BT OSE100 User manual

© BT Industries AB
Valid only for serial number:
BT 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: 2005-03-08ITS

© BT Industries AB 222714-040
2
It is important that you read this
Operator’s Manual for your own
safety!
Before you start to use this truck it is of extreme importance that
you have read the contents of the entire Operator’s Manual to
be able to use the truck in a safe and efficient manner.
This Operator’s Manual contains information on how you should
use the truck, 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 uncertainty of
how to use this truck.
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
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Table of Contents
Safety regulations ............................................................................... 5
Warning symbols .............................................................................. 5
General safety regulations ................................................................ 7
Warning and information plates and symbols ............................... 12
Presentation of the truck ................................................................. 14
Intended application of the truck ..................................................... 14
Prohibited application of the truck .................................................. 14
Truck data ...................................................................................... 15
Truck dimensions ........................................................................... 16
Identification 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 ................................................. 39
Replacing the battery ...................................................................... 39
Charging the battery ....................................................................... 41
Battery maintenance ....................................................................... 42
Daily service and function checks .................................................. 44

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Table of Contents
Maintenance ...................................................................................... 47
Cleaning and washing .................................................................... 49
Maintenance chart .......................................................................... 51
Lubrication chart ............................................................................. 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

Safety regulations
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Safety regulations
Warning symbols
Always follow the warnings given in this Operator’s Manual
and on the truck to avoid accidents and incidents from occur-
ring.
Warning levels
Warning texts regarding safety are given in four levels and pro-
vide information on the risks, describe the consequences and
instruct how to avoid accidents.
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 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.

Safety regulations
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Prohibitory symbols
NO SMOKING
If smoking occurs in situations where a restriction against
smoking is stated, a serious accident can occur.
NAKED FLAMES PROHIBITED
If naked flames are 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 worn to avoid personal injury.

Safety regulations
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General safety regulations
Always carry out daily service before the truck is used, see
chapter Daily service and function checks. The working order of
all safety equipment, guards and safety switches should be
checked before you use the truck. Such safety equipment must
not be disengaged or removed.
• Check to make sure that all warning and machine designation
plates are clean and undamaged.
The battery must be secured in its intended compartment. The
battery shall have a weight that corresponds with the information
stated on the truck’s identification plate.
The truck must not be used if it is damaged or has faults that
affect safety or its safe use. 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
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 where the atmosphere contains dust or gases
that can cause fires or explosions.
- As a towing truck for trailers.
- To tow other trucks.
- To transport/lift passengers.
Operator’s responsibility
• The truck shall only be driven by personnel that have been
specially trained and have the management’s permission to
drive the truck.
• Each country (state) has its own safety regulations. It is the
operator’s obligation to know and follow these.This also
applies to local regulations and for different types of handling.
If the recommendations in this manual deviate from your
national regulations, the local safety regulations should be
followed.
• The truck should be insured in accordance with local direc-
tives and laws where the truck is used.

Safety regulations
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• Any accidents that have caused personal injury or damage to
buildings or equipment must be reported to the supervisor.
Incidents and faults on the truck shall also be reported.
• The truck shall only be driven with care, good judgement and
in a responsible manner.
• Local regulations regarding personal safety equipment shall
be followed.
• The truck should not be driven with oily hands or oily shoes
due to the risk of slipping.
Working area
• If there are marked truck routes these shall be used.
• The truck should only be driven on hard and even surfaces,
e.g. concrete or asphalt.
• Ensure that the floor where the truck is to be used has suffi-
cient load bearing capacity for the total weight of the truck
including the maximum load and the weight of the operator.
• Take special care if there are protruding parts from racks,
shelves or walls that can cause personal injury 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.
• Always drive the truck in a responsible manner and with full
control. Sudden starts and braking as well as cornering at
high speed should be avoided.
• Reduce the speed if the surface is slippery to prevent the
truck from sliding or overturning.
• Adapt your speed to suit the driving conditions, and where
there are pedestrians or other trucks in the working area.
Reduce speed when the line of vision is limited and when
pedestrians or other vehicles can be encountered.
• Pay particular attention to other personnel as well as fixed
and moving objects within the working area and thereby avoid
accidents.
• Always be prepared to stop if other personnel are in the work-
ing area.
• Keep a safe distance from all vehicles ahead.

Safety regulations
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• Always keep a safe distance from the edges of loading bays
and loading ramps. Be attentive to marked risk areas.
• Sound the horn when overtaking and when the attention of
other personnel is required.
• Always give way to a loaded truck at junctions and in confined
aisles.
•Never allow passengers to ride on the truck.
•Never drive with any part of your body outside the operator
compartment.
Handling loads
• Drive with care when collecting or depositing a load.
• Only handle loads that are within the truck’s permitted lifting
capacity. The length/width of the forks should be adapted to
the load’s shape and dimensions.
• Only handle loads that are stable and arranged in a safe
manner.
• 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 truck so that it obstructs emergency exits.
•Never park the truck so that it obstructs traffic or work.
Handling the battery
• Always handle the battery and its connections with care.
Read and follow the instructions carefully before replacing or
charging the battery. See chapter Battery.
• 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.

Safety regulations
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Maintenance and repair
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.
Modifications or conversions to the truck that affect the safe use
or function are not permitted.

Safety regulations
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Warning and information plates and symbols
© BT Industries AB 222714-040
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Warning and information
plates and symbols
The figure shows the position and significance of the plates and
symbols 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

Warning and information plates and symbols
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1
4
5
6
7
8
9
10
11
12
13
2
3
14
15

Presentation of the truck
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Presentation of the truck
The truck is an order picking truck designed to pick orders from
ground level and the 1st and 2nd level in warehouse racks. The
truck is designed for order picking with correct ergonomic pos-
ture. The operator's environment has been specially designed to
provide a work position and an overview of truck handling for
safe and comfortable operation.
The truck has a maximum lifting capacity of 1000 kg.
The truck has a 24V electrical system and the speed is regulated
by means of a transistor controller to provide gentle control of
acceleration and speed while driving. For reasons of safety and
stability the speed in the direction of the forks is lower than the
forward speed. Additionally, the speed is reduced 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 described in the Operator’s
Manual may not be marketed in your country.
Intended application of the truck
The truck is solely designed and manufactured to handle goods.
The trucks should be fitted with the appropriate accessories rele-
vant to the application.
Prohibited application of the
truck
The truck is designed for indoor order picking. It is not permitted
to use the trucks for other purposes including the following:
- 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

Presentation of the truck
© BT Industries AB 222714-040
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Truck data
The table provides information regarding some technical data,
which is of value with daily use of the truck.
* 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.
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 equivalent noise level according to
EN 12053, dBA
71
Vibration level according to EN 13059, m/s20,9
Permitted drive wheel, material Vulkollan
Powerthane
siped Tractothan

Presentation of the truck
© BT Industries AB 222714-040
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Truck dimensions
The illustration shows external dimensions for the truck in its
standard design.
Dimensions OSE100
b1Chassis, mm 790
b5Width across fork, mm justerbar 300 > 750
WaTurning 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

Presentation of the truck
© BT Industries AB 222714-040
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e Fork width, mm 115
l2Truck length incl. back of fork, mm 1690
l20 Platform length, mm 548
l24 Instep width, mm 471
x Back of fork to wheel centre, mm 158
y Wheel base, mm 1351
h1Height of truck, min., mm 1550
h3Lift movement, mm 1020
h4Height of truck, max., mm 2570
h7Instep height, mm 180
h9Initial 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
m2Floor clearance mid wheelbase, mm 70
Dimensions OSE100

Presentation of the truck
© BT Industries AB 222714-040
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Identification plate
The illustration shows the identification plate used on the truck.
Modification plate
The illustration shows the modification plate which is found on
the truck if it is supplied 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
AMODEL
BNO.
CRATED CAPACITY kg
DWEIGHT WITHOUT BATTERY kg
EBATTERY WEIGHT MAX
MIN
kg
kg
FBATTERY VOLTAGE V
GBATTERY TYPE — CLASS
ACC TO UL583
Item Text
AModification plate
BType
CSerial number
DPlace of manufacture
EPlace of manufacture
FModification number
GDate
A
B
C
D
E
E
F
G
A
B
CD
E
F
G

Presentation of the truck
© BT Industries AB 222714-040
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Capacity plate
The illustration shows the capacity plate used on the truck.
Item Text Unit
HNO
ILIFT HEIGHT mm
JACTUAL CAPACITY kg
KLOAD CENTRE mm

Main components
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Main components
1. Steering unit:
The truck can be manoeuvred by the operator either stand-
ing in the driver’s compartment or walking by the side of the
truck. The speed is reduced to 6.0 km/h when operating
from the side. The brake is activated in the steering unit’s
raised position.
2. Identification plate:
With type designation, serial number, year of manufacture,
weight without battery, battery weight, rated capacity, 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 steering motor:
Servo-steering for the drive wheel.
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.