BT OM BT OMW BT OMC BT OMCW Product family OM Master Service Manual – PDF DOWNLOAD
DESCRIPTION:
BT OM BT OMW BT OMC BT OMCW Product family OM Master Service Manual – PDF DOWNLOAD
Part number: 153875-040
Introduction, maintenance :
- 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 followed to the letter.
- The operator may adapt them to local conditions, 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.
Safety regulations with maintenance 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.
TABLE OF CONTENTS:
BT OM BT OMW BT OMC BT OMCW Product family OM Master Service Manual – PDF DOWNLOAD
Master Service Manual Product family OM 1
BT OM BT OMW BT OMC BT OMCW 1
Contents Master Service Manual 7
Valid from serial number: 7
T-code 7
Model 7
Serial No 7
Notes 7
1 Document list 7
Section 7
C-code 7
T-code 7
Document 7
Issued 7
Technical service data 9
Valid from serial number: 9
T-code 9
Model 9
Serial No 9
Notes 9
Model 9
OM 9
OMW 9
OMC 9
OMCW 9
Drive motor 9
Transmission/gear 9
Drive wheel 10
Support arm wheels 10
Hydraulic unit 10
Fuses 11
Batteries 11
All models 11
Driving speeds 12
Lifting/lowering speeds 12
Current consumption 13
Weight 13
Introduction, maintenance 15
1 Safety regulations with maintenance work 15
WARNING! 15
WARNING! 16
WARNING! 16
NOTE! 16
CAUTION! 16
2 Cleaning and washing 17
NOTE! 17
2 1 External cleaning 17
NOTE! 17
2 2 Cleaning the motor compartment 17
NOTE! 17
2 3 Electrical components 18
NOTE! 18
3 Safe lifting of the truck 18
WARNING! 18
4 Information plates, only Japan 19
Service schedule 21
Valid from serial number: 21
T-code 21
Model 21
Serial No 21
Notes 21
1 Maintenance chart 21
Pos 21
Work to carry out 21
Intervals in hours 21
250 21
500 21
1000 21
3000 21
Intervals in Days/Weeks/Months 21
3 M 21
6 M 21
12 M 21
36 M 21
0000 21
Chassis 21
0500 21
Cabin 21
0640 21
Manoeuvring controls 21
1700 22
Drive motor 22
2550 22
Drive unit 22
3370 22
Brakes 22
3500 22
Wheels 22
5000 22
Electrical panel 22
5110 23
Battery 23
5810 23
Pump motor 23
5830 23
Steering motor 23
6000 23
Hydraulic system 23
7100 23
Mast 23
7160 24
Initial lift 24
9500 24
Extra equipment 24
2 Lubrication chart 26
Item 26
Service point 26
Intervall/Running hours 26
Lubricant 26
Volume 26
250 h 26
500 h 26
1000 h 26
Oil and grease specification 29
Valid from serial number: 29
T-code 29
Model 29
Serial No 29
Notes 29
Lubricant 29
Type of lubricant 29
Specification 29
To be used for 29
> – 15C 29
< – 15C 29
Oil and grease specification 31
Valid from serial number: 31
T-code 31
Model 31
Serial No 31
Notes 31
Lubricant 31
Type of lubricant 31
Specification 31
To be used for 31
> – 15C 31
< – 15C 31
Taking Delivery of the Truck 33
Valid from serial number: 33
T-code 33
Model 33
Serial No 33
Notes 33
1 General 33
1 1 Getting the truck in order 33
Transmission, Gear 35
Valid from machine number: 287595AA- 35
1 General 35
2 Gear components/data 36
2 1 Component identification 36
Pos No 36
Component 36
2 2 Technical gear data 37
Truck type 37
OM 0 85 37
3 Dismantling/fitting of gear from/in truck 38
3 1 Dismantling: 38
1 Remove the front cover plate of the chassis 38
2 Jack up the truck and block it in a safe manner 38
3 Remove the steering chain from the gear by removing the chain locks 38
4 Loosen and remove the six M12 bolts holding the gear to the motor plate 38
5 Lower the gear to the floor 38
6 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 38
3 2 Fitting: 38
1 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 38
2 Put the gear in position and make sure that the lower motor bearing and gear wheel is in its correct position 38
3 Fit the M12 bolts through the motor plate and tighten them 90 Nm The bolts shall be lubricated prior to assembly 38
4 Mount the steering chain and adjust the slack according to the picture 39
5 Lower the truck to the ground and fit the front cover plate 39
4 Oil level check/exchange 39
4 1 Check/filling of oil 39
4 2 Exchange of oil 40
1 Draining the old oil out of the gear is done by removing the lower gear cover completely 40
2 Change the O-ring seal at every oil change Make sure that the new O-ring isn’t damaged when fitted 40
3 Fit the cover and tighten the bolts 25 Nm The bolts shall be lubricated prior to assembly 40
4 Fill up oil in accordance with filling instructions 40
5 Exchange of drive shaft seal ring 41
5 1 Dismantling: 41
1 Remove the drive wheel from the gear 41
2 Remove the lower gear cover and drain the gear from oil 41
3 Loosen the drive shaft nut Remove the nut and spacer ring 41
4 Knock the drive shaft out Gently with a brass drifter and a hammer 41
5 Pull the bearing off the drive shaft with tool 08-13022 41
6 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 41
7 Remove the seal ring from the drive shaft 41
5 2 Assembly: 42
1 Place the drive shaft outer bearing in the gear housing 42
2 Press the new seal ring in place in the gear housing Be careful when pressing it in place so that the seal is seated correctly in the gear housing 42
3 Place the shaft bearing shims on the drive shaft, having the same total thickness as the original Make sure that only undamaged shims is used 42
4 Press the drive shaft , with shims, into the gear housing/ shaft bearing Check that the splines of the drive shaft is aligned with the splines of the crown wheel 42
5 Place the spacer ring on to the drive shaft end and fit the shaft nut Always use a new nut The drive shaft nut shall be lub 42
6 Before fitting the lower cover, change the O-ring Make sure that it is not damaged when fitted Fit the cover and tighten the bolts 25 Nm The bolts shall be lubricated prior to assembly 42
7 Fill up oil in accordance with filling instructions, section 4 2 42
8 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 42
6 Leakage from the top cover 43
1 Dismantle the gear and radial steering ball bearing from the truck as described in section 3 1 43
2 After removing the radial bearing loosen all eleven bolts holding the top cover to the gear housing 43
3 Remove the cover from the gear and clean the surface of the cover and housing carefully 43
4 Apply liquid sealant type Loc-Tite 574 to the surfaces Follow the instructions given on the container 43
5 Fit the cover bolts and tighten with a torqe of 25 Nm The bolts shall be lubricated prior to assembly 43
6 Fill up oil in accordance with filling instructions, section 4 2 43
7 Fit the gear and radial bearing to the truck as described in section 3 2 43
Electromagnetic brake 45
Valid from machine number: 287595AA- 45
1 General 45
2 Function 46
2 1 Releasing the brake 46
2 2 Braking 46
3 Maintenance 47
3 1 Adjustment of gap 48
3 1 1 Adjustment procedure: 48
1 Loosen the tension of the four mounting bolts 48
2 Turn the lock nuts anti-clockwise and tighten the bolts slightly while checking the gap with a 0 5 mm feeler gauge 48
3 Tighten the mounting bolts 25 Nm 48
4 Recheck the gap with the feeler gauge 48
3 2 Exchange of brake disc/magnetic coil 49
3 2 1 Exchange procedure: 49
1 Disconnect the electrical wires of the brake 49
2 Dismount the speed sensor mounted on top of the brake coil 49
3 Loosen and remove the four mounting bolts and remove the brake coil 49
4 Replace the brake disc on the hub/magnetic coil and make a visual check of the wear of the friction plate Replace the friction plate if the surface is worn uneven 49
5 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 49
6 Mount the coil on the motor end and carry out adjustment of the gap according to section 3 1 49
7 Reconnect the electrical wiring of the brake 49
8 Fit the speed sensor 49
3 2 2 Transport securing screws 50
3 3 Check/adjustment of the braking force 51
Warning! 51
Electric parking brake, magnetic brake 53
Valid from serial number: 53
T-code 53
Model 53
Serial no 53
Note 53
1 General 53
2 Function 54
2 1 Releasing the brake 54
2 2 Braking 55
3 Maintenance 56
3 1 Adjustment of gap 56
3 1 1 Adjustment procedure: 56
3 2 Exchange of brake disc/magnetic coil 57
3 2 1 Exchange procedure: 57
3 3 Check/adjustment of the braking force 58
WARNING! 58
Wire guidance 59
T code 59
Model 59
Serial No 59
Notes 59
1 General 59
2 Generator 60
2 1 Technical data 60
Power supply 60
Model LDU-22 60
Model LDU-21 60
3 Antennas 61
3 1 Antenna cable 62
4 Wire guidance electronic card 62
4 1 Components 62
4 2 Connectors 63
Connector 63
Type 63
No 63
Active 63
Function 63
Connector 63
Type 63
No 63
Active 63
Function 63
4 3 Display 64
4 3 1 Input signals 64
Segment 64
Function 64
4 3 2 Output signals / operating modes 64
Segment 64
Function 64
4 3 3 Error codes 65
Code 65
Description 65
5 Miscellaneous 67
6 Description of function 67
6 1 Travelling in the fork direction 67
6 2 Travelling in the drive wheel direction 68
6 3 Control signals 69
Operating mode 69
L 69
A 69
P 69
7 Adjustments 70
7 1 Truck computer A2 70
7 1 1 Steering angle 70
7 2 Wire guidance electronic card A3 70
Menu 71
Description 71
Area 71
Display 73
Description 73
7 2 1 Adjustment of the steering angle offset 73
7 2 2 Fine adjustment of the steering angle offset 73
7 2 3 Antenna adjustment for the drive wheel direction 74
7 2 4 Antenna adjustment for the fork direction 74
7 2 5 Final adjustment 75
7 2 6 Storing parameters 75
7 2 7 Antenna adjustment in the antenna 1 mode 75
8 Installing a new wire guidance electronic card 76
POS 76
Truck model 76
ID number 76
POS 77
Truck model 77
ID number 77
9 Troubleshooting 78
9 1 Control signals 78
9 1 1 Verifying the reference signal 78
kHz 78
mA 78
9 1 2 Lateral signal verification 78
9 1 3 Verifying the steering angle signal 78
Electrical system 79
Valid from serial number: 79
T-code 79
Model 79
Serial No 79
Notes 79
1 General 79
1 1 References: 80
2 Symbols and circuit diagrams 80
2 1 List of symbols 80
Symbol 80
Description 80
Symbol 80
Description 80
2 2 Circuit diagram(1/8) 82
2 3 Circuit diagram (2/8) 83
2 4 Circuit diagram (3/8) 84
2 5 Circuit diagram (4/8) 85
2 6 Circuit diagram (5/8) 86
2 7 Circuit diagram (6/8) 87
2 8 Circuit diagram (7/8) 88
2 9 Circuit diagram (8/8) 89
2 10 List of components 90
Symbol 90
Designation 90
Function 90
Remark 90
3 Description of function 93
3 1 Ignition key in the 0 position 93
3 2 Ignition key in the I position 93
3 3 Driver presence control (outside narrow aisle) 94
3 4 Driving 94
3 5 Driving in narrow aisle 95
3 5 1 Driving in rail guided aisle 95
3 5 2 Driving in wire guided aisle 95
3 6 Steering 95
3 7 Steering wheel indicator 95
3 8 Braking 96
3 8 1 Plug brake (electric) 96
3 8 2 Automatic plug braking (selectable parameter) 96
3 8 3 Service brake 96
3 8 4 Parking brake 96
3 9 Cabin lift 97
3 10 Cabin gates 97
3 11 Front gate, only “walk through” 97
3 12 Lift height limitation (option) 97
3 13 Cabin lowering 98
3 14 Initial lift 98
3 15 Initial lowering 98
4 Standard settings and adjustments 98
Electrical system 99
Valid from serial number: 99
T-code 99
Model 99
Serial No 99
Notes 99
1 General 99
1 1 References: 100
1 2 General description of the electrical system 100
1 2 1 Battery, battery supply, power fuses (sheet 1) 100
1 2 2 Drive motor circuit (sheet 2) 101
1 2 3 Inputs to the electronic card A2 (sheet 3) 101
1 2 4 Inputs till the electronic card A2 (sheet 4) 102
1 2 5 Speed control, display communication, (sheet 5) 102
1 2 6 Steering, extra equipment (sheet 6) 103
1 2 7 Outputs from the electronic card A2 (sheet 7) 103
1 2 8 Wire guidance (sheet 8) 103
2 Symbols and circuit diagrams 104
2 1 List of symbols 104
Symbol 104
Description 104
2 2 Circuit diagram T-code 355, 457, 1/8 106
2 3 Circuit diagram T-code 355, 457, 2/8 107
2 4 Circuit diagram T-code 355, 457, 3/8 108
2 5 Circuit diagram T-code 355, 457, 4/8 109
2 6 Circuit diagram T-code 355, 457, 5/8 110
2 7 Circuit diagram T-code 355, 457, 6/8 111
2 8 Circuit diagram T-code 355, 457, 7/8 112
2 9 Circuit diagram T-code 355, 457, 8/8 113
2 10 Circuit diagram T-code 356, 458, 1/8 114
2 11 Circuit diagram T-code 356, 458, 2/8 115
2 12 Circuit diagram T-code 356, 458, 3/8 116
2 13 Circuit diagram T-code 356, 458, 4/8 117
2 14 Circuit diagram T-code 356, 458, 5/8 118
2 15 Circuit diagram T-code 356, 458, 6/8 119
2 16 Circuit diagram T-code 356, 458, 7/8 120
2 17 Circuit diagram T-code 356, 458, 8/8 121
2 18 List of components 122
Symbol 122
Designation 122
Function 122
Remark 122
2 19 Electrical diagram Option Buzzer 125
2 20 List of components 126
Symbol 126
Designation 126
Function 126
Remark 126
2 21 Electrical diagram Option Gate warning 127
2 22 List of components 128
Symbol 128
Designation 128
Function 128
Remark 128
2 23 Electrical diagram Option Extra hydraulic function 129
2 24 List of components 130
Symbol 130
Designation 130
Function 130
Remark 130
3 Description of function 131
3 1 Ignition key in the 0 position 131
3 2 Start 131
3 3 Deadman’s handle 132
3 4 Driver presence control (outside narrow aisle) 132
3 4 1 Open cabin gates 132
3 4 2 Closed cabin gates 132
3 5 Driving 133
3 6 Driving in narrow aisle 133
3 6 1 Driving in rail guided aisle 133
3 6 2 Driving in rail guided aisle 134
3 7 Travel speed 134
3 7 1 Outside narrow aisles: 134
3 7 2 In narrow aisles, rail steering / wire guidance: 134
3 8 Steering 135
3 9 Steering wheel indicator 135
3 10 Braking 135
3 10 1 Plug brake (electric) 135
3 10 2 Automatic plug braking (selectable parameter) 135
3 10 3 Service brake 136
3 10 4 Parking brake 136
3 11 End-of-aisle brake 136
3 12 Cabin lift 136
3 13 Cabin gates 137
3 14 Load sensing, only “OMW, OMCW” 137
3 15 Lift height limitation 137
3 16 Cabin lowering 137
3 17 Initial lift 137
3 18 Initial lowering 138
3 19 Slack chain guard 138
3 20 Miscellaneous 138
4 Standard settings and adjustments 138
Electrical system 139
Valid from serial number: 139
T-code 139
Model 139
Serial No 139
Notes 139
1 General 139
1 1 References: 140
1 2 General description of the electrical system 140
1 2 1 Battery, battery supply, power fuses (sheet 1) 140
1 2 2 Drive motor circuit (sheet 2) 141
1 2 3 Inputs to the electronic card A2 (sheet 3) 141
1 2 4 Inputs till the electronic card A2 (sheet 4) 142
1 2 5 Speed control, display communication, (sheet 5) 142
1 2 6 Steering, extra equipment (sheet 6) 142
1 2 7 Outputs from the electronic card A2 (sheet 7) 143
1 2 8 Wire guidance (sheet 8) 143
2 Symbols and circuit diagrams 144
2 1 List of symbols 144
Symbol 144
Description 144
2 2 Circuit diagram T-code 355, 457 (1/8) 146
2 3 Circuit diagram T-code 355, 457 (2/8) 147
2 4 Circuit diagram T-code 355, 457 (3/8) 148
2 5 Circuit diagram T-code 355, 457 (4/8) 149
2 6 Circuit diagram T-code 355, 457 (5/8) 150
2 7 Circuit diagram T-code 355, 457, (6/8) 151
2 8 Circuit diagram T-code 355, 457 (7/8) 152
2 9 Circuit diagram T-code 355, 457 (8/8) 153
2 10 Circuit diagram T-code 356, 458 (1/8) 154
2 11 Circuit diagram T-code 356, 458 (2/8) 155
2 12 Circuit diagram T-code 356, 458 (3/8) 156
2 13 Circuit diagram T-code 356, 458 (4/8) 157
2 14 Circuit diagram T-code 356, 458 (5/8) 158
2 15 Circuit diagram T-code 356, 458 (6/8) 159
2 16 Circuit diagram T-code 356, 458 (7/8) 160
2 17 Circuit diagram T-code 356, 458 (8/8) 161
2 18 Electrical circuit diagrams t-code 356 and 458 162
2 19 List of components 170
Symbol 170
Designation 170
Function 170
Remark 170
2 20 Electrical diagram Option Buzzer 173
2 21 List of components 174
Symbol 174
Designation 174
Function 174
Remark 174
2 22 Electrical diagram Option Extra hydraulic function 175
2 23 List of components 176
Symbol 176
Designation 176
Function 176
Remark 176
3 Description of function 177
3 1 Ignition key in the 0 position 177
3 2 Start 177
3 3 Deadman’s handle 178
3 4 Driver presence control (outside narrow aisle) 178
3 4 1 Open cabin gates 178
3 4 2 Closed cabin gates 178
3 5 Driving 179
3 6 Driving in narrow aisle 179
3 6 1 Driving in rail guided aisle 179
3 6 2 Driving in aisle with wire guidance 180
3 7 Travel speed 180
3 7 1 Outside narrow aisles: 180
3 7 2 In narrow aisles, rail steering / wire guidance: 180
3 8 Steering 181
3 9 Steering wheel indicator 181
3 10 Braking 181
3 10 1 Plug brake (electric) 181
3 10 2 Automatic plug braking (selectable parameter) 181
3 10 3 Service brake 182
3 10 4 Parking brake 182
3 11 End-of-aisle brake 182
3 12 Cabin lift 182
3 13 Cabin gates 183
3 14 Load sensing, only “OMW, OMCW” 183
3 15 Lift height limitation 183
3 16 Cabin lowering 183
3 17 Initial lift 184
3 18 Initial lowering 184
3 19 Slack chain guard 184
3 20 Miscellaneous 184
4 Standard settings and adjustments 184
Electric System 185
Valid for serial number: 185
T code 185
Model 185
Machine no 185
Note 185
1 General 185
1 1 References 186
1 2 General description of the electric system 186
1 2 1 Battery, battery measurement, power fuses(sheet 1) 186
1 2 2 Travel drive motor (sheet 2) 187
1 2 3 Inputs to the A2 logic card (sheet 3) 187
1 2 4 Inputs to the A2 logic card (sheet 4) 187
1 2 5 Inputs to the A2 logic card (sheet 5) 188
1 2 6 Speed control, display communication, (sheet 6) 188
1 2 7 Steering, optional equipment (sheet 7) 189
1 2 8 Outputs from the A2 logic card (sheet 8) 189
1 2 9 Wire guidance (sheet 9) 190
2 List of symbols and electric circuit diagrams 190
2 1 List of symbols 190
Symbol 190
Description 190
2 2 Electric circuit diagram, T code 355 and 457, 1/9 193
2 3 Electric circuit diagram, T code 355 and 457, 2/9 194
2 4 Electric circuit diagram, T code 355 and 457, 3/9 195
2 5 Electric circuit diagram, T code 355 and 457, 4/9 196
2 6 Electric circuit diagram, T code 355 and 457, 5/9 197
2 7 Electric circuit diagram, T code 355 and 457, 6/9 198
2 8 Electric circuit diagram, T code 355 and 457, 7/9 199
2 9 Electric circuit diagram, T code 355 and 457, 8/9 200
2 10 Electric circuit diagram, T code 355 and 457, 9/9 201
2 11 Electrical circuit diagrams T-code 355 and 457 202
2 12 Component list 210
Symbol 210
Designation 210
Function 210
Note 210
3 Functional description 214
3 1 Key in 0 position 214
3 2 Start 214
3 3 Control panel selection 214
3 4 Dead man’s handle 215
3 5 Presence control (outside narrow aisles) 215
3 5 1 Open cabin gates 215
3 5 2 Closed cabin gates 215
3 6 Driving 216
3 7 Narrow aisle driving 216
3 7 1 Aisle driving with guiderail steering 216
3 7 2 Aisle driving with wire guidance 217
3 8 Travel speed 217
3 8 1 Out of aisle 217
3 8 2 In a narrow aisle, guiderail or wire guidance mode 217
3 9 Steering 218
3 10 Steering wheel indicator 218
3 11 Braking 218
3 11 1 Motor braking (electric) 218
3 11 2 Automatic motor braking (adjustable parameter) 218
3 11 3 Service brake 219
3 11 4 Parking brake 219
3 12 End-of-aisle brake 219
3 13 Cabin lifting 219
3 14 Cabin gates 220
3 15 Load detection (only “OMW, OMCW”) 220
3 16 Height limiter 220
3 17 Cabin lowering 220
3 18 Initial lift 221
3 19 Initial lowering 221
3 20 Slack chain guard 221
3 21 Miscellaneous 221
4 Default settings and adjustments 221
Transistor regulator 223
Valid from machine number: 287595AA- 223
1 Transistor regulator 223
1 1 Motor connections 223
Terminal number 224
Function 224
2 Control circuit 224
Terminal- number 224
Con 224
Function 224
3 Technical specification 225
PARAMETER 225
SETTING 225
UNITS 225
DESCRIPTION 225
4 LED indications 226
LED No 226
Colour 226
Indicates 226
Diagnosis 226
5 Maintenance 227
5 1 Safety 227
WARNING! 227
5 2 Cleaning 227
1 Remove power by disconnecting the battery 227
2 Discharge the capacitors in the controller, by connecting a load (such as a contactor coil or the horn) across the controller’s B+ and B- terminals, before doing any work on the controller 227
3 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 227
4 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 227
6 Safety control 228
6 1 Checking the transistor regulator’s safety circuits 228
Warning 228
! 228
Control cables 229
Valid from serial number: 229
T-code 229
Model 229
Serial number 229
Notes 229
1 Slack chain breaker 229
2 Adjusting the slack chain breaker 229
Electronic card 231
Valid from serial number: 231
T-code 231
Model 231
Serial No 231
Notes 231
1 Electronic card 149167 version -001 and -002 231
1 1 General 231
2 Connections 232
2 1 Connector no 1, display 232
Terminal number 232
LED no 232
Connection 232
Active 232
Function 232
2 2 Connector no 2, cabin 233
Terminal number 233
LED no 233
Connection 233
Active 233
Function 233
2 3 Connector no 3, height , speed and aisle indication 234
Terminal number 234
LED no 234
Connection 234
Active 234
Function 234
2 4 Connector no 4, drive and steer signals 235
Terminal number 235
LED no 235
Connection 235
Active 235
Function 235
2 5 Connector no 5, wire guidance option 236
Terminal number 236
LED no 236
Connection 236
Active 236
Function 236
2 6 Connector no 6, potentiometer circuits, voltage supply 237
Terminal number 237
LED no 237
Connection 237
Active 237
Function 237
2 7 Connector no 7, brake, valves, contactors 238
Terminal number 238
LED no 238
Connection 238
Active 238
Function 238
2 8 Connector no 8, power supply steering 238
Terminal number 238
LED no 238
Connection 238
Active 238
Function 238
3 LED’s, switches, potentiometer 239
LED 239
Colour 239
Function 239
Switch 239
Function 239
Potentiometer 239
Function 239
4 Display 240
240
4 1 Time 241
Function 241
Value 241
4 2 Warning codes 242
Character 242
Error code 242
Warning! 242
4 2 1 Warning codes without registering 243
Code no 243
Type of error 243
Probable cause 243
Effect on the truck 243
4 2 2 Warning codes with registering 245
Code no 245
Type of error 245
Code no 245
Type of error 245
4 3 Error codes 246
Caracter 246
Error code 246
247
247
247
WARNING 247
! 247
4 3 1 Error codes with registering 248
Code no 248
Type of error 248
Probable cause 248
5 Running time 249
Caracter 249
Time 249
6 Steering potentiometer (STEERPOT) 250
7 Parameters 251
7 1 Programming parameters 251
Note! 251
No 251
Parameter type 251
Unit 251
Min/ Max 251
Std value 251
Remarks 251
Electronic card 253
Valid from serial number: 253
T-code 253
Model 253
Serial No 253
Notes 253
1 Electronic card 149167 version -003 and -004 253
1 1 General 253
2 Connections and voltage on A2 254
2 1 Connector no 1, display 254
Terminal number 254
LED no 254
Connection 254
Active 254
Function 254
2 2 Connector no 2, cabin 255
Terminal number 255
LED no 255
Connection 255
Active 255
Function 255
2 3 Connector no 3, height , speed and aisle indication 256
Terminal number 256
LED no 256
Connection 256
Active 256
Function 256
2 4 Connector no 4, drive and steer signals 257
Terminal number 257
LED no 257
Connection 257
Active 257
Function 257
2 5 Connector no 5, wire guidance option 258
Terminal number 258
LED no 258
Connection 258
Active 258
Function 258
2 6 Connector no 6, potentiometer circuits, voltage supply 259
Terminal number 259
LED no 259
Connection 259
Active 259
Function 259
2 7 Connector no 7, brake, valves, contactors 260
Terminal number 260
LED no 260
Connection 260
Active 260
Function 260
2 8 Connector no 8, power supply steering 260
Terminal number 260
LED no 260
Connection 260
Active 260
Function 260
3 LED’s, switches, potentiometer 261
LED 261
Colour 261
Function 261
Switch 261
Function 261
Potentiometer 261
Function 261
4 Display 262
262
4 1 Time 263
Function 263
Value 263
4 2 Warning codes/Error codes 263
WARNING! 263
4 2 1 Warning codes 263
Character 263
Warning code 263
4 2 2 Error codes 264
264
264
264
4 3 Parameters 264
4 4 Running time 265
4 4 1 Display the running meter reading and fork height 265
Caracter 265
Time 265
5 Warning codes / Error codes 265
WARNING 265
! 265
5 1 Warning codes without registering 266
Code 266
11 266
Code 266
12 266
Code 267
13 267
Code 267
14 267
Code 268
15 268
Code 268
16 268
Code 269
17 269
Code 269
18 269
Code 270
21 270
Code 270
22 270
Code 271
23 271
Code 271
25 271
Code 272
26 272
Code 272
27 272
Code 273
30 273
Code 273
31 273
Code 274
32 274
5 2 Warning codes with registering 274
Code 274
50 274
Code 275
51 275
Code 275
52 275
Code 276
53 276
Code 276
54 276
Code 277
55 277
Code 277
57 277
Code 278
58 278
Code 278
59 278
Code 279
60 279
Code 279
61 279
5 3 Error codes with registering 280
Code 280
100 280
Code 280
110 280
Code 281
111 281
Code 281
112 281
Code 282
113 282
Code 282
114 282
Code 283
115 283
Code 283
120 283
Code 284
121 284
Code 284
122 284
Code 285
123 285
Code 285
125 285
Code 286
126 286
Code 286
127 286
Code 287
131 287
Code 287
132 287
Code 288
133 288
Code 288
140 288
Code 289
141 289
6 Steering potentiometer (STEERPOT) 290
7 Parameters 291
7 1 Programming parameters 291
Note! 291
No 292
Parameter type 292
Unit 292
Min/ Max 292
Std value 292
Remarks 292
Electronic card 295
Valid from serial number: 295
T-code 295
Model 295
Serial No 295
Notes 295
1 Electronic card 149167 version – 005, 006 and 007 295
1 1 General 295
2 Connections and voltage on A2 296
2 1 Connector no 1, display 296
Terminal number 296
LED no 296
Connection 296
Active 296
Function 296
2 2 Connector no 2, cabin 296
Terminal number 296
LED no 296
Connection 296
Active 296
Function 296
2 3 Connector no 3, height , speed and aisle indication 297
Terminal number 297
LED no 297
Connection 297
Active 297
Function 297
2 4 Connector no 4, drive and steer signals 297
Terminal number 297
LED no 297
Connection 297
Active 297
Function 297
2 5 Connector no 5, wire guidance option 298
Terminal number 298
LED no 298
Connection 298
Active 298
Function 298
2 6 Connector no 6, potentiometer circuits, voltage supply 298
Terminal number 298
LED no 298
Connection 298
Active 298
Function 298
2 7 Connector no 7, brake, valves, contactors 299
Terminal number 299
LED no 299
Connection 299
Active 299
Function 299
2 8 Connector no 8, power supply steering 299
Terminal number 299
LED no 299
Connection 299
Active 299
Function 299
3 LED’s, switches, potentiometer 300
LED 300
Colour 300
Function 300
Switch 300
Function 300
Potentiometer 300
Function 300
4 Display 301
301
4 1 Time 302
Function 302
Value 302
4 2 Warning codes/Error codes 302
WARNING! 302
4 2 1 Warning codes 302
Character 302
Warning code 302
4 2 2 Error codes 303
303
303
303
4 3 Parameters 303
4 4 Running time 304
4 4 1 Display the running meter reading and fork height 304
Caracter 304
Time 304
5 Warning codes / Error codes 305
WARNING 305
5 1 Warning codes without registering 305
Code 305
11 305
Code 305
12 305
1 Check whether the cables 27 and 140 supply power to U10 Note! Inspect the flexible lead connectors X14 and X30 Check whether the cables 52 and 53, between U10 and A2, are intact 306
2 If the lifting speed is slow or lifting does not operate, error code 12 is generated Check whether the emergency-lowering valve is closed Inspect the hydraulic system 306
3 Replace the height sensor 306
4 If the measures above do not rectify the problem, then replace the A2 electronic card 306
Code 307
13 307
1 Check whether the magneto switch S104 is correctly installed 307
2 Check whether the magnet is correctly installed 307
3 Check whether the cables 22 and 54 are intact Note! Inspect the flexible lead connectors X14 and X30 307
4 If the measures above do not rectify the problem, then replace the A2 electronic card 307
Code 308
14 308
Code 308
15 308
1 Check whether the cables 27 and 140 and the connector X32 supply voltage to U11 Check whether the cables 55 and 56 and the connector X32, between U11 and A2, are intact 309
2 Replace the speed sensor U11 309
3 If the measures above do not rectify the problem, then replace the A2 electronic card 309
Code 310
17 310
1 Verify that none of the lifting chains is slack or broken Tension/replace the lifting chain 311
2 Inspect the adjustment of the micro-switches S81 and S82 311
3 Inspect the operation of the micro-switches S81 and S82 311
4 Inspect the cables 22, 111 and 51 Note! Inspect the flexible lead connectors X15, X16, X18, X19 and X27 311
5 If the measures above do not rectify the problem, then replace the A2 electronic card 311
Code 312
18 312
1 The A2 electronic card features an on-board battery that will supply power for many years When the battery is exhausted, the A2 electronic card must be replaced 312
Code 312
19 312
1 Reprogramme the customer-specific parameters 312
2 Om ovanstående inte hjälper, byt A2-kortet 312
Code 313
21 313
1 Verify that the accelerator control returns to the neutral position when not actuated 313
2 Check whether the potentiometer R1 is intact 313
3 Inspect the cables 96, 66 and 97 as well as the flexible lead connectors X16, X17, X19, X20, X21, X22 and X28 between R1 and the A2 electronic card 313
4 If the measures above do not rectify the problem, then replace the A2 electronic card 313
Code 314
22 314
1 Check whether the potentiometer R2 is intact 314
2 Inspect the cables 98, 69 and 99 as well as the flexible lead connector X13, between R2 and the A2 electronic card 314
3 If the measures above do not rectify the problem, then replace the A2 electronic card 314
Code 315
23 315
1 Check whether the operator is operating the truck incorrectly 315
2 Inspect the power supply cables 22 and 40 as well as the flexible lead connectors X15, X18, X21, X22 and X26 Inspect cable 41 as well as the flexible lead connectors X15, X18, X21, X22 and X26 between S101 and A2 315
3 Replace the dead man’s handle S101 315
4 If the measures above do not rectify the problem, then replace the A2 electronic card 315
Code 316
25 316
1 Press the SELECT button on the A2 electronic card to advance to the warning and error code register 316
Code 316
26 316
1 Press the SELECT button on the A2 electronic card to advance to the warning and error code register 316
Code 317
27 317
1 Inspect the measuring cables 70, 71 and 72, the battery cable connections and the A2 electronic card 317
2 Check whether the measuring cables 70, 71 and 72 are intact 317
3 Verify that the battery is OK 317
4 If the measures above do not rectify the problem, then replace the A2 electronic card 317
Code 318
30 318
1 Verify that nothing, which can affect the dead man’s handle, is stuck to the dead man’s handle 319
2 Inspect the power supply cables 22 and 40 as well as the flexible lead connectors X15, X18, X21, X22 and X26 Inspect cable 41 as well as the flexible lead connectors X15, X18, X21, X22 and X26 between S101 and A2 319
3 Replace the dead man’s handle S101 319
4 If the measures above do not rectify the problem, then replace the A2 electronic card 319
Code 320
31 320
1 Kontrollera att inget som kan aktivera dödmansfunktionen sitter fast på dödmansknappen 321
2 Inspect the cable 22 as well as the flexible lead connectors X15, X18, X21 and X22 to S101 Inspect the cable 42 as well as the flexible lead connectors X15, X18, X21 and X22 to A2 321
3 Replace the micro-switch in the dead man’s handle S100 321
4 If the measures above do not rectify the problem, then replace the A2 electronic card 321
Code 322
32 322
1 Inspect the cable 22 to S109 and the cable 50 to A2 Note! Inspect the flexible lead connectors X15, X16, X18, X19, X21 and X22 322
2 Replace the micro-switch S109 322
3 If the measures above do not rectify the problem, then replace the A2 electronic card 322
5 2 Warning codes with registering 323
Code 323
53 323
1 Inspect the cable 40 to Y41 and the cable 93 to A2 323
2 Measure the Ohm resistance in the coil at Y41 It should be approx 20 Ohms 323
3 If the measures above do not rectify the problem, then replace the A2 electronic card 323
Code 324
54 324
1 Inspect the cable 40 to Y30 and the cable 87 to A2 324
2 Measure the Ohm resistance in the coil at Y30 It should be approx 20 Ohms 324
3 If the measures above do not rectify the problem, then replace the A2 electronic card 324
Code 325
55 325
1 Inspect the cable 40 to K30 and the cable 95 to A2 325
2 Measure the Ohm resistance in the coil at K30 It should be approx 20 Ohms 325
3 If the measures above do not rectify the problem, then replace the A2 electronic card 325
Code 326
57 326
1 Inspect the cable 40 to K11and the cable 91 to A2 326
2 Measure the Ohm resistance in the coil at K11 It should be approx 20 Ohms 326
3 If the measures above do not rectify the problem, then replace the A2 electronic card 326
Code 327
58 327
1 Inspect the cable 40 to K13 and the cable 92 to A2 327
2 Measure the Ohm resistance in the coil at K13 It should be approx 30 Ohms 327
3 If the measures above do not rectify the problem, then replace the A2 electronic card 327
Code 328
59 328
‘ 328
1 Inspect the cable 82 between A2/509 and A4/ X23:6 328
2 Replace the A4 electronic card 328
3 If the measures above do not rectify the problem, then replace the A2 electronic card 328
Code 329
60 329
1 Verify that the indicator H2 is intact At OMC, the indicator has been replaced by the resistor R3 (470 Ohms, 5 Watts) 329
2 Inspect the cable 40 to H2/R3 and the cable 86 to A2 329
3 If the measures above do not rectify the problem, then replace the A2 electronic card 329
Code 330
61 330
1 Check whether the cables 96, 66 and 97, between the potentiometer R1 and the A2 electronic card, are intact Note! Inspect the flexible lead connectors X16, X17, X20, X21/ 22 and X28 330
2 Replace the potentiometer R1 330
3 If the measures above do not rectify the problem, then replace the A2 electronic card 330
5 3 Error codes with registering 331
Code 331
100 331
1 Inspect the cable 40 to Y10 and the cable 85 to A2 Note! Inspect the flexible lead connector X34 331
2 Measure the Ohm resistance in the coil at Y10 It should be approx 10 Ohms 331
3 If the measures above do not rectify the problem, then replace the A2 electronic card 331
Code 332
102 332
1 Inspect the voltage on output 7 of A1 If it is 24 volts, then inspect the cables 60 to K10 and A2/309 332
2 If it is 0 volt, the safety relay circuit has been triggered Inspect the motor circuit of M1, e g , the connector points of K11 and 13, the carbon brushes and the carbon brush bridge in M1 as well as the motor cabling 332
3 If the measures above do not rectify the problem, then replace the A1 electronic card 332
Code 333
110 333
1 Check whether the cable 74 between A2 and A4 is intact 333
2 Inspect/readjust the wire guidance system 333
3 Replace the A4 electronic card and adjust the wire guidance system 333
4 If the measures above do not rectify the problem, then replace the A2 electronic card 333
Code 334
111 334
1 Inspect S120 and verify that the operator understands how it operates 335
2 Verify that the magneto switch S79 or S80 has not closed when the truck is outside the narrow aisle 335
3 Inspect the cable 22 to S120 and the cable 49 to the A2 electronic card Note! Inspect the flexible lead connectors X15, X16, X18, X19, X21 and X22 Also inspect the strapping if the truck is not prepared for wire guidance 335
4 Inspect S120 335
5 If the measures above do not rectify the problem, then replace the A2 electronic card 335
Code 336
112 336
1 Inspect the wire generator 337
2 Inspect the fuse F on the A4 electronic card 337
3 Inspect/readjust the wire guidance system 337
4 Check whether the cable 75 between A2 and A4 is intact 337
5 Replace the A4 electronic card 337
6 If the measures above do not rectify the problem, then replace the A2 electronic card 337
Code 338
113 338
1 Check that the wire generator is operating 339
2 Check that the cable has been correctly set in the floor It should not be buried too deep or shallow Refer to the chapter 4200, section 9 1 1 Checking the reference signal 339
3 Inspect the fuse F on the A4 electronic card 339
4 Check whether the cables between the antennas and the A4 electronic card are intact 339
5 Inspect/readjust the wire guidance system 339
6 If the measures above do not rectify the problem, then replace the A2 electronic card 339
Code 340
114 340
341
1 Inspect/readjust the wire guidance system 341
2 Inspect the potentiometer R2 341
3 Inspect the cables 98, 69 and 99 as well as the flexible lead connector X13 341
4 Check that the cable has been correctly set in the floor It should not be buried too deep or shallow 341
5 If the measures above do not rectify the problem, then replace the A2 electronic card 341
Code 342
115 342
1 Verify that the sensor and/or mountings have not been destroyed through mechanical stress 343
2 Verify that the electric operation of the sensors S3 and S4 is correct by subjecting them to a magnet 343
3 Inspect the cables 22 and 126 to the sensors S3 and S4 Note! Inspect the flexible lead connectors X40, X41 and X42 343
4 If the measures above do not rectify the problem, then replace the A2 electronic card 343
Code 344
120 344
1 Restart the truck 344
2 Replace the A2 electronic card 344
Code 344
121 344
1 Restart the truck 345
2 Does LED 801 light? If not, inspect the fuse F51, 20A 345
3 If the measures above do not rectify the problem, then replace the A2 electronic card 345
Code 346
122 346
1 Check that the fans are operating 347
2 Check that the steering has no mechanical seizure 347
3 Inspect the cables 101 and 102 as well as the flexible lead connector X12 to M6 347
4 Inspect the steering motor M6 347
5 If the measures above do not rectify the problem, then replace the A2 electronic card 347
Code 348
123 348
1 Inspect the cables 101 and 102 as well as the flexible lead connector to M6 349
2 Check whether the carbons in the steering motor M6 are OK 349
3 Verify that the steering motor is OK 349
4 If the measures above do not rectify the problem, then replace the A2 electronic card 349
Code 350
125 350
1 Inspect the cables 67 and 68 as well as the flexible lead connectors X17, X21 and X27 to U1 351
2 Inspect the tachometer carbon brushes 351
3 Inspect the tachometer 351
4 If the measures above do not rectify the problem, then replace the A2 electronic card 351
Code 352
126 352
1 Inspect the fuse F51 and 20A as well as the cables 1 and 23 to input 801 on A2 353
2 Inspect the cables 101 and 102 as well as the flexible lead connector X12 to M6 353
3 Check whether the carbons in the steering motor M6 are OK 353
4 Verify that the steering motor is OK 353
5 If the measures above do not rectify the problem, then replace the A2 electronic card 353
Code 354
127 354
1 Restart the truck 354
2 Replace the A2 electronic card 354
Code 354
130 354
1 Restart the truck 354
2 Replace the A2 electronic card 354
Code 354
131 354
1 Inspect the fuse F51 Restart the truck 354
2 Replace the A2 electronic card 354
Code 355
132 355
1 Inspect the fuse F53 355
2 Replace the A2 electronic card 355
Code 355
133 355
1 Restart the truck Replace the A2 electronic card 355
Code 355
140 355
1 Restart the truck Change the value of a parameter and then restart Do not forget to reset the parameter after the truck has started 355
2 If the measures above do not rectify the problem, then replace the A2 electronic card 355
Code 356
141 356
1 Restart the truck 356
2 Replace the A2 electronic card 356
6 Steering potentiometer (STEERPOT) 356
7 Parameters 357
7 1 Programming parameters 357
Note! 357
No 357
Parameter type 357
Unit 357
Min/ Max 357
Std value 357
Remarks 357
Hydraulic system 361
Valid from machine number: 287595AA- 361
1 General 361
2 Hydraulic diagram 362
2 1 Symbols 363
Symbol 363
Description 363
Symbol 363
Description 363
2 2 Component description 364
3 Description of function 365
3 1 Cabin lift 365
3 2 Cabin lowering 365
3 3 Fork lift 365
3 4 Fork lowering 366
3 5 Hydraulic data 366
3 5 1 Operating pressure 366
3 5 2 Relief pressure 366
3 5 3 Pump flow 366
Hydraulic system 367
Valid from serial number: 367
T-code 367
Model 367
Serial number 367
Notes 367
1 General 367
2 Hydraulic diagram 368
2 1 Symbols 369
Symbol 369
Description 369
Symbol 369
Description 369
2 2 Component description 370
3 Operating description 371
3 1 Cage lifting 371
3 2 Cage lowering 371
3 3 Fork lift 371
3 4 Fork lowering 372
3 5 Hydraulic data 372
3 5 1 Working pressure 372
3 5 2 Safety pressure 372
3 5 3 Pump flow 372
3 6 Valve assembly 373
Valve block 375
Valid from machine number: 287595AA- 375
1 General 375
1 1 Komponents and descriptions 376
J 376
2 Valves 377
2 1 By-pass valveY30 377
2 2 Directional valves Y34, Y41, Y69 and Y70 378
2 3 Pressure relief valve 378
Warning 378
2 3 1 Adjustment 379
2 4 Emergency lowering valve 379
Main lift chain system 381
Valid from serial number: 381
T- code 381
Model 381
Machine no 381
Remarks 381
1 General 381
2 Checking the chain setting 381
3 Chain inspection 382
3 1 Noise 382
3 2 Surface rust 382
3 3 Rusty links 382
3 4 Stiff links 382
3 5 Bolt rotation 383
383
3 6 Loose bolts 383
3 7 Outline wear 384
3 8 Stretching 385
Type of chain 385
Nominal disc height H2 ( mm) 385
Minimum disc height H3 (mm) 385
Pitch P (mm) 385
Nominal chain length for 20/30/ 50 discs (mm) 385
Maximum permitted chain length for 20/30/50 discs (mm) 385
3 9 Damage 385
3 10 Damaged discs 386
3 11 Damaged bolts 386
3 12 Dirty chain 386
4 Cleaning 386
NOTE! 386
5 Lubrication 387
NOTE! 387
Ambient temperature 387
Viscosity class 387
Recommended Products* 387
NOTE! 387
Lift cylinder 389
Valid from serial number: 389
T-code 389
Model 389
Serial number 389
Notes 389
1 General 389
2 Tools 389
Tool number 389
Note 389
3 Lift cylinder 390
3 1 Dismantling/assembling the cylinder from/in the mast 390
3 1 1 Dismantling 390
3 1 2 Assembling 391
NOTE! 391
Warning! 391
3 2 Dismantling the cylinder 392
3 3 Dismantling the piston rod seals, guide ring, guide ring holder and locking ring from the lift cylinder 392
3 4 Assembling the locking ring, piston rod seal, guide ring and guide ring holder in the lift cylinder 393
3 5 Dismantling and assembling the lowering brake valve 393
3 6 Assembling the cylinder 393
NOTE! 393
Extra equipment – 9500 395
1 Dry powder extinguisher 395
In the event of fire, the powder extinguisher should be employed as follows: 395
1 Remove the safety catch 395
2 Aim the nozzle at the base of the flames 395
3 Press the handle down 395
1 1 Regular checks of the powder extinguisher – truck driver 396
1 2 Inspection of powder extinguisher in service inspection of the truck 396
BSM0642-040 pdf 0
1- Modification of the OME truck 5
1 1 Software package update – 5710 5
Parameter 8 5
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