pressure switch. There is also an adjustable flow limiter
and a hydraulic cylinder for lifting the platform.

ponents

OL S6 6000
Hydraulic system
Version no T-code
001 347
2.2 Main components

1 Lifting cylinder Platform lift
2 Flow limiter Limits the lowering
speed of the platform
3 Hydraulic unit Y41=lowering valve,
electromagnetic
M3=Pump motor
4 Valve block S61=Pressure switch
Y45=Solenoid valve
with slow closing
2.3 Description
2.3.1 Lift
When the platform lift control is activated, the pump contactor
Y45 to the lifting cylinder.
2.3.2 Lower
When the platform lower control is activated, solenoid valves
Y41 and Y45 are fully opened so that the fluid in the delivery
pipes can flow back to the fluid reservoir.
the control board on the truck, to ensure that Y45 is fully
The lowering speed can be adjusted using the flow limiter.
The default setting for the flow limiter is 0.1 m/s, with no load
on the forks.

The operating pressure with the rated load is 160 bar.

OL S6 6000
Hydraulic system
Version no T-code
001 347
2.3.4 Pressure relief valve

The pressure relief valve opens when the pressure reaches:
170 bar
2.3.5 Pressure switch

The purpose of the pressure switch is to adjust the braking
force, and in the OS 1.0 it is also used to limit the speed. The
switch must open when the pressure in the hydraulic system
corresponds to a load on the forks of 750 kg.
3 Adjustments
3.1 Adjusting the pressure control valve

The pressure control valve is set to the correct value at the
factory, but it needs to be adjusted when a valve or the entire
hydraulic system is changed.
The machine must be able to lift a load of between
1,000-1,050 kg.
1. Cap nut
2. Adjusting screw, pressure control.
Turn clockwise to increase pressure
Turn anti-clockwise to reduce pressure.
• Unscrew the cap nut (1) using a non-adjustable spanner,

13 mm.
• Place a load of 1,000 kg on the forks and check that the
machine can lift it.
• If the machine can lift 1,000 kg, place an additional 100 kg
on the forks. Check whether the machine can lift the load.
• If the machine can lift 1,100 kg, adjust the pressure control
valve by turning the adjusting screw (2) anti-clockwise
using a 4 mm Allen key until the machine can no longer lift
the load.

OL S6 6000
Hydraulic system
Version no T-code
001 347

OL S6 6000
Hydraulic system
Hydraulic system

348 OS 1.0 256600AA- Trucks without platform lift
1 General
including a electromagnetic valve (on-off) for the lowering and
a pressure relif valve, a valve block with one soft closing elec-
tromagnetic valve for the fork lift and two pressure switches,
and one cylinder for the fork lift.

OL S6 6000
Hydraulic system
Version no T-code
001 348
2 Funktionsbeskrivning

OL S6 6000
Hydraulic system
Version no T-code
001 348
2.2 Main components

1 Lift cylinder Fork lift
2 Hydraulic unit Y41 = Lowering valve
M3 = Pump motor
Y45 = Soft closing electromagnetic
valve for the forks
2.3 Description
pump contactor closes and starts the pump motor,at the same
time the valve Y45 is opened, the oil flows through the non re-
turn valve and Y45 to the lift cylinders.

When control for lowering of the forks is activated the magne-
tic valves Y41 and Y45 is opened fully to let the oil in the pres-
sure lines return to the oil tank.
the truck logic card to make sure that Y45 is completely closed
before Y41 closes.

The operating pressures at rated load are: 145 bar
2.3.4 Relief valve

The relief valve opens at the following pressures: 150 bar

OL S6 6000
Hydraulic system
Version no T-code
001 348

load weight.
corresponds to an approximate load on the forks of 500kg (ap-
prox. 75 bar hydraulic pressure, depending on the fork length).

The purpose of the pressure switch is to give the truck elec-
tronics an input to reduce the speed
corresponds to an approximate load on the forks of 500kg (ap-
prox. 75 bar hydraulic pressure, depending on the fork length).

OL S6 6000
Hydraulic system
Hydraulic system

platform lift
1 General
including an electromagnetic valve (on-off) for the lowering
and a pressure releif valve, a valve block with soft closing
electromagnetic valves for the platform and fork lift and two
pressure switches, one cylinder for the platform lift and one
for the fork lift.

OL S6 6000
Hydraulic system
Version no T-code
002 348

OL S6 6000
Hydraulic system
Version no T-code
002 348
2.2 Main components
Pos. Description Remarks

no.
1 Lift cylinder Fork lift
2 Lift cylinder Platform
3 Flow restrictor For the platform cylinder
Y41 = Lowering valve, electro magnetic
Y45 =Soft closing electro magnetic valve
for the forks
Y69 =Soft closing electromagnetic valve
for the platform
2.3 Description
pump contactor closes and starts the pump motor,at the same
time the valve Y45 is opened, the oil flows through the non re-
turn valve and Y45 to the lift cylinders.

When control for lowering of the forks is activated the magne-
tic valves Y41 and Y45 is opened fully to let the oil in the pres-
sure lines return to the oil tank.
before Y41 closes.

OL S6 6000
Hydraulic system
Version no T-code
002 348

When the control (push button or floor pedal) for the lifting of
the platformis activated the pump contactor closes and starts
the pump motor,at the same time the valve Y69 is opened, the
oil flows through the non return valve to the lift cylinders.

When control for lowering of the platform is activated the mag-
netic valves Y41 and Y69 is opened fully to let the oil in the
pressure lines return to the oil tank.
before Y41 closes.

The operating pressures at rated load are: 145 bar
2.3.6 Relief valve

The relief valve opens at the following pressures: 150 bar
2.3.7 Flow restrictor for the platform cylinder

The function of the flow restrictor is to make sure that the lo-
wering speed does not exceed 0,6 m/s in the case of a burs-
ting hose. The restrictor is in the shape of a washer mounted
inside the hose connection.
When the hose is re-fitted after removal, check that the washer
is in place.

load weight.
(approx. 75 bar hydraulic pressure, depending on the fork
length).

The purpose of the pressure switch is to give the truck elec-
tronics an input to reduce the speed.
(appox. 75 bar, depending on the fork length).

OL S6.0 6000
Hydraulic system
SSD P-Å Gustafsson 001 425
Hydraulic system

425 OS1.0 WL 256600GA-
1 General
including a solenoid valve for lowering and a pressure control
valve. It also includes a valve block with a slow-closing elec-
tromagnetic valve for lifting the forks, two pressure monitors
and a cylinder for lifting the forks.
The hydraulic system consists of two independent hydraulic
units. One of the units is fixed onto the chassis, and includes
a solenoid valve for fork lowering, a pressure control valve, a
valve block with a slow-closing electromagnetic valve for lift-
ing the cabin, and a pressure monitor. This unit handles the
lifting and lowering of the cabin. The second unit is fixed
under the floor of the operator area, and includes a solenoid
valve for lowering, and a pressure control valve.

OL S6.0 6000
Hydraulic system
Version no T-code
001 425

ponents
6

<
<
<
0
0


OL S6.0 6000
Hydraulic system
Version no T-code
001 425
2.2 Main components
No. Description Note

1 Lifting cylinder Cabin lift
2 Throttle valve Cabin lift
3 Hydraulic unit Y41 = Lowering valve, electromagnetic
M3 = Pump motor
Y45 =Slow-closing electromagnetic
valve for forks
5 Lifting cylinder Fork lift

6 Throttle valve
7 Hydraulic unit Y42 = Lowering valve, electromagnetic
M4 = Pump motor

OL S6.0 6000
Hydraulic system
Version no T-code
001 425
2.3 Description
2.3.1 Fork lift
When the fork lift control is activated, the pump contactor
Y45 to the lifting cylinders.
2.3.2 Fork lower

When the fork lower control is activated, solenoid valves Y41
and Y45 are fully opened so that the fluid in the delivery pipes
can flow back to the fluid reservoir.
closes.
The lowering speed cannot be adjusted - it is determined by
the flow valve in the valve block of the hydraulic system.

The operating pressure with the specified load is: 145 bar
2.3.4 Safety valve

The safety valve opens when the pressure reaches: 150 bar

Master Service Manual Product Family OL

Uploaded by

Copyright:

Available Formats

Master Service Manual Product Family OL

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Master Service Manual Product Family OL

Uploaded by

Copyright:

Available Formats

Master Service Manual

Ring binder number: Part number: 147638-040

© BT Industries AB Service Manual 1998-11-04 English 1 (2)

2 (2) Service Manual 1998-11-04 English

Valid from serial number:

7FRGH 0RGHO 6HULDO1R 1RWHV

© BT Industries AB Service Manual 1999-09-03 English 1 (4)

6HFWLRQ &FRGH 7FRGH 'RFXPHQW ,VVXHG

2 (4) Service Manual 1999-09-03 English

6HFWLRQ &FRGH 7FRGH 'RFXPHQW ,VVXHG

© BT Industries AB Service Manual 1999-09-03 English 3 (4)

4 (4) Service Manual 1999-09-03 English

© BT Industries AB Service Manual 1998-11-04 English 1 (2)

2 (2) Service Manual 1998-11-04 English

T-code Model Serial No Notes

1.1 Issued operator’s manuals

T-code Model Serial number Order Issued

© BT Industries AB Service Manual 1999-06-22 English 1 (2)

T-code Model Serial number Order Issued

2 (2) Service Manual 1999-06-22 English

General product information

T-code Model Serial No Notes

© BT Industries AB Service Manual 1994-12-23 English 1 (8)

1.1 Intended application of OS 2.0/OS 3.0

1.2 Forbidden application of OS 2.0/OS 3.0

2 (8) Service Manual 1994-12-23 English

Model designation OS 2.0 OS 3.0

For further dimensions refer to the diagram in section Truck

© BT Industries AB Service Manual 1994-12-23 English 3 (8)

4 (8) Service Manual 1994-12-23 English

4 Presentation of main components

© BT Industries AB Service Manual 1994-12-23 English 5 (8)

15. Battery/Recharging connector;

6 (8) Service Manual 1994-12-23 English

© BT Industries AB Service Manual 1994-12-23 English 7 (8)

5 Signs on the truck

Technical service data

T-code Model Serial No Notes

MODELL PPO 1500MX

© BT Industries AB Service Manual 1998-06-12 English 1 (4)

MODELL PPO 1500MX

2 (4) Service Manual 1998-06-12 English

MODELL PPO 1500MX

© BT Industries AB Service Manual 1998-06-12 English 3 (4)

4 (4) Service Manual 1998-06-12 English

Technical service data

T-code Model Serial No Notes

MODEL OS 1.8X OS 1,0W OS 1,0WL

© BT Industries AB Service Manual 1999-01-18 English 1 (4)

MODEL OS 1.8X OS 1,0W OS 1,0WL

2 (4) Service Manual 1999-01-18 English

MODEL OS 1.8X OS 1,0W OS 1,0WL

© BT Industries AB Service Manual 1999-01-18 English 3 (4)

MODEL OS 1.8X OS 1,0W OS 1,0WL

4 (4) Service Manual 1999-01-18 English

Technical service data

T-code Model Serial No Notes

MODEL OS 1.0 OS 2.0 OS 3.0

© BT Industries AB Service Manual 1995-03-01 English 1 (4)

7FRGH 0RGHO 6HULDO1R 1RWHV

6HFWLRQ &FRGH 7FRGH 'RFXPHQW ,VVXHG

6HFWLRQ &FRGH 7FRGH 'RFXPHQW ,VVXHG