BT OSE100 Operator'S Manual Download Page 1

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BT Products AB
S-595 81 MJÖLBY SWEDEN

Operator’s Manual

WARNING!

Do not use the truck before

first reading through the

OPERATOR’S MANUAL.

NOTE!

Keep for future reference.

OSE100

Valid from serial number: 744051-

Order number: 222714-040
Issued: 2005-03-0

ITS

Summary of Contents for OSE100

Page 1: ...Products AB S 595 81 MJÖLBY SWEDEN Operator s Manual en WARNING Do not use the truck before first reading through the OPERATOR S MANUAL NOTE Keep for future reference OSE100 Valid from serial number 744051 Order number 222714 040 Issued 2005 03 08 ITS ...

Page 2: ...safety regulations and how to keep the truck in a safe condition by following daily service routines Only personnel who have been trained on the operation of this type of truck are permitted to use this truck It is your employer s responsibility to ensure that you have suffi cient knowledge of how to use your truck safely Do not hesitate to contact your supervisor if you feel the slightest uncerta...

Page 3: ...ication plate 18 Modification plate 18 Capacity plate 19 Main components 20 Controls and instruments 22 Display and programming 29 Warning codes 31 Error codes 32 Accessories 34 Driving 35 Starting the truck 35 Braking 36 Deceleration 36 Steering 36 Parking the truck 36 Transporting loads 37 Order picking 37 Collecting a load 38 Depositing a load 38 Battery 39 Fitting the battery and battery lock ...

Page 4: ...hart 55 Oil and grease specification 55 Transporting and storing the truck 57 The truck s dimensions and weight as standard 57 Lifting the truck 58 Towing and transporting a defective truck 59 Storing the truck 59 Starting after a period of disuse 59 Recycling discarding 60 Discarding the battery 60 Scrapping the truck 60 ...

Page 5: ...cidents DANGER Warns that an accident will occur if you do not follow the instructions The consequences are serious personal injury or possibly death and or extremely large material damage WARNING Warns that accidents can occur if the instructions are not fol lowed The consequences are serious personal injury or possibly death and or large material damage CAUTION Warns that accidents can occur if ...

Page 6: ...e used in situations where naked flames are prohibited a serious accident can occur GENERAL PROHIBITION If the prohibition is ignored a serious accident can occur Ordinance symbols SAFETY SHOES When the directive for safety shoes is given safety shoes must always be worn to avoid personal injury PROTECTIVE GLASSES When the directive for protective glasses is given protective glasses must always be...

Page 7: ...rnal order picking in a warehouse when picking from floor level and from the first and second level of warehouse shelving applies to standard design trucks If the truck is to be used in cold storage rooms the truck must be especially built for this type of use It is not permitted to use the truck for purposes that it has not been designed and produced for e g the following applications In areas wh...

Page 8: ... or damage to the truck It is prohibited for persons to be present in the area around the truck when there is a risk of personal injury e g areas that can be reached by falling goods lowering load handling devices or in the truck s manoeuvring area Driving and conduct while driving It is not permitted to stand on the pallet and or forks Always drive the truck from a specified operator position Alw...

Page 9: ...ner Particular care should be exercised when handling long and high loads Parking the truck Always park the truck with the load carrier and the operator cabin fully lowered The brake is automatically applied if you do not activate the deadman s handle Always park in designated areas if available Never leave the truck parked with the current on Never park the truck on an incline Never park the truc...

Page 10: ...revent faults and accidents see the Maintenance chart in chapter Mainte nance Only qualified and BT trained personnel are permitted to maintain adjust or repair the truck All replacement parts shall be BT approved spare parts Modifications or conversions to the truck that affect the safe use or function are not permitted ...

Page 11: ...Safety regulations BT Industries AB 222714 040 11 ...

Page 12: ...s located on the truck 1 Modification plate 2 Travel direction 3 Hydraulic control Lift 4 Hydraulic control Lower 5 Signal Horn 6 Identification plate 7 Serial number 8 Hydraulic oil filling 9 Lifting points 10 Passengers prohibited 11 Capacity plate 12 Do not walk under elevated load 13 Do not stand on the forks 14 Hydraulic lever Lifting the forks 15 Hydraulic lever Lowering the forks ...

Page 13: ...Warning and information plates and symbols BT Industries AB 222714 040 13 1 4 5 6 7 8 9 10 11 12 13 2 3 14 15 ...

Page 14: ...d in both direc tions if the platform is lifted higher than 500 mm The forks are lifted by using a powerful and compact hydraulic unit that is automatically shut off when the forks reach their high est 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 Note that some of the truck models describe...

Page 15: ...ation plate Truck type OSE100 Rated capacity kg 1000 Lift height mm platform height 680 mm 1100 Instep height mm 180 Travel speed forward without load km h 12 Travel speed forward with rated load km h 8 Travel speed in fork direction without load km h 10 5 Travel speed in fork direction with rated load km h 6 Weight without battery 1150 mm forks kg 1162 Turning radius Wa mm 1490 Continuous equival...

Page 16: ...he illustration shows external dimensions for the truck in its standard design Dimensions OSE100 b1 Chassis mm 790 b5 Width across fork mm justerbar 300 750 Wa Turning radius mm 1540 l Fork length mm 800 1000 1150 h12 h20 h23 h3 h7 l20 h13 m2 l1 l2 y h1 h4 e b1 b5 Wa x L24 h9 ...

Page 17: ...471 x Back of fork to wheel centre mm 158 y Wheel base mm 1351 h1 Height of truck min mm 1550 h3 Lift movement mm 1020 h4 Height of truck max mm 2570 h7 Instep height mm 180 h9 Initial lift 780 h12 Platform height mm 1200 h13 Height of lowered fork mm 80 h20 Picking height mm 2800 h23 Total lift height mm 1880 m2 Floor clearance mid wheelbase mm 70 Dimensions OSE100 ...

Page 18: ... as non standard or if it has been modi fied after leaving the manufacturer The plate includes informa tion according to the table below Item Text Unit A MODEL B NO C RATED CAPACITY kg D WEIGHT WITHOUT BATTERY kg E BATTERY WEIGHT MAX MIN kg kg F BATTERY VOLTAGE V G BATTERY TYPE CLASS ACC TO UL583 Item Text A Modification plate B Type C Serial number D Place of manufacture E Place of manufacture F ...

Page 19: ...esentation of the truck BT Industries AB 222714 040 19 Capacity plate The illustration shows the capacity plate used on the truck Item Text Unit H NO I LIFT HEIGHT mm J ACTUAL CAPACITY kg K LOAD CENTRE mm ...

Page 20: ...ty battery voltage manufacturer and battery type only ASME 3 Cover Removable which provides good accessibility when servic ing 4 Driv wheel motor Central placement of the drive wheel and drive motor 5 Lifting points For the truck weight see the identification plate 6 Battery Recharging connector The battery is charged via the permanently fitted charging connector 7 Battery 24 V 8 Electrical steeri...

Page 21: ...Main components BT Industries AB 222714 040 21 2 6 7 9 8 5 10 5 3 11 4 ...

Page 22: ...ravel direction selector and speed control 2 Control for lifting and lowering the operator platform 3 Horn 4 Display 5 Keypad 6 Emergency switch off 7 Battery disconnector and battery connector 8 Steering unit and brake 9 Control for lifting and lowering the forks 1 2 3 4 5 1 2 3 7 8 9 ...

Page 23: ...ttons activate a microswitch to start the pump motor with lifting and to control the solenoid valve when lower ing The lowering speed of the platform is controlled by a flow valve The diagram illustrates the controls seen from the operator s position Lift the platform by pressing A and lower by pressing B Note The forks cannot be lowered when the truck has been switched off Pallet to ground protec...

Page 24: ...lit the running time can be read off from the numerical field Parameter control C When checking the set parameters the indicator window C will light The parameter list can then be read off from the numerical field Battery indicator D When this symbol is lit the battery capacity in is shown in the numerical field as set out below 100 Fully charged battery 0 Discharged battery The symbol starts to f...

Page 25: ...keyboard for logging in using a PIN code Start the truck by entering your PIN code and then press I If you state the PIN code incorrectly a red LED comes on Switch off the truck by pressing 0 It is the four figures entered last that apply as the PIN code This means that with incorrect entry you only need to start from the first number in the PIN code Emergency switch off 6 The truck is equipped wi...

Page 26: ...gency situation risk of an accident Welding work NOTE The battery can be damaged When welding using an electric power source the welding cur rent can enter the battery It is necessary to disconnect the battery To charge the battery pull out the battery disconnector and con nect the charger connector to the truck s permanent battery con nector After charging replace the battery disconnector ...

Page 27: ... brake reversing brake Will be activated when the operator moves the speed control in the opposite driving direction When reversing the speed in this way the truck s driving system is being used most efficiently The mechanical brake is activated when the steering unit is raised B2 which is the position it should be when the truck is not in use For common order picking operations the steering unit ...

Page 28: ...to start the pump motor with lifting and to control the solenoid valve when lower ing The lowering speed of the forks is controlled by a flow valve The diagram illustrates the controls seen from the operator s position Lift the forks by pressing A and lower by pressing B Note The forks cannot be lowered when the truck has been switched off C D ...

Page 29: ...ay Step between the different functions above by turning the speed control Programming To re programme the operator specific parameters if the change is permitted carry out the following NOTE Truck handling The handling characteristics of the truck will change if you change any of the truck specific parameters Do not change any parameters without possessing the necessary know how Truck with keyboa...

Page 30: ... the nearest 5th value 3 Acceleration 10 100 80 10 low acceleration 100 full acceleration To the nearest 5th value 4 Automatic speed reduction 40 100 80 Braking power when the speed control is returned to the neutral position 40 low speed reduction 100 high speed reduction To the nearest 5th value 5 Speed with the plat form raised more than 0 5 m 0 100 100 Max speed with the platform raised more t...

Page 31: ...isplayed Code No Error type Effect on the truck C19 The truck s parameter values are not OK standard values entered Truck driving characteristics changed C20 Speed control not in neutral at start Truck cannot be driven C26 No communication with the steer servo when starting the truck Truck cannot be driven C28 Emergency switch off has been activated The truck is stopped C29 Time for service Cause ...

Page 32: ... truck is stopped E106 Too high current on digital output or field current too high The truck is stopped E107 Main contactor not turned on The truck is stopped E108 Contactor welded The truck is stopped E110 System error The truck is stopped E113 Steer servo unspecified error The truck is stopped E114 E134 Steer servo error The truck is stopped E135 Potentiometer must be calibrated use parameter 3...

Page 33: ... stopped E160 Faulty safety reversing function The truck is stopped E200 Shunt winding open The truck is stopped E201 Faulty M minus transistor unit The truck is stopped E202 Faulty current shunt in transistor unit The truck is stopped E214 CAN time out transistor unit The truck is stopped Code No Error type Effect on the truck ...

Page 34: ... enable easy replacement of the battery since it can be pulled out sideways In the standard configuration the battery rests on a level surface in which case it needs to be lifted out by crane for replacement Battery replacement table This table has rollers and can accommodate two batteries for swift battery replacement from the side Writing board The board features a paper clip to keep A4 size she...

Page 35: ...s activated The maximum travel speed of 12 km h can only be achieved when the operator stands on the ride on platform Always drive with great care when cornering Always reduce speed when approaching a corner WARNING Loss of function Safety risk Always check the safety functions listed below before begin ning the day s work That the speed control functions in both directions That the horn functions...

Page 36: ...tomatically reduced as soon as the speed control is released and returns to the neutral position Steering Steer by using the steering unit If the truck gets caught against an obstacle do not use more force to steer than used when steering the truck under normal conditions Try to free yourself by carefully driving forwards and backwards at the same time as you turn the steering unit WARNING Risk of...

Page 37: ...truding loads The load can collide with personnel fixed or moving objects A truck with a protruding load requires more room when cor nering Drive the truck with the load trailing when the load impairs the line of vision If necessary when the operator s vision is impaired ask someone to direct operations so that transportation can take place without the risk of causing personal injury or material d...

Page 38: ...ing off of the pallet Never lift a load if the truck is moving Start slowly and then increase the speed Depositing a load Stop the truck and lower the forks Do not lower the forks until the truck has come to a standstill Leave the load so that it does not block e g truck aisles or emergency exits CAUTION Lost stability Lowering a loaded pallet when the truck is still moving can result in the load ...

Page 39: ...e that the battery cables are correctly connected to the battery WARNING Risk of short circuiting An incorrectly connected battery can cause short circuiting Check that the polarity is correct Compare the markings on the cables with those on the battery s poles The battery can be changed from either side as well as from above Replacing the battery Only replace the battery with a battery of the sam...

Page 40: ...nnect the intermediate cables and slide in the charged battery Lower the battery lock into position and make sure it is prop erly fastened Connect the battery connector to the battery Close the battery compartment cover Reset the emergency switch off WARNING Falling battery If the truck should overturn the battery can fall if the battery catches are not fastened Ensure the battery catches are fast...

Page 41: ...soap and water If the fluid has come into contact with the eyes wash the eyes immediately using an eye shower contact a doctor ALWAYS WEAR PROTECTIVE GLASSES AND PROTECTIVE GLOVES WHEN CHECKING THE BATTERY Before charging Park the truck in the assigned charging area Ensure nothing prevents ventilation above the battery Remove the emergency disconnector Make sure the battery charger is switched off...

Page 42: ...o disconnect from the charger Battery maintenance Carry out battery maintenance after recharging WARNING Corrosive acid The battery fluid contains sulphuric acid Fluid spilt on the skin should be rinsed off immediately Wash thoroughly with soap and water If the fluid has come into contact with the eyes wash the eyes immediately using an eye shower contact a doctor ALWAYS WEAR PROTECTIVE GLASSES AN...

Page 43: ...should not exceed 50 C Measure the density of the battery fluid using an acid tester Hold the acid tester absolutely vertical and extract sufficient fluid so that the hydrometer float moves freely Correct density values at different fluid temperatures for a fully charged battery Temperature C Density g cm3 15 1 31 0 1 30 15 1 29 30 1 28 45 1 27 ...

Page 44: ...Always report any faults or damage to the management with out delay Never use a truck that has faults Pos no Check points Action 1 Operating control Check its function forwards backwards 2 Hydraulic functions Check its function 3 Horn Check its function 4 Steering Check its function 5 Running time Carry out maintenance as set out in the table in chapter Maintenance 6 Platform Brake switch Check it...

Page 45: ...Daily service and function checks BT Industries AB 222714 040 45 1 2 3 4 1 2 3 5 6 7 8 9 10 11 12 13 12 11 ...

Page 46: ...Daily service and function checks BT Industries AB 222714 040 46 ...

Page 47: ...service clean Oil or water makes the floor slippery Never wear loose objects or jewellery when working on the truck The truck is equipped with a fan for cooling the electrical system The fan keeps running as long as the main contactor K 10 is activated Note the danger for finger or hand injuries WARNING Short circuiting Burns When working with the truck s electrical system short circuiting burns c...

Page 48: ...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 cur rent can enter the battery The battery should therefore be disconnected Remove at least 100 mm 4 of paint around the welding grinding area through sand blasting or the use o...

Page 49: ...g working procedures consult the Service Manual for the truck In addition to the maintenance points in the maintenance chart all service and repair work should be carried out by personnel with special training for this type of truck 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 ...

Page 50: ...ashing unit Clean the motor compartment using a well known degreasing agent diluted to a suitable concentration Rinse off loose grime using tepid water 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 Risk of short circuiting Electrical component...

Page 51: ...inks I 0380 3 Force grease into the lubricant nipples note 6 I 0380 4 Inspect the lift limiter switch I 0380 5 Inspect guide pin wear and apply grease note 6 I 0450 Frame mounted components 0450 0 Inspect the mounting bolts of the motor plate I 1700 Motors 1700 1 Inspect any play in the connectors I T1 I T 1700 2 Inspect the carbon brushes in the drive motor M 1700 3 Clean the drive motor C 1700 4...

Page 52: ...tch I I 5000 3 Inspect lift lower function of the forks I 5000 4 Inspect correct operation of the platform switch I I 5000 5 Inspect correct operation of the horn I I 5000 6 Inspect cable wear I 5000 7 Inspect correct operation of operator controls I I 5000 8 Inspect the error code log operating hours and all segments in the display panel I I 5110 Battery 5110 1 Inspect the electrolyte level 10 15...

Page 53: ...tips I 5400 4 Inspect contactor mobility I 6100 Hydraulic system 6100 1 Inspect hoses and couplings for leakage I 6100 2 Inspect hoses for wear I 6100 3 Inspect the tank I 6100 4 Replace the oil and clean the filter L5 L 7100 Mast 7100 1 Inspect the mounting of the lift cylinder I 7100 2 Lubricate lifting chains L 7100 3 Inspect the mounting bolts I 7100 4 Lubricate the mast rails at the steering ...

Page 54: ...Maintenance BT Industries AB 222714 040 54 2550 5000 5700 5000 5000 3500 5110 0000 0450 4110 5400 3100 5000 6100 1700 1700 1700 7100 7160 ...

Page 55: ...5 C 15 C A Grease BT 055 73100 tin BT 055 73040 spray BT 055 73100 tin BT 055 73040 spray Initial lift mast chains B Hydraulic oil ISO L HM32 ISO VG32 Hydraulic system C Transmission oil Hypoid oil SAE 80W 90 Hypoid oil SAE 75W Drive transmission D Grease See table below See table below Mast rollers profiles E Grease Grafloscon A G1 Klüber Grafloscon A G1 Klüber Gear ring Ambient temperature Visco...

Page 56: ...Maintenance BT Industries AB 222714 040 56 2550 6100 7100 7160 ...

Page 57: ...ruck The truck s dimensions and weight as standard NOTE the truck s dimensions and weight can vary with different accessories The truck s dimensions and weight OSE100 Length mm Fork length 1150 mm 2840 Width mm 790 Height mm 1550 Weight without battery kg 1294 Battery weight kg 465 620 Ah 350 530 ...

Page 58: ... lifted from the wrong lifting points Always lift the truck from the marked lifting points Lift from the truck s centre of gravity when using another fork lift truck Secure the truck to the lifting truck s forks Lift with the greatest of care WARNING Risk of overturning The truck can overturn if it is lifted incorrectly Always lift the truck secured to and with the centre of gravity between the li...

Page 59: ...ve the battery connector if you do not intend to use the truck for periods longer than one week Maintenance charge the battery every third month and check the fluid level Hydraulic system Change the oil in the hydraulic system when stored for peri ods longer than one year see the oil specification in the Lubrication chart in chapter Maintenance Drive unit Block up the truck s drive section to take...

Page 60: ...s posing recycling batteries Spent batteries shall be returned sent to the manufacturer of the battery or its representatives see the sign on the battery for dis posal recycling You can also return batteries to your local BT representative who will then take care of returning the battery to the manufacturer Scrapping the truck The truck consists of parts that contain recyclable metals and plastics...

Page 61: ...raulic system Oil tank Polythene Pump unit Steel and aluminium Hoses Rubber and steel Cylinders Cast iron and steel Electrical system Cables Copper cores with PVC sheaths Electronic board Reinforced glass fibre circuit board laminate Motors Steel and copper ...

Page 62: ...r information __________________________ Eriksson Lars V P Projects and Product Safety For deliveries to countries outside the European Union differences may occur with regard to requirements for documentation in the local language THE SWEDISH MACHINERY TESTING INSTITUTE Fyrisborgsgatan 3 S 754 50 Uppsala Telefon Telephone 46 18 56 15 00 Telefax 46 18 12 72 44 Modification no _____________________...

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