BT OSE100 Operator's Manual
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BT OSE100 Operator's Manual

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

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Summary of Contents for BT OSE100

  • Page 1 OPERATOR’S MANUAL. NOTE! Keep for future reference. Operator’s Manual OSE100 Valid from serial number: 744051- Order number: 222714-040 Issued: 2005-03-08 ITS Valid only for serial number: BT Products AB S-595 81 MJÖLBY SWEDEN © BT Industries AB...
  • Page 2 Always follow the warnings given in this Operator’s Manual and on the truck to avoid accidents and incidents from occurring. BT Products AB © BT Industries AB 222714-040...

  • Page 3: Table Of Contents

    Depositing a load ................38 Battery ....................39 Fitting the battery and battery lock ..........39 Replacing the battery ..............39 Charging the battery ............... 41 Battery maintenance ............... 42 Daily service and function checks ..........44 © BT Industries AB 222714-040...
  • Page 4 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 © BT Industries AB 222714-040...

  • Page 5: Safety Regulations

    CAUTION! Warns that accidents can occur if the instructions are not fol- lowed. The consequences are personal injury and/or material dam- age. NOTE! Marks the risk of a crash/breakdown if the instructions are not followed. © BT Industries AB 222714-040...
  • Page 6 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 worn to avoid personal injury. © BT Industries AB 222714-040...

  • Page 7: General Safety Regulations

    The truck may not be used if it has been repaired, modified or adjusted unless it has been checked and approved by personnel authorised by BT. Operating the truck The truck is designed and produced to be your tool for internal...
  • Page 8 • Always be prepared to stop if other personnel are in the work- ing area. • Keep a safe distance from all vehicles ahead. © BT Industries AB 222714-040...
  • Page 9 • Always wear protective glasses when working with the bat- tery. • Make sure the battery in the truck is of a weight that corre- sponds with the information on the truck’s identification plate. • Make sure the battery is secured in its compartment. © BT Industries AB 222714-040...
  • Page 10 Maintenance instructions should be followed to prevent 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.
  • Page 11 Safety regulations © BT Industries AB 222714-040...

  • Page 12: Warning And Information Plates And Symbols

    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 © BT Industries AB 222714-040...
  • Page 13 Warning and information plates and symbols © BT Industries AB 222714-040...

  • Page 14: Presentation Of The Truck

    - In areas that contain dust or gases which can cause fires or explosions - As a tow-truck for trailers - To tow other trucks - To transport/lift passengers - To drive on gravel or grass © BT Industries AB 222714-040...

  • Page 15: Truck Data

    Tractothan * Deviations may occur on trucks adapted to specific application; the correct value can be found on the truck’s identification plate. In such cases the truck is also fitted with a modification plate. © BT Industries AB 222714-040...

  • Page 16: Truck Dimensions

    The illustration shows external dimensions for the truck in its standard design. Dimensions OSE100 Chassis, mm Width across fork, mm justerbar 300 > 750 Turning radius, mm 1540 l Fork length, mm 800 / 1000 / 1150 © BT Industries AB 222714-040...
  • Page 17 1020 Height of truck, max., mm 2570 Instep height, mm Initial lift Platform height, mm 1200 Height of lowered fork, mm Picking height, mm 2800 Total lift height, mm 1880 Floor clearance mid wheelbase, mm © BT Industries AB 222714-040...

  • Page 18: Identification Plate

    The plate includes informa- tion according to the table below. Item Text Modification plate Type Serial number Place of manufacture Place of manufacture Modification number Date © BT Industries AB 222714-040...

  • Page 19: Capacity Plate

    Presentation of the truck Capacity plate The illustration shows the capacity plate used on the truck. Item Text Unit LIFT HEIGHT ACTUAL CAPACITY LOAD CENTRE © BT Industries AB 222714-040...

  • Page 20: Main Components

    9. Emergency switch off: Press the emergency switch to shut off the power. 10. Initial lift mast: The forks can be lifted/lowered separately. 11. Hydraulic unit: Pump motor, pump and oil tank are integrated in a compact unit. © BT Industries AB 222714-040...
  • Page 21 Main components © BT Industries AB 222714-040...

  • Page 22: Controls And Instruments

    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 © BT Industries AB 222714-040...
  • Page 23 +/- 150 mm from the floor. From this position, the forks can only be lowered further by releasing the lowering button and then pressing it again. Horn (3) The horn sounds as long as the button is pressed. © BT Industries AB 222714-040...
  • Page 24 The truck can still be driven so that it can be taken to the charging station. Error indicator (E) When this symbol flashes an error code is displayed in the numerical field. For the significance of the code see table “Error codes” on page 32. © BT Industries AB 222714-040...
  • Page 25 Press in the emergency switch off to cut the power supply in the event of: - An accident. - Emergency situation, risk of an accident. - With welding work. • Release the emergency switch off by turning the knob in the direction of the arrow. © BT Industries AB 222714-040...
  • Page 26 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. © BT Industries AB 222714-040...
  • Page 27 If the operator leaves the truck while driving, the truck will be stopped by means of the motor brake and after that the mechan- ical brake will be applied. The braking power for leaving the truck while driving can be adjusted using parameter 7 “Brake”. © BT Industries AB 222714-040...
  • Page 28 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. © BT Industries AB 222714-040...

  • Page 29: Display And Programming

    • To locate the required parameter turn the speed control until the display shows the correct parameter number. • Press the horn button once to change the value. The parameter symbol on the display starts flashing. • Change the value by turning the speed control. © BT Industries AB 222714-040...
  • Page 30 40/100 40: low speed the truck walking by 100: full speed the side Max. speed 6 km/h To the nearest 5th value Brake 60/100 Brake power when the opera- tor leaves the platform while driving © BT Industries AB 222714-040...

  • Page 31: Warning Codes

    Cause of error is shown on the display Battery voltage too low Cause of error is shown on the display Battery voltage too high Cause of error is shown on the display High temperature in transistor Driving performance reduced panel © BT Industries AB 222714-040...

  • Page 32: Error Codes

    Communication error The truck is stopped E140 Check sum error The truck is stopped E141 Faulty software The truck is stopped E150 Communication fault The truck is stopped E151 Communication fault The truck is stopped © BT Industries AB 222714-040...
  • Page 33 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 © BT Industries AB 222714-040...

  • Page 34: Accessories

    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 sheets in place. © BT Industries AB 222714-040...

  • Page 35: Driving

    - That the hydraulic functions are operational. • Start gently by accelerating slowly until you reach the desired speed. WARNING! Dangerous driving. Accidents can occur. Always drive with care, good judgement and responsibility as set out in the general safety regulations. © BT Industries AB 222714-040...

  • Page 36: Braking

    • Raise the steering unit; the parking brake is activated and the brakes are applied. • Lower the forks fully to the floor. • Turn off the truck. WARNING! Unauthorised use. Accidents can happen. Always remove the ignition key when the truck is left unat- tended. © BT Industries AB 222714-040...

  • Page 37: Transporting Loads

    There is a risk of injury due to crushing with unintentional low- ering of the forks or a fault with the hydraulic system. Never stand with your feet under the forks/platform. • Ensure the load is secured on a pallet. © BT Industries AB 222714-040...

  • Page 38: Collecting A Load

    Lowering a loaded pallet when the truck is still moving can result in the load falling off the pallet. Never lower a load if the truck is moving. • Start slowly and then increase the speed. © BT Industries AB 222714-040...

  • Page 39: Battery

    Battery sizes from 465 Ah to 620 Ah are available for the truck if the battery is manufactured according to BT Products original drawings. Fitting the battery and battery lock •...
  • Page 40 Ensure the battery catches are fastened. WARNING! Falling battery. When changing the battery, it can be dropped. Always lift the battery using an approved lifting device and use a battery yoke intended for the battery. © BT Industries AB 222714-040...

  • Page 41: Charging The Battery

    Short-circuits, naked flames and sparks in the vicinity of the battery can cause an EXPLOSION. Always switch off the charging current BEFORE removing the battery connector. Provide good ventilation, especially if the battery is charged in a confined area. © BT Industries AB 222714-040...

  • Page 42: Battery Maintenance

    • Fill using distilled water. The fluid level should be 10 - 15 mm above the cell plates. • Refit all of the cell caps. • Rinse off and dry the battery. © BT Industries AB 222714-040...
  • Page 43 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 Density g/cm 1.31 1.30 1.29 1.28 1.27 © BT Industries AB 222714-040...

  • Page 44: Daily Service And Function Checks

    Check for damage, remove dirt and the like Wheels Check for damage, remove oil, metal chips and the like Lifting device Check for damage, remove dirt and the like Battery Check the acid level and the charge condition © BT Industries AB 222714-040...
  • Page 45 Daily service and function checks © BT Industries AB 222714-040...
  • Page 46 Daily service and function checks © BT Industries AB 222714-040...

  • Page 47: Maintenance

    500 operating 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. BT recommends that you contact your closest BT representative to sign a service and maintenance agreement to ensure the truck’s operating economy and safety.
  • Page 48 • When working underneath the truck, support the truck on trestle-blocks. 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. © BT Industries AB 222714-040...

  • Page 49: Cleaning And Washing

    • Use a well-known degreasing agent, diluted to a suitable con- centration. • 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 lubrication chart in chapter Maintenance. © BT Industries AB 222714-040...
  • Page 50 • 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 components can be damaged. Do not break the guarantee seal on the electronic board. © BT Industries AB 222714-040...

  • Page 51: Maintenance Chart

    3100 Brake 3100.1 Clean and verify correct functioning of the service brake and parking brake 3100.2 Inspect brake disc wear and verify correct tighten- ing torque (48 Nm) 3100.3 Inspect play in the neutral position © BT Industries AB 222714-040...
  • Page 52 Inspect all battery, truck and charger connections 5110.3 Verify that the cell and pole protectors are not damaged 5110.4 Inspect the fluid density and temperature 5110.5 Suck up excess fluid from the battery pan 5110.6 Verify the battery locking device © BT Industries AB 222714-040...
  • Page 53 6 = If the machine is used in cold stores or other severe environ- ments, perform this item every 250 hours. When points are carried out according to higher hour intervals, even the points at lower time intervals are to be carried out, unless otherwise stated above. © BT Industries AB 222714-040...
  • Page 54 Maintenance 5000 5000 5000 5700 7100 5000 4110 7160 5400 1700 3100 6100 1700 3500 5110 0450 0000 1700 2550 © BT Industries AB 222714-040...

  • Page 55: Lubrication Chart

    Anticorit LBO 160 TT, Fuchs DEA > + 5°C VG 150 Klüberoil 4UH 1-150N, Klüber Lubrication < +45°C Anticorit LBO 160, Fuchs DEA Rexoil, Rexnord Kette >+ 45°C VG 220 Klüberoil 4UH 1-220N, Klüber Lubrication <+ 80°C © BT Industries AB 222714-040...
  • Page 56 Maintenance 7100 7160 6100 2550 © BT Industries AB 222714-040...

  • Page 57: Transporting And Storing The Truck

    NOTE! the truck’s dimensions and weight can vary with different accessories. The truck’s dimensions and weight OSE100 Length Fork length 1150 mm 2840 Width Height 1550 Weight without battery 1294 Battery weight 465/620 Ah 350/530 © BT Industries AB 222714-040...

  • Page 58: Lifting The Truck

    • 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 lifting truck’s forks. © BT Industries AB 222714-040...

  • Page 59: Towing And Transporting A Defective Truck

    Daily service and function checks. • When stored for a period greater than three months carry out preventive maintenance as set out in the instructions, 500 hours interval. © BT Industries AB 222714-040...

  • Page 60: Recycling/Discarding

    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.
  • Page 61 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 © BT Industries AB 222714-040...
  • Page 62 *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 _______________________________________________ __________________________________________________________________ Place & date of issue) Signature __________________________________________________________________ (Company) (Clarification of signature) © BT Industries AB 222714-040...

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