Master Service Manual Product Family OM: BT Om BT Omw BT Omc BT Omcw

Master Service Manual
Product family OM
BT OM
BT OMW
BT OMC
BT OMCW
Ring binder number: Part number: 153875-040

© BT Industries AB Issued: 2005-11-08 ITS
Service Message
OME
BSM number: BSM0642-040
Date: 2006-10-05
Issued by: BTE/ITS
This notification contains supplementary information about the fol-

lowing truck model(s). The service manual (s) will be completed
with this information at a later date as applicable.
T code Model Product number Date of Chapter

Service manual edition
355, OME100M, 153875-xxx 2005-11-08 5710
356, OME100,
457, OME100MW,
458, OME100W
© BT
Service Message
T-code Date BSM number
355,356,457,458 2006-10-? BSM??????-040
This page is intentionally left blank
2 OME © BT
Service Message
Modification of the OME truck
BSM number Date T-code
BSM??????-040 2006-10-? 355,356,457,458
1- Modification of the OME truck
1.1 Software package update – 5710

The OME software package 149173-007 has been upgraded to softwa-
re package 149173-008. The program package change imply a modifi-
cation of parameter 8.
Parameter 8
The max value of the autoreverseparameter (parameter 8) is changed
to 165%. Max autoreversing is now corresponding to max reversing
with drivestick.
OBSERVE!
Please observe that these trucks earlier were called: OM, OMW, OMC
and OMCW.
© BT OME 3
Service Message
Modification of the OME truck
T-code Date BSM number
355,356,457,458 2006-10-? BSM??????-040
4 OME © BT
F-code Section C-code
OM
Contents Master Service Manual
IIssued by Approved by Version no T-code
ITS Eva-Karin Sparrlöf 001 355, 356, 457, 458
Contents
Master Service Manual
Part number: 153875-040
Issued 1996-04-18
Valid from serial number:
T-code Model Serial No Notes

355 OM 287595AA-
356 OMW 287595AA-
457 OMC 307476AA-
458 OMCW 307476AA-
1 Document list
Section C-code T-code Document Issued

Introduction 1996-05-09
M4 355, 356, 457, 458 Technical data 2005-11-08
P Content, P 1994-01-21
P1 Introduction, maintenance 2005-11-08
P2 355, 356, 457, 458 Maintenance schedule 2005-11-08
P3.1 355, 356 Oil and grease specification 1998-07-09
P3.2 355, 356, 457, 458 Oil and grease specification 1998-07-09
© BT Industries AB Service Manual 2005-11-08 English 1 (2)

OM
Contents Master Service Manual
Version no T-code
001 355, 356, 457, 458
Section C-code T-code Document Issued

S Content, S 1996-04-18
S0 0000 355, 356 Taking delivery of truck 1999-05-21
S2 2550 355, 356 Transmission, gear 1996-05-29
S3 3370.1 355, 356 Electromagnetic brake 1996-09-10
3370.2 355, 356 Electromagnetic brake 2001-05-21
S4 4200 355, 356 Wire guidance 2000-01-20
S5 5000.1 355, 356 Electrical system 1998-09-23
5000.2 355, 356, 457, 458 Electrical system 1998-09-23
5000.3 355,356,457,458 Electrical system 2005-11-08
5000.4 355, 457 Electrical system 2005-11-08
5460 355, 356 Transistor regulator 1996-06-27
5590 355-356, 457-458 Control cables 1999-06-03
5710.1 355, 356 Electronic card 1998-10-02
5710.2 355, 356, 457, 458 Electronic card 1998-10-02
5710.3 355,356,457,458 Electronic card 2005-11-08
S6 6000.1 355, 356 Hydraulic system 1996-06-27
6000.2 355,356,457,458 Hydraulic system 2001-02-16
6210 355, 356 Valve block 1996-09-05
S7 7120 355, 356, 457, 458 Main lift chain system 2002-12-02
7310 355, 356, 457, 458 Lift cylinder 1998-10-07
S9 9500 355,356,457,458 Extra equipment, dry powder 2005-11-08
extinguisher
2 (2) Service Manual 2005-11-08 English

OM M4
Technical service data
ITS K-G Andersson 001 355,356,457,458


355 OM 287595AA-
356 OMW 287595AA-
457 OMC 307476AA-
458 OMCW 307476AA-
Model
OM OMW OMC OMCW
Drive motor
Type TTL 140BB-D2 TTL 140BB-D2 TTL 140BB-D2 TTL 140BB-D2
Power, kW 1.8 1.8 1.8 1.8
Intermittence, % 60 60 60 60
Min carbon brush 12 12 12 12
length, mm
Min commutator 60 60 60 60
diameter, mm
Transmission/gear
Type 2-step angular 2-step angular 2-step angular 2-step angular
Gear ratio 14.20:1 14.20:1 14.20:1 14.20:1
Oil volume, Litre 1.75 1.75 1.75 1.75
Oil type Hypoid oil Hypoid oil Hypoid oil Hypoid oil
Normal temperature SAE 80W/90 SAE 80W/90 SAE 80W/90 SAE 80W/90
< -15o C SAE 75W SAE 75W SAE 75W SAE 75W

OM M4
Version no T-code
001 355,356,457,458
Model
OM OMW OMC OMCW
Drive wheel
Wheel dimension, mm Dia 250x75 Dia 250x75 Dia 250x75 Dia 250x75
Material in wheel Vulkollan Vulkollan Vulkollan Vulkollan
Wheel pressure with- 1116 1119 1042 1045
out load, kg
Wheel pressure with 624 627 558 561
rated load, kg
Torque wheel bolts, Nm 90 90 90 90
Support arm wheels
Wheel dimension, mm Dia 230x85 Dia 230x85 Dia 230x85 Dia 230x85
Material in wheel Vulkollan Vulkollan Vulkollan Vulkollan
Axle pressure without 1012 1015 903 906
load, 600 Ah battery, kg
Axle pressure with 2365 2368 2237 2240
rated load,
600 Ah battery, kg
Hydraulic unit
Pump motor, type TTL 160 P2A TTL 160 P2A TTL 160 P2A TTL 160 P2A
Power, kW 5,0 5,0 5,0 5,0
Revolutions/min at 2100 2100 2100 2100
work pressure
Intermittents, % 20 20 20 20
Min carbon brush 12 12 12 12
length, mm
Min commutator 68 68 68 68
diameter, mm
Pressure at rated load, 125 125 125 125
bar
Relief pressure, bar 140 140 140 140
Pump flow at rated 19 19 19 19
load, Litre/min
Tank volume, Litre 17 17 17 17
OM M4
Version no T-code
001 355,356,457,458
Model
OM OMW OMC OMCW
Oil type Mineral oil Mineral oil Mineral oil Mineral oil
Normal temperature ISO-L-HM32 ISO-L-HM32 ISO-L-HM32 ISO-L-HM32
< -15 oC ISO-L-HV32 ISO-L-HV32 ISO-L-HV32 ISO-L-HV32
Fuses
Drive motor circuit, F1 P/N 29223 P/N 29223 P/N 29223 P/N 29223
Amperage 160 160 160 160
Pump motor circuit, F3 P/N 29223 P/N 29223 P/N 29223 P/N 29223
Amperage 160 160 160 160
Control circuits, F50 P/N 122308- P/N 122308- P/N 122308- P/N 122308-
100 100 100 100
Amperage 10 10 10 10
Steering supply, F51 P/N 122308- P/N 122308- P/N 122308- P/N 122308-
200 200 200 200
External equipment, P/N 122308- P/N 122308- P/N 122308- P/N 122308-
F52 100 100 100 100
24 V supply for card P/N 122308- P/N 122308- P/N 122308- P/N 122308-
outputs, F53 100 100 100 100
Batteries All models
Dimension WxLxH, mm 353 x 621 x 775
Capacity, Ah 480 / 600
Weight, kg 360-500 / 440-500

OM M4
Version no T-code
001 355,356,457,458
Model
OM OMW OMC OMCW
Driving speeds
Outside aisle, lowered 2,5 2,5 2,5 2,5
cabin, m/s
In Japan: 2,1 2,1 2,1 2,1
Outside aisle, straight 1.1 1.1 1.1 1.1
wheel,
cabin lifted 0,6 m, m/s
Outside aisle, straight 0.7 0.7 -------- --------
wheel,
cabin lifted 2,4 m, m/s
Outside aisle, lifted 0.7 0.7 0.7 0.7
cabin 0,6m, steering
angle > 10 degrees,
m/s
Rail guided aisle, cabin 2.5 2.5 2.5 2.5
lifted < 1,9 m, m/s
Rail guided aisle, 1,9 m OPTIPACE OPTIPACE -------- --------
< cabin lifted < 4,7 m,
m/s
Wire guided aisle, 2.5 2.5 2.5 2.5
cabin lifted < 1,7 m, m/s
Wire guided aisle, 1,7 OPTIPACE OPTIPACE -------- --------
m < cabin lifted < 3,4 m,
m/s
Wire guided aisle, 0.7 0.7 -------- --------
cabin lifted > 3.4 m, m/s
Lifting/lowering speeds
Cabin lift without load, 0,25 0,25 0,25 0,25
m/s
Cabin lift with rated 0,20 0,20 0,20 0,20
load, m/s
Initial lift without load, 0,35 ------- 0,35 -------
m/s
Initial lift with rated 0,25 ------- 0,25 -------
load, m/s

OM M4
Version no T-code
001 355,356,457,458
Model
OM OMW OMC OMCW
Cabin, lowering with- 0,37 0,37 0,37 0,37
out load, m/s
Cabin, lowering with 0,40 0,40 0,40 0,40
rated load, m/s
Initial lift, lowering with- 0,15 ------- 0,15 -------
out load, m/s
Initial lift, lowering with 0,20 ------- 0,20 -------
rated load, m/s
Current consumption
Driving without load, 75 75 75 75
Ampere
Driving with rated load, 85 85 85 85
Ampere
Cabin lift without load, 195 195 195 195
Ampere
Cabin lift with rated 265 265 265 265
load, Ampere
Initial lift without load, 115 ------- 115 -------
Ampere
Initial lift with rated 160 ------- 160 -------
load, Ampere
Weight
Truck without battery, 1625 1620 1365 1360
kg (h12=4,2 m) (h12=4,2 m) (h12= 1,75 m) (h12=1,75 m)
Truck with 600 Ah 2090 2085 1830 1825
battery, kg (h12=4,2 m) (h12=4,2 m) (h12=4,2 m) (h12=4,2 m)
Note:
Certain data in the table can be missing due to corresponding
tests not being made yet or information not being available at
the moment.

OM M4
Version no T-code
001 355,356,457,458

OM P1.0
Introduction, maintenance
ITS K-G Andersson 001 355,356
All points in the service program should be carried out to
attain the highest safety and the least possible downtime. The
service intervals are only a guide and do not need to be fol-
lowed to the letter. The operator may adapt them to local con-
ditions, but it is important that the intervals comply with BT’s
minimum requirements.
The service intervals are based on the running times and can
be adapted to most normal 8 hour shifts. The following run-
ning times have been used when calculating the intervals:
Day time: 08.00-17.00 (20 hr./week)
2-shifts: 06.00-14.00, 14.00-22.00 (40 hr./week)
3-shifts: 06.00-14.00, 14.00-22.00, 22.00-06.00
(60 hr./week)
Ensure the truck is given a regular maintenance service after
250 driving hours. The truck´s safety, efficiency and service
life is dependent on the service and maintenance it is given.
Only use BT approved spare parts when service and repair
work are carried out.
1. Safety regulations with

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.
WARNING!
Short-circuiting/Burns.
When working with the truck’s electrical system, short-
circuiting/burns can occur if a metal object comes into con-
tact with live electrical connections.
Remove watches, rings or other types of metal jewellery.
© BT Products AB Service Manual 2005-11-08 English 1 (6)

OM P1.0
Version no T-code
001 355,356
• Always disconnect the battery by pulling out the emer-

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

OM P1.0
Version no T-code
001 355,356
2. Cleaning and washing

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

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

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

OM P1.0
Version no T-code
001 355,356
2.3. Electrical components

• Blow electric motors down using compressed air.
• Clean the electrical panels, electronic boards, contactors,
connections, solenoid valves, etc. using a damp cloth and
a cleaning agent.
NOTE!
Electrical components can be damaged.
Do not break the guarantee seal on the electronic board.
3. Safe lifting of the truck

All lifting must be carried out on a flat, non-slip and firm sur-
face. Avoid new laid asphalt or asphalt on a hot summer’s
day.
• Apply the parking brake to prevent the truck from moving
during the lift. If the lift applies the brake on the drive wheel,
chock the other wheels so that the truck stands still.
• Select a lifting point so that the lift is as easy as possible
(one corner at a time). If the truck has marked lifting points
on the under side of the chassis these can be used to
obtain a well balanced lift.
• Ensure that the surface under the jack is clean and free
from oil and grease.
• Ensure that your hands and the jack’s lever are free from
oil and grease.
• Use the lever that belongs to the jack. A lever that is too
short requires more force than is necessary. If the lever is
too long there is a risk of the jack being overloaded.
• Support the truck:
• as close to the part of the chassis that is lifted as possible
to reduce the falling height if the truck tips over.
• so that the truck cannot roll.
• Never raise up the jack to lift higher
• Never work under a lifted truck unless it is well supported.
WARNING!
Risk of crushing.
A badly supported truck can fall.
Never work under a truck that is not supported on trestle-
blocks and secured by a lifting device.

OM P1.0
Version no T-code
001 355,356
4. Information plates, only Japan

OM P1.0
Version no T-code
001 355,356

OM P2
Service schedule
ITS K-G Andersson 001 355,356,457,458
Service schedule

355 OM 287595AA-
356 OMW 287595AA-
457 OMC 307476AA-
458 OMCW 307476AA-
1. Maintenance chart
Pos. Work to carry out

Intervals in hours 250 500 1000 3000
Intervals in Days/Weeks/Months 3M 6M 12 M 36 M
0000 Chassis
0000.1 Check that the truck identification plate X
is legible
0000.2 Check for wear to door catches and X
catches on the battery cover
0000.3 Check for crack formation and damage X
0500 Cabin
0500.1 Check the mounting bolts X
0500.2 Check for crack formation and damage X
0500.3 Check for damage to the operator's seat X
0640 Manoeuvring controls
0640.1 Check the operation of the accelerator X
0640.2 Check the raising/lowering operations X
0640.3 Check operation of the brakes X
0640.4 Check the mounting X
0640.5 Check the steering X
0640.6 Check the deadman's handles X
0640.7 Check the horn X

OM P2
Service schedule
Version no T-code
001 355,356,457,458

1700 Drive motor
1700.1 Check for loose connections X
1700.2 Check the carbon brushes X
1700.3 Clean the motor X
2550 Drive unit
2550.1 Check for leakage X
2550.2 Check the oil level X
2550.3 Change the oil in the drive gear X X
2550.4 Check for abnormal noises X
3370 Brakes
3370.1 Clean X
3370.2 Check the brake discs for wear X
3370.3 Check the play in the released position X
3500 Wheels
3500.1 Remove string and other rubbish X
3500.2 Check for wear to the drive wheel and X
bolts
5000 Electrical panel
5000.1 Clean and check its mounting X
5000.2 Tighten the cable connections X
5000.3 Check the contactor points X
5000.4 Check the contactors’ movement X
5000.5 Check the emergency stop X

OM P2
Service schedule
Version no T-code
001 355,356,457,458

5110 Battery
5110.1 Check the electrolyte level, 10-15 mm X
above the cell plates
5110.2 Check the connections to the battery X
truck and charger
5110.3 Check that the cell and pole guard are X
undamaged
5110.4 Check the fluid density and temperature X
5810 Pump motor
5830 Steering motor
6000 Hydraulic system
6000.1 Check for leakage from hoses and cou- X
plings
6000.2 Check the tank X
6000.3 Check the oil level X
6000.4 Change the oil and oil filter X
6000.5 Change the air filter X
7100 Mast
7100.1 Check the lifting cylinders' mountings X
7100.2 Lubricate the lifting chains X
7100.4 Lubricate the mast rails by the guide roll- X
ers
7100.5 Lubricate the chain roller's contact sur- X
faces

OM P2
Service schedule
Version no T-code
001 355,356,457,458

7160 Initial lift
7160.1 Lubricate the lifting chains X
7160.2 Lubricate the chain roller's contact sur- X
faces
7160.3 Adjust the forks X
9500 Extra equipment
9500.1 Check the fire extinguisher X

OM P2
Service schedule
Version no T-code
001 355,356,457,458

OM P2
Service schedule
Version no T-code
001 355,356,457,458
2. Lubrication chart
Item Service point Intervall/Running Lubricant Volume

hours
250 h 500 h 1000 h
2550 Drive gear C O C 1.75 L
3500 Wheel bearings L A
4100 Steering chain L A
6000 Hydraulic system C O B 17 L
7110 Mast channels L A
7120 Lifting chains L D
7160 Chain initial lift L D
7160 Mast channels ini- L A
tial lift
L = Lubrication C = Check O = Oil change/Filter change

OM P2
Service schedule
Version no T-code
001 355,356,457,458

OM P2
Service schedule
Version no T-code
001 355,356,457,458

OM P3
Oil and grease specification
SSD K Hallman 001 355,356


355 OM 287595AA-312181AA
356 OMW 287595AA-312181AA
Lubri- Type of Specification To be

cant lubricant > - 15°C < - 15°C used for
A Grease BT 055 73100 (Tin) BT 055 73100 (Tin) Bearings,
BT 055 73040 (Spray) BT 055 73040 (Spray) chains and
mast rails
B Hydraulic oil ISO-L-HM 32 ISO VG 32 Hydraulic
systems
C Transmission oil Hypoid oil SAE 80W/ Hypoid oil SAE 75W Gears
90
D Grease Wolfracoat Cd Wolfracoat Cd Chain rollers

OM P3
Version no T-code
001 355,356

OM P3
SSD K Hallman 002 355,356,457,458


355 OM 312182AA-
356 OMW 312182AA
457 OMC 312182AA
458 OMCW 312182AA
Lubri- Type of Specification To be

cant lubricant > - 15°C < - 15°C used for
A Grease BT 055 73100 (Tin) BT 055 73100 (Tin) Bearings and
BT 055 73040 (Spray) BT 055 73040 (Spray) mast rails
B Hydraulic oil ISO-L-HM 32 ISO VG 32 Hydraulic
systems
C Transmission oil Hypoid oil SAE 80W/ Hypoid oil SAE 75W Gears
90
D Grease BT 73040 (spray) BT 163588 (spray) Chains
BT 68101 (spray)
E Grease Staburags NBU 8EP Staburags NBU 8EP Steering
bearings

OM P3
Version no T-code
002 355,356,457,458

OM S0 0000
Taking Delivery of the Truck
SSD Christer Nylin 001 355-356


355 OM 287595AA-
356 OMW 287595AA-
1 General
Use a truck and an overhead crane to unpack the truck.
1.1 Getting the truck in order

• Cut away the band (a, pic. 1) holding the forks onto the pal-
let. Take out the forks.
• Remove the battery hatches.
• Remove the carton of accessories and the can of oil.
• Cut away the two bands holding the truck to the pallet
(b, pic. 1) at the mast. Leave in place the two bands by the
battery compartment.
• Remove the boards between the cabin and the mast, one
from each side of the cabin (c, pic. 1).
• Remove the supports from under the mast’s cross and top
joists and at the mast’s shaft pins (d, pic. 1).
• Remove the pallets stacked under the mast.
• Affix a hawser to the upper section of the frame. See pic. 2.
• Affix two hawsers behind the support arm wheels.
• Cut away the two bands holding the truck to the pallets at
the battery compartment (e, pic. 1).
• Lift the truck using a truck and an overhead crane.
• Remove the double bands and boards from the cabin.
(f, pic. 1).
• Fill the hydraulic system with the accompanying hydraulic
fluid.
• Fit the rollers for the battery compartment conveyor.
• Connect the battery.

OM S0 0000
Version no T-code
001 355-356
• Lift the fork yoke at the top and fit the forks.
• Execute preventative maintenance as per instructions for
the 250-hour service interval. See section P2.
• Try, if possible, to re-use the pallets and other packing as
much as possible.
f
c
Pic 1
Pic 2

OM S2.0 2550
Transmission, Gear
TDC K Hallman 001 355,356
Transmission, Gear
Valid from machine number: 287595AA-
1. General
The gear in this truck is a 2-step angular gear with conical
roller bearings for the drive shaft and pinion. The bearings are
pre-tensioned approx. 5/100 of a millimeter to minimize the
risk of play in the bearings. The gear and radial steering ball
bearing is assembled together as one unit mounted under the
motor plate in the chassis.
This service instruction covers descriptions for dismantling
the gear from the truck and re-fitting, filling/exchanging of oil
and measures, incase of leakage. A complete overhaul of the
gear is such an extensive work that it shall be done in a work-
shop by specially trained personell.

OM S2.0 2550
Transmission, Gear
Version no T-code
001 355,356
2. Gear components/data
The main components and data of the gear are shown in the
picture and tables below.
2.1. Component identification
2
3
4
15 14
13
6
12
11 8
10 9
Pos No Component
1 Radial bearing
2 Upper cover
3 Gear wheels, primary step
4 Pinion bearings
5 Pinion
6 Lower cover
7 Crown wheel
8 O-ring
9 Drive shaft bearings

OM S2.0 2550
Transmission, Gear
Version no T-code
001 355,356
Pos No Component
10 Seal protection
11 Drive shaft sealing
12 Drive shaft
13 Shims, drive shaft bearings
14 Shims, pinion bearings
15 Gear housing
2.2. Technical gear data
Truck type OM 0.85

Gear, type 2-step angular
Gear ratio 14.20:1
Oil volume 1.75 litre
Oil type Hypoid oil
Oil, Normal SAE 80W/90
temperature
Oil, < -15o C SAE 75W

OM S2.0 2550
Transmission, Gear
Version no T-code
001 355,356
3. Dismantling/fitting of gear from/in

truck
3.1. Dismantling:
1. Remove the front cover plate of the chassis.
2. Jack up the truck and block it in a safe manner.
3. Remove the steering chain from the gear by removing the
chain locks.
4. Loosen and remove the six M12 bolts holding the gear to
the motor plate.
5. Lower the gear to the floor.
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.
3.2. Fitting:
1. To fit the radial bearing to the gear, tighten all bolts symet-
ric with a torque of 25 Nm. The bolts shall be lubricated
prior to assembly.
2. Put the gear in position and make sure that the lower
motor bearing and gear wheel is in its correct position.
3. Fit the M12 bolts through the motor plate and tighten them
90 Nm. The bolts shall be lubricated prior to assembly.

OM S2.0 2550
Transmission, Gear
Version no T-code
001 355,356
4. Mount the steering chain and adjust the slack according to

the picture.
5. Lower the truck to the ground and fit the front cover plate.
4. Oil level check/exchange
4.1. Check/filling of oil
• The oil level in the gear shall be checked every 250 work-
ing hours.
• Check the oil level by removing the oil filling plug at the
front of the gear housing.
• Fill oil up to the hole to get the correct oil level.,
1.75 litre.

OM S2.0 2550
Transmission, Gear
Version no T-code
001 355,356
4.2. Exchange of oil

Exchange of oil shall be done after every 1000 working hours.
1. Draining the old oil out of the gear is done by removing

the lower gear cover completely.
2. Change the O-ring seal at every oil change. Make sure
that the new O-ring isn’t damaged when fitted.
3. Fit the cover and tighten the bolts 25 Nm. The bolts shall
be lubricated prior to assembly.
4. Fill up oil in accordance with filling instructions.

OM S2.0 2550
Transmission, Gear
Version no T-code
001 355,356
5. Exchange of drive shaft seal ring

Exchange of the drive shaft sealing can be done while the
gear still is fitted to the truck.
In the case of oil leakage from the drive shaft follow the proce-
dure below:
5.1. Dismantling:
1. Remove the drive wheel from the gear.
2. Remove the lower gear cover and drain the gear from oil.
3. Loosen the drive shaft nut. Remove the nut and spacer
ring.
4. Knock the drive shaft out. Gently with a brass drifter and a
hammer.
5. Pull the bearing off the drive shaft with tool 08-13022
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.
7. Remove the seal ring from the drive shaft.
7 6 5 2

OM S2.0 2550
Transmission, Gear
Version no T-code
001 355,356
5.2. Assembly:
When assemblying the gear after exchange of the drive shaft
seal, follow the procedure described below.
1. Place the drive shaft outer bearing in the gear housing.

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.
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.
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.
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 lubri-
cated prior to being fitted to the shaft.
Thighten the shaft nut with a torque of 400 Nm and lock it
with a centre punch mark in the groove of the shaft.
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.
7. Fill up oil in accordance with filling instructions, section
4.2.
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.

OM S2.0 2550
Transmission, Gear
Version no T-code
001 355,356
6. Leakage from the top cover

When having a leakage at the gear top cover follow the pro-
cedure described below:
2, 5
3, 4
1. Dismantle the gear and radial steering ball bearing from

the truck as described in section 3.1.
2. After removing the radial bearing loosen all eleven bolts
holding the top cover to the gear housing.
3. Remove the cover from the gear and clean the surface of
the cover and housing carefully.
4. Apply liquid sealant type Loc-Tite 574 to the surfaces.
Follow the instructions given on the container.
5. Fit the cover bolts and tighten with a torqe of 25 Nm.The
bolts shall be lubricated prior to assembly.
6. Fill up oil in accordance with filling instructions, section
4.2.
7. Fit the gear and radial bearing to the truck as described in
section 3.2.

OM S2.0 2550
Transmission, Gear
Version no T-code
001 355,356

OM S3.0 3370
Electromagnetic brake
1. General
The brake is a two-stage electromagnetic brake with a com-
mon magnetic coil for both stages. The brake has two half-
circle pressure plates.
The delay between the stages is partly due to the first stage
having a higher spring pressure and partly due to the plastic
coating on the underside of that half of the magnet coil that
affects stage one, the magnetic force is reduced, see the first
picture in chapter 2.
The delay between the stages is approx: 0,15-0,2 seconds.

OM S3.0 3370
Version no T-code
001 355,356
2. Function
The magnetic brake is the trucks service brake and parking
brake.
2.1. Releasing the brake

With the key-switch on and the right deadman handle acti-
vated, the magnetic coil receives voltage and pulls the two
pressure plates to the coil with magnetic force.
Because of the plastic coating on the half of the magnetic coil
for the 1:st stage it is released at different speeds, a double
clicking sound can be heard from the brake. The brake disc is
now free/released.
2.2. Braking
When the power is cut, right deadman handle released or the
brake button is pushed down, the pressure plate of the 1:st
stage is released from the coil and starts braking the brake
disc, see picture.

OM S3.0 3370
Version no T-code
001 355,356
After the delay time the 2:nd stage pressure plate is released
and increases the braking force.
The brake force is divided approx: 65% for the 1:st stage and
35% for the 2:nd stage.
3. Maintenance
Basically the brake is maintenance free in normal work envi-
ronments. However it is recommended according to the pre-
ventive maintenance schedule to clean the brake, check the
brake disc for wear and to check the gap between the mag-
netic coil housing and the pressure plate on a regular basis.

OM S3.0 3370
Version no T-code
001 355,356
3.1. Adjustment of gap
As the brake disc wears, it is necessary to adjust the gap

between the magnetic coil and the pressure discs. The nomi-
nal gap between the coil housing and pressure plate, in
applied position, shall be 0.5 mm. The maximum gap before
readjustment is necessary is 1.0 mm.
3.1.1. Adjustment procedure:
1. Loosen the tension of the four mounting bolts.

2. Turn the lock nuts anti-clockwise and tighten the bolts
slightly while checking the gap with a 0.5 mm feeler
gauge.
3. Tighten the mounting bolts 25 Nm.
4. Recheck the gap with the feeler gauge.

OM S3.0 3370
Version no T-code
001 355,356
3.2. Exchange of brake disc/magnetic coil

The brake disc shall be exchanged when its total thickness
has been reduced to 6 mm.
3.2.1. Exchange procedure:
1. Disconnect the electrical wires of the brake.

2. Dismount the speed sensor mounted on top of the brake
coil.
3. Loosen and remove the four mounting bolts and remove
the brake coil.
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.
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.
6. Mount the coil on the motor end and carry out adjustment
of the gap according to section 3.1.
7. Reconnect the electrical wiring of the brake.
8. Fit the speed sensor.

OM S3.0 3370
Version no T-code
001 355,356
3.2.2. Transport securing screws
When mounting a new brake coil, it is necessary to remove

the transport securing screws before mounting the speed
sensor.
Un-screw the four slotted screws and remove them.

OM S3.0 3370
Version no T-code
001 355,356
3.3. Check/adjustment of the braking force

The braking force is adjusted with eight Allen screws on the
top of the magnetic coil, four for each brake stage.
The brake force is set and adjusted at the factory and should
normally not require any readjustment. However ensure that
the brake force is correctly adjusted if the magnetic coil is
exchanged.
Adjustment and checking of the setting is made by measuring

how deep into the coil the screws are turned down.
The correct adjustment, measurement T,is:
Stage 1: 3,25 turns from the upper side of the coil.
Stage 2: 1,25 turns from the upper side of the coil.
Warning!
Too weak brake.
Incorrect setting of the brake force.
This type of brake is used in other trucks with a different
setting. Ensure that you have mounted a correct magnetic
coil by checking the setting after renewal of the magnetic
coil.

OM S3.0 3370
Version no T-code
001 355,356

OM S3 3370
Electric parking brake, magnetic brake
Issued by Approved by Version no T-code
SSD Christer Nylin 002 355,356
Electric parking brake, magnetic

brake
T-code Model Serial no Note

355 OM 353121AA-
356 OMW 353121AA-
1. General
The brake is a two-stage electromagnetic brake with a com-
mon magnetic coil for both stages. The brake has two half-
circle pressure plates.
The time lag between the stages is controlled by a thin brass
plate situated between the magnet housing and the pressure
plate in the first stage. This reduces the magnetic force. See
the first picture in the chapter "Releasing the brake".
The delay between the stages is approx: 0,15-0,2 seconds.

OM S3 3370
Version no T-code
002 355,356
2. Function
The magnetic brake is the trucks service brake and parking
brake.
2.1. Releasing the brake

With the key-switch on and the right deadman handle acti-
vated, the magnetic coil receives voltage and pulls the two
pressure plates to the coil with magnetic force.
Because of the thin brass plate on the magnet housing side in
the first stage, the two stages are lifted at different speeds,
while a clicking sound can be heard from the brake. The
brake disc is now released.

OM S3 3370
Version no T-code
002 355,356
2.2. Braking
When the current is interrupted, the right dead man's handle
is released or the brake button is depressed, then the pres-
sure plate in the first stage is released from the magnet hou-
sing, applying the brake on the brake disc. See the picture.
After the delay time the 2:nd stage pressure plate is released
and increases the braking force.
The brake power is distributed with approx. 65% applied in

the first stage and 35% in the second stage. This is achieved
through lack of a pressure spring under one of the adjusting
screws in the second stage.

OM S3 3370
Version no T-code
002 355,356
3. Maintenance
Basically the brake is maintenance free in normal work envi-
ronments. However it is recommended according to the pre-
ventive maintenance schedule to clean the brake, check the
brake disc for wear and to check the gap between the mag-
netic coil housing and the pressure plate on a regular basis.
3.1. Adjustment of gap
As the brake disc wears, it is necessary to adjust the gap

between the magnetic coil and the pressure discs. The nomi-
nal gap between the coil housing and pressure plate, in
applied position, shall be 0.3 mm. The maximum gap before
readjustment is necessary is 0,8 mm.
3.1.1. Adjustment procedure:

• Loosen the tension of the four mounting bolts.
• Turn the locking nut counter-clockwise and slightly tighten
the bolts. Verify the opening at four (4) points using a 0.3
mm feeler gauge.
• Tighten the mounting bolts 25 Nm.
• Recheck the gap with the feeler gauge.

OM S3 3370
Version no T-code
002 355,356
3.2. Exchange of brake disc/magnetic coil

The brake disc shall be exchanged when its total thickness
has been reduced to 6 mm.
3.2.1. Exchange procedure:

• Disconnect the electrical wires of the brake.
• DIsassemble the speedometer bearing affixed to the brake
coil.
• Loosen and remove the four mounting bolts and remove
the brake coil.
• 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.
• Unwind the lock nuts on the coil at least 6 mm to make
sure there is a gap between the coil and the pressure plate
when the coil is refitted.
• Mount the coil on the motor end and carry out adjustment
of the gap according to chapter “Adjustment of gap”.
• Reconnect the electrical wiring of the brake.
• Assemble the spedometer bearing.

OM S3 3370
Version no T-code
002 355,356
3.3. Check/adjustment of the braking force

The braking force is set using the three allen screws on top of
the magnet housing, two adjuster screws for braking stage 1
and one adjuster screw for braking stage 2.
NOTE! There is no compression spring under the second
adjuster screw for braking stage 2.
The brake force is set and adjusted at the factory and should
normally not require any readjustment. However ensure that
the brake force is correctly adjusted if the magnetic coil is
exchanged.
Adjustment and checking of the setting is made by measuring

how deep into the coil the screws are turned up/down.
The correct adjustment, measurement T,is:
Stage 1: 1,5 turns down from the upper side of the coil.
Stage 2: 1,5 turns down from the upper side of the coil.
WARNING!
Too weak brake.
Incorrect setting of the brake force.
This type of brake is used in other trucks with a different
setting. Ensure that you have mounted a correct magnetic
coil by checking the setting after renewal of the magnetic
coil.

F code Section C code
OM S4 4200
Wire guidance
Issued by Approved by Version no. T code
SSD J Torstensson 001 355,356
Wire guidance
T code Model Serial No. Notes

355 OM 0.85C 287595AA-
356 OM 0.85W 287595AA-
1. General
Wire guidance is used to steer the truck automatically in nar-
row aisles. A generator generates alternating current in a ca-
ble installed in the floor which the truck follows. This cable runs
in the narrow aisles in a closed loop from the generator to aisle
1, then on to aisle 2 and so on. From the last aisle, the cable
then returns to the generator. The maximum length the gener-
ator can manage to feed is approx. 750-1,000 m. If longer runs
are required, an additional generator with a separate wire cir-
cuit should be installed.
The current in the guide wire generates a magnetic field

around the cable wire. This field is used to steer the truck. The
magnetic field is detected by way of antennas fitted under the
truck. The antennas are connected to the control unit that con-
trols steering. The entire system is monitored by the onboard
computer which will stop the truck if a malfunction is detected.

OM S4 4200
Wire guidance
Version no. T code
001 355,356
2. Generator
The generator must be connected to a power outlet with a
nominal voltage of 220 V (LDU-22). The generator can also be
ordered for 110 V (LDU-21).
Internally, the unit consists of a voltage card that converts the
line voltage to a lower operating voltage. There is a generator
card with output stages for feeding current onto the wire. There
is also a back-up battery that supplies power in case of a pow-
er failure. In this case a buzzer sounds.
There are two LEDs on the outside. H1 (yellow) lights to show
the guidewire loop is connected and intact. H2 (green) indi-
cates that the line voltage is alright. X1 is a connector for line
voltage while X2 is used for output to the wire. S1 is a push-
button for testing the buzzer and the back-up battery condition.
2.1. Technical data

Power supply Model LDU-22 Model LDU-21
220 V 50 Hz 110 V 50/60 Hz
Output current 75 mA +/- 5%
Frequency 6.25 kHz +/- 3.5%
Output voltage 7.5 Veff at no load
Battery 2 x 12 V 3 Ah
Battery back-up > 6 hours
Maximum cable approx. 750 m
length
Wire dimension > 0.75 mm2
Fuse 0.4 A (slow-blow fuse) on the
voltage card

OM S4 4200
Wire guidance
Version no. T code
001 355,356
3. Antennas
Two antennas are mounted under the truck. The rear-mounted
antenna (W2) is used only when travelling in the drive wheel
direction, while both the front (W1) and rear antennas are
used when travelling in the fork direction.
It is important that the antennas are installed along the truck
centre line (+/- 5 mm) and point in the right direction. They
should be mounted with the arrows pointing in the fork direction
(see the picture).
Each antenna consists of three coils that detect the magnetic

field generated by the wire in the floor. Each coil has its own
function. One detects when the antenna moves in the vertical
plane and is referred to as a reference signal. The other de-
tects lateral movement of the antenna and is referred to as lat-
eral signal, while the third detects the angle in relation to the
guide wire, i.e. when the antenna twists, and is referred to as
the angle signal. The signals from the coils are amplified by a
pre-amplifier card in the antenna. These signals are then pro-
cessed by the control unit.
The height, at which the antennas are mounted on the truck,
depends on the depth at which the wire is installed in the floor,
the magnitude of current in the wire (magnetic field) and envi-
ronmental conditions (installation position). Refer to the
chapter “Troubleshooting” for verification.

OM S4 4200
Wire guidance
Version no. T code
001 355,356
3.1. Antenna cable

A 5-wire cable is used for connection of the antennas. To shut
out external noise, the shield conductor should be connected to
the chassis across the control unit and antenna. This does not
apply to older types of control units with version number -001
and older types of antennas as the shield in this case is inter-
nally connected to signal minus.
4. Wire guidance electronic card

This card controls steering with inputs from the antenna and
certain signals from the truck computer, e.g., steering re-
sponse and current travel speed. System status information is
sent to the truck computer for malfunction processing.
This is a digital card and any adjustment is done using param-
eters without the use of potentiometers. As such it is important
to keep in mind that all data is stored in RAM (operating mem-
ory) during adjustment, and that the adjustments must be
saved to EEPROM, electrically programmable memory prior to
turning off the power. Otherwise the data will lost and the pro-
cedure must be repeated.
The card is available in four versions: -001 to -004. Unless oth-
erwise noted, all versions are indicated.
4.1. Components
F Operating voltage fuse (F 315m A)
X20 Operating voltage connector, etc.
X22 Logic input/output connector (black)
X21 Analogue output signal connector (blue)
X23 Analogue input signal connector (yellow)

OM S4 4200
Wire guidance
Version no. T code
001 355,356
X24 Antenna 1 and 2 connector (orange)

X25 Not used
X26 Terminal connector (for PC)
X27 Shield conductor connectors
H1-H4 Display
H5 Malfunction indicator (see the Error Code table)
H6 Not used
H7 Safety relay not released OK
H8 Internal power supply is OK
S1-S3 Pushbuttons (+) (-) (↵)
4.2. Connectors
See the Circuit Diagram under C code 5000.
Con- Type No. Active Function

nector
X20:9 Out 74 + 24 V Wire guidance OK
X22:1 Out 76 + 24 V Locked onto wire
X22:2 Out 75 + 24 V Wire detected
X21:11 Out 77 +/-7.5 V Steering set point
X21:6 Out 78 0V Steering set point,
reference
Con- Type No. Active Function

nector
X23:12 In 79 +/-7.5 V Travel speed
X23:6 In 82 +/-7.5 V Steering angle
X22:12 In 80 + 24 V Active wire steering
X20:1 In 84 + 24 V Supply voltage
X20:6 In 81 0V Supply voltage
X23:13 In 81 0V Analogue reference
X20:5 In 84 + 24 V + to safety relay

OM S4 4200
Wire guidance
Version no. T code
001 355,356
4.3. Display
The built-in display has been developed for use in the field.
The configuration and all parameters have been preset at the
factory, while adjustment of the antenna and steering angle
offsets can be done at the customer's site using the service
keys S1-S3.
There are four characters in the display, one (H1) for input sig-
nals, one (H2) for output signals/operating modes and two
(H3, H4) for error codes (in some cases, H1 and H2 are also
used to display error codes).
This applies to the normal mode and not the adjustment mode.
4.3.1. Input signals

Input signals are displayed by one segment (a-dp) in H1 cor-
responding to one signal. Several segments may be lit at the
same time.
Segment Function
a-e Not used
f The segment lights when wire guidance is active
g-dp Not used
4.3.2. Output signals / operating modes

Output signals and various operating modes are displayed by
one segment (a-dp) in H2 corresponding to one signal. Sever-
al segments may be lit at the same time.
Segment Function
a The segment lights when an antenna malfunc-
tion has occurred
b The segment lights when a malfunction has
occurred (emergency switch)
c The segment is lit while travelling in the drive
wheel direction and is off when travelling in the
fork direction.
d The segment lights when a malfunction in the
steering angle signal has occurred
e The segments light when the truck is locked onto
the wire and is steered by antenna position 2
f The segment lights when wire guidance is in
charge of steering

OM S4 4200
Wire guidance
Version no. T code
001 355,356
Segment Function
g The segment lights when a malfunction in the
speed signal has occurred
dp The segment lights when the truck is not mov-
ing
4.3.3. Error codes

The characters H3-H4 correspond to an error code. In some
cases LED H5 is used in combination with an error code. At
this time H1 and H2 are also used. When everything is alright,
error code 00 is displayed.
Code Description
Err1 Microcontroller has stopped working
H5 lit Oscillator not operating
H5 blinks at 2 Oscillator disconnected
Hz
Err2 No watchdog reset
Err3 & H5 lit Incorrect watchdog reset
01 Welded relay contacts
02 Watchdog transistor not operating
03 Watchdog not operating
04 Relay contacts do not close
05 Relay contacts do not open
08 Steering angle potentiometer defective
09 Pull-up resistor for steering angle potenti-
ometer defective
0A All steering potentiometers defective
0B PWM signal for analogue outputs defective
0D External steering potentiometer 1 defective
0E External steering potentiometer 2 defective
0F The difference between steering potentio-
meters 1 or 2 is too large
10 VCC (+5 V) defective

OM S4 4200
Wire guidance
Version no. T code
001 355,356
Code Description
11 +15 V defective
12 External noise
14 EPROM checksum incorrect
15 Read/write error test in external RAM
16 Read/write error test in internal RAM
17 Parameter checksum 1 is incorrect
18 Parameter checksum 2 incorrect
19 Header checksum incorrect
1E Emergency stop bit in controller cannot be
set
21 Test programme error
28 External noise at start-up
29 External noise during operation
32 “Tracking wire” signal is lost during simula-
tion
34 The emergency switch is defective during
simulation 1
35 The emergency switch is defective during
simulation 2
36 The reference signal is incorrect during
simulation 1
37 The reference signal is incorrect during
simulation 2
3B-003 Reference signal too low (<100)
3C “Locked on wire” signal lost
3D “Tracking wire” signal lost
3F Emergency switch test
41 Test of the lateral signal during travel
46 WG and MAN signals not present
47 Tachometer signal not operating
48 Lateral signal defect in active antenna

OM S4 4200
Wire guidance
Version no. T code
001 355,356
Code Description
49 Angle signal defect in active antenna
4A Reference signal defective in active
antenna
67-68 Steering signal interrupted by external
switch
6A-6C External steering potentiometer defective
(warning)
A1-A8 Output stages 1-8 defective
-003 ) Alteration introduced from serial number 138973-003.
5. Miscellaneous
There is a switch in the operator's cabin S120 for wire guid-
ance. This switch should be engaged when travelling in narrow
aisles.
6. Description of function
The description follows the functional course of events. See
the diagram under C code 5000.
6.1. Travelling in the fork direction

The operator steers towards the wire at an angle of at most
about 20°. When antenna no. 1 approaches the wire, the op-
erator pushes switch S120 to request wire guidance. Output
X20:9 (WG OK) should then be high, since an error code
would otherwise be generated. The truck computer signals to
place the wire guidance electronic card in the auto mode, and
input X22:12 then goes high.
When antenna no. 1 detects the magnetic field, the electronic
card switches to the auto mode, and output X22:2 (Tracking
wire) goes high. The truck computer then switches from man-
ual steering to wire guidance and controls steering with refer-
ence from the set point on the wire guidance electronic card,
outputs X21:11 and X21:6.
OM S4 4200
Wire guidance
Version no. T code
001 355,356
The truck is now steered automatically, and when the first an-
tenna is right on top of the wire, the wire guidance electronic
card switches to antenna position 2 and output X22:1 (Locked
onto wire) goes high.
6.2. Travelling in the drive wheel direction

The operator steers towards the wire at an angle of at most
about 20°. When antenna no. 2 approaches the wire, the op-
erator pushes switch S120 to request wire guidance. Output
X20:9 (WG OK) should then be high, since an error code
would otherwise be generated. The truck computer signals to
place the wire guidance electronic card in the auto mode, and
input X22:12 then goes high.
When antenna no. 2 detects the magnetic field, the electronic
card switches to the auto mode, and output X22:2 (Tracking
wire) goes high. The truck computer then switches from man-
ual steering to wire guidance and controls steering with refer-
ence from the set point on the wire guidance electronic card,
outputs X21:11 and X21:6.
The truck is now operated automatically. When the second an-
tenna is right above the wire, X22:1 (Locked on wire) goes
high.

OM S4 4200
Wire guidance
Version no. T code
001 355,356
6.3. Control signals

In order to calculate the set point the truck computer should
use for steering, three signals are used: lateral signal (L), an-
gle signal (A) and the current steering angle (P), which corre-
spond to the sum of the signal from the potentiometer R2 and
the STEERPOT potentiometer on the A2 card.
Control signal = (L+A) - P
The lateral and angle signals are compensated depending on
the reference signal. In case the distance to the cable in the
floor somehow varies, this will be compensated for. When trav-
elling in the fork direction, the reference signal from antenna 1
is used, while in the drive wheel direction that of antenna 2 is
used.
The speed signal, input X23:12, is used to adapt the level of
amplification at different travel speeds.
Different antenna signals are used depending on the selected
operating mode of the truck. The table below shows the inter-
nal signals of the antennas that are used for the above calcu-
lation.
Operating mode L A P
When travelling on the wire in W1 Lat- W1 R2*
the fork direction eral Angle
Locked onto wire in the fork W1 Lat- W2 Lat- R2*
direction eral eral
When travelling on the wire in W2 Lat- W2 R2*
the drive wheel direction eral Angle
Locked onto wire in the drive W2 Lat- W2 R2*
wheel direction eral Angle
Control signal = (L+A) - P

*) P is the sum of R2 and the fine adjustment potentiometer
STEERPOT on the A2 electronic card.

OM S4 4200
Wire guidance
Version no. T code
001 355,356
7. Adjustments
7.1. Truck computer A2

Prior to adjustment of the wire guidance equipment, it is imper-
ative that the steering angle has been correctly set in the truck
computer.
7.1.1. Steering angle

• Park the truck with the steering wheels pointing straight for-
ward to the entrance of a narrow aisle, and do not request
wire guidance.
• Adjust the STEERPOT potentiometer on the A2 box until
both the yellow LEDs under the pot light simultaneously.
7.2. Wire guidance electronic card A3

When it is necessary to adjust the box, first enter the setting
mode by pressing one of the pushbuttons under the display.
To return to the normal mode, press all three pushbuttons at
the same time.
From programme version -003, the following applies:
The display is usually dimmed. To enter the setting mode,
press all three pushbuttons (S1-S3) at the same time. The dis-
play brightness then increases. To return to the normal mode,
press all three pushbuttons at the same time.
When the setting mode has been selected, the display shows
various menus; the two characters on the left, H1 and H2,
show the main menu and those on the right, H3 and H4, show
the sub-menu. The current position is displayed with a blinking
number. All main menus do not have sub-menus.
Use the S1 and the S2 pushbuttons to increase and decrease
the set values. Use S3 to select a menu.
To switch from a main menu to a sub-menu, press Enter. To
return to the main menu, press the S1 and S2 buttons at the
same time.

OM S4 4200
Wire guidance
Version no. T code
001 355,356
The table below shows the available menus of the unit:
Menu Description Area

1.2 Automatic offset adjustment of steering angle
1.4 Automatic reset of antenna offset
1.5 Automatic readjustment of steering angle
1.9 Angle adjustment in antenna 1 mode in the selected travel direction +/- 127
1.11 Change of selected travel direction (with S1 and S2) F=Forward
R=Reverse
2 Side adjustment of the truck while travelling in the fork direction +/- 127
4 Angle adjustmemt of the truck while travelling in the fork direction +/- 127
5 Side adjustment of the truck while travelling in the drive wheel +/- 127
direction
6 Angle adjustment in antenna 1 mode while travelling in the drive +/- 127
wheel direction (3-wheel)
7 Angle adjustment of the truck while travelling in the drive wheel +/- 127
direction
8 Shows the value of the steering angle offset +/- 127
9.2 Selection of basic parameters for each truck 1-21-003
1. Continue to menu 9.2, then press S3.
2. The display shows POS 0.
3. Select the desired parameter set using S1 and S2
4. Confirm by pressing S3.
9.3 All parameters will be stored in EEPROM
1. Continue to menu 9.3, then press S3
2. POS 0 is diplayed. Press S3
3. EPcr is dispalyed
4. Store by pressing S3 for more than 2 sec.
10.0 Change of selected travel direction (with S1 and S2) F=Forward
R=Reverse
10.1 Shows the current lateral signal for the selected travel direction +/- 127
10.2 Shows the current angle signal for the selected travel direction +/- 127
10.3 Shows the current reference signal for the selected travel direction 0-519
10.4 Shows the current value for the steering angle potentiometer +/- 127
10.5 Shows the average value of the steering angle after the last stop +/- 127

OM S4 4200
Wire guidance
Version no. T code
001 355,356
Menu Description Area

10.6 Shows the average value of the lateral signal since the last stop +/- 127
10.7 Shows the average value of the angle signal since the last stop +/- 127
10.8 Shows the lowest value of the lateral signal since the last stop +/- 127
10.9 Shows the highest value of the lateral signal since the last stop +/- 127
10.10 Displays the value of the travel speed signal +/- 512
(50 units/volt)
10.12 The frequency the unit needs to detect1 5-7-003
11.0 Shows the ID number that was saved last 10-71-003
11.1 - Shows the ID number from position 1-21 in the memory (see the 10-71-003
11.21 section “Installing a new wire guidance electronic card”)
11.22 Shows the current ID number 10-71-003
11.23 Shows the serial number of the box
11.24 Shows the programme version number
The following applies to versions 138973-001 and 138973-

002:
11.0 Shows the ID number that was saved last 10-50

11.1 - Shows the ID number from position 1-5 in the memory (see the 10-50
11.5 section “Installing a new wire guidance electronic card”)
11.6 Shows the current ID number 10-50
11.7 Shows the serial number 1-9999
11.8 Shows the programme version 1.0.0-
-003 ) Alteration introduced from serial number 138973-003.

1) See the section reference signal in the troubleshooting
chapter.

OM S4 4200
Wire guidance
Version no. T code
001 355,356
Other display information:
Display Description
noSP The truck is not standing still (speed <> 0)
noFo The travel direction is not the fork direction
nobS The truck type is not steered by articulated cen-
tre (CTX)
no1S Not in the antenna 1 mode
no3W The truck type does not have 3 wheels
F The fork direction has been selected
r The drive wheel direction has been selected
7.2.1. Adjustment of the steering angle offset

• Park the truck with the steering wheels pointing straight for-
ward to the entrance of the narrow aisle. Verify that both
LEDs under the STEERPOT are lit. If they do not light,
adjust the STEERPOT potentiometer according to the
adjustment instructions for the A2 truck computer.
• Switch on the setting mode.
• Auto adjust the steering angle offset in menu 1.2.
- Any possible error signal from the A2 card for the steering
angle will now be compensated for. A new offset value is
saved in menu 8.
7.2.2. Fine adjustment of the steering angle offset
• Enter the narrow aisle, request the wire a couple of meters
into the aisle in the drive wheel direction and then come to
a slow stop.
Verify that the signal “Locked on wire” is active and then
drive slowly as far as possible in the drive wheel direction
and come to a slow stop.
- During this time, the unit will log the maximum and mini-
mum values for the steering angle (P), and it will calcu-
late an average value.
• Readjust the steering angle value in menu 1.5.
- The average value is then adjusted in menu 8. This
adjustment can be verified by driving the truck for about
20 seconds, and then reading the average value in
menu 10.5. This is the most important adjustment
during the entire procedure. The value should never
exceed 0 +/- 1. If the value is higher, repeat the fine
adjustment procedure.

OM S4 4200
Wire guidance
Version no. T code
001 355,356
• Drive slowly in the drive wheel direction and verify that the
LED sunder the STEERPOT light symmetrically. If neces-
sary, adjust the STEERPOT potentiometer, then readjust
(menu 1.5).
- If the STEERPOT potentiometer needs to be adjusted,
the steering angle value is affected and the wire guid-
ance logic card must then be readjusted.
7.2.3. Antenna adjustment for the drive wheel direction

• Continue to drive slowly in the drive wheel direction as far
as possible, then come to a slow stop.
mum values for the angle signal (V), and it will calculate
an average value.
• Memorize the average value in menu 10.7.
• Adjust menu 6 to this value.
7.2.4. Antenna adjustment for the fork direction

• Continue to drive slowly in the fork direction as far as pos-
sible, then come to a slow stop.
mum values for the lateral signal (L), and it will calculate
an average value.
• Memorize the average value in menu 10.6.
• Multiply this value by a truck-specific constant correspond-
ing to machine type 2.
- If the multiplied value exceeds +/- 80, verify the adjust-
ment under the item “Fine adjustment of the steering
angle offset”.
- If this does not remedy the situation, then manually
adjust the W1 antenna in the lateral direction.
• Adjust menu 4 to the calculated value.
- If the test procedure is repeated several times, the value
in menu 4 will change to the new one. For example, If the
value in menu 4 is +20 and the new average value is -5,
then menu 4 must be adjusted to (-5*2=-10) +20-10=+10

OM S4 4200
Wire guidance
Version no. T code
001 355,356
7.2.5. Final adjustment

Drive in the fork direction and drive wheel direction at different
speeds and verify the following:
- both LEDs (1) light symmetrically
- that the value in menu 10.5 equals 0 +/-1. If not, perform
fine adjustmet in menu 8
- the value in menu 10.6 is as close to 0 as possible. Fine
adjust using menu 4.
7.2.6. Storing parameters

• Store the settings in menu 9.3 when the adjustments are
complete.
- Parameters can be stored at any time during the adjust-
ment. This prevents data loss in case power needs to be
turned off due to an error code.
7.2.7. Antenna adjustment in the antenna 1 mode

This adjustment is only necessary when the truck cannot find
the wire in the fork direction at the same angle from right and
left in relation to the wire.
• Disconnect the cables of the aisle transmitters (inputs 306
and 307 on the A2 electronic card) and the centre aisle
transmitter (106) (if present).
- This should be done to prevent an error code later on in
the adjustment procedure.
• Reverse the truck slowly on the wire and read the value in
menu 10.2 (angle signal). This value is changing continu-
ously. Stop the truck when the value is as close to zero as
possible.
• Switch off wire guidance using the switch in the cabin and
check that forward travel is engaged (menu 10.0,
r=reverse, F=forward); if not, change using S1 or S2, then
press S3.
• Read the value in menu 10.2.
- The value corresponds to the angle signal for the W1
antenna in the antenna 1 mode. This value is obtained
because the switch is turned off.
• Adjust menu 1.9 to this value.
• Store all parameters as explained in the section “Storing
parameters”.

OM S4 4200
Wire guidance
Version no. T code
001 355,356
8. Installing a new wire guidance

electronic card
This card is used in several truck models. The basic parame-
ters are different for different truck types. Because of this, it is
necessary to set the correct parameters for the truck when a
new electronic card is installed.
The memory area consists of 21 positions-003 of which 14 are
used to store basic parameters. These are stored at the facto-
ry and can be selected in menu 9.2. Trucks with serial number
preceding -003 only have 5 positions.
Each parameter set has an ID number which can be verified in
menus 11.0. Use this number to make sure the correct param-
eters have been selected.
The table below shows the different parameters sets and their
corresponding ID numbers:
POS Truck model ID number

1 CTX with short time constant 10
when shifting from high to low
power upon entering a narrow
aisle.
2 OP / OPW 20
3 TRT / VR 30
4 OM / OMW 40
5 OPW SPACE (wider OPW 50
model)
6 CTX with very long time constant 60
upon entering a narrow aisle.
Recommended for machines
with long mast length and heavy
loads since the truck could be
forced across the wire and an
error code would be generated
as a result
7 CTX with a long time constant 70
upon entering a narrow aisle. A
compromise of positions 1 and 6

OM S4 4200
Wire guidance
Version no. T code
001 355,356
In position 8-14 the above parameters are used however with

two additions and new ID numbers:
• Output X22:9 turns on when the unit “tracks the wire” but
the operator has not selected wire guidance. The output
can be used to e.g. engage a buzzer. Note max. 500 mA
DC current consumption.
• Output X22:8 turns on if the lateral signal >75% of the per-
missible value. The output can be used to e.g. reduce the
maximum travel speed when the truck veers off the centre
of the wire. Note max. 10 mA DC current consumption.
POS Truck model ID number

8 CTX with short time constant 11
upon entering a narrow aisle
9 OP / OPW 21
10 TRT / VR 31
11 OM / OMW 41
12 OPW SPACE (wider OPW 51
model)
13 CTX with very long time constant 61
upon entering a narrow aisle.
Recommended for machines
with long mast length and heavy
loads since the truck could be
forced across the wire and an
error code would be generated
as a result
14 CTX with a long time constant 71
upon entering a narrow aisle. A
compromise of positions 8 and
13
Positions 15-21 are not used.

OM S4 4200
Wire guidance
Version no. T code
001 355,356
9. Troubleshooting
9.1. Control signals

9.1.1. Verifying the reference signal
Drive slowly on the wire and read the reference signal in menu
10.3. The value should stay between 350 and 500 when an-
tenna height, current and cable depth are correct.
Depending on the used frequency, the current in the wire cable
should match the values in the table below in order to obtain
the correct reference signal.
kHz mA
5.2 90
6.25 75
7.0 65
9.1.2. Lateral signal verification

Drive slowly on the wire and read the lateral signal in menu 10.1.
The value should stay between -50 and 50 when the wire has
been set properly in the floor. Error code (3C) is displayed when
the value exceeds the absolute value of 100. The lateral signal
must also stay symmetrical. This can be verified in menu 10.6
which is the average value since the latest stop in the selected
travel direction. The value should be 0 +/-10.
9.1.3. Verifying the steering angle signal

Drive slowly on the wire and read the steering angle signal val-
ue in menu 10.4. The value should stay between -10 and 10.
The steering angle signal value must also stay symmetrical.
This can be verified in menu 10.5 which is the average value
since the latest stop in the selected travel direction. The value
should be 0 +/-1.

OM 5000
Electrical system
SSD C Nylin 001 355, 356
Electrical system

355 OM 287595AA-299208AA
356 OMW 287595AA-299208AA
1. General
The transistor controller (A1) regulates the speed step less up
A
to maximum speed. When starting the truck, the controller
LD1
LD2
checks the speed potentiometer circuit before closing the
B-
LD3
LD4
M
safety circuit. The controller is equipped with four light diodes
71
B+
(LED’s) showing controller status and fault indication.
The logic card on OM holds the microprocessor that senses

switches, control voltage, etc. and gives instructions to the
external electronics, contactors and valves, etc.
To hold the preprogrammed information in the electronic unit
when the battery is disconnected the unit gets its power from
an internal battery. Any faults registered by the microproces-
sor are shown on the display. The error codes are explained
in connection with the electronic card. The electronic card’s
inputs and outputs are marked with the connection number
and can easily be connected/disconnected. The inputs and
outputs, which have two fixed positions, have LEDs as indica-
tors, green for input and red for output.
The set parameters, actual error codes or warning codes and

warning / error codes that have been stored in the logic card
memory can be read in the display window in the drivers com-
partment.

OM 5000
Electrical system
Version no T-code
001 355, 356
The control functions for the truck’s electrical steering system

is integrated in the A2-card. The other components in the
electrical steering system is the steering motor and the steer-
ing wheel tachometer.
The electrical steering system and its components are not
described in detail in this instruction.
1.1. References:
For more information about the electrical system main com-
ponents, see its respective C-code.
2. Symbols and circuit diagrams
2.1. List of symbols
Symbol Description Symbol Description

Accumulator Brake (coil)
Capacitive proximity Proximity switch,

switch, operated on the
normally open approach of a magnet;
normally open
Key switch Switch (normally open)

(normally open)
Push-button switch Push-button switch

normally closed (non locking)
normally open

OM 5000
Electrical system
Version no T-code
001 355, 356

Emergency stop Connector
Contactor Horn
Fuse Lamp
Variable resistor D.C. series motor,

(potentiometer) armature winding
D.C. series motor Motor, general
Series winding Valve

OM 5000
Electrical system
Version no T-code
001 355, 356
2.2. Circuit diagram(1/8)

OM 5000
Electrical system
Version no T-code
001 355, 356
2.3. Circuit diagram (2/8)

OM 5000
Electrical system
Version no T-code
001 355, 356

OM 5000
Electrical system
Version no T-code
001 355, 356

OM 5000
Electrical system
Version no T-code
001 355, 356

OM 5000
Electrical system
Version no T-code
001 355, 356

OM 5000
Electrical system
Version no T-code
001 355, 356

OM 5000
Electrical system
Version no T-code
001 355, 356

OM 5000
Electrical system
Version no T-code
001 355, 356
2.10. List of components
Symbol Designation Function Remark

A1 Transistor regulator Drive motor
A2 Electronic card Main card
A3 Electronic card Display
A4 Electronic card Wire guidance Option: Wire guidance
BT Battery + 24V
E1 Fluorescent beam Cabin light

fitting
fitting
E3 Spot light Work lights Option
F1 Fuse Drive motor 160 A

F3 Fuse Pump motor 200 A
F50 Fuse Control current 10 A
F51 Fuse Steering motor 20 A
F52 Fuse External equipment 10 A
F53 Fuse Control current, output 10 A
H1 Horn
H2 Warning light
K10 Contactor Main contactor

K11 Contactor Driving in fork direction
K13 Contactor Driving in drive wheel
direction
K30 Contactor Pump motor

OM 5000
Electrical system
Version no T-code
001 355, 356
M1 Motor Drive motor

M3 Motor Pump motor
M6 Motor Steering motor
R1 Potentiometer Speed control, driving

R2 Potentiometer Steering indication
S17 Switch Ignition

S18 Switch Horn
S21 Switch Emergency stop
S34 Switch Fork lift
S41 Switch Fork lowering
S48 Switch Brake
S65 Switch Walk trough gate
S69 Switch Cabin lift
S70 Switch Cabin lowering
S79 Magnet switch Aisle indication
S80 Magnet switch Aisle indication As an option could a
photo cell be used
S81 Switch Chain guard
S87 Switch Gate control
S99 Switch Work lights Option
S100 Switch Left dead man’s handle Option: For narrow aisle
S101 Conductive sensor Right dead man’s handle
S104 Switch Height reference
S109 Switch Cabin height limit by-pass
S120 Switch Selecting wire guidance Option: Wire guidance

OM 5000
Electrical system
Version no T-code
001 355, 356
U1 Tachometer Steering wheel

U10 Pulse transmitter Cabin height measurement
U11 Pulse transmitter Drive speed measurement
W1 Antenna Option: Wire guidance

Y10 Brake coil Parking brake release

Y30 Valve coil By-pass
Y34 Valve coil Fork lift
Y41 Valve coil Fork lowering
Y69 Valve coil Cabin lift/lowering
Y70 Valve coil Cabin lowering

OM 5000
Electrical system
Version no T-code
001 355, 356
The description follows the operating sequence. A detailed
description of the main components can be found in corre-
sponding chapters (C-code).
3.1. Ignition key in the 0 position.

When the battery is connected to the truck, the inputs 408,
607 (via fuse F50) and 801 (via fuse F51).on the electronic
card (A2) are fed with 24V voltage and the electronic card
starts. The stabilized voltage, 7.5V, comes from A2, output
601,to potentiometer (R1) in the accelerator.
3.2. Ignition key in the I position

The truck gets voltage when the operator turns on the key,
(I position). The voltage flows through the control fuse (F50),
the emergency stop (S21), ignition lock (S17) and to the tran-
sistor regulators (A1) input 1.
The transistor regulator for the drive motor (A1) checks that
the internal safety function works and makes the main con-
tactor (K10) which provides voltage to the drive motor arma-
ture and pump contactor as well as information to A2,
input309.
When K10 closes voltage is supplied to the electronic card
(A2), input 608, and to all the switches and pulse transmitters
connected to the inputs of A2.
A2 sends control pulses to the tachometer (U1) and the steer-
ing motor (M3).
All lamps on the display comes on to show the lamps in nor-
mal mode: time, running time, battery status, any error codes
and the software’s version number.
The time the truck has the key in position I, is measured and
stored in the electronic unit.

OM 5000
Electrical system
Version no T-code
001 355, 356
3.3. Driver presence control

(outside narrow aisle).
If the cabin gates are open an operator presence verification
must be done
Before any of the trucks working functions are operational the
operator must verify his presence in the cabin by doing the
following.
- Actuate the right dead man handle (S101) with the right
hand. Parking brake released.
- Turn the steering wheel with the left hand to genarate a
steering pulse.
Now the trucks drive and hydraulic functions are operational.
The operator must verify his presence everytime the right
dead man handle has been released.
If the operator presses down the rocker when the key is
turned to the I position the rocker must return to the neutral
position and a new presence control carried out before the
truck can be driven.
3.4. Driving.
The truck travels in the same direction as the speed regulator
(the rocker) is pressed. When the rocker is pressed down, the
voltage goes from the potentiometer R1 to input 404 on A2.
The voltage decides both the direction and the speed.
When the rocker is pressed down the potentiometer (R1) is
activated and the selected travel direction contactor receives
voltage from A2 and makes (output 707 or 708). The more
the rocker is pressed down the greater the voltage that flows
from R1 to A2. A1 governs the drive motor’s speed by means
of the information from A2 The current flows through the fuse
(F1), M1’s rotor, K11/K13, M1’s series windings to A1’s tran-
sistor connection (M).
The speed of the drive motor is measured by means of the
pulse transmitter U11, placed on the drive motor.
The drive motor’s running time is measured and stored in the
electronic unit.

OM 5000
Electrical system
Version no T-code
001 355, 356
3.5. Driving in narrow aisle.

When driving in narrow aisles the left dead man handle
(S100) must be actuated.
3.5.1. Driving in rail guided aisle.

When entrering the aisle the magnet swtches S79 and S80
are actuated by magnets in the floor, the magnet switches
can be replaced by a photo cell designated S80.
The steering wheel of the truck is disconnected and the
A2-card controls/regulates the steering at the steered wheels
middle position.
For adjusting the steered wheels middle position, see the
description of the A2-card, C-code 5710.
The maximum speed of the truck is now automatically
adjusted depending of the cabin height.
3.5.2. Driving in wire guided aisle.

Wire guidance is requested by the operator by pushing the
button for switch S120. The wire guidance box A4 will then-
take control of the steering system of the truck.
For a complete description of the truck in wire guidance
mode, see C-code 4500.
3.6. Steering
When the steering wheel is turned a signal goes from tacho-
meter (U1) to A2, input 405, which progressively supplies
power to the steering motor (M3). This leads to the faster the
steering movement the quicker the steering motor rotates.
The progressiveness also results in the higher the driving
speed the slower the steering speed.
When the steering motor turns, the potentiometer (R2)
changes the voltage on A2, input 407.
The steering sensitivity is an adjustable parameter, see the
description of the A2-card C-code 5710.
3.7. Steering wheel indicator

When the steering is turned, potentiometer R2 gives a signal
to input 407 on A2, which shows the travel direction on the
display.

OM 5000
Electrical system
Version no T-code
001 355, 356
3.8. Braking.
There are four ways to brake:
3.8.1. Plug brake (electric).

When operator changes the travel direction by means of the
rocker, the travel direction contactors (K11 and K13) switch.
The electronic card (A2) receives information from A1 that
motor braking is taking place and changes the regulation of
A1. The drive motor functions, during plug braking, as a gen-
erator and current goes to the transistor regulator, connection
A, and through the built-in brake diodes.
3.8.2. Automatic plug braking (selectable parameter).

The automatic plug braking is a selectable and adjustable
parameter, see the description of the A2-card C-code 5710.
When the speed control is released to neutral a generated
signal is detected by the A2-card at input 308. The electronic
card micro processor then supplies voltage to the opposite
direction contactor (for example to K13 when driving in the
fork direction).
The braking force during auto-plug braking is determined by
the current reference value set by the electronic card at input
A1-11.
The braking force is adjustable up to 100% of the maximum
by adjusting the parameter. The auto-plug mode stays on
until the generated signal disappears from input 308 or til the
operator applies the speed control.
The automatic plug braking de-actuated by setting the
parameter to 0.
3.8.3. Service brake.

When the operator presses down the brake switch (S48), the
voltage disappears from A2, output 701, and the brake is
applied.
3.8.4. Parking brake.

When the right deadman’s handle is released, the voltage
disappears from A2, output 701, and the brake is applied.

OM 5000
Electrical system
Version no T-code
001 355, 356
3.9. Cabin lift

When the operator presses the switch (S69) for the cabin lift,
A2 receives a voltage on the input 203. The by-pass valve
(Y30) closes and the directional valve (Y69) opens. The
pump contactor K30 closes and the pump motor (M3) starts
and both pumps gives oil to the lift cylinders.
If the battery guard reads the remaining capacity to 20% or
lower, the pump motor function is blocked.
3.10. Cabin gates

The cabin height when the operator must have the cabin
gates closed is a progamable parameter, see the description
of the A2-card C-code 5710.
The cabin gates closes the switches S87 and S88 when they
are closed and then +24V is supplied at input 208.
When the cabin reaches the programmed height with the
gates open all drive, lift and lowering functions of the truck be
blocked.
If the gates then are closed, all work functions of the truck can
be used again.
3.11. Front gate, only “walk through”

The front gate closes switch S65.
If the front gate is open, and one or both of the side gates are
open, all work functions of the truck will be blocked at
1200 mm lift height. If the side gates then are closed the
blocking will be cancelled.
If the front gate is open, and the side gates are closed the
blocking of the work functions will occur at 3000 mm lift
height. If the front gate then is closed the blocking will be can-
celled,
3.12. Lift height limitation (option)

One liftheight limitation for the truck out of narrow aisle and
one lift height for the truck in narrow aisle can be pro-
grammed, see the description of the A2-card C-code 5710.
When the cabin reaches the height limitation the cabin lift will
be stopped. If the cabin is to be lifted above this height the
optional switch (S109) should be pressed down, which gives
a signal to A2 and the lift continues.

OM 5000
Electrical system
Version no T-code
001 355, 356
3.13. Cabin lowering

When the operator presses the switch for cabin lowering
(S70), A2 recives a voltage on the input 204. A2 opens the
directional valve (Y69) and the lowering valve (Y70). The oil
returns to the tank.
3.14. Initial lift

When the operator presses the switch for initial lift (S34), A2
receives a voltage on the input 205. A2 opens the direction
valves (Y34) and activates the pump contactor K30. The
pump motor (M2) starts and one pump gives oil to the initial
lift cylinder.
3.15. Initial lowering

When the operator presses the switch for initial lowering
(S41), A2 receives a voltage on the input 206. A2 opens the
direction valve (Y41). The oil returns to the tank and the forks
are lowered.
4. Standard settings and adjustments

All settings (parameters) and adjustments of the electrical
system are described in the description of the A2-card,
C-code 5710.

OM S5 5000
Electrical system
SSD K Hallman 002 355,356,457,458
Electrical system

355 OM 287595AA-
356 OMW 287595AA
457 OMC 307476AA-
458 OMCW 307476AA-
1. General
A
LD1
LD2
M B-
LD3
LD4
71
B+

partment.

OM S5 5000
Electrical system
Version no T-code
002 355,356,457,458

1.1. References:
1.2. General description of the electrical

system
Reference to sheet (1 - 8) are references to the page number
in the electrical diagram.
1.2.1. Battery, battery supply, power fuses (sheet 1)
• One of K10's contacts connects the +24 V supply partly to
the pump contactor K30 and the pump motor M3 (also see
sheet 2) and partly to the input 607 on the electronic card
A2.
• K10's other contact connects +24 V to the drive motor M1.
• F1 (160 A) is the fuse for the drive motor M1.
• F3 (250 A) is the fuse for the pump motor M3.
• G1 is the battery 24 V.
• The battery’s power consumption is measured through a
“calibrated” cable, shunt wire, directly by the electronic
card A2 via terminals 409 and 410.
OM S5 5000
Electrical system
Version no T-code
002 355,356,457,458
1.2.2. Drive motor circuit (sheet 2)

• The main contactor K10 receives its pulse voltage via the
transistor panel’s safety circuit, terminal 7.
• K11 and K13 are forward resp. reverse contactors.
• A1 is the transistor regulator that controls the driving
speed.
• A2 is the electronic card for drive, control and cage func-
tions.
• K30 is the pump motor contactor.
• M3 is the pump motor.
1.2.3. Inputs to the electronic card A2 (sheet 3)

• The battery voltage +24 V is used for the sensors and
switches that provide information to A2's inputs.
• Input 105, A2, is used to inform the electronics on which
side of the driver cab the control panel is located.
• S101, right deadman’s handle, must be activated for the
truck to function.
• S100, left deadman’s handle, used when driving in narrow
aisles.
• S69 is the operating switch for the cab lift.
• S70 is the operating switch for the cab lowering.
• S34 is the operating switch for the fork lift.
• S41 is the operating switch for the fork lowering.
• S48 is the operating switch for applying the travel brake.
• S87 and S88 are switches located in the cage gates. They
are open when the gates are open and closed when the
gates are closed.
• S109 is the operating switch for further lift. This is used if
height limits are programmed according to the customer’s
wishes. (not standard)
• S81 and S82 are slack chain guards. They are closed
when the chains are tensioned and open when the chains
are slack.
• S18 is the switch for the horn.
• H1 is the horn.

OM S5 5000
Electrical system
Version no T-code
002 355,356,457,458
1.2.4. Inputs till the electronic card A2 (sheet 4)

• U10 is the pulse sensor that gives A2 information on the
driver cab’s height position.
• S104 is a magnetic switch and is used as a reference
transducer in the height measuring system.
truck’s speed, and travel direction.
• S79 and S80 are magnetic switches that indicate whether
the truck is in a narrow aisle or not. As an accessory photo-
cells can be fitted instead of magnetic switches.
• S3 and S4 are magnetic switches for the aisle end brakes
and are only available as extra equipment. When the truck
drives into a narrow aisle it passes the special magnets
that are positioned there for the aisle end brakes. Switch
S3 or S4 closes. When the truck later drives out it passes
the magnets again, which make the switches open and
automatic braking is obtained if certain conditions are met.
• S65 is the switch that senses whether the load carrier is
placed on the forks (not standard).
• E1 and E2 are cab lighting.
1.2.5. Speed control, display communication, (sheet 5)

• R1 gives information to A2 about the desired driving speed
and direction.
• K11 travel contactor, forwards, receives +24 V from A2,
output 707, when the truck shall be driven in the direction
of the forks.
• K13 travel contactor, reverse, receives +24 V from A2, out-
put 708, when the truck shall be driven in the direction of
the steering wheel.
• Outputs 101,102,103 and 104 on A2 are used for commu-
nications with the display, A3.
• S21 is the emergency stop switch.
• S17 is the ignition key switch.

OM S5 5000
Electrical system
Version no T-code
002 355,356,457,458
1.2.6. Steering, extra equipment (sheet 6)

• F50 (10 A) is the fuse for A2’s voltage supply.
• F53 (10 A) is the fuse for A2’s 24 V outputs.
• F51 (20 A) is the fuse for the steering servo’s voltage supply.
• F52 (10 A) is the fuse for extra equipment.
• M6 is the steering motor.
• U1 is the tacho-generator for the steering. U1 gives a + or -
voltage to A2, input 405 and 406. The polarity and voltage
depend on the steering direction and the steering speed.
• R2 is a potentiometer located on the truck’s steering motor
and provides A2 with information on the truck’s steering angle.
• Output 610 and 611 voltage 24 V (overvoltage protection)
to pulse sensors U10 and U11.
• X36 is the contact (24 V) for extra equipment, placed under
the control panel.
• S99 is the operating switch for extra equipment (not stand-
ard).
• X37 is the contact (24 V) for extra equipment, placed in the
roof of the cab.
1.2.7. Outputs from the electronic card A2 (sheet 7)

• Y10 is the magnetic coil in the electromechanical brake.
When the brake is released the coil is activated by A2
output 701 +24 V.
• H2 is the warning lamp located on the rear chassis. The lamp
flashes when the right-hand deadman’s handle is activated.
• R3 replaces H2 on OMC and OMCW.
• Y30 is on/off valve for the double pump.
• Y69 and Y70 are the on/off valves for lifting/lowering of the
driver’s cab.
• Y34 and Y41 are the on/off valves for lifting/lowering of the
forks.
• K30 is the pump motor contactor, activated by lifting either
the cab or forks.
1.2.8. Wire guidance (sheet 8)

• S120 is the operating switch for wire guidance on/off.
Trucks without wire guidance have no operating switch.
A2, input 607 is then connected directly to +24 V.
• See the description under C-code 4200.

OM S5 5000
Electrical system
Version no T-code
002 355,356,457,458

Symbol Description
Accumulator
Sensing capacitive switch, normally open
Sensing inductive switch, normally open
Key switch, normally open
Switch (normally open)
Push-button switch normally closed
Pressure switch, normally open, non-locking
Pressure switch, normally open, locking
Emergency switch
Connector
Contactor (coil)
Fuse

OM S5 5000
Electrical system
Version no T-code
002 355,356,457,458
Symbol Description
Brake (coil)
Proximity switch,
operated on the approach of a magnet;
normally open
Horn
Lamp / LED
Sensing switch, actuated by hydraulic

pressure, normally open
Diode
Condenser
Valve (coil)
Variable resistor (potentiometer)
series motor, armature winding
Series winding
Motor, general symbol

OM S5 5000
Electrical system
Version no T-code
002 355,356,457,458
2.2. Circuit diagram T-code 355, 457, 1/8

OM S5 5000
Electrical system
Version no T-code
002 355,356,457,458

OM S5 5000
Electrical system
Version no T-code
002 355,356,457,458

OM S5 5000
Electrical system
Version no T-code
002 355,356,457,458

OM S5 5000
Electrical system
Version no T-code
002 355,356,457,458

OM S5 5000
Electrical system
Version no T-code
002 355,356,457,458

OM S5 5000
Electrical system
Version no T-code
002 355,356,457,458

OM S5 5000
Electrical system
Version no T-code
002 355,356,457,458

OM S5 5000
Electrical system
Version no T-code
002 355,356,457,458

OM S5 5000
Electrical system
Version no T-code
002 355,356,457,458

OM S5 5000
Electrical system
Version no T-code
002 355,356,457,458

OM S5 5000
Electrical system
Version no T-code
002 355,356,457,458

OM S5 5000
Electrical system
Version no T-code
002 355,356,457,458

OM S5 5000
Electrical system
Version no T-code
002 355,356,457,458

OM S5 5000
Electrical system
Version no T-code
002 355,356,457,458

OM S5 5000
Electrical system
Version no T-code
002 355,356,457,458

OM S5 5000
Electrical system
Version no T-code
002 355,356,457,458


fitting
fitting

G1 Battery + 24 V
H1 Horn
H2 Warning light

direction

OM S5 5000
Electrical system
Version no T-code
002 355,356,457,458

M3 Motor Pump motor

R3 Resistance Load in circuit Only OMW, OMCW
S3 Magnetic switch Aisle end brake

S17 Switch Ignition
S18 Switch Horn
S34 Switch Fork lift Only OM, OMC
S41 Switch Fork lowering Only OM, OMC
S48 Switch Brake
S65 Switch Load sensing Only OMW, OMCW
photo cell be used

OM S5 5000
Electrical system
Version no T-code
002 355,356,457,458




Y69 Valve coil Cabin lift/lowering

OM S5 5000
Electrical system
Version no T-code
002 355,356,457,458
2.19. Electrical diagram Option Buzzer

OM S5 5000
Electrical system
Version no T-code
002 355,356,457,458

H3 Buzzer Warning signal

direction
S130 Switch Selector buzzer on/off
V11 Diod
V13 Diod

OM S5 5000
Electrical system
Version no T-code
002 355,356,457,458
2.21. Electrical diagram Option Gate warning

OM S5 5000
Electrical system
Version no T-code
002 355,356,457,458

K100 relay
PZ1 Buzzer Warning signal

S103 Magnetic switch Sensing in bottom of cab
V100 Diod
V101 Diod

OM S5 5000
Electrical system
Version no T-code
002 355,356,457,458
2.23. Electrical diagram Option Extra

hydraulic function

OM S5 5000
Electrical system
Version no T-code
002 355,356,457,458


S35 Switch Extra function

Y35 Valve coil Extra function
V35 Diod

OM S5 5000
Electrical system
Version no T-code
002 355,356,457,458
3.1. Ignition key in the 0 position

When the battery is connected to the truck, the inputs 408, 607
(via fuse F50) and 801 (via fuse F51).on the electronic card
(A2) are fed with 24V voltage and the electronic card starts.
The stabilized voltage, 7.5V, comes from A2, output 601,to po-
tentiometer (R1) in the accelerator.
3.2. Start
input309.
ing motor (M3).
All lamps on the display come on to then only show the lamps’
normal status; time of day, fork height/operating time, battery
status, any error codes and the software’s version number.

OM S5 5000
Electrical system
Version no T-code
002 355,356,457,458
3.3. Deadman’s handle

The right-hand deadman’s handle must be activated in order
to use the truck. In narrow aisles even the left-hand dead-
man’s handle must be activated. When the right-hand dead-
man’s handle is activated the brakes are released. The
deadman’s handle is time monitored to prevent malfunction.
The time elapses from when the deadman’s handle is actuat-
ed, but not when travel or hydraulic movements are per-
formed. The deadman’s handle must be released within 3
minutes otherwise the travel and hydraulic movements are
blocked. The time starts to elapse again after “reactivation”.

(outside narrow aisle)
3.4.1. Open cabin gates
must be done
following.
• Actuate the right dead man handle (S101) with the right
• Turn the steering wheel with the left hand to genarate a
steering pulse.
Presence acknowledgement must be done within 5 seconds of
deactivating the right-hand deadman’s handle.
If the operator presses down the rocker when the key is turned
to the I position the rocker must return to the neutral position
and a new presence control carried out before the truck can be
driven.
3.4.2. Closed cabin gates
Presence acknowledgement as set out in the section “Open
cage gates” only needs to be done once the gates have been
closed.

OM S5 5000
Electrical system
Version no T-code
002 355,356,457,458
3.5. Driving
electronic unit.
3.6. Driving in narrow aisle


When entering an aisle either the magnetic switch S79 or S80
is activated by the magnets in the floor, the magnetic switches
can also be replaced by a photocell designated S80.
middle position.
The maximum speed of the truck is now automatically adjust-
ed depending of the cabin height.

OM S5 5000
Electrical system
Version no T-code
002 355,356,457,458

Wire guidance is requested by the driver by pressing the but-
ton for switch S120. The wire guidance box A4 takes over con-
trol of the truck’s steering system when the wire guidance
system “sees the wire”.
Both inputs 306 and 307 must be high to obtain maximum wire
guidance speed. This is achieved by the magnetic switch S79
or S80 being activated by the magnets in the floor.
Note the strapping between the inputs on sheet 8.
For a complete description of the truck in wire guidance mode,
see C-code 4500.
3.7. Travel speed

• Full speed = 9 km/h
• Half speed = 4 km/h
• Creep speed = 2,5 km/h
• Max current limit with acceleration is 220 A, with motor
brake 330 A.
The travel speeds are stated for the "worst conditions", i.e. the
forks are always estimated to be at the maximum lifting height.
3.7.1. Outside narrow aisles:

Open gates and cage height above the programmable param-
eter gives max. travel speed = 0.
• Fork height below 1.2 m results in maximum speed = full
speed.
• Fork height between 1.2 m and 3.0 m results in maximum
speed = half speed. When turning more than 10°, the max-
imum speed is reduced to creep speed.
• Fork heights above 3.0 m results in maximum speed =
creep speed.
3.7.2. In narrow aisles, rail steering / wire guidance:

speed.
• Fork height above 2.5 m results in step-less speed reduc-
tion which depends on the stability and braking require-
ments.

OM S5 5000
Electrical system
Version no T-code
002 355,356,457,458
3.8. Steering

display.
3.10. Braking
3.10.1. Plug brake (electric).

3.10.2. Automatic plug braking (selectable parameter).

fork direction).
A1-11.

OM S5 5000
Electrical system
Version no T-code
002 355,356,457,458

parameter to 0.
3.10.3. Service brake.

applied.
3.10.4. Parking brake.

When the right deadman’s handle is released, the voltage dis-
appears from A2, output 701, and the brake is applied.
3.11. End-of-aisle brake

When entering an aisle, no automatic speed reduction is requi-
red. When departing an aisle, if the truck speed exceeds the
creep speed when the truck passes a predetermined point
(approx. 7 m from end of aisle), it must interrupt its travel and
engage the brake.
If the travel speed is equal to or lower than creep speed, the
truck can pass the "braking point" without engaging the brakes.
Bistable magnet switches, S3 and S4, are fitted to the truck.
Permanent magnets are installed in the floor of the narrow aisle.
3.12. Cabin lift

When the operator presses the switch (S69) for the cabin lift,
A2 receives a voltage on the input 203. The by-pass valve
(Y30) closes and the directional valve (Y69) opens. The
pump contactor K30 closes and the pump motor (M3) starts
and both pumps gives oil to the lift cylinders.

OM S5 5000
Electrical system
Version no T-code
002 355,356,457,458
3.13. Cabin gates

gates open all drive, 0-3.0 m, lift and lowering functions of the
truck be blocked.
If the gates then are closed, all work functions of the truck can
be used again.
3.14. Load sensing, only “OMW, OMCW”

When a load carrier is placed on forks the switch S65 makes.
If the driver cab is lifted without the load carrier on the forks all
the trucks operating functions are blocked at a lifting height of
1200 mm.
3.15. Lift height limitation


When the operator presses the switch for cabin lowering
(S70), A2 recives a voltage on the input 204. A2 opens the
directional valve (Y69) and the lowering valve (Y70). The oil
returns to the tank.
3.17. Initial lift

When the operator presses the switch for initial lift (S34), A2
receives a voltage on the input 205. A2 opens the direction
valves (Y34) and activates the pump contactor K30. The
pump motor (M2) starts and one pump gives oil to the initial
lift cylinder.

OM S5 5000
Electrical system
Version no T-code
002 355,356,457,458

When the operator presses the switch for initial lowering
(S41), A2 receives a voltage on the input 206. A2 opens the
direction valve (Y41). The oil returns to the tank and the forks
are lowered.
3.19. Slack chain guard

The slack chain guards S81 and S82, sheet 3, monitor that the
cage lift chains are tensioned. If any of the chains are slack,
one of the slack chain guards opens and cuts the cage lower-
ing movement. A lifting movement of 200 mm is permitted.
3.20. Miscellaneous
Wire guidance has its own instructions.
When the truck is not equipped with wire guidance, +20 V
must be connected directly to A2/209.
The horn and the cage lighting and the extra functions, such
as spotlights, radio and on-board computer receive a +24 V
supply via F52.

All settings (parameters) and adjustments of the electrical sys-
tem are described in the description of the A2-card,
C-code 5710.

OM S5 5000
Electrical system
ITS K-G Andersson 003 355,356,457,458
Electrical system

355 OM 365014AA-
356 OMW 365014AA-
457 OMC 365014AA-
458 OMCW 365014AA-
1. General
A
LD1
LD2
M B-
LD3
LD4
71
B+

partment.

OM S5 5000
Electrical system
Version no T-code
003 355,356,457,458

1.1. References:
1.2. General description of the electrical

system
Reference to sheet (1 - 8) are references to the page number
in the electrical diagram.
1.2.1. Battery, battery supply, power fuses (sheet 1)
• One of K10's contacts connects the +24 V supply partly to
the pump contactor K30 and the pump motor M3 (also see
sheet 2) and partly to the input 607 on the electronic card
A2.
• K10's other contact connects +24 V to the drive motor M1.
• The battery’s power consumption is measured through a
“calibrated” cable, shunt wire, directly by the electronic
card A2 via terminals 409 and 410.
OM S5 5000
Electrical system
Version no T-code
003 355,356,457,458
1.2.2. Drive motor circuit (sheet 2)

• The main contactor K10 receives its pulse voltage via the
transistor panel’s safety circuit, terminal 7.
• K11 and K13 are forward resp. reverse contactors.
• A1 is the transistor regulator that controls the driving
speed.
• A2 is the electronic card for drive, control and cage func-
tions.
1.2.3. Inputs to the electronic card A2 (sheet 3)

• The battery voltage +24 V is used for the sensors and
switches that provide information to A2's inputs.
• Input 105, A2, is used to inform the electronics on which
side of the driver cab the control panel is located.
• S101, right deadman’s handle, must be activated for the
truck to function.
• S100, left deadman’s handle, used when driving in narrow
aisles.
• S69 is the operating switch for the cab lift.
• S70 is the operating switch for the cab lowering.
• S34 is the operating switch for the fork lift.
• S41 is the operating switch for the fork lowering.
• S48 is the operating switch for applying the travel brake.
• S87 and S88 are switches located in the cage gates. They
are open when the gates are open and closed when the
gates are closed.
• S109 is a control switch for continued lift. Used if you pro-
gram height limits in accordance with customer wishes.
(not standard).
• S81 and S82 are slack chain guards. They are closed
when the chains are tensioned and open when the chains
are slack.
• S18 is the switch for the horn.
• H1 is the horn.

OM S5 5000
Electrical system
Version no T-code
003 355,356,457,458
1.2.4. Inputs till the electronic card A2 (sheet 4)

driver cab’s height position.
• S104 is a magnetic switch and is used as a reference
transducer in the height measuring system.
truck’s speed, and travel direction.
• S79 and S80 are magnetic switches that indicate whether
the truck is in a narrow aisle or not. As an accessory photo-
cells can be fitted instead of magnetic switches.
• S3 and S4 are magnetic switches for the aisle end brakes
and are only available as extra equipment. When the truck
drives into a narrow aisle it passes the special magnets
that are positioned there for the aisle end brakes. Switch
S3 or S4 closes. When the truck later drives out it passes
the magnets again, which make the switches open and
automatic braking is obtained if certain conditions are met.
• S65 is the switch that senses whether the load carrier is
placed on the forks (not standard).
• E1 and E2 are cab lighting.
1.2.5. Speed control, display communication, (sheet 5)

• R1 gives information to A2 about the desired driving speed
and direction.
• K11 travel contactor, receives +24 V from A2, output 707,
when the truck should drive in the direction of the forks.
• K13 travel contactor, receives+24 V from A2, output 708,
when the truck should drive in the direction of the steering
wheel.Outputs 101,102,103 and 104 on A2 are used for
communications with the display, A3.
• S21 is the emergency stop switch.
• S17 is the ignition key switch.
1.2.6. Steering, extra equipment (sheet 6)

• F50 (10 A) is the fuse for A2’s voltage supply.
• F53 (10 A) is the fuse for A2’s 24 V outputs.
• F51 (20 A) is the fuse for the steering servo’s voltage supply.
• F52 (10 A) is the fuse for extra equipment.

OM S5 5000
Electrical system
Version no T-code
003 355,356,457,458
• U1 is the tacho-generator for the steering. U1 gives a + or -

voltage to A2, input 405 and 406. The polarity and voltage
depend on the steering direction and the steering speed.
• R2 is a potentiometer located on the truck’s steering motor
and provides A2 with information on the truck’s steering angle.
• Output 610 and 611 voltage 24 V (overvoltage protection)
to pulse sensors U10 and U11.
• X36 is the contact (24 V) for extra equipment, placed under
the control panel.
• S99 is the operating switch for extra equipment (not stand-
ard).
• X37 is the contact (24 V) for extra equipment, placed in the
roof of the cab.
1.2.7. Outputs from the electronic card A2 (sheet 7)

• Y10 is the magnetic coil in the electromechanical brake.
When the brake is released the coil is activated by A2
output 701 +24 V.
• H2 is the warning lamp located on the rear chassis. The lamp
flashes when the right-hand deadman’s handle is activated.
• Y30 is on/off valve for the double pump.
• Y69 is a proportional valve for lifting. Used with both cab
and fork lifting. The valve is controlled by a prepro-
grammed ramp function when it opens and closes.
• Y70 is a lowering valve for cab lowering. The valve is con-
trolled by a preprogrammed ramp function when it opens
and closes.
• Y41 is a lowering valve for fork lowering. The valve closes
gradually.
• K30 is the pump motor contactor, activated by lifting either
the cab or forks.

• S120 is the operating switch for wire guidance on/off.
Trucks without wire guidance have no operating switch.
A2, input 607 is then connected directly to +24 V.
• See the description under C-code 4200.

OM S5 5000
Electrical system
Version no T-code
003 355,356,457,458

Symbol Description
Accumulator
Sensing capacitive switch, normally open
Sensing inductive switch, normally open
Switch (normally open)
Push-button switch normally closed
Pressure switch, normally open, non-locking
Pressure switch, normally open, locking
Emergency switch
Connector
Contactor (coil)
Fuse

OM S5 5000
Electrical system
Version no T-code
003 355,356,457,458
Symbol Description
Brake (coil)
Proximity switch,
operated on the approach of a magnet;
normally open
Horn
Lamp / LED
Sensing switch, actuated by hydraulic

Diode
Condenser
Valve (coil)
series motor, armature winding
Series winding

OM S5 5000
Electrical system
Version no T-code
003 355,356,457,458
2.2. Circuit diagram T-code 355, 457 (1/8)

OM S5 5000
Electrical system
Version no T-code
003 355,356,457,458

OM S5 5000
Electrical system
Version no T-code
003 355,356,457,458

OM S5 5000
Electrical system
Version no T-code
003 355,356,457,458

OM S5 5000
Electrical system
Version no T-code
003 355,356,457,458

OM S5 5000
Electrical system
Version no T-code
003 355,356,457,458
2.7. Circuit diagram T-code 355, 457, (6/8)

OM S5 5000
Electrical system
Version no T-code
003 355,356,457,458

OM S5 5000
Electrical system
Version no T-code
003 355,356,457,458

OM S5 5000
Electrical system
Version no T-code
003 355,356,457,458

OM S5 5000
Electrical system
Version no T-code
003 355,356,457,458

OM S5 5000
Electrical system
Version no T-code
003 355,356,457,458

OM S5 5000
Electrical system
Version no T-code
003 355,356,457,458

OM S5 5000
Electrical system
Version no T-code
003 355,356,457,458

OM S5 5000
Electrical system
Version no T-code
003 355,356,457,458

OM S5 5000
Electrical system
Version no T-code
003 355,356,457,458

OM S5 5000
Electrical system
Version no T-code
003 355,356,457,458

OM S5 5000
Electrical system
Version no T-code
003 355,356,457,458
2.18. Electrical circuit diagrams t-code 356

and 458
1/8 Prod B
210466

1 2 3 4 5 6 7 8
A A
© BT Industries AB
5
Sh. 1
A2
M1 M DRIVE MOTOR
A1
B TRANSISTOR PANEL ELECTRONIC CARD B
A1 A2
22
Sh. 3
59
B+ 8 308 INP. PLUG BRAKE MODE
4 60
A 7 309 INP. DRIVE CHOPPER OK
4
1
8 63
K13 K11 M 6 401 OUT. CHOPPER REF.
C 5/5C 5/5B C
3
2
Service Manual
M1 LED 1
2 6 D2 D17 64
Sh. 1 6 LED 2 10 402 OUT. SPEED REF, VALUE
LED 3
4
1
LED 4
65
K11 K13 11 403 OUT. CURRENT LIMIT
5/5B 5/5C
3
2
B- 1
D MAIN CONTACTOR
D
1
1/2C
1/2C
K10
1
3
K30
2005-11-08
7/3D
2
2
4
003
M3
OM
F-code
3 D1 A2 40
M Sh. 1 3
Version no
PUMP MOTOR FAN. CHASSIS

X130 M10 X130
E E
English
+ -
M
S5
T-code
Section
210466
F 2/8 Prod B F
355,356,457,458
1 2 3 4 5 6 7 8
5000
C-code
25 (46)
Electrical system
003
OM
F-code
Version no
26 (46)
1 2 3 4 5 6 7 8
A A
ELECTRONIC CARD
A2
S5
T-code
Section
Electrical system
22 22
Sh. 2 4 107 INP. SET WALK THROUGH
S101
X15 X18 X22 X26 X26 X22 X18 X15
Br Bk 41
201 INP. RIGHT DEAD MAN'S HANDLE
X15 X18 X22 X26
355,356,457,458
Bl
40
Sh. 2 4 S100 X22 X18 X15
B 13 14 42 B
202 INP. LEFT DEAD MAN'S HANDLE
C-code
5000
S69 X22 X18 X15

13 14 43
203 INP. CABIN LIFT
S70 X22 X18 X15

13 14 44
204 INP. CABIN LOWER
S48 X22 X19 X16

21 22 47
207 INP. NO BRAKE REQUEST
Service Manual
C C
S87, S88 ONLY ON OMW
X24 S87 X24 X25 S88 X25 X19 X16
13 14 110 13 14 48
208 INP. GATES CLOSED
S109 X22 X19 X16

13 14 50
210 INP. OVERRIDE
X27 S81 S82 X27 X19 X16

D 21 22 111 21 22 51 D
211 INP. CHAIN GUARD
2005-11-08
SIGNAL HORN S18 X22 X20 X17
13 14 109
609 HORN FILTER
H1
- IN +
English
E E
F 210466 F
3/8 Prod B
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A ELECTRONIC CARD A
© BT Industries AB
A2
U10
X14 X30 X30 X14
27 R Wh 52
Sh. 6 301 INP. HEIGHT METER A
A
+
X14 X30 X30 X14
140 Bk Bl 53
Sh. 6 302 INP. HEIGHT METER B
|R B
-
X14 X31 S104 X31 X14
22 54
Sh. 3 5 303 INP. CABIN < 600mm
B B
U11
X32 X32
R Wh 55
304 INP. DRIVE MEAS. A
A
+
X32 X32
Bk Bl 56
305 INP. DRIVE MEAS. B
|R B
-
57
Sh. 8
C C
Service Manual
58
Sh. 8
X11 S79 X11

57
306 INP. IN AISLE FRONT
X10 S80 X10

58
307 INP. IN AISLE BACK
X41 S3 X41
D 126 D
106 INP. AISLE MIDDLE
S80
2005-11-08
X40 X40
Br Bk
X42 S4 X42
X40
40 Bl+Wh
003
Sh. 3 5
OM
F-code
X15 X18 X26 S65 X26 X19 X16

13 14 61
Version no
310 INP. LOAD SENSOR

CABIN LIGHTS
E1
R Bk
English
E E
X15 X18
(E1 AND E2 ONLY ON OMW)
E2
R Bk
S5
T-code
Section
F 210466 F
355,356,457,458
4/8 Prod B
1 2 3 4 5 6 7 8
5000
C-code
27 (46)
Electrical system
003
OM
F-code
Version no
1 2 3 4 5 6 7 8
28 (46)
A A
ELECTRONIC CARD
A2
S5
X28 X22 X20 X17

T-code
Section
96
Electrical system
601 POT. FEED 7.35 VDC
3
X28 X22 X19 X16
66
R1 404 INP. SPEED REFERENCE VALUE
1
355,356,457,458
X28 X22 X20 X17

B 97 B
602
2/3C
2/3D
POT. -
1
3
K11
C-code
5000
40 A1 A2 91
2
4
Sh. 4 6 707 OUT. DRIVE, FORK DIRECTION
K13
2/3D
2/3C
A1 A2 92
1
3
708 OUT. DRIVE, STEER WHEEL DIRECTION

2
4
C C
Service Manual
DISPLAY
A3
X20 X17
121
SERIE + 1 101 SERIE + SUPPLY
X20 X17
122
SERIE - 2 102 SERIE - SUPPLY
X20 X17
123
RX + 3 103 TX +
D D
2005-11-08
X20 X17
124
RX - 4 104 TX -
EMERGENCY SWITCH OFF EMERGENCY SWITCH OFF

CHASSIS CABIN KEY
S22 X15 X18 X22 S21 S17 X22 X18 X15
28 21 22 21 21 22 25 15 61a 22
Sh. 6 Sh. 4 8
E E
English
210466
F 5/8 Prod B F
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
© BT Industries AB
F50
1 ELECTRONIC CARD
Sh. 1 A2
10A
28 28
Sh. 5 607 +24VDC BATTERY
F53
2 26
Sh. 2 608 +24VDC SUPPLY OUTPUTS
10A
F51
B 23 B
801 +24VDC STEER SUPPLY
20A
40 40
Sh. 5 7 802 0V
F52 M6 X12
10A R Bk 101
M 803 OUT. +STEER MOTOR
X15 X15
X12
102
X18 X18 804 OUT. -STEER MOTOR
Service Manual
C C
U1 X27 X22 X17
Bk R 67
M 405 INP. STEERING WHEEL TACHO +
X22 X22
X27 X22 X17
68
406 INP. STEERING WHEEL TACHO -
1
24 40 X13
98
S99 X36 603 STEER POT. +
EXTERNAL EQUIPMENT
5
D (OPERATORS PANEL) D
1
X13
69
2005-11-08
X22 R2 407 INP. STEER POT.
2
WORKING LIGHT
E3 X13
108 99
003
24 40 604 STEER POT. -

OM
F-code
X37
EXTERNAL EQUIPMENT
Version no
E4
(ROOF) 108 27
610 OUT. PWR SUPPLY: BALL BEARING SENSORS
27
Sh. 4
English
E 140 E
611 OUT. GROUND: BALL BEARING SENSORS
140
Sh. 4
S5
T-code
Section
210466
6/8 Prod B
F F
355,356,457,458
1 2 3 4 5 6 7 8
5000
C-code
29 (46)
Electrical system
003
OM
F-code
1 2 3 4 5 6 7 8 Version no
30 (46)
A A
S5
T-code
Section
Electrical system
ELECTRONIC CARD
A2
X34 Y10 X34

40 85
Sh. 6 701 OUT. BRAKE
355,356,457,458
B X35 H2 X35
B
86
702 OUT. WARNING LIGHT
C-code
5000
R3
470R/5W Y70
REPLACES H2 ON OMCW 1 2 94
605 OUT. CABIN LOWER VALVE
Y30
C 1 2 87 C
703 OUT. BYPASS VALVE
Service Manual
Y69
1 2 88
706 OUT. PROP LIFT VALVE
Y41
1 2 93
709 OUT. FORK LOWER VALVE
2/2D
1
K30
A1 A2 95
711 OUT. PUMP
2
D D
2005-11-08
108 INP. MAX HALF SPEED
109 INP. MAX CREEP SPEED
E E
English
210466
7/8 Prod B
F F
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A X15 X18 X22 A

22
Sh. 5
© BT Industries AB
WIRE GUIDANCE ELECTRONIC CARD
A4 A2
W1
S120 X22 X19 X16
1 WHITE 5 7 49
X24:1 X20:5 209 INP. WIRE GUIDANCE OFF
2 BROWN
X24:2
OMW WITHOUT WIRE GUIDANCE
3 GREEN
X24:3
B B
4 YELLOW ANTENNA 1 84
X24:8 X20:1 511 OUT. +24VDC SUPPLY FOR WIRE GUIDANCE
5 GREY
X24:9
74
X20:9 501 INP. WIRE GUIDANCE OK.
76
X22:1 503 INP. LOCKED ON WIRE
7 SCREEN
W2
C 1 WHITE 75 C
X24:5 X22:2 502 INP. WIRE DETECT
Service Manual
2 BROWN
X24:6
79
X23:12 506 OUT. TRUCKSPEED / TRAVELDIR.
3 GREEN
X24:7
X24:11 X22:12 507 OUT. WIRE GUIDANCE REQUEST
X102
5 GREY 57
X24:12 Sh. 4
X20:6 X102
D 58 D
Sh. 4
2005-11-08
81
X23:13 508 0V SUPPLY FOR WIRE GUIDANCE
7 SCREEN
003
82
X23:6 509
OM
INP. STEER ANGLE OUT. STEER WHEELANGLE

F-code
Version no
77
+/- 7,5VX21:11 504 INP. STEER REFERENCE
E STEERREFERENCE E
English
78
0V X21:6 505 INP. REF. GROUND
S5
T-code
Section
210466
F 8/8 Prod B F
355,356,457,458
1 2 3 4 5 6 7 8
5000
C-code
31 (46)
Electrical system
OM S5 5000
Electrical system
Version no T-code
003 355,356,457,458


fitting
fitting

G1 Battery + 24 V
H1 Horn
H2 Warning light

direction

OM S5 5000
Electrical system
Version no T-code
003 355,356,457,458

M3 Motor Pump motor

R3 Resistance Load in circuit Only OMW, OMCW

S17 Switch Ignition
S18 Switch Horn
S34 Switch Fork lift Only OM, OMC
S41 Switch Fork lowering Only OM, OMC
S48 Switch Brake
S65 Switch Load sensing Only OMW, OMCW
photo cell be used

OM S5 5000
Electrical system
Version no T-code
003 355,356,457,458




Y69 Valve coil Cabin and fork lifting

OM S5 5000
Electrical system
Version no T-code
003 355,356,457,458
2.20. Electrical diagram Option Buzzer

OM S5 5000
Electrical system
Version no T-code
003 355,356,457,458

H3 Buzzer Warning signal
K11 Contactor Driving in direction of forks

K13 Contactor Driving in direction of steering
wheel
S130 Switch Selector, buzzer on/off
V11 Diod
V13 Diod

OM S5 5000
Electrical system
Version no T-code
003 355,356,457,458
2.22. Electrical diagram Option Extra

hydraulic function

OM S5 5000
Electrical system
Version no T-code
003 355,356,457,458


S35 Switch Extra function

Y35 Valve coil Extra function
V35 Diod

OM S5 5000
Electrical system
Version no T-code
003 355,356,457,458
3.1. Ignition key in the 0 position

When the battery is connected to the truck, the inputs 408, 607
(via fuse F50) and 801 (via fuse F51).on the electronic card
(A2) are fed with 24V voltage and the electronic card starts.
The stabilized voltage, 7.5V, comes from A2, output 601,to po-
tentiometer (R1) in the accelerator.
3.2. Start
input309.
ing motor (M3).
All lamps on the display come on to then only show the lamps’
normal status; time of day, fork height/operating time, battery
status, any error codes and the software’s version number.

OM S5 5000
Electrical system
Version no T-code
003 355,356,457,458
3.3. Deadman’s handle

The right-hand deadman’s handle must be activated in order
to use the truck. In narrow aisles even the left-hand dead-
man’s handle must be activated. When the right-hand dead-
man’s handle is activated the brakes are released. The
deadman’s handle is time monitored to prevent malfunction.
The time elapses from when the deadman’s handle is actuat-
ed, but not when travel or hydraulic movements are per-
formed. The deadman’s handle must be released within 3
minutes otherwise the travel and hydraulic movements are
blocked. The time starts to elapse again after “reactivation”.

(outside narrow aisle)
must be done
following.
• Actuate the right dead man handle (S101) with the right
• Turn the steering wheel with the left hand to genarate a
steering pulse.
Presence acknowledgement must be done within 5 seconds of
deactivating the right-hand deadman’s handle.
If the operator presses down the rocker when the key is turned
to the I position the rocker must return to the neutral position
and a new presence control carried out before the truck can be
driven.
Presence acknowledgement as set out in the section “Open
cage gates” only needs to be done once the gates have been
closed.

OM S5 5000
Electrical system
Version no T-code
003 355,356,457,458
3.5. Driving
electronic unit.
3.6. Driving in narrow aisle

3.6.1. Driving in rail guided aisle

When entering an aisle either the magnetic switch S79 or S80
is activated by the magnets in the floor, the magnetic switches
can also be replaced by a photocell designated S80.
middle position.
The maximum speed of the truck is now automatically adjust-
ed depending of the cabin height.

OM S5 5000
Electrical system
Version no T-code
003 355,356,457,458
3.6.2. Driving in aisle with wire guidance

Wire guidance is requested by the driver by pressing the but-
ton for switch S120. The wire guidance box A4 takes over con-
trol of the truck’s steering system when the wire guidance
system “sees the wire”.
Both inputs 306 and 307 must be high to obtain maximum wire
guidance speed. This is achieved by the magnetic switch S79
or S80 being activated by the magnets in the floor.
Note the strapping between the inputs on sheet 8.
For a complete description of the truck in wire guidance mode,
see C-code 4500.
3.7. Travel speed

• Creep speed = 2,5 km/h
• Max current limit with acceleration is 220 A, with motor
brake 330 A.
The travel speeds are stated for the "worst conditions", i.e. the
forks are always estimated to be at the maximum lifting height.
3.7.1. Outside narrow aisles:

Open gates and cage height above the programmable param-
eter gives max. travel speed = 0.
speed.
• Fork heights above 3.0 m results in maximum speed =
creep speed.
3.7.2. In narrow aisles, rail steering / wire guidance:

speed.
ments.

OM S5 5000
Electrical system
Version no T-code
003 355,356,457,458
3.8. Steering

display.
3.10. Braking
3.10.1. Plug brake (electric)

3.10.2. Automatic plug braking (selectable parameter)

fork direction).
A1-11.

OM S5 5000
Electrical system
Version no T-code
003 355,356,457,458

parameter to 0.
3.10.3. Service brake

applied.
3.10.4. Parking brake

When the right deadman’s handle is released, the voltage dis-
appears from A2, output 701, and the brake is applied.

When entering an aisle, no automatic speed reduction is requi-
red. When departing an aisle, if the truck speed exceeds the
creep speed when the truck passes a predetermined point
(approx. 7 m from end of aisle), it must interrupt its travel and
engage the brake.
truck can pass the "braking point" without engaging the brakes.
Bistable magnet switches, S3 and S4, are fitted to the truck.
Permanent magnets are installed in the floor of the narrow aisle.
3.12. Cabin lift

When the driver actuates the button for cab lift S69, A2
receives a voltage on input 203. A2 activates the bypass
valve Y30 and closes the proportional valve Y69 (ramp func-
tion) and activates the pump contactor K30. The pump motor
M3 starts and both pumps feed oil to the lift cylinders.

OM S5 5000
Electrical system
Version no T-code
003 355,356,457,458
3.13. Cabin gates

gates open all drive, 0-3.0 m, lift and lowering functions of the
truck be blocked. If the gates then are closed, all work func-
tions of the truck can be used again.
Warning buzzer for gates open can be programmed. See the
description for the A2 card, C code 5710.
The buzzer will then sound for 30 seconds, if one or both gates
are open when the cab’s lifting height is above the height of
the reference sensor S 104. (Does not apply to OMC/OMCW.)
3.14. Load sensing, only “OMW, OMCW”

When a load carrier is placed on forks the switch S65 makes.
If the driver cab is lifted without the load carrier on the forks all
the trucks operating functions are blocked at a lifting height of
1200 mm.
3.15. Lift height limitation


When the driver actuates the button for cab lowering S70, A2
receives a voltage on input 204. A2 opens the prop. valve
Y70 (ramp function). Oil can then return to the tank. The cab
is lowered.

OM S5 5000
Electrical system
Version no T-code
003 355,356,457,458
3.17. Initial lift

When the driver actuates the button for initial lift S34, A2
receives a voltage on input 205. A2 activates the proportional
valve Y69 and pump contactor K30. The pump motor M3
starts and one pump feeds oil to the intial lift cylinder.

When the driver actuates the button for initial lowering S41,
voltage is fed to A2 input 206. A2 opens the valve Y41 (gradual
opening function) and oil can return to the tank. The forks are
lowered.

The slack chain guards S81 and S82, sheet 3, monitor that the
cage lift chains are tensioned. If any of the chains are slack,
one of the slack chain guards opens and cuts the cage lower-
ing movement. A lifting movement of 200 mm is permitted.
3.20. Miscellaneous
Wire guidance has its own instructions.
When the truck is not equipped with wire guidance, +20 V
must be connected directly to A2/209.
The horn and the cage lighting and the extra functions, such
as spotlights, radio and on-board computer receive a +24 V
supply via F52.

All settings (parameters) and adjustments of the electrical sys-
tem are described in the description of the A2-card,
C-code 5710.

F Code Section C Code
OM S5 5000
Electric System
Issued by Approved by Version no. T code
ITS 004 355,457
Electric System
Valid for serial number:
T code Model Machine no. Note

355 OM 365014AA-
457 OMC 365014AA-
1. General
This document presents the electric OM system with twin
command. See drawing no. 183479.
The transistor regulator (A1) performs continuous adjustment
of the speed from zero to maximum speed. When starting the
truck, the regulator checks the speed potentiometer circuit pri-
A
or to closing the safety circuit. The regulator has four LEDs,
LD1 which show the status and any error conditions of the regula-
LD2
LD3
LD4
M B- tor.
71
B+
The OM logic card contains microprocessors which sense
switch settings, control voltages, etc. and which send instruc-
tions to external electronics, contactors, valves, etc.
Preset information, performance parameters, etc. stored in the
electronic unit, receive power from an internal battery when
the main battery onboard the truck is disconnected. Any error
messages sensed by the microprocessor are shown on the
display. The messages are explained in the section on the log-
ic card. Inputs and outputs on the logic card are marked with
connector numbers and are easy to connect and disconnect.
Inputs and outputs with two fixed position also have LEDs that
light up in green for input mode and red for output mode.
Set parameters, possible error codes or warning codes as well

as warning/error codes that were stored in the logic card mem-
ory can be read on the display at the drive console.
© BT Industries AB Service Manual 2005-11-08 Svenska 1 (38)

OM S5 5000
Electric System
Version no. T code
004 355,457
Control functions for the electric steering system on the truck

are integrated in the A2 logic card. The other components used
for the electric steering system are the steering motor and the
steering wheel tachometer.
The electric steering system and its components are not de-
scribed in this document.
1.1. References
For additional information regarding the main components of
the electric system, please refer to the respective C code.
1.2. General description of the electric sys-

tem
Sheet references (1 - 9) apply to page numbers in the electrical
diagram.
1.2.1. Battery, battery measurement, power fuses(sheet 1)
• One of the K10 contacts switches +24 V to the pump con-
tactor K30 and the pump motor M3 (also see sheet 2) as
well as to input 607 on the A2 logic card.
• The other K10 contact switches +24 V to the drive motor
M1.
• Current consumption of the battery is measured using a
"calibrated" cable, a so called shunt wire, by the A2 logic
card via connectors 409 and 410.
2 (38) Service Manual 2005-11-08 Svenska

OM S5 5000
Electric System
Version no. T code
004 355,457
1.2.2. Travel drive motor (sheet 2)

• The main contactor K10 receives positive voltage via the
transistor panel safety circuit, connector 7.
• K11 and K13 are forward and reverse contactors.
• A1 is the transistor regulator that governs travel speed.
• A2 is the logic card used for drive, steering, and cabin
operations.
1.2.3. Inputs to the A2 logic card (sheet 3)
• The battery voltage of +24 V is used to power the sensors
and switches that feed information to the A2 inputs.
• Input 105, A2, is used to inform the electronics of which
control panel to use.
• S202, control panel selection.
• S101/S201, right dead man's handle, must be active in
order for the truck to operate.
• S100/S200, left dead man's handle, is used for narrow
aisle driving.
• S69/S269 is the operating switch for cabin lifting.
• S70/S270 is the operating switch for cabin lowering.
• K200 is a relay for control panel switching.
• S34/S234 is the operating switch for fork lifting.
• S41/S241 is the operating switc for fork lowering.
• S48/S248 is the operating switch for applying the service
brake.
• S87 and S88 are switches situated in the cabin gates. The
switches are open when the gates are open and closed
when the gates are closed.
• S109/S209 is the operating switch for continued lifting.
This is used if height limiting has been programmed upon
request from the customer. (Optional equipment)
• S81 and S82 are slack chain guards. They remain closed
as long as the chains are tensioned, however, they open
when slack appears in the chains.
• S18/S218 is the switch for the horn.
• K201 is a relay for control panel switching.
• H1 is the horn.
© BT Products AB Service Manual 2005-11-08 Svenska 3 (38)
OM S5 5000
Electric System
Version no. T code
004 355,457

• U10 is the pulse transducer that sends information to A2
about the driver cabin height position.
• S104 is a magneto switch used as a reference sensor in
the height measurement system of the operator's cabin.
• U11 is the pulse transducer that sends information to A2
about the truck speed and the travel direction.
• S79 and S80 are magneto switches that indicate whether
the truck is in a narrow aisle. Optionally, the truck can be
equipped with photocells instead of magneto switches.
• S3 and S4 are magneto switches for end-of-aisle braking.
They are fitted as an option only. When the truck enters a
narrow aisle, it passes special magnets that activate the
end-of-aisle brake. When this happens, the S3 and S4
switches close. When the truck later leaves the narrow
aisle, it passes a magnet again, which then opens the
switches, and automatic braking can be achieved if other
conditions are met.
• S65 is the switch that detects whether a load carrier has
been fitted on the forks (optional equipment).
• E1 and E2 are the cabin lights.
1.2.6. Speed control, display communication,

(sheet 6)
• R1/R101 provide information to A2 about the desired drive
speed and the travel direction.
• K200/K201/K202 are the relay coils used for control panel
switching.
• K203 uses a time delay to prevent interruptions in the
tachometer circuit when switching the control panels.
• The K11 drive contactor receives +24 V from A2 output 707
when the truck drives in the fork direction.
• The K13 drive contactor receives +24 V from A2 output
708 when the truck drives in the steering wheel direction.
• Outputs 101,102,103 and 104 on A2 are used to communi-
cate with the display, A3.
• S21/S221 is the emergency stop switch.
• S17 is the ignition lock.

OM S5 5000
Electric System
Version no. T code
004 355,457
1.2.7. Steering, optional equipment (sheet 7)

• F50 (10 A) is the fuse protecting the A2’s voltage feed.
• F53 (10 A) is the fuse protecting the A2 24 V outputs.
• F51 (20 A) is the fuse protecting the power steering volt-
age feed.
• F52 (10 A) is the fuse protecting optional equipment.
• U1/US are the tacho-generators used for steering. U1/U2
supply + or - voltage to A2 inputs 405 and 406. The polarity
and voltage depend on the steering direction and steering
speed.
• K202 is used to switch the operator's control panels.
• K203 uses a delay to prevent interruptions in the tachome-
ter circuit when switching the operator's control panels.
• R2 is a potentiometer situated in the steering motor of the
truck. It supplies A2 with information on the steering angle
of the truck.
• Outputs 610 and 611 supply 24 V (overvoltage protected)
to the pulse transducers U10 and U11.
• X36 is the contact (24 V) for optional equipment. It is situ-
ated under the control panel.
• S99 is the operating switch for optionally installed equip-
ment (Optional equipment).
• X37 is the contact (24 V) for optional equipment. It is situ-
ated in the cabin ceiling.
1.2.8. Outputs from the A2 logic card (sheet 8)

• Y10 is the magnet coil in the electromechanical brake.
When the brake is released, the coil is activated by +24 V
on output 701 on A2 .
• H2 is the warning lamp on the rear chassis. The lamp
blinks when the right dead man's handle is engaged.
• Y30 is used to switch the twin-pump valve on/off.
• Y69 is the proportional valve for lifting. It is used for cabin
and fork lifting. Opening and closing of the valve is control-
led by a preprogrammed ramp function.
• Y70 is the lowering valve for lowering the cabin. Opening
and closing of the valve is controlled by a preprogrammed
ramp function.

OM S5 5000
Electric System
Version no. T code
004 355,457
• Y41 is the lowering valve for lowering the forks. The valve
features a soft-close mechanism.
• K30 is the pump motor contactor. It is activated for cabin
and fork lifting.

• S120 is the operating switch for on/off control of the wire
guidance mode. There is no operating switch on trucks not
equipped for wire guidance. In this latter case, A2 input
607 is then directly connected to +24 V.
• See the description under C code 4200.
2. List of symbols and electric circuit

diagrams
Symbol Description
Battery
Capacitive sensor switch, normally open
Inductive sensor switch, normally open
Switch (usually open)
Push-button switch,
usually closed

OM S5 5000
Electric System
Version no. T code
004 355,457
Symbol Description
Push-button switch, normally open,
returning spring action
Push-button switch, normally open, no

spring action
Emergency switch
Contact
Contactor (coil)
Fuse
Brake (coil)
Sensor switch, affected by a magnet, nor-

mally open
Horn
Lamp or LED
Sensor switch, affected by hydraulic

Diode

OM S5 5000
Electric System
Version no. T code
004 355,457
Symbol Description
Capacitor
Valve (coil)
Serial motor, armature winding
Serial winding

OM S5 5000
Electric System
Version no. T code
004 355,457
2.2. Electric circuit diagram, T code 355

and 457, 1/9

OM S5 5000
Electric System
Version no. T code
004 355,457

and 457, 2/9

OM S5 5000
Electric System
Version no. T code
004 355,457

and 457, 3/9

OM S5 5000
Electric System
Version no. T code
004 355,457

and 457, 4/9

OM S5 5000
Electric System
Version no. T code
004 355,457

and 457, 5/9

OM S5 5000
Electric System
Version no. T code
004 355,457

and 457, 6/9

OM S5 5000
Electric System
Version no. T code
004 355,457

and 457, 7/9

OM S5 5000
Electric System
Version no. T code
004 355,457

and 457, 8/9

OM S5 5000
Electric System
Version no. T code
004 355,457

and 457, 9/9

OM S5 5000
Electric System
Version no. T code
004 355,457
2.11. Electrical circuit diagrams T-code 355

and 457
1/8 Prod B
210465

1 2 3 4 5 6 7 8
A 5 A
Sh. 1
© BT Products AB
A2
M1 M DRIVE MOTOR
A1
TRANSISTOR PANEL ELECTRONIC CARD
A1 A2
B 22 B
Sh. 3
59
B+ 8 308 INP. PLUG BRAKE MODE
4 60
A 7 309 INP. DRIVE CHOPPER OK
4
1
8 63
K13 K11 M 6 401 OUT. CHOPPER REF.
5/5C 5/5B
3
2
M1 LED 1
C 2 6 D2 D1 7 64 C
Service Manual
Sh. 1 6 LED 2 10 402 OUT. SPEED REF. VALUE
LED 3
4
1
LED 4
65
K11 K13 11 403 OUT. CURRENT LIMIT
5/5B 5/5C
3
2
B- 1
MAIN CONTACTOR
1/2C
1/2C
K10
1
1
3
D D
K30
2
4
7/3D
2005-11-08
M3
3 D1 A2 40
M
004
Sh. 1 3
OM
F Code
PUMP MOTOR
Version no.
FAN. CHASSIS
X130 M10 X130
+ -
E M E
Svenska
S5
T code
Section
355,457
210465
F 2/8 prod B F
1 2 3 4 5 6 7 8
5000
C Code
19 (38)
Electric System
004
OM
F Code
Version no.
1 2 3 4 5 6 7 8
20 (38)
A ELECTRONIC CARD A
CONNECTED WHEN PANEL IS FACING FORKS A2
X15 X18 X21 X21/X22 X20 X17

22 125
S5
Electric System
105 INP. OPERATORS PANEL POSITION

T code
Sh. 2 4
Section
355,457
X21/X22 S101
X26 X26 X21/X22 X18 X15
Br Bk 41
201 INP. RIGHT DEAD MANS HANDLE
X15 X18 X21/X22 X26
Bl
40
Sh. 2 4 S100 X21/X22 X18 X15
13 14 42
202 INP. LEFT DEAD MAN'S HANDLE
B B
S69 X21/X22 X18 X15
13 14 43
5000
203
C Code
INP. CABIN LIFT
S70 X21/X22 X18 X15

13 14 44
204 INP. CABIN LOWER
S34 X21/X22 X18 X15

13 14 45
205 INP. FORK LIFT
C C
Service Manual
S41 X21/X22 X18 X15
13 14 46
206 INP. FORK LOWER
S48 X21/X22 X19 X16

21 22 47
207 INP. NO BRAKE REQUEST
S87, S88 ONLY ON OM

X24 S87 X24 X25 S88 X25 X19 X16
13 14 110 13 14 48
208 INP. GATES CLOSED
D D
2005-11-08
S109 X21/X22 X19 X16
13 14 50
210 INP. OVERRIDE
X27 S81 S82 X27 X19 X16

21 22 111 21 22 51
211 INP. CHAIN GUARD
SIGNAL HORN
S18 X21/X22 X20 X17
13 14 109
609 HORN FILTER
H1
E IN E
Svenska
- +
210465
3/8 Prod B
F F
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
© BT Products AB
A 57 A
Sh. 8
58 ELECTRONIC CARD
Sh. 8 A2
U10
X14 X30 X30 X14
27 R Wh 52
Sh. 6 301 INP. HEIGHT METER A
A
+
X14 X30 X30 X14
140 Bk Bl 53
Sh. 6 302 INP. HEIGHT METER B
B |R B B
-
X14 X31 S104 X31 X14
22 54
Sh. 3 5 303 INP. CABIN < 600mm
U11
X32 X32
R Wh 55
304 INP. DRIVE MEAS. A
A
+
X32 X32
Bk Bl 56
305 INP. DRIVE MEAS. B
|R B
-
Service Manual
C C
X11 S79 X11
57
306 INP. IN AISLE FRONT
X10 S80 X10

58
307 INP. IN AISLE BACK
X41 S3 X41
126
106 INP. AISLE MIDDLE
S80
X40 X40 X42 S4 X42
D Br Bk D
2005-11-08
X40
40 Bl+Wh
Sh. 3 5
X15 X18 X26 S65 X26 X19 X16
13 14 61
004
X15 310 INP. LOAD SENSOR

OM
F Code
Version no.
X18 CABIN LIGHTS

E1
Bk R JUMPER
E1, E2 ONLY ON OM
E E
Svenska
E2
Bk R
S5
T code
Section
355,457
210465
4/8 Prod B
F F
1 2 3 4 5 6 7 8
5000
C Code
21 (38)
Electric System
004
OM
F Code
Version no.
22 (38)
1 2 3 4 5 6 7 8
A ELECTRONIC CARD A
A2
X28 X21/X22 X20 X17

S5
Electric System
96
T code
601 POT. FEED 7.35 VDC

Section
355,457
1
X28 X21/X22 X19 X16
66
R1 404 INP. SPEED REFERENCE VALUE
3
X28 X21/X22 X20 X17
97
602 POT. -
2/3C
2/3C
B B
1
3
K11
2
4
40 A1 A2 91
5000
C Code
Sh. 4 6 707 OUT. DRIVE, FORK DIRECTION
K13
2/3C
2/3C
A1 A2 92
1
3
708 OUT. DRIVE, STEER WHEEL DIRECTION

2
4
C DISPLAY C
Service Manual
A3
X20 X17
121
SERIE + 1 101 SERIE + SUPPLY
X20 X17
122
SERIE - 2 102 SERIE - SUPPLY
X20 X17
123
RX + 3 103 TX +
D D
X20 X17
124
RX - 4 104 TX -
2005-11-08
EMERGENCY SWITCH OFF EMERGENCY SWITCH OFF
CHASSIS CABIN KEY
S22 X15 X18 X21/X22 S21 S17 X21/X22 X18 X15
28 21 22 21 21 22 25 15 61a 22
Sh. 6 Sh. 4 8
E E
Svenska
210465
5/8 Prod B
F F
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
F50
A 1 ELECTRONIC CARD A
Sh. 1 A2
© BT Products AB
10A
28 28
Sh. 5 607 +24VDC BATTERY
F53
2 26
Sh. 2 608 +24VDC SUPPLY OUTPUTS
10A
F51
23
801 +24VDC STEER SUPPLY
B 20A B
40 40
Sh. 5 7 802 0V
F52 M6 X12
10A R Bk 101
M 803 OUT. +STEER MOTOR
X18 X15
X12
102
X18 X18 804 OUT. -STEER MOTOR
C U1 C
X27 X21 X17
Service Manual
R Bk 67
M 405 INP. STEERING WHEEL TACHO +
X21/X22 X21/X22 X22
X27 X21 X17

68
406 INP. STEERING WHEEL TACHO -
1
24 40 THE MAST
S99 X36 WITH PANEL FACING X22
EXTERNAL EQUIPMENT
5
(OPERATORS PANEL)
X13
D 98 D
X21/X22 603 STEER POT. +
2005-11-08
WORKING LIGHT
1
E3 X13
108 69
24 40 R2 407 INP. STEER POT.
2
X37
004
EXTERNAL EQUIPMENT E4 X13

OM
F Code
(ROOF) 108 99
604 STEER POT. -
Version no.
27 27
Sh. 4 610 OUT. PWR. SUPPLY: BALL BEARING SENSORS
E E
Svenska
140 140
Sh. 4 611 OUT. GROUND: BALL BEARING SENSORS
S5
T code
Section
355,457
210465
F 6/8 Prod B F
1 2 3 4 5 6 7 8
5000
C Code
23 (38)
Electric System
004
OM
F Code
1 2 3 4 5 6 7 8 Version no.
24 (38)
A A
ELECTRONIC CARD
S5
Electric System
A2
T code
Section
355,457
X34 Y10 X34

40 85
Sh. 6 701 OUT. BRAKE
X35 H2 X35
86
702 OUT, WARNING LIGHT
B B
R3
5000
C Code
470R/5W Y70
1 2 94
605 OUT. CABIN LOWER VALVE
REPLACES H2 ON OMC
Y30
1 2 87
703 OUT. BYPASS VALVE
C Y69 C
Service Manual
1 2 88
706 OUT. PROP LIFT VALVE
Y41
1 2 93
709 OUT. FORK LOWER VALVE
2/2D
1
K30
A1 A2 95
711 OUT. PUMP
2
D D
108 INP. MAX HALF SPEED
2005-11-08
109 INP. MAX CREEP SPEED
E E
Svenska
210465
F 7/8 Prod B F
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A X15 X18 X21/X22 A

22
© BT Products AB
Sh. 5
WIRE GUIDANCE ELECTRONIC CARD
A4 A2
W1
S120 X21/X22 X19 X16
1 WHITE 5 7 49
X24:1 X20:5 209 INP. WIRE GUIDANCE OFF
2 BROWN
X24:2
JUMPER FOR OM WITHOUT WIRE GUIDANCE
3 GREEN
X24:3
B B
X24:8 X20:1 511 OUT. +24VDC SUPPLY FOR WIRE GUIDANCE
5 GREY
X24:9
74
X20:9 501 INP. WIRE GUIDANCE OK.
76
X22:1 503 INP. LOCKED ON WIRE
7 SCREEN
W2
C 1 WHITE 75 C
X24:5 X22:2 502
Service Manual
INP. WIRE DETECT
2 BROWN
X24:6
79
X23:12 506 OUT. TRUCKSPEED / TRAVELDIR.
3 GREEN
X24:7
X24:11 X22:12 507 OUT. WIRE GUIDANCE REQUEST
X102
5 GREY 57
X24:12 Sh. 4
X20:6 X102
D 58 D
Sh. 4
2005-11-08
81
X23:13 508 0V SUPPLY FOR WIRE GUIDANCE
7 SCREEN
004
82
INP. STEER ANGLE X23:6 509 OUT. STEER WHEELANGLE
OM
F Code
Version no.
77
+/- 7,5VX21:11 504 INP. STEER REFERENCE
E STEERREFERENCE E
Svenska
78
0V X21:6 505 INP. REF. GROUND
S5
T code
Section
355,457
210465
F 8/8 Prod B F
1 2 3 4 5 6 7 8
5000
C Code
25 (38)
Electric System
OM S5 5000
Electric System
Version no. T code
004 355,457
2.12. Component list

Symbol Designation Function Note
A2 Logic card Main logic card
A3 Logic card Display
A4 Logic card Wire guidance Option: Wire guidance
E1 Fluorescent light Cabin light

fixtures
E2 Fluorescent light Cabin light
fixtures
E3 Headlights Work lights Option
E4 Headlights Work lights Option

F50 Fuse Operating current 10 A
F52 Fuse Optional equipment 10 A
F53 Fuse Operating current, output 10 A
G1 Battery + 24 V
H1 Horn
H2 Warning lamp

K11 Contactor Travelling in the fork direction
K13 Contactor Travelling in the drive wheel
direction
K200 Relay Control panel switching

OM S5 5000
Electric System
Version no. T code
004 355,457

K203 Time relay Control panel switching

M3 Motor Pump motor

R3 Resistor Circuit load Only OMW, OMCW
S3 Magneto switch End-of-aisle brake

S4 Magneto switch End-of-aisle brake
S17 Power switch Start key
S18 Power switch Horn
S21 Power switch Emergency switch
S34 Power switch Fork lifting Only OM, OMC
S41 Power switch Fork lowering Only OM, OMC
S48 Power switch Brakes
S65 Power switch Load detection Only OMW, OMCW
S69 Power switch Cabin lifting
S70 Power switch Cabin lowering
S79 Magneto switch Aisle indication
S80 Magneto switch Aisle indication Optionally, photocells
may be used
S81 Power switch Slack chain guard
S82 Power switch Slack chain guard
S87 Power switch Gate monitoring
S88 Power switch Gate monitoring

OM S5 5000
Electric System
Version no. T code
004 355,457

S99 Power switch Work lights Option
S100 Power switch Left dead man's handle Option: For aisle con-
trol
S101 Capacitive sensor Right dead man's handle
S104 Magneto switch Height reference
S109 Power switch Lift height limiter, bypass
S120 Power switch Activating wire guidance Option: Wire guidance
S200 Power switch Left dead man's handle
S201 Capacitive sensor Right dead man's handle
S202 Power switch Operator position
S209 Power switch Lift height limiter, bypass
S218 Power switch Horn
S221 Power switch Emergency switch
S234 Power switch Fork lifting
S241 Power switch Fork lowering
S248 Power switch Brakes
S269 Power switch Cabin lifting
S270 Power switch Cabin lowering
U1 Tachometer Steering sensor

U2 Tachometer Steering sensor
U10 Pulse transducer Cabin lift height measuring
U11 Pulse transducer Travel speed measuring

Y10 Coil Releases the brake

Y30 Valve coil Bypass
Y69 Valve coil Cabin and fork lifting

OM S5 5000
Electric System
Version no. T code
004 355,457


OM S5 5000
Electric System
Version no. T code
004 355,457
3. Functional description
This description follows the functional course of events. De-
tailed descriptions of each of the main components can be
found in the respective chapters.
3.1. Key in 0 position

When the battery is connected to the truck, the A2 logic card
receives 24 V power via inputs 408 and 607 over the fuse
F50, and via input 801 over the fuse F51, and the logic card
consequently powers up.
Stabilised voltage of 7.5 V is output from A2 output 601 to the
potentiometer (R1) in the speed controller.
3.2. Start
The truck is started by the operator turning the key to position
I. Voltage is fed via the operating fuse F50, the emergency
stop switch S21 and the key switch S17 to the transistor regu-
lator A1, input 1.
The transistor regulator for the drive motor A1 verifies that the
internal safety function is operating properly, and it then closes
the main contactor K10 that feeds voltage to the drive motor
armature and the pump contactor as well as information to A2,
input 309.
When K10 is closed, the A2 logic card, input 608, and all mi-
cro-switches and pulse transducers connected to the A2 input
receive power.
A2 sends control pulses to the tachometer U1 and the steering
motor M3.
All the indicator lamps in the display light briefly, and then only
the lamps for the normal position, time of day, fork height/op-
erating hours, battery status, and any possible error codes as
well as the firmware version number light.
The time that the key has been in position I is measured and
3.3. Control panel selection

Switch 202 is used to select the desired control panel.
S202 in neutral position (button in out position) activates the
controls for the fork direction. S202 in the active position (but-
ton depressed) activates the controls in the steering wheel di-
rection.

OM S5 5000
Electric System
Version no. T code
004 355,457
When S202 is closed (i.e. active) voltage is fed to the relays

K200, K201, K202 and K203. These relays in turn switch the
two control panels. Relay K203 has a time delay that prevents
any interruption when switching between the two steering ta-
chometers.
3.4. Dead man's handle

In order to be able to operate the truck, the right dead man's
handle must be engaged, and when travelling in narrow aisles
the left dead man's handle must also be engaged. When the
right dead man's handle is engaged, the brake is released. To
prevent malfunction, the dead man's handle is time-controlled.
The time is counted from the time the dead man's handles are
engaged, but is disregarded during truck travel or hydraulic
movements. Unless the dead man's handles are released
within a period of 3 minutes, truck travel and hydraulic opera-
tion functions are prevented. Once released, and then re-en-
gaged, the time starts counting from zero.
3.5. Presence control (outside narrow

aisles)
If the cabin gates are open, the operator must confirm his
presence.
All truck operations are prevented until the operator confirms
his presence through the following procedures:
• Engage the right dead man's handle S101/S201 using the
right hand. Release the parking brake.
• Turn the steering wheel with the left hand in order to gener-
ate a steering pulse.
It is only after this that the truck's drive and hydraulic functions
start to operate.
Confirmation of a present operator must be made within 5 sec-
onds of releasing the right dead man’s handle.
If the operator pushes down the speed controller when the key
is set to the I position, the controller must be returned to the
neutral position and the presence verification must be repeat-
ed in order for the truck to become operational.
Confirmation of a present operator, as explained in the section
“Open cabin gates” needs only be made once after the gates
have been closed.

OM S5 5000
Electric System
Version no. T code
004 355,457
3.6. Driving
The truck travels in the direction in which the controller is
moved. When driving, a voltage from the potentiometer R1/
R101 is fed to A2, input 404. This voltage determines both the
travel direction and speed.
When the speed rocker switch is depressed, the potentiometer
R1/R101 is actuated and the selected travel direction contac-
tor receives voltage from A2, output 707 or 708, and it closes
. The more the speed rocker switch is depressed, the higher/
lower the voltage fed from R1 to A2. A1 controls the drive mo-
tor revolutions based on the information received from A2.
Current is fed through the fuse F1, the M1 rotor, K11/K13, the
M1 field winding onto the M connector on the A1 logic card.
The speed is measured using the pulse transducer U11 situ-
ated on the drive motor.
The drive motor operating time is measured and stored in the
electronic unit.
3.7. Narrow aisle driving

The left dead man's handle, S100/S200, must be engaged for
narrow aisle driving.
3.7.1. Aisle driving with guiderail steering

When entering the aisle, the magneto switch S79 or S80 is ac-
tuated by magnets embedded in the floor. The magneto
switches may have been optionally replaced by a photocell
S80.
Upon this, the steering wheel of the truck is disengaged and
the A2 logic card controls steering in a position close to the
steering wheel centre position.
To adjust the steering wheel centre position, see the descrip-
tion of the A2 logic card, C code 5710.
The maximum speed of the truck is now automatically adapted
to the selected cabin height.

OM S5 5000
Electric System
Version no. T code
004 355,457
3.7.2. Aisle driving with wire guidance

The operator can request wire guidance by depressing the
button actuating the switch S120. The wire guidance box A4
then takes over control of the truck's steering system once the
wire guidance system is “tracking the wire”.
In order to maintain wire guidance speed, both inputs 306 and
307 must be high. This is achieved through actuation of mag-
neto switch S79 or S80 via the magnets embedded in the floor.
Pay attention to the jumper placement between the inputs on
sheet 8.
For a complete description of the trucks' wire guidance mode,
see C code 4500.
3.8. Travel speed

• Creep speed = 2.5 km/h
• The maximum current limit during acceleration is 220 A,
and when motor braking 330 A.
The travel speed is indicated for the “worst operating condi-
tions”, i.e. the forks are always expected to be at the maximum
lifting position.
3.8.1. Out of aisle

An open gate and a cabin height exceeding the programmed
limit result in a travel speed of 0.
• Fork height under 1.2 m results in maximum speed = full
speed.
• Fork heights above 3,0 m results in maximum speed =
creep speed.
3.8.2. In a narrow aisle, guiderail or wire guidance mode

• Fork height under 2.5 m results in maximum speed = full
speed.
ments.

OM S5 5000
Electric System
Version no. T code
004 355,457
3.9. Steering
When the steering wheel is turned, a signal from the tachom-
eter U1/U2 s fed to the input 405 on A2, which progressively
actuates the steering motor M3. The faster the steering wheel
motion, the faster the steering wheel motor turns. This rate of
progressiveness also implies that the faster the driving speed,
the lower will be the steering speed.
When the steering motor is turned, the steering wheel potenti-
ometer R2 is actuated and voltage is fed to A2, input 407.
Steering response can be set through a parameter. See the
description for the A2 logic card, C code 5710.

When the steering wheel is turned, the potentiometer R2
sends a signal to input 407 on the A2 logic card, indicating the
travel direction in the display.
3.11. Braking
Braking can be achieved in four different ways.
3.11.1. Motor braking (electric)

When the operator changes travel direction using the travel di-
rection selector, the travel direction contactors (K11 and K13)
switch. The A2 logic card, input 308, receives information from
A1 that motor braking is in effect and adjusts the control of A1.
While braking, the drive motor operates as a generator and
current is fed to the transistor regulator connector A and on-
wards through the built-in braking diode.
3.11.2. Automatic motor braking (adjustable parameter)

The automatic motor brake can be set and adjusted using the
firmware parameters. See the description for the A2 logic card,
C code 5710.
When the travel speed controller is released to the neutral po-
sition, a signal is sent from the transistor regulator by the A2
logic card on input 308. The logic card microprocessor then
feeds voltage to the opposite travel contactors, e.g. to K13
when travelling in the fork direction.
The braking force during automatic motor braking is deter-
mined by the current reference value set by the logic card con-
nector A1-11.

OM S5 5000
Electric System
Version no. T code
004 355,457
The braking force can be adjusted to 100% of maximum brak-

ing current by adjusting the parameter. The automatic motor
braking function remains engaged until the generated signal is
taken off input 308 or until the operator operates the speed
controller.
Automatic motor braking can be disengaged by setting the pa-
rameter to 0.
3.11.3. Service brake

When the operator presses down on the brake button S48/
S248, the current flow from A2, output 701, to the brake coil
Y10 is interrupted. The service brake is then applied.
3.11.4. Parking brake

When the right dead man's handle is released, the current flow
from the A2 logic card to the brake coil Y10 is interrupted. The
brake is then engaged.

When entering an aisle, no automatic speed reduction is re-
quired. When departing a narrow aisle, if the truck speed ex-
ceeds the creep speed when the truck passes a
predetermined point (approx. 7 m from end of aisle), it must in-
terrupt its travel and engage the brake.
truck can pass the "braking point" without engaging the
brakes. Bistable magneto switches, S3 and S4, are fitted to
the truck. Permanent magnets are installed in the floor of the
narrow aisle.
3.13. Cabin lifting

When the operator operates the cabin lift button S69/S269,
then the A2 logic card receives voltage on input 203. A2 then
actuates the bypass valve Y30 and closes the proportional
valve Y69 (ramp function), and it also engages the pump con-
tactor K30. The pump motor M3 starts to operate and both
pumps feed oil to the lifting cylinders.
If the battery guard detects the remaining battery capacity at a
20% or lower level, the pump motor function is blocked.

OM S5 5000
Electric System
Version no. T code
004 355,457
3.14. Cabin gates

The cabin height, at which the operator needs to keep the
gates lowered, can be programmed by the firmware parame-
ters. See the description for the A2 logic card, C code 5710.
The cabin gates close the switches S87 and S88 when they
are lowered, and feed +24 V to input 208. When the cabin is
lifted to the programmed height, 0-3.0 m, the drive, lift and low-
ering functions are blocked in case the gates are open.When
the gates are then lowered into position, all truck operations
again become operational.
It is possible to program the warning buzzer for open gates.
See the description for the A2 logic card, C code 5710.
The buzzer will then sound for 30 seconds if one or both gates
are open when the cabin lift height exceeds that of the refer-
ence sensor S 104. (This does not apply to OMC/OMCW.)
3.15. Load detection (only “OMW, OMCW”)

Switch S65 closes when a load carrier is placed on the forks.
If the cabin is lifted without a load carrier on the forks, all work
modes of the truck are blocked at a 1200 mm lifting height.
3.16. Height limiter

A height limit for truck outside narrow aisle and truck in narrow
aisle can be programmed. See the description for the A2 logic
card , C code 5710.
When the cabin reaches the height limit, further lifting is pre-
vented. To lift the cabin above this height, switch S109/S209
must be depressed. This feeds a signal to A2 and lifting can
continue.

When the operator operates the cabin lower button S70/270,
the A2 logic card receives voltage on input 204. A2 then opens
the proportional valve Y70 (ramp function). The oil is then re-
turned to the reservoir. The cabin is lowered.

OM S5 5000
Electric System
Version no. T code
004 355,457
3.18. Initial lift

When the operator operates the initial lift button S34/S234, the
A2 logic card receives voltage on input 205. A2 then actuates
the proportional valve Y69 and the pump contactor K30. The
pump motor M3 starts to operate and a pump feeds oil to the
initial lifting cylinder.

When the operator operates the initial lowering button S41/
S241, the A2 logic card receives voltage on input 206. A2 then
opens the valve Y41 (soft-opening function) and the oil can re-
turn to the reservoir. The forks are lowered.

The slack chain guards S81 and S82 (sheet 3) monitor slack-
ness of the cabin lifting chains. If slack is detected in any of the
chains, one of the slack chain guards is triggered and stops
lowering of the cabin. Lifting movement of 200 mm, however,
is allowed.
3.21. Miscellaneous
The wire guidance system uses its own set of instructions.
If the truck is not fitted with wire guidance, +20 V must be di-
rectly connected to A2/209.
The horn and cabin lighting, as well as any optional accesso-
ries such as spotlights, radio and onboard computer, receive
a power supply of +24 V via F52.
4. Default settings and adjustments

All settings, parameters and adjustments of the electric sys-
tem are described in the A2 logic card description in C code
5710.

OM S5 5000
Electric System
Version no. T code
004 355,457

OM S5.0 5460
Transistor regulator
TDC C. Nylin 001 355,356
1. Transistor regulator
Transistor regulator PUB 24 220 CD 3.
1.1. Motor connections

The transistor regulator has four connections for power
cables, as set out in the table below.

OM S5.0 5460
Version no T-code
001 355,356
Terminal Function
number
A Brake diode to the motor’s series field and
armature
B- Battery minus
B+ Battery plus
M Minus connection to the motor’s series field
2. Control circuit
The transistor controller have an integrated 11-pin connector
to provide the low power logic control connections. The desig-
nation of the pins are according to the table below.
Terminal- Con. Function

LD1 number
LD2
LD3 M 1 I Supply voltage +24 V
LD4 2 I Safety test
7 1 3 Not used
7 1 B+
8 2
9 3 4 I Not used
4
10 5
11 6 5 I Not used
6 I Minus for terminals 10 and 11
7 O Safety signal for main contactor
8 O Electrical motor brake
9 O Not used
10 I Reference value 0 - 5 V
11 I Current limit 0 - 5 V
I=Input
O=Output

OM S5.0 5460
Version no T-code
001 355,356
3. Technical specification
The technical specification for the BT-version of the Atlas-
Copco PUB 24220 CD3 transistor controller is according to
the table below.
PARAMETER SETTING UNITS DESCRIPTION

Operating voltage 24 Volt
Maximum voltage 29 Volt Overvoltage point
Minimum operating 14 Volt Undervoltage point
voltage
Frequency 16 kHz
Contactor voltage 24 Volt
oC
Ambient operating -35 - +55
temperature
Heatsink overtem- 85 oC 0A at 125oC
perature cutback
oC
Heatsink undertem- -20 50% current limit at start
perature cutback
Current Limit, Main 220 Amp
Current Limit, Plug 100-330 Amp Maximum plug current in the
armature. Depending on throttle
position.
Min. Duty Cycle 0 % Speed (duty factor) at minimum
throttle setting
Speed 100 % Modulation

OM S5.0 5460
Version no T-code
001 355,356
4. LED indications
LD1
LD2
LD3 M B-
LD4
71
B+
The controller have got four LED’s to indicate the operation

and diagnostic of faults.
LED No Colour Indicates Diagnosis

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

OM S5.0 5460
Version no T-code
001 355,356
5. Maintenance
There are no user-servicable parts inside the transistor con-
troller. No attempt should be made to open the controller.
OPENING THE CONTROLLER WILL VOID THE WAR-
RANTY!
It is however recommended that the controller exterior be
cleaned periodically.
5.1. Safety
The controller is inherently a high power device. When work-
ing around any battery powered vehicle, proper safety pre-
cautions should be taken. These include, but are not limited
to: proper training, wearing eye protection, avoiding loose
clothing, removing watches and jewelry, and using insulated
wrenches.
WARNING!
Risk of short circuits.
Remove all watches and jewelry and always use insulated
tools.
5.2. Cleaning
Although the controller requires virtually no maintenance if
properly installed, the following minor maintenance is recom-
mended on a regular 250 hours basis.
1. Remove power by disconnecting the battery.

2. Discharge the capacitors in the controller, by connecting a
load (such as a contactor coil or the horn) across the con-
troller’s B+ and B- terminals, before doing any work on the
controller.
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.
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.

OM S5.0 5460
Version no T-code
001 355,356
6. Safety control
6.1. Checking the transistor regulator’s

safety circuits
This check applies to all BT- trucks equipped with a transistor regulator
type: PUB 24 220 CD 3 .
• Lift up the truck using the points marked with lighting eyes.
• Place stable supports under the chassis, one on each side of the drive
wheel.
• Lower the truck on the supports.
Warning
!
The truck can overturn.

Risk of great personal injury and damage to property.
Ensure the truck is stable and that the drive wheel does not have contact with
the ground
• Remove the cover over the motor compartment.
• Swing out the panel with the electronic card A2. You can now work with
the transistor panel.
• Turn the ignition key so that the electronic card is voltage fed.
• Connect a 0,7 mm2 cable between the battery minus (B-) and the contact
for the control current (pin number 2, see diagram) on the transistor reg-
ulator. The main contactor K 10 should now release to indicate that the
transistor regulator’s safety system functions. If K 10 does not release,
replace the entire transistor regulator.
• Return the truck to its original condition after the check.
• Reset the safety circuits by turning the ignition key to the 0 position.

OM S5 5590
Control cables
SSD C Nylin 001 355-356, 457-458
Control cables
T-code Model Serial number Notes

355 OM 287595AA-
356 OMW 287595AA-
457 OMC 287595AA-
458 OMCW 287595AA-
1 Slack chain breaker

The slack chain breakers S81 and S82 (see Electrical
description 5000) monitor the tension of the cage lifting
chains. If slack occurs on any of the chains, one of the slack
chain breakers breaks and stops the lowering movement of
the cage. A lifting movement of 200 mm is permitted with an
actuated slack chain breaker.
2 Adjusting the slack chain breaker

• Inspect the seat and spring on the mounting. Repair any
defects.
• Adjust the distance between the proximity breaker’s break-
roller and the lever. Distance: 0–2 mm.
• The adjustment should be made during a normal service
(every third month) and when replacing the chains or when
adjusting the lifting chains.

OM S5 5590
Control cables
Version no T-code
001 355-356, 457-458

OM S5 5710
Electronic card
SSD K Hallman 001 355, 356
Electronic card

355 OM 287595AA-299208AA
356 OMW 287595AA-299208AA
1. Electronic card 149167 version

-001 and -002
1.1. General
The electronic card is equipped with green LED’s on the
inputs from micro switches and sensors and red LED’s on the
outputs to the contactors and valves. This card is also
equipped with a potentiometer for fine adjustment of the
straight position of the steering and three switches for setting
the programable parameters and displaying the history of the
warning and fault codes.

OM S5 5710
Electronic card
Version no T-code
001 355, 356
2. Connections
The LED’s at the connections are described in the tables as
shown below:
I = Input, green LED
O = Output, red LED
2.1. Connector no 1, display
Terminal LED no. Connec- Active Function

number tion
101 O +24 V Display — Series (+)
102 O 0V Display — Series (-)
103 O Display — TX (+), transmit data
104 O Display — TX (-), transmit data
105 105 I +24 V Driver controls in the fork direction
106 106 Spare, not connected
107 Spare, not connected

OM S5 5710
Electronic card
Version no T-code
001 355, 356
2.2. Connector no 2, cabin

number tion
201 201 I +24 V Right deadman’s handle
202 202 I +24 V Left deadman’s handle
203 203 I +24 V Cabin lift
204 204 I +24 V Cabin lowering
205 205 I +24 V Fork lift
206 206 I +24 V Fork lowering
207 207 I 0V Service brake
208 208 I +24 V Gate closed
209 209 I +24 V Wire guidance not active
210 210 I +24 V By-pass, lift limitation
211 211 I +24 V Chain guard

OM S5 5710
Electronic card
Version no T-code
001 355, 356
2.3. Connector no 3, height , speed and

aisle indication

number tion
301 301 I 0/24 V Cabin height, channel A ( pulses)
302 302 I 0/24 V Cabin height, channel B ( pulses)
303 303 I + 24 V Cabin height reference, 0.6 m
304 304 I 0/24 V Drive speed, M1, channel A (pulses)
305 305 I 0/24 V Drive speed, M1, channel B (pulses)
306 306 I +24 V Aisle indication, fork direction
307 307 I +24 V Aisle indication, drive wheel direction
308 308 I +24 V Plug braking
309 309 I +24 V The safety circuit of A1 is OK
310 310 I +24 V Gates closed, only walk through
311 311 I +24 V Spare, not connected

OM S5 5710
Electronic card
Version no T-code
001 355, 356
2.4. Connector no 4, drive and steer sig-

nals

number tion
401 O (-) Reference 0 V to the transistor
regulator
402 O 0-5V Reference voltage, driving speed
403 O 0-5V Reference voltage, current limit
404 I 0,75-6,75 V Reference voltage from R1
405 I +2/ -2 V Steering tacho +
406 I 0v Steering tacho -
407 I +7,5/ -7,5 V Reference voltage from R2, steering
angle
408 I +24 V Battery indicator, voltage
measurement +
409 I (-) Battery indicator, voltage
measurement -
410 I Battery indicator, current
measurement +
411 I Spare, not connected

OM S5 5710
Electronic card
Version no T-code
001 355, 356
2.5. Connector no 5, wire guidance option

number tion
501 501 I +24 V Wire guidance OK
502 502 I +24 V Wire detected
503 503 I +24 V Locked on wire
504 I +/-7,5 V Reference voltage wire guidance
505 I 0V Reference negative for 504
506 O +/-7,5 V Travel direction/truck speed
507 507 O +24 V Wire request
508 O 0V Negative, for wire guidance box
509 O +/-7,5 V Steering angle
511 O +24 V Voltage supply, for wire guidance box

OM S5 5710
Electronic card
Version no T-code
001 355, 356
2.6. Connector no 6, potentiometer cir-

cuits, voltage supply

number tion
601 O +7,5 V Voltage to R1
602 O 0V 0 volt to R1
603 O + 7,5 V + voltage to R2
604 O - 7,5 V - voltage to R2
605 O 0V Spare, negative, not connected
607 607 I + 24 V Battery voltage
608 608 I + 24 V Battery voltage from S17
609 I + 24 V Horn, filter
610 0V Spare, negative, not connected
611 0V Spare, negative, not connected

OM S5 5710
Electronic card
Version no T-code
001 355, 356
2.7. Connector no 7, brake, valves,

contactors

number tion
701 701 O 0V Brake. ( +24 V deactivates the brake)
702 702 O +24 V Warning light
703 703 O +24 V Valve for engaging pump no 2 at
cabin lift
704 704 O +24 V Valve, cabin lift
705 705 O +24 V Valve, fork lift
706 O Spare, not connected
707 707 O + 24 V Contactor K11, travel fork direction
708 708 O + 24 V Contactor K13, travel drive wheel
direction
709 709 O +24 V Valve, fork lowering
710 710 O +24 V Valve, cabin lowering
711 711 O +24 V Contactor K30, pump
2.8. Connector no 8, power supply steering

number tion
801 801 I + 24 V Battery voltage from F51
802 I (-) Battery negative
803 O Steering motor +
804 O Steering motor -
805 Not connected

OM S5 5710
Electronic card
Version no T-code
001 355, 356
3. LED’s, switches, potentiometer
LED Colour Function

STEER PWR Green Voltage feed to the steering control electronics
STEER 2X Yellow Steered wheel in straight position
CENTER
Switch Function
SELECT Switch to program parameters and error codes
UP Switch to program parameters and error codes
DOWN Switch to program parameters and error codes
Potentiometer Function
STEERPOT Adjustment of the steering, drive wheel straight
PROPVALVE Not in use on this truck type

OM S5 5710
Electronic card
Version no T-code
001 355, 356
4. Display
There is a possibility to look at the machine specific register
and program the clock for, e.g. summer or winter time.
Proceed as follows to look at the machine specific register:
• Press button SELECT, on the electronic card A2.

• Press SELECT once again to step to the next function.
The character window (B) will present the different functions:
• Height measuring, max fork height (showing as default)
• Time
• Warning and Error codes
• Parameters
• Running time
The address register will be shown in the left-hand section
and the value in the right-hand section for the ”Warning/Error
codes” and ”Parameters”.
.

OM S5 5710
Electronic card
Version no T-code
001 355, 356
4.1. Time
When it is possible to program the clock the character win-
dow for hours will flash and after pressing SELECT the min-
utes will flash.
• Change by stepping up using UP and down using DOWN
• Save the values and display the function by pressing
SELECT.
Function Value
hours 09 = 9h
minutes 35 = 35 min
When error codes are displayed in the character window (B)
the character box (F) will light and when the parameters are
displayed in character window (B) the character box (E) will
light. However, it is not possible to reprogram the parameters
in this mode. To change to the programming mode, see “Pro-
gramming parameters”.
Programming mode will quit if you do not press a key during a
10 second period.

OM S5 5710
Electronic card
Version no T-code
001 355, 356
4.2. Warning codes
Character Error code
Example: 26
When an error has occurred a signal sounds and a code is

displayed, for 10 sec, in the right-hand section of the charac-
ter window (B). The error is also shown in the character box
(F). If the error remains after 1 min the warning and signal will
be activated again for a 2 sec period.
This happens as long as the error is not rectified, the truck
can still be driven with all functions, as set out in the table.
Warning!
Ignoring error indications.
The safety of the truck is jeopardised.
Always check the operation of the truck before use.

OM S5 5710
Electronic card
Version no T-code
001 355, 356
4.2.1. Warning codes without registering
Code Type of error Probable cause Effect on the truck

no.
11 The steering servo elec- Steering jamming Reduced speed (creep
tronics have overheated speed) with reduced cur-
rent limit for the steering
motor
12 The height pulse sen- Faulty pulse sensor or Creep speed
sor gives no signal broken cable
when
lifting/lowering the cabin
above the reference
switch
13 Signal from height refer- Fault in reference switch Creep speed
ence switch is missing or cables
14 Signal from speed sen- Faulty sensor or broken Creep speed
sor channel A, missing cables
15 Signal from speed sen- Faulty switch or broken Creep speed
sor channel B, missing cables
16 Incorrect signal from Cables swapped, sensor Creep speed
speed sensors, channels incorrect mounting
swapped
17 Signal from chain Slack or broken chain Cabin lowering is blocked.
guards missing Only cabin lift max
200mm
18 Back-up battery in the Faulty electronicbox Data stored in the mem-
electronicbox discharge ory will be lost
19 The parameters of the The truck parameters is Changed parameters,
truck has been replaced lost, faulty electronicbox default values used
by default value
21 The potentiometer R1 The speed regulator actu- Drive function blocked.
gives too high voltage ated when key-switch on Speed regulator return to
when key-switch on or faulty potentiometer / neutral to inhibit the block-
broken cables ing
22 Wrong signal from Faulty potentiometer or Speed reduction. Wire
steering potentiometer broken cables guidance not allowed
R2

OM S5 5710
Electronic card
Version no T-code
001 355, 356
Code Type of error Probable cause Effect on the truck

no.
23 Deadman error Right deadman handle Drive function blocked.
active when key-switch on Release deadman handle
25 Error signal from driv- Fault in drivers for valves, Depends on the faulty unit
ers. contactors or cables
Check error reg.)
26 Wrong signal from Faulty potentiometer R1 Drive function blocked
speed potentiometer R1 or cables
27 The voltage measure- Intermittent contact or Flashing battery indicator
ment cables of the bat- broken cables
tery indicator are
disconnected
30 The right deadman’s The deadman’s handle The brake is activated.
handle is activated in been actevated too long Deactivate the dead-
spite of no function or faulty sensor/ cables man’s handle to inhibit the
being made during a brake function
longer time
31 The left deadman’s han- The deadman’s handle The brake is activated.
dle is activated in spite been actevated too long Deactivate the dead-
of no function being or faulty switch/ cables man’s handle to inhibit the
made during a longer brake function
time
32 The lift limit by-pass The lift limit by-pass The brake is activated.
switch is activated in switch been activated too Deactivate the dead-
spite of no function long or faulty switch/ man’s handle to inhibit the
being made during a cables brake function
longer time

OM S5 5710
Electronic card
Version no T-code
001 355, 356
4.2.2. Warning codes with registering
Code Type of error Code Type of error

no. no.
50 Fault in driver for valve Y69, cabin 57 Fault in driver for contactor K11,
lift fork direction
51 Fault in driver for valve Y70, cabin 58 Fault in driver for contactor K13,
lower steer wheel direction
52 Fault in driver for valve Y34, fork lift 59 Fault in driver for the signal wire
guidance activated
53 Fault in driver for valve Y41, fork 60 Fault in driver for the warning lamp
lower
54 Fault in driver for valve Y30, 2.nd 61 Fault in potentiometer R1 or bro-
pump ken cables
55 Fault in driver for contactor K30,
pump
The warning code is automatically registered. (Not shown on

the display.)
Registration takes place in the first of 80 possible positions
and moves the previous error one step downward.
With warning errors 50 - 61 the valve, contactor or cables are
either broken or short circuited. Even the electronoc card can
be broken
Only the actual function is disabled; other functions are not
affected.

OM S5 5710
Electronic card
Version no T-code
001 355, 356
4.3. Error codes
Caracter Error code
Example: 125
When an error has occurred a buzzer sounds at the same

time as an error code is displayed in the right-hand section of
the character window (B). (The error is also shown in the
character box (F).) The signal sounds until the ignition is
switched off and the voltage to the truck is cut.
If the error remains when the ignition is switched on again the
code will be shown and the signal will sound again.
Depending on the cause of the problem, the truck may oper-
ate in emergency mode. ( slow speed)
When an error code is shown the code is automatically regis-
tered in the error register. (The meaning of the error code is
shown in the table) Registration takes place in the first of 80
possible positions and moves the previous error one step
downward.

OM S5 5710
Electronic card
Version no T-code
001 355, 356
Press SELECT to get to the warning code/fault code register.
When the register is shown in the character window the latest

code is shown with the error code.
.
To see the date when the error occurred, press DOWN once
and to see the time press DOWN once again.
.
To see more of the registered errors, press UP.

.
WARNING
!

Always check the operation of the truck before use.

OM S5 5710
Electronic card
Version no T-code
001 355, 356
4.3.1. Error codes with registering
Code Type of error Probable cause

no
100 Fault in the drive stage for the brake coil Defective cable to Y10.
Defective brake coil
102 The safety circuit of A1 is activated Faulty transistor controller
110 The safety circuit of the wire guidance box 24 V is missing at terminal 209
have cut out without wire guidance requested.
24 V is missing at terminal 501
when wire guidance is requested.
111 Wire guidance not requested in a wire guided Driver error, request wire guidance
aisle Short circuit in wiring harness or
switch
112 Lost “wire detected” Incorrect adjustment of wire
guidance
113 Lost “locked on wire” Incorrect adjustment of wire
guidance
114 Steering angle too large Incorrect adjustment of steering
potentiometer
115 Aisle mid. sw. (S3, S4) closed outside aisle
120 Memory fault in the electronic unit. Faulty electronic card
121 Fault in the drive circuits of the steering servo Faulty electronic card
122 Steering servo electronics too hot Overload/faulty electronic card
123 Control voltage does not match reference Faulty electronic card
125 Faulty test pulses from steering tachometer Faulty tachometer, connections,
cables or electronic card
126 Steering motor circuit error Faulty steering motor, connec-
tions, cables orelectronic card
127 Communication error in A2 (steering) Faulty electronic card
130 Communication error in A2 (slave processor) Faulty electronic card
131 Safety relay 1 out of order Faulty electronic card
132 +24 V is missing to the steering control Faulty electronic card, broken
cables or broken fuse
133 Safety relay 2 out of order Faulty electronic card
140 Program error (wrong check sum) Faulty electronic card
141 Program error (wrong values) Faulty electronic card

OM S5 5710
Electronic card
Version no T-code
001 355, 356
5. Running time
When time meter reading is shown, the character box (d) is
illuminated. The time is shown as follows:
Caracter Time
.
Ignition time
. .
Total movement time

. .
Drive motor time

. .
Pump motor time

. .

OM S5 5710
Electronic card
Version no T-code
001 355, 356
6. Steering potentiometer
(STEERPOT)
The potentiometer is used for fine adjustment of the steering

wheel (drive wheel) centre position.
• Drive the truck (outside the aisle) so that it will travel in a
straight line, stop the truck by gently braking to avoid
changing the drive wheel alignment.
• Set the potentiometer to its middle position, 12 o’clock.
• Adjust the potentiometer R2 on the steering motor as accu-
rate as possible by measuring the resistance.
The potentiometer must be disconnected while measuring.
Measure the resistance at the end positions of the potenti-
ometer, set the potentiometer in its middle position by
using the ohm-meter.
• Fine adjust the STEERPOT so that both LED’s are lit at the
same time.

OM S5 5710
Electronic card
Version no T-code
001 355, 356
7. Parameters
The significance of the different parameters are shown in the
table in section ”Program parameters”. To see the different
parameters, press UP or DOWN.
7.1. Programming parameters

• Press down the brake button on the control panel at the
same time as the ignition key is turned.
• Step using UP and DOWN to the parameter you wish to
change.
• Press SELECT (the character window flashes).
• Change the value using UP/DOWN.
• Press SELECT to accept the value (the character window
stops flashing).
If you wish to change more parameters, step using UP/
DOWN to the parameter you wish to change and repeat from
press SELECT (the character window flashes).
Note!
Truck handling.
Modifying specific truck parameters will change the driving
characteristics of the truck.
Do not change any parameters without the necessary
know-how.
No. Parameter type Unit Min/ Std. Remarks

Max value
01 Steering sensitivity 1-5 3 1 = little sensitivity
5 = great sensitivity
In steps of 1
02 Drive motor, max speed % 10 - 100 In per cent of max. speed.
100 In steps of 5
03 Maximum drive speed % 10 - 100 In per cent of max. wire guid-
when in wire guidance 100 ance speed.
mode In steps of 5
04 Drive motor, half speed % 10 - 100 In per cent of max.half
100 speed.
In steps of 5

OM S5 5710
Electronic card
Version no T-code
001 355, 356

Max value
05 Drive motor, creep speed % 10 - 100 In per cent of max.creep
100 speed. In steps of 5
06 Drive motor, acceleration % 10 - 100 In per cent of max. accelera-
100 tion. In steps of 5
07 Drive motor, reversing % 10 - 100 In per cent of max. motor
power 100 reverse power.
In steps of 5
08 Auto plug braking % 0 - 100 100 In per cent of max. brake
power.
In steps of 5.
0 = disconnected
09 Max cabin height mm 1800 - In steps of 50
5000
10 Height limit outside aisle mm 0- 5000 In steps of 50
5000
11 Height limit in aisle mm 0- 5000 In steps of 50
5000
12 Cabin height when the mm 0- 3000 In steps of 50
gates must be closed 3000
13 Cabin height for max. mm 0- 1900 Cabin height when
speed in narrow aisle 1900 OPTIPACE starts.
In steps of 50
14 Time display, normal run- 1-5 1 1 = ignition time
ning time 2 = total movement time
3 = drive motor time
4 = pump motor time
15 Battery measurement 1 - 20 1 Setting the discharge curve
of the battery. The discharge
must be tested for each
installation In steps of 1
19 Clock year 0 - 99 In steps of 1
20 Clock day 1 - 31 In steps of 1
21 Clock month 1 - 12 In steps of 1

OM S5 5710
Electronic card
SSD K Hallman 002 355,356,457,458
Electronic card

355 OM 299209AA-
356 OMW 299209AA-
457 OMC 307476AA-
458 OMCW 307476AA-
1. Electronic card 149167

version -003 and -004
1.1. General
The electronic card is equipped with green LED’s on the
inputs from micro switches and sensors and red LED’s on the
outputs to the contactors and valves. This card is also
equipped with a potentiometer for fine adjustment of the
straight position of the steering and three switches for setting
the programable parameters and displaying the history of the
warning and fault codes.

OM S5 5710
Electronic card
Version no T-code
002 355,356,457,458
2. Connections and voltage on A2

The LED’s at the connections are described in the tables as
shown below:
O = Output, red LED
2.1. Connector no 1, display

number tion
106 106 I +24 V Aisle end brake

OM S5 5710
Electronic card
Version no T-code
002 355,356,457,458
2.2. Connector no 2, cabin

number tion

OM S5 5710
Electronic card
Version no T-code
002 355,356,457,458
2.3. Connector no 3, height , speed and

aisle indication

number tion
310 310 I +24 V Load sensing, forks, only walk
through version

OM S5 5710
Electronic card
Version no T-code
002 355,356,457,458
2.4. Connector no 4, drive and steer sig-

nals

number tion
401 O (-) Reference 0 V to the transistor
regulator
407 I +7,5/ -7,5 V Reference voltage from R2, steering
angle
408 I +24 V Battery indicator, voltage
measurement +
409 I (-) Battery indicator, voltage
measurement -
410 I Battery indicator, current
measurement +

OM S5 5710
Electronic card
Version no T-code
002 355,356,457,458
2.5. Connector no 5, wire guidance option

number tion

OM S5 5710
Electronic card
Version no T-code
002 355,356,457,458
2.6. Connector no 6, potentiometer cir-

cuits, voltage supply

number tion
608 608 I + 24 V Battery voltage from K10 for outputs
610 O + 24 V Voltage supply to speed and height
measuring
611 O 0V 0 volt, negative, to speed and height
measuring

OM S5 5710
Electronic card
Version no T-code
002 355,356,457,458
2.7. Connector no 7, brake, valves,

contactors

number tion
703 703 O +24 V Valve for engaging pump no 2 at
cabin lift
704 704 O +24 V Valve, cabin lift
705 705 O +24 V Valve, fork lift
706 O Spare, not connected
707 707 O + 24 V Contactor K11, travel fork direction
708 708 O + 24 V Contactor K13, travel drive wheel
direction
709 709 O +24 V Valve, fork lowering
710 710 O +24 V Valve, cabin lowering
2.8. Connector no 8, power supply steering

number tion
805 Not connected

OM S5 5710
Electronic card
Version no T-code
002 355,356,457,458
3. LED’s, switches, potentiometer
LED Colour Function

CENTER
Switch Function
PROPVALVE Not in use on this truck type

OM S5 5710
Electronic card
Version no T-code
002 355,356,457,458
4. Display
There is a possibility to look at the machine specific register
and program the clock for, e.g. summer or winter time.

• Time
• Parameters
• Running time
Programming is completed if no buttons are pressed for 10
seconds.
.

OM S5 5710
Electronic card
Version no T-code
002 355,356,457,458
4.1. Time
When it is possible to program the clock the character win-
dow for hours will flash and after pressing SELECT the min-
utes will flash.
• Save the values and display the function by pressing
SELECT.
Function Value
hours 09 = 9h
minutes 35 = 35 min
4.2. Warning codes/Error codes

With the function “Warning codes/Error codes” the address
register number is shown in the left-hand section and the value
in the right-hand section.
To read off the significance of the Warning code/Error code,
see the heading “Warning/Error codes”.
WARNING!
The truck’s safety is jeopardised.
Always check the operation of the truck before the truck is
used.
4.2.1. Warning codes
Charac- Warning code

ter
Example: 26
When a fault occurs a buzzer sounds and a code is displayed

for 10 seconds, on the right-hand section of the character dis-
play B. The fault is also shown in the character box F. If the
fault remains after 1 minute the warning and buzzer will repeat
for 2 seconds. This occurs as long as the fault is not rectified.

OM S5 5710
Electronic card
Version no T-code
002 355,356,457,458
4.2.2. Error codes

When a fault occurs a buzzer sounds at the same time as a
code is displayed on the right-hand section of the character
display B. The fault is also shown in the character box F. The
error code is shown until the key is turned and the truck’s volt-
age supply is cut.
If the fault remains when the key is turned again, the code will
be shown again and the buzzer will sound. Depending on the
cause it may be possible to emergency drive the truck at low
speed.
When the error code is shown the code is automatically regis-
tered in the error register. Registration takes place in the first
of the 80 possible places and moves the previous error one
step down.
Press SELECT to step to the register for warning and error
codes.
When the register is shown in the character display, the latest

fault is shown first with the error code.
.
To see the date when the fault occurred, press DOWN once
and to see the time press DOWN once again.
.
To see more of the registered faults, press UP.

.
4.3. Parameters
With the function “Parameters” the address register’s number
will be shown in the left-hand section and the value in the right-
hand section.
When parameters are shown in the character display B the
character box E will light. Parameters however can not be re-
programmed in this mode. To make changes switch to the pro-
gramming mode, see the heading “Programming
parameters”.

OM S5 5710
Electronic card
Version no T-code
002 355,356,457,458
4.4. Running time
4.4.1. Display the running meter reading and fork height

The character display shows the time and fork height. When
the running meter setting is shown, the character box D
comes on.
• The fork height Fh is shown as the default value.
Press UP to step through the different displays.
Caracter Time
.
Ignition time
. .
Total movement time

. .
Drive motor time

. .
Pump motor time

. .
Fork height inmetres, with

intial lift in highest position
5. Warning codes / Error codes

WARNING
!

Always check the operation of the truck before the truck is
used.

OM S5 5710
Electronic card
Version no T-code
002 355,356,457,458
5.1. Warning codes without registering
Code 11
Description The steering servo electronic has reached
over temperature, Steering servo current
limited
Effect on the truck Reduced speed, crawling speed with
reduced current limit for the steering motor
Cause of fault Jammed steering
Defective steering motor
Defective electronic card A2
Note
Code 12
Description Height pulse sensor gives no pulses with
cage lifting/lowering above the reference
height
Effect on the truck Crawling speed
Cause of fault Defective height sensor
Defective lifting system
Low lifting speed
Defective wiring to sensor
Note

OM S5 5710
Electronic card
Version no T-code
002 355,356,457,458
Code 13
Description No signal from height reference switch.
Height reference sensor does not change
level at reference height
Effect on Crawling speed
the truck
Cause of Defective/incorrectly adjusted reference
fault sensor
Defective wiring to reference sensor
Note
Code 14
Description Incorrect signal from speed sensor,
channel A
the truck
Cause of Defective speed sensor
fault
Defective wiring to speed sensor
Note

OM S5 5710
Electronic card
Version no T-code
002 355,356,457,458
Code 15
Description Incorrect signal from speed sensor,
channel B
the truck
Cause of Defective speed sensor
fault
Defective wiring to speed sensor
Note
Code 16
Description Incorrect signal from speed sensor. Signals
from the speed sensor do not correspond
with the throttle potentiometer
the truck
Cause of Incorrectly connected speed sensor
fault
Defective speed sensor
Note

OM S5 5710
Electronic card
Version no T-code
002 355,356,457,458
Code 17
Description Slack chain switch activated
Effect on Cage lowering blocked. Cage lift max
the truck 200 mm.
Cause of Slack lifting chain
fault
Incorrectly adjusted switch
Defective wiring to switch
Defective switch
Broken lifting chain
Note
Code 18
Description Battery level, back-up battery in memory low
Effect on Data stored in the memory will be lost
the truck
Cause of Defective electronic card A2
fault
Note

OM S5 5710
Electronic card
Version no T-code
002 355,356,457,458
Code 21
Description Potentiometer R1 give incorrect voltage when
ignition is switched on, start up
Effect on Driving blocked
the truck
Cause of Driver error, throttle activated when ignition is
fault switched on
Defective potentiometer
Defective wiring to potentiometer
Note Repeat to release blocking

Restart can reset the fault
Code 22
Description Incorrect signal from steering potentiometer
R2. Steering potentiometer outside permitted
range
Effect on Speed reduction. Wire guidance not permitted
the truck
Cause of Defective potentiometer
fault
Defective wiring to potentiometer
Note

OM S5 5710
Electronic card
Version no T-code
002 355,356,457,458
Code 23
Description Right-hand deadman’s handle activated dur-
ing start up
the truck
Cause of Driver error
fault
Defective deadman’s handle
Defective wiring to deadman’s handle
Note Release right-hand deadman’s handle

Code 25
Description Fault in output stage
Effect on Lack of functionality depending on the cause
the truck of the error
Cause of See code 50 - 60, log for more information
fault
Note

OM S5 5710
Electronic card
Version no T-code
002 355,356,457,458
Code 26
Description Fault in an input stage
the truck
Cause of See code 61, log for more information
fault
Note
Code 27
Description Fault in battery measuring
Effect on Flashing battery indicator
the truck
Cause of Bad contact on battery measuring cables
fault
Defective wiring, battery measuring cables
Defective battery
Note

OM S5 5710
Electronic card
Version no T-code
002 355,356,457,458
Code 30
Description Right-hand deadman’s handle activated > 3
min without any truck function being used
Effect on Brakes activated
the truck
fault
Code 31
Description Left-hand deadman’s handle activated > 3
min without any truck function being used
the truck
fault
Note Release left-hand deadman’s handle

OM S5 5710
Electronic card
Version no T-code
002 355,356,457,458
Code 32
Description Override-switch activated > 3 min without
any truck function being used
the truck
Cause of Defective switch
fault
Defective wiring to switch
Note
5.2. Warning codes with registering
Code 50
Description Output 704 short circuited/not connected
Effect on Cage lift not functional
the truck
Cause of Defective wiring to Y69
fault
Defective valve, coil
Note

OM S5 5710
Electronic card
Version no T-code
002 355,356,457,458
Code 51
Effect on Cage lowering not functional
the truck
fault
Note
Code 52
Effect on Fork lift not functional
the truck
fault
Note

OM S5 5710
Electronic card
Version no T-code
002 355,356,457,458
Code 53
Effect on Fork lowering not functional
the truck
fault
Note
Code 54
Effect on Low cage lift speed
the truck
fault
Note

OM S5 5710
Electronic card
Version no T-code
002 355,356,457,458
Code 55
Effect on Pump motor does not start
the truck
Cause of Defective wiring to K30
fault
Defective contactor, coil
Note
Code 57
Effect on Cannot drive in direction of forks
the truck
fault
Note

OM S5 5710
Electronic card
Version no T-code
002 355,356,457,458
Code 58
Effect on Cannot drive in direction of steering wheel
the truck
fault
Note
Code 59
Effect on Wire guidance, no value for steering angle
the truck received
Cause of Defective wiring to A4
fault
Note

OM S5 5710
Electronic card
Version no T-code
002 355,356,457,458
Code 60
Effect on Warning lamp does not function
the truck
Cause of Defective lamp H2
fault
Defective wiring to lamp H2
Note
Code 61
Description Throttle potentiometer R1 outside permitted
range
Effect on Truck cannot be driven
the truck
Cause of Defective wiring to R1
fault
Defective potentiometer R1
Note

OM S5 5710
Electronic card
Version no T-code
002 355,356,457,458
5.3. Error codes with registering
Code 100
Effect on Brakes do not release
the truck
fault
Defective brake Y10, coil
Note
Code 110
Description Signal WG OK drops with wire guidance
Effect on Safety relay on electronic card A4 tripped.
the truck Emergency braking
Cause of Incorrectly adjusted electronic card A4
fault
Note

OM S5 5710
Electronic card
Version no T-code
002 355,356,457,458
Code 111
Description Wire guidance not requested in wire guid-
ance aisle
Effect on Emergency braking
the truck
Cause of Driver error. Switch S120 must be activated
fault in wire guidance aisle
Defective switch S120
Defective wiring to S120
Incorrect position on magnet switches S79,
S80
Note
Code 112
Description Have not received signal “see wire”, wire not
detected
the truck
fault
Defective wiring to A4
Defective wire guidance generator
Note

OM S5 5710
Electronic card
Version no T-code
002 355,356,457,458
Code 113
Description Lost wire, derailed
the truck
fault
Defective wiring to A4
Inferior installation
Note
Code 114
Description Too large steering movement in wire guid-
ance aisle
Effect on
the truck
fault
Defective potentiometer R2
Defective wiring to R2
Inferior installation
Note

OM S5 5710
Electronic card
Version no T-code
002 355,356,457,458
Code 115
Description Aisle centre sensor activated outside of an
aisle
Effect on
the truck
Cause of Sensor S3 or S4 exposed to mechanical
fault effects, impact.
Defective sensor S3 or S4
Defective wiring to S3, S4
Note
Code 120
Description Memory cells for the steering set value con-
tains incorrect values
Effect on General error
the truck
Cause of Dislodged electronic card A2
fault
Note A restart can reset the error

OM S5 5710
Electronic card
Version no T-code
002 355,356,457,458
Code 121
Description Steering safety relay deactivated due to an
error voltage in the drive stage or communi-
cations error
Effect on
the truck
Cause of Defective control fuse F51
fault
Dislodged electronic card A2
Code 122
Description High heat in the steering-servo
Effect on
the truck
Cause of Too high ambient temperature
fault
Jammed steering
Defective wiring to steering motor
Note

OM S5 5710
Electronic card
Version no T-code
002 355,356,457,458
Code 123
Description Output voltage to the steering motor does
not correspond with the requested steering
Effect on
the truck
Cause of Defective wiring to steering motor
fault
Defective steering motor brushes
Note
Code 125
Description Error in the steering tachometer test
Effect on
the truck
Cause of Defective wiring to U1
fault
Defective steering tachometer brushes
Defective steering tachometer U1
Note

OM S5 5710
Electronic card
Version no T-code
002 355,356,457,458
Code 126
Description Error in connection test of steering motor
Effect on
the truck
fault
Defective wiring to steering motor
Defective steering motor brushes
Note
Code 127
Description Communications error between master/con-
trol processor
Effect on
the truck
Cause of Electronic card A2 dislodged
fault

OM S5 5710
Electronic card
Version no T-code
002 355,356,457,458
Code 131
Description Error in test of safety relay during start up
Effect on
the truck
Cause of Defective control fuseF51
fault
Code 132
Description Steering servo has no voltage
Effect on
the truck
fault
Electronic card A2 exposed to mechanical
effects, impact
Note

OM S5 5710
Electronic card
Version no T-code
002 355,356,457,458
Code 133
Effect on
the truck
Cause of Defective electronic card A2
fault
Code 140
Description Incorrect checksum in programme memory
during start up
Effect on
the truck
Cause of Electronic card A2 dislodged
fault

OM S5 5710
Electronic card
Version no T-code
002 355,356,457,458
Code 141
Description Height calculation does not work in the pro-
gramme
Effect on
the truck
Cause of Electronic Card A2 dislodged
fault

OM S5 5710
Electronic card
Version no T-code
002 355,356,457,458
6. Steering potentiometer
(STEERPOT)
The potentiometer is used for fine adjustment of the steering

wheel (drive wheel) centre position.
• Drive the truck (outside the aisle) so that it will travel in a
straight line, stop the truck by gently braking to avoid
changing the drive wheel alignment.
• Adjust the potentiometer R2 on the steering motor as accu-
rate as possible by measuring the resistance.
Measure the resistance at the end positions of the potenti-
ometer, set the potentiometer in its middle position by
using the ohm-meter.
same time.

OM S5 5710
Electronic card
Version no T-code
002 355,356,457,458
7. Parameters
The significance of the different parameters are shown in the
table in section ”Program parameters”. To see the different
parameters, press UP or DOWN.
7.1. Programming parameters

• Press the brake button on the control panel at the same
time as turning the ignition key.
• Step using UP and DOWN to the parameter you wish to
change.
• Press SELECT to accept the value (the character window
stops flashing).
If you wish to change more parameters, step using UP/
DOWN to the parameter you wish to change and repeat from
press SELECT (the character window flashes).
Note!
Truck handling.
Modifying specific truck parameters will change the driving
characteristics of the truck.
Do not change any parameters without the necessary
know-how.

OM S5 5710
Electronic card
Version no T-code
002 355,356,457,458

Max value
In steps of 1
02 Drive motor, max speed % 10 - 100 In per cent of max. speed.
100 In steps of 5
03 Maximum drive speed % 10 - 100 In per cent of max. wire guid-
when in wire guidance 100 ance speed.
mode In steps of 5
04 Drive motor, half speed % 10 - 100 In per cent of max.half
100 speed.
In steps of 5
In steps of 5
power.
In steps of 5.
0 = disconnected
5000
5000
5000
In steps of 50

OM S5 5710
Electronic card
Version no T-code
002 355,356,457,458

Max value
4 = pump motor time
15 Battery measurement 1 - 20 1 Setting the battery’s
discharge curve in steps of 1
The setting must be tested
for each installation.
A lower paramter value
permits greater discharge

OM S5 5710
Electronic card
Version no T-code
002 355,356,457,458

OM S5 5710

ITS K-G Andersson 003 355,356,457,458
Electronic card

355 OM 365014AA-
356 OMW 365014AA-
457 OMC 365014AA-
458 OMCW 365014AA-
1 Electronic card 149167 version -

005, 006 and 007
1.1 General
The electronic card is equipped with green LED’s on the inputs from
micro switches and sensors and red LED’s on the outputs to the
contactors and valves. This card is also equipped with a potentiom-
eter for fine adjustment of the straight position of the steering and
three switches for setting the programable parameters and display-
ing the history of the warning and fault codes.

OM S5 5710
Version no T-code
003 355,356,457,458
2 Connections and voltage on A2

The LED’s at the connections are described in the tables as shown
below:
O = Output, red LED
2.1 Connector no 1, display

number tion
106 106 I +24 V Aisle end brake
108 108 I +24 V Speed limitation, max half speed
109 109 I +24 V Speed limitation, max crawl spped
2.2 Connector no 2, cabin

number tion

OM S5 5710
Version no T-code
003 355,356,457,458
2.3 Connector no 3, height , speed and

aisle indication
number tion
310 310 I +24 V Load sensing, forks, only walk through ver-
sion
2.4 Connector no 4, drive and steer signals

number tion
401 O (-) Reference 0 V to the transistor regulator
407 I +7,5/ -7,5 V Reference voltage from R2, steering angle
408 I +24 V Battery indicator, voltage measurement +
409 I (-) Battery indicator, voltage measurement -
410 I Battery indicator, current measurement +

OM S5 5710
Version no T-code
003 355,356,457,458
2.5 Connector no 5, wire guidance option

number tion
2.6 Connector no 6, potentiometer circuits,

voltage supply
number tion
608 608 I + 24 V Battery voltage from K10 for outputs
610 O + 24 V Voltage supply to speed and height measuring
611 O 0V 0 volt, negative, to speed and height
measuring

OM S5 5710
Version no T-code
003 355,356,457,458
2.7 Connector no 7, brake, valves,

contactors

number tion
703 703 O +24 V Valve for connecting pump no. 2 with
cabin lift. Y30
704 704 O +24 V Valve, cab lift. Used in vers.002
705 705 O +24 V Valve, fork lift. Used in vers.002
706 O Proportional valve lift. Y69
707 707 O + 24 V Contactor K11, travel, direction of forks
708 708 O + 24 V Contactor K13, travel, direction of steer-
ing wheel
709 709 O +24 V Valve, fork lowering. Y41
710 710 O +24 V Valve, cab lowering. Used in vers.002
2.8 Connector no 8, power supply steering

number tion
805 Not connected

OM S5 5710
Version no T-code
003 355,356,457,458
3 LED’s, switches, potentiometer

LED Colour Function
CENTER
Switch Function
PROPVALVE Adjustment of the start ramp for the proportional valve.
Applies to the cab’s lift and lowering function.

OM S5 5710
Version no T-code
003 355,356,457,458
4 Display
There is a possibility to look at the machine specific register and pro-
gram the clock for, e.g. summer or winter time.

• Time
• Parameters
• Running time
Programming is completed if no buttons are pressed for 10 seconds.
.

OM S5 5710
Version no T-code
003 355,356,457,458
4.1 Time
When it is possible to program the clock the character window for
hours will flash and after pressing SELECT the minutes will flash.
• Save the values and display the function by pressing SELECT.
Function Value
hours 09 = 9h
minutes 35 = 35 min
4.2 Warning codes/Error codes

With the function “Warning codes/Error codes” the address register
number is shown in the left-hand section and the value in the right-
hand section.
To read off the significance of the Warning code/Error code, see the
heading “Warning/Error codes”.
WARNING!
The truck’s safety is jeopardised.
Always check the operation of the truck before the truck is used.
4.2.1 Warning codes
Character Warning code
Example: 26
When a fault occurs a buzzer sounds and a code is displayed for 10

seconds, on the right-hand section of the character display B. The
fault is also shown in the character box F. If the fault remains after 1
minute the warning and buzzer will repeat for 2 seconds. This occurs
as long as the fault is not rectified.

OM S5 5710
Version no T-code
003 355,356,457,458
4.2.2 Error codes

When a fault occurs a buzzer sounds at the same time as a code is
displayed on the right-hand section of the character display B. The
fault is also shown in the character box F. The error code is shown
until the key is turned and the truck’s voltage supply is cut.
If the fault remains when the key is turned again, the code will be
shown again and the buzzer will sound. Depending on the cause it
may be possible to emergency drive the truck at low speed.
When the error code is shown the code is automatically registered
in the error register. Registration takes place in the first of the 80
possible places and moves the previous error one step down.
Press SELECT to step to the register for warning and error codes.
When the register is shown in the character display, the latest fault
is shown first with the error code.
.
To see the date when the fault occurred, press DOWN once and to
see the time press DOWN once again.
.
To see more of the registered faults, press UP.

.
4.3 Parameters
With the function “Parameters” the address register’s number will be
shown in the left-hand section and the value in the right-hand sec-
tion.
When parameters are shown in the character display B the charac-
ter box E will light. Parameters however can not be reprogrammed
in this mode. To make changes switch to the programming mode,
see the heading “Programming parameters”.

OM S5 5710
Version no T-code
003 355,356,457,458
4.4 Running time
4.4.1 Display the running meter reading and fork height

The character display shows the time and fork height. When the run-
ning meter setting is shown, the character box D comes on.
• The fork height Fh is shown as the default value.
Press UP to step through the different displays.
Caracter Time
.
. . Ignition time
.
. . Total movement time

.
Drive motor time

. .
. . Pump motor time
Fork height inmetres, with intial

lift in highest position

OM S5 5710
Version no T-code
003 355,356,457,458
5 Warning codes / Error codes

WARNING
!Ignoring error indications.
Always check the operation of the truck before the truck is used.
5.1 Warning codes without registering
Code 11
Description The steering servo electronic has reached
over temperature, Steering servo current
limited
Effect on the truck Reduced speed, crawling speed with
reduced current limit for the steering
motor
Cause of fault 1. Jammed steering
2. Defective steering motor
3. Defective electronic card A2
Note
Code 12
Description Height pulse sensor gives no pulses with
cage lifting/lowering above the reference
height
Effect on the truck Crawling speed
Cause of fault 1. Defective wiring to sensor
2. Low lifting speed, defective lifting sys-
tem
3. Defective height sensor
Note

OM S5 5710
Version no T-code
003 355,356,457,458
Height pulse sensor U10
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.
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.
3. Replace the height sensor.
4. If the measures above do not rectify the problem, then replace
the A2 electronic card.

OM S5 5710
Version no T-code
003 355,356,457,458
Code 13
Description No signal from height reference switch.
Height reference sensor does not change level
at reference height
Effect on the Crawling speed
truck
Cause of 1. Defective/incorrectly adjusted reference sen-
fault sor
2. The magnet on the lift cabin is missing
3. Defective wiring to reference sensor
Note
Height reference switch S104
1. Check whether the magneto switch S104 is correctly installed.

2. Check whether the magnet is correctly installed.
3. Check whether the cables 22 and 54 are intact.
Note!
Inspect the flexible lead connectors X14 and X30.

OM S5 5710
Version no T-code
003 355,356,457,458
Code 14
Description Incorrect signal from speed sensor, channel A
truck
Cause of 1. Defective wiring to speed sensor
fault
2. Defective speed sensor
Note
Code 15
Description Incorrect signal from speed sensor, channel B
truck
Cause of 1. Defective wiring to speed sensor
fault
2. Defective speed sensor
Note

OM S5 5710
Version no T-code
003 355,356,457,458
Speed sensor U11
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.
2. Replace the speed sensor U11

OM S5 5710
Version no T-code
003 355,356,457,458
Code 17
Description Slack chain switch activated
Effect on the Cage lowering blocked. Cage lift max 200 mm.
truck
Cause of 1. Slack/broken lifting chain
fault
2. Incorrectly adjusted switch
3. Defective switch
4. Defective wiring to switch
Note

OM S5 5710
Version no T-code
003 355,356,457,458
Slack chain guards S81 and S82
1. Verify that none of the lifting chains is slack or broken.

Tension/replace the lifting chain.
2. Inspect the adjustment of the micro-switches S81 and S82.
3. Inspect the operation of the micro-switches S81 and S82.
4. Inspect the cables 22, 111 and 51.
Note! Inspect the flexible lead connectors X15, X16, X18, X19
and X27.

OM S5 5710
Version no T-code
003 355,356,457,458
Code 18
Description Battery level, back-up battery in memory low
Effect on the Data stored in the memory will be lost
truck
Cause of 1. Defective electronic card A2
fault
Note
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.
Code 19
Description Incorrect parameter setting, new start valve has
been loaded.
Effect on the Possibly a customer specific parameter has
truck been replaced by a default valve. Must be pro-
grammed manually.
Cause 1. A disturance in the electrical system
Remark
1. Reprogramme the customer-specific parameters.

2. Om ovanstående inte hjälper, byt A2-kortet.

OM S5 5710
Version no T-code
003 355,356,457,458
Code 21
Description Potentiometer R1 gives incorrect voiltage when
the key is switched on, start-up.
Effect on the Immobilized
truck
Cause 1. Driver error, accelerator actuated when key is
switched on.
2. Defective potentiometer
3. Defective cables to potentiometer
Remark New attempt required to unblock immobilization.
Restart can reset the fault.
Speed potentiometer R1
1. Verify that the accelerator control returns to the neutral position

when not actuated.
2. Check whether the potentiometer R1 is intact.
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.

OM S5 5710
Version no T-code
003 355,356,457,458
Code 22
Description Incorrect signal from steering potentiometer R2.
Steering potentiometer outside permitted range
Effect on the Speed reduction. Wire guidance not permitted
truck
Cause of 1. Defective potentiometer
fault
2. Defective wiring to potentiometer
Note
Potentiometer for steer signal feedback, R2
1. Check whether the potentiometer R2 is intact.

connector X13, between R2 and the A2 electronic card

OM S5 5710
Version no T-code
003 355,356,457,458
Code 23
Description Right-hand deadman’s handle activated during
start up
Effect on the Driving blocked
truck
Cause of 1. Driver error
fault
2. Defective wiring to deadman’s handle
3. Defective deadman’s handle
Right dead man's handle S101
1. Check whether the operator is operating the truck incorrectly.

2. Inspect the power supply cables 22 and 40 as well as the flexi-
ble 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.
3. Replace the dead man's handle S101.

OM S5 5710
Version no T-code
003 355,356,457,458
Code 25
Description Fault in output stage
Effect on the Lack of functionality depending on the cause of
truck the error
Cause of 1. See code 50 - 60, log for more information
fault
Note
1. Press the SELECT button on the A2 electronic card to advance

to the warning and error code register.
Note! When the key is switched off, the error must be present
in order to be recorded in the error log.
Code 26
Description Fault in an input stage
Effect on the Driving blocked
truck
Cause of 1. See code 61, log for more information
fault
Note
1. Press the SELECT button on the A2 electronic card to advance

to the warning and error code register.
Note! When the key is switched off, the error must be present
in order to be recorded in the error log.

OM S5 5710
Version no T-code
003 355,356,457,458
Code 27
Description Fault in battery measuring
Effect on the Flashing battery indicator
truck
Cause of 1. Bad contact on battery measuring cables
fault
2. Defective wiring, battery measuring cables
3. Defective battery
Note
Measuring the battery
1. Inspect the measuring cables 70, 71 and 72, the battery cable
connections and the A2 electronic card.
2. Check whether the measuring cables 70, 71 and 72 are intact.
3. Verify that the battery is OK.

OM S5 5710
Version no T-code
003 355,356,457,458
Code 30
Description Right-hand deadman’s handle activated > 3 min
without any truck function being used
Effect on the Brakes activated
truck
fault

OM S5 5710
Version no T-code
003 355,356,457,458
Right dead man's handle S101
1. Verify that nothing, which can affect the dead man’s handle, is
stuck to the dead man's handle.
2. Inspect the power supply cables 22 and 40 as well as the flexi-
ble 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.
3. Replace the dead man's handle S101.

OM S5 5710
Version no T-code
003 355,356,457,458
Code 31
Description Left-hand deadman’s handle activated > 3 min
without any truck function being used
truck
fault
Note Release left-hand deadman’s handle

OM S5 5710
Version no T-code
003 355,356,457,458
Left dead man's handle S100
1. Kontrollera att inget som kan aktivera dödmansfunktionen sitter

fast på dödmansknappen.
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.
3. Replace the micro-switch in the dead man's handle S100.

OM S5 5710
Version no T-code
003 355,356,457,458
Code 32
Description Override-switch activated > 3 min without any
truck function being used
truck
Cause of 1. Defective wiring to switch
fault
2. Defective switch
Note
Override switch S109
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.
2. Replace the micro-switch S109.

OM S5 5710
Version no T-code
003 355,356,457,458
5.2 Warning codes with registering
Code 53
Effect on the Fork lowering not functional
truck
Cause of 1. Defective wiring to Y41
fault
2. Defective valve, coil
Note
Fork lowering valve Y41
1. Inspect the cable 40 to Y41 and the cable 93 to A2.

2. Measure the Ohm resistance in the coil at Y41. It should be
approx. 20 Ohms.

OM S5 5710
Version no T-code
003 355,356,457,458
Code 54
Effect on the Low cage lift speed
truck
fault
2. Defective valve, coil
Note
Hydraulic valve Y30

approx. 20 Ohms.

OM S5 5710
Version no T-code
003 355,356,457,458
Code 55
Effect on the Pump motor does not start
truck
Cause of 1. Defective wiring to K30
fault
2. Defective contactor, coil
Note
Pump contactor K30
1. Inspect the cable 40 to K30 and the cable 95 to A2.

2. Measure the Ohm resistance in the coil at K30. It should be
approx. 20 Ohms.

OM S5 5710
Version no T-code
003 355,356,457,458
Code 57
Effect on the Cannot drive in direction of forks
truck
fault
Note
Drive contactor K11, fork direction
1. Inspect the cable 40 to K11and the cable 91 to A2.

approx. 20 Ohms.

OM S5 5710
Version no T-code
003 355,356,457,458
Code 58
Effect on the Cannot drive in direction of steering wheel
truck
fault
Note
Drive contactor K13, steering wheel direction
1. Inspect the cable 40 to K13 and the cable 92 to A2.

approx. 30 Ohms.

OM S5 5710
Version no T-code
003 355,356,457,458
Code 59
Effect on the Wire guidance, no value for steering angle
truck received
Cause of 1. Defective cabling between A2 and A4
fault
Note
Output from A2 to input at A4, steering angle value

‘
1. Inspect the cable 82 between A2/509 and A4/ X23:6.

2. Replace the A4 electronic card.

OM S5 5710
Version no T-code
003 355,356,457,458
Code 60
Effect on the Warning indicator/resistor does not operat
truck
Cause of 1. Defective indicator H2/resistor R3
fault
2. Defective cabling to the indicator H2/resistor
R3
Note
Warning indicator H2/Resistor R3
1. Verify that the indicator H2 is intact. At OMC, the indicator has

been replaced by the resistor R3 (470 Ohms, 5 Watts).
2. Inspect the cable 40 to H2/R3 and the cable 86 to A2.

OM S5 5710
Version no T-code
003 355,356,457,458
Code 61
Description Throttle potentiometer R1, speed control, out-
side permitted range
Effect on the Truck cannot be driven
truck
Cause of 1. Defective wiring to R1
fault
2. Defective potentiometer R1
Note
Speed control potentiometer R1
1. Check whether the cables 96, 66 and 97, between the potenti-
ometer R1 and the A2 electronic card, are intact.
Note! Inspect the flexible lead connectors X16, X17, X20, X21/
22 and X28.
2. Replace the potentiometer R1.

OM S5 5710
Version no T-code
003 355,356,457,458
5.3 Error codes with registering
Code 100
Effect on the Brakes do not release
truck
fault
2. Defective brake coil Y10
Note
Brake coil Y10

Note! Inspect the flexible lead connector X34.
approx. 10 Ohms.

OM S5 5710
Version no T-code
003 355,356,457,458
Code 102
Description Monitoring in the transistor regulator signals a
fault
Effect on the Driving does not operate; K10 goes low
truck
Cause of 1. Inspect the safety relay circuit
fault
2. Check travel circuits
Remark
Safety relay circuit in the A1 regulator
1. Inspect the voltage on output 7 of A1. If it is 24 volts, then

inspect the cables 60 to K10 and A2/309.
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.

OM S5 5710
Version no T-code
003 355,356,457,458
Code 110
Description Signal WG OK drops with wire guidance
Effect on the Safety relay on electronic card A4 tripped. Emer-
truck gency braking
Cause of 1. Check the cables
fault
2. Incorrectly adjusted electronic card A4
Note
Safety relay circuit of wire guidance system

(Only for wire guidance)
1. Check whether the cable 74 between A2 and A4 is intact.

2. Inspect/readjust the wire guidance system.
3. Replace the A4 electronic card and adjust the wire guidance
system.

OM S5 5710
Version no T-code
003 355,356,457,458
Code 111
Description Wire guidance not requested in wire guidance
aisle
Effect on the Emergency braking
truck
Cause of 1. Driver error. Switch S120 must be activated in
fault wire guidance aisle
2. Incorrect position on magnet switches S79,
S80
3. Defective wiring to S120
4. Defective switch S120
Note

OM S5 5710
Version no T-code
003 355,356,457,458
Wire guidance switch S120
1. Inspect S120 and verify that the operator understands how it

operates.
2. Verify that the magneto switch S79 or S80 has not closed when
the truck is outside the narrow aisle.
3. Inspect the cable 22 to S120 and the cable 49 to the A2 elec-
tronic 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.
4. Inspect S120.

OM S5 5710
Version no T-code
003 355,356,457,458
Code 112
Description Have not received signal “see wire”, wire not
detected
truck
Cause of 1. Defective wire guidance generator
fault
2. Defective fuse on A4 electronic card
4. Defective wiring to A4
Note

OM S5 5710
Version no T-code
003 355,356,457,458
Wire not detected
1. Inspect the wire generator.

2. Inspect the fuse F on the A4 electronic card.
4. Check whether the cable 75 between A2 and A4 is intact.

OM S5 5710
Version no T-code
003 355,356,457,458
Code 113
Description Lost wire, derailed
truck
Cause of 1. Defective wire guidance generator
fault
2. Inferior installation
3. Defective fuse on A4 electronic card
4. Defective wiring to A4
Note

OM S5 5710
Version no T-code
003 355,356,457,458
Emergency braking
If several trucks show the same problem
1. Check that the wire generator is operating.

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.
If only one truck shows the problem
3. Inspect the fuse F on the A4 electronic card.

4. Check whether the cables between the antennas and the A4
electronic card are intact.

OM S5 5710
Version no T-code
003 355,356,457,458
Code 114
Description Too large steering movement in wire guidance
aisle
Effect on the
truck
Cause of 1. Incorrectly adjusted wire guidance system
fault
2. Defective potentiometer R2
3. Defective wiring to R2
4. Inferior installation
Note

OM S5 5710
Version no T-code
003 355,356,457,458
Steering response of potentiometer R2

.

2. Inspect the potentiometer R2
connector X13.
4. Check that the cable has been correctly set in the floor. It
should not be buried too deep or shallow.

OM S5 5710
Version no T-code
003 355,356,457,458
Code 115
Description Aisle centre sensor activated outside of an aisle
Effect on the
truck
Cause of 1. Sensor S3 or S4 exposed to mechanical
fault effects, impact.
2. Defective sensor S3 or S4
3. Defective wiring to S3, S4
Note

OM S5 5710
Version no T-code
003 355,356,457,458
Sensors S3 and S4 for end-of-aisle braking
1. Verify that the sensor and/or mountings have not been

destroyed through mechanical stress.
2. Verify that the electric operation of the sensors S3 and S4 is
correct by subjecting them to a magnet.
3. Inspect the cables 22 and 126 to the sensors S3 and S4.
Note! Inspect the flexible lead connectors X40, X41 and X42.

OM S5 5710
Version no T-code
003 355,356,457,458
Code 120
Description Memory cells for the steering set value contains
incorrect values
Effect on the General error
truck
Cause of 1. Dislodged electronic card A2
fault
1. Restart the truck.

Code 121
Description Steering safety relay deactivated due to an error
voltage in the drive stage or communications
error
Effect on the
truck
Cause of 1. Defective control fuse F51
fault
2. Dislodged electronic card A2

OM S5 5710
Version no T-code
003 355,356,457,458
Fuse F51

2. Does LED 801 light? If not, inspect the fuse F51, 20A.

OM S5 5710
Version no T-code
003 355,356,457,458
Code 122
Description High heat in the steering-servo
Effect on the
truck
Cause of 1. Too high ambient temperature
fault
2. Jammed steering
3. Defective wiring to steering motor
Note

OM S5 5710
Version no T-code
003 355,356,457,458
Steering servo
1. Check that the fans are operating.

2. Check that the steering has no mechanical seizure.
3. Inspect the cables 101 and 102 as well as the flexible lead con-
nector X12 to M6.
4. Inspect the steering motor M6.

OM S5 5710
Version no T-code
003 355,356,457,458
Code 123
Description Output voltage to the steering motor does not
correspond with the requested steering
Effect on the
truck
Cause of 1. Defective wiring to steering motor
fault
2. Defective steering motor brushes
Note

OM S5 5710
Version no T-code
003 355,356,457,458
Steering motor M6
nector to M6.
2. Check whether the carbons in the steering motor M6 are OK.
3. Verify that the steering motor is OK.

OM S5 5710
Version no T-code
003 355,356,457,458
Code 125
Description Error in the steering tachometer test
Effect on the
truck
Cause of 1. Defective wiring to U1
fault
2. Defective steering tachometer brushes
3. Defective steering tachometer U1
Note

OM S5 5710
Version no T-code
003 355,356,457,458
Steering tachometer U1

nectors X17, X21 and X27 to U1.
2. Inspect the tachometer carbon brushes.
3. Inspect the tachometer.

OM S5 5710
Version no T-code
003 355,356,457,458
Code 126
Description Error in connection test of steering motor
Effect on the
truck
fault
2. Defective wiring to steering motor
3. Defective steering motor brushes
Note

OM S5 5710
Version no T-code
003 355,356,457,458
Steering servo
1. Inspect the fuse F51 and 20A as well as the cables 1 and 23 to
input 801 on A2.
nector X12 to M6.
3. Check whether the carbons in the steering motor M6 are OK.
4. Verify that the steering motor is OK.

OM S5 5710
Version no T-code
003 355,356,457,458
Code 127
Description Communications error between master/control
processor
Effect on the
truck
Cause of 1. Electronic card A2 dislodged
fault

Code 130
Description Communication error between the master/slave
processors
Effect on the
truck
Cause 1. Electronic card A2 dislodged
Remark Restart can reset the fault

Code 131
Effect on the
truck
Cause of 1. Defective control fuseF51
fault
1. Inspect the fuse F51. Restart the truck.


OM S5 5710
Version no T-code
003 355,356,457,458
Code 132
Description Steering servo has no voltage
Effect on the
truck
fault
2. Electronic card A2 exposed to mechanical
effects, impact. Defective electronic card A2
Note
1. Inspect the fuse F53.

Code 133
Effect on the
truck
Cause of 1. Defective electronic card A2
fault
1. Restart the truck. Replace the A2 electronic card.
Code 140
Description Incorrect checksum in programme memory dur-
ing start up
Effect on the
truck
Cause of 1. Electronic card A2 dislodged
fault
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.

OM S5 5710
Version no T-code
003 355,356,457,458
Code 141
Description Programming error
Effect on the
truck
Cause of 1. Electronic Card A2 dislodged
fault

6 Steering potentiometer (STEERPOT)
The potentiometer is used for fine adjustment of the steering wheel

(drive wheel) centre position.
• Drive the truck (outside the aisle) so that it will travel in a straight
line, stop the truck by gently braking to avoid changing the drive
wheel alignment.
• Adjust the potentiometer R2 on the steering motor as accurate
as possible by measuring the resistance.
Measure the resistance at the end positions of the potentiome-
ter, set the potentiometer in its middle position by using the ohm-
meter.
same time.

OM S5 5710
Version no T-code
003 355,356,457,458
7 Parameters
The significance of the different parameters are shown in the table
in section ”Program parameters”. To see the different parameters,
press UP or DOWN.
7.1 Programming parameters

• Press the brake button on the control panel at the same time as
turning the ignition key.
• Step using UP and DOWN to the parameter you wish to change.
• Press SELECT to accept the value (the character window stops
flashing).
If you wish to change more parameters, step using UP/DOWN to the
parameter you wish to change and repeat from press SELECT (the
character window flashes).
Note!
Truck handling.
Modifying specific truck parameters will change the driving char-
acteristics of the truck.
Do not change any parameters without the necessary know-how.

Max value
In steps of 1
02 Drive motor, max speed % 10-100 100 In per cent of max. speed.
(note 1) In steps of 5
03 Maximum drive speed when % 10 - 100 In per cent of max. wire guid-
in wire guidance mode 100 ance speed. In steps of 5
04 Drive motor, half speed % 10 - 100 In per cent of max.half speed.
100 In steps of 5
In steps of 5

OM S5 5710
Version no T-code
003 355,356,457,458

Max value
power. In steps of 5.
0 = disconnected
5000
5000
5000
In steps of 50
4 = pump motor time
15 Battery measurement 1 - 20 10 Setting of the battery’s dis-
charge curve.
In increments of 1.
The setting must be made
through testing for each instal-
lation.
A lower parameter value allows
a lower discharge
16 Warning buzzer gates open 0 -1 0 0 = Buzzer warning off
1 = Buzzer warning on
17 Card set for use of propor- 0 -1 1 0 = on/off valves
tional valves 1 = proportional valves
18 Delay time, Lifting/Lowering 0 = long delay time, for order
picking.
1 - 3 short delay time, for pallet
handling, where 3 is the short-
est time

OM S5 5710
Version no T-code
003 355,356,457,458
Note 1: Value for Japan. See also information plate on truck:

OM S5 5710
Version no T-code
003 355,356,457,458

OM S6.0 6000
Hydraulic system
TDC K.Hallman 001 355,356
Hydraulic system
1. General
The hydraulic system consist of the following functions:
a) Lifting / lowering of the cabin with 2 lift cylinders.
b) Lifting / lowering of the forks with 1 lift cylinder.
In the description the same symbols are used as seen on the
hydraulic drawings.

OM S6.0 6000
Hydraulic system
Version no T-code
001 355,356
2. Hydraulic diagram

OM S6.0 6000
Hydraulic system
Version no T-code
001 355,356
2.1. Symbols
The table gives explanations to the symbols used in the
hydraulic diagram.

Single-acting Directional control
hydraulic cylinder valve 3/2,
three ports, two
distinct positions,
electro-magnetic
controlled
Filter Directional control
valve 4/3,
four ports, three
distinct positions,
electro-magnetic
controlled
Reservoir (Tank) Working (pres-
sure) line
Non-return valve Working (pres-

sure) line with
junction
Non-return valve, Pilot (control) line

spring loaded
(valve for broken
hoses)
One-way restrictor Enclosure of two

valve (lowering or more functions
restriction valve) contained in one
unit

OM S6.0 6000
Hydraulic system
Version no T-code
001 355,356

Gate-valve (emer- Electric motor and
gency lowering) two pumps with
fixed displace-
ment on the same
shaft, one direction
of flow
Pressure relief
valve
2.2. Component description

The table gives explanations to the component descriptions
used in the hydraulic diagram.
Pos. Designation Function Remark

Y30 Solinoid valve Closes by cabin lift
Y34 Solinoid valve Fork lift Soft opening/closing
valve
Y41 Solinoid valve Fork lowering Soft opening/closing
valve
Y69 Solinoid valve Control valve cabin lift Soft opening/closing
valve
Y70 Solinoid valve Cabin lowering Soft opening/closing
valve
2 Non-return Closes by cabin lowering Stops the pumps from
valve running backwards
3 Pressure Open by overload 140 Bar
relief valve
4 Flow restric- Reduces cabin loweringspeed
tor
5 Flow restric- Reduces cabin loweringspeed
tor

OM S6.0 6000
Hydraulic system
Version no T-code
001 355,356

6 Emergency Emergency lowering, cabin
lowering
valve
7 Non-return Safety valve Closes in case of a bro-
valve ken hose
3.1. Cabin lift

When the cabin lifts both pumps starts. They are working on
the same pump motor shaft. The valve Y69 opens in a soft
way. One of the pumps is giving its pressure through the non-
return valve (2) and Y69 to the main lift cylinders. The other
pump is giving its pressure throughY30, the nonreturn valve
(2) and Y69 to the main lift cylinders.
During cabin lift is Y30 closed.
The overload valve (3) will open if the load is too heavy.
3.2. Cabin lowering

The valve Y70 opens when lowering the cabin.
The oil returns from the cylinders through the activated valve,
the flow restrictor (4) and the oil filter to the tank.
There is an emergency lowering valve (6) in the valve block.
Each main liftcylinder have a safety valve(7) built-in in its bot-
tom part.
3.3. Fork lift

When the forks lifts both pumps starts. Valve Y30 is open dur-
ing fork lift. This means that only one pump gives pressure to
the fork lift cylinder.
Fork lift is done with help of the valve Y34.

OM S6.0 6000
Hydraulic system
Version no T-code
001 355,356
3.4. Fork lowering.

Fork lowering is done with help of the valve Y41.
The oil returns from the cylinder through the activated valve,
the reduction (5) and the oil filter to the tank.
3.5. Hydraulic data

3.5.1. Operating pressure
The operating pressure at rated load is: 125 bar
3.5.2. Relief pressure

The relief valve opens at the following pressure: 140 bar
3.5.3. Pump flow

The pump flow at at operating pressure for the rated load is:
18 litre/min

OM S6 6000
Hydraulic system
ITS C Nylin 002 355,356,457,458
Hydraulic system

355 OM 365014AA-
356 OMW 365014AA-
457 OMC 365014AA-
458 OMCW 365014AA-
1 General
The hydraulic system consists of the functions:
a) Lifting/lowering the driver cage with 2 lift cylinders.
b) Lifting/lowering the forks with 1 lift cylinder.
Only those designations that can be found on the hydraulics
diagram are used in the text.

OM S6 6000
Hydraulic system
Version no T-code
002 355,356,457,458
2 Hydraulic diagram

OM S6 6000
Hydraulic system
Version no T-code
002 355,356,457,458
2.1 Symbols
The table explains the symbols used on the
hydraulic diagram.

Single acting hydraulic Prop. valve.
cylinder Two ports, continuously
opening and closing,
electromagnetically con-
trolled.
Filter Directional valves, four

ports, two distinct posi-
tions, electromagneti-
cally controlled.
Tank Pressure pipe.
Non-return valve Pressure pipe with cou-

pling.
Non-return valve, Pilot pipe.

spring-loaded
(hose rupture valve)
One way throttle valve Limit for units contain-

(lowering brake valve) ing two or more func-
tions.

OM S6 6000
Hydraulic system
Version no T-code
002 355,356,457,458

Shutoff valve Electric motor and two
(emergency lowering) pumps with a fixed dis-
placement on the same
shaft, one-way flow.
Pressure limit valve Flow limiting valve.

Two ports.
2.2 Component description

The component designations used on the hydraulic diagrams
are explained in the table.
Pos. Description Function Remarks

Y30 Solenoid valve Activated with cage lift.
Y41 Solenoid valve Fork lowering. Gradual opening/clos-
ing valve.
Y69 Proportional Control valve cage and fork lifting. Opened and closed with
valve the ramp function from
the program.
Y70 Proportional Cage lowering Opened and closed with
valve the ramp function from
the program.
PR1 Overflow valve Opens with an overload, forks. 160 Bar
PR2 Overflow valve Opens with an overload, cage. 117 Bar
F1 Flow valve Gives max. cage lowering speed. 30l/min
F2 Flow valve Gives max. fork lowering speed. 8l/min
Y5 Emergency low- Emergency lowering, cage.
ering valve

OM S6 6000
Hydraulic system
Version no T-code
002 355,356,457,458
3 Operating description
3.1 Cage lifting

When the cage is lifted the double pumps start. They act on
the same pump motor shaft. The valve Y30 is actuated. The
flow from one of the pumps runs through Y30 to the other
pump’s flow, the collective flow runs through the non-return
valve to the lift cylinders. The flow is controlled by propor-
tional valve Y69, that lies as a hydraulic shunt back to the
tank. Y69 is controlled by a pre-programmed ramp function.
When the lift is started Y69 is open, during the lift it is closed,
during the stop phase it opens again.
The overflow valve PR2 opens in the event of an overload.
3.2 Cage lowering

Y70 is actuated with lowering.
Oil now runs from the lift cylinders through the activated pro-
portional valve Y70, which is controlled by a pre-programmed
ramp function. On via the flow valve F1, preset to a max flow
of 30l/min, to the tank via the oil filter.
A manual emergency lowering valve Y5, is located in the
valve assembly.
Each air cylinder has a hose rupture valve in the bottom stud.
3.3 Fork lift

When the forks are lifted the double pumps start. Valve Y30 is
not activated while the forks are lifted. This means that only
one pump provides pressure to the lift cylinders. Oil runs
through Y30, via the non-return valve to the fork cylinder.
Fork lifting takes place with the help of proportional valve
Y69, which lies as a hydraulic shunt back to the tank. Y69 is
controlled by a pre-programmed ramp function. When the lift
is started Y69 is open, during the lift it is closed, during the
stop phase it opens again.
The overflow valve PR1 opens in the event of an overload.

OM S6 6000
Hydraulic system
Version no T-code
002 355,356,457,458
3.4 Fork lowering

Valve Y41 is activated when the forks are lowered.
The oil now runs from the fork cylinder through the activated
valve Y41, which is a gradually opening/closing valve. On via
the flow valve F2, preset to a max flow of 8 l/min, to the tank
via the oil filter.
3.5 Hydraulic data

3.5.1 Working pressure
Working pressure at max load is: 125 bar.
3.5.2 Safety pressure

Overflow valve opens at the following pressure: 140 bar.
3.5.3 Pump flow

Pump flow at the working pressure for max. load is: 18 litres/
min.

OM S6 6000
Hydraulic system
Version no T-code
002 355,356,457,458
3.6 Valve assembly

OM S6 6000
Hydraulic system
Version no T-code
002 355,356,457,458

OM S6.0 6210
Valve block
Valve block
1. General
All active valves on the valve block are electromagnetic

valves activated by signals from the electronic card of the
truck. For complete understanding of the function of the
valves, see also C-code 5000 and5710.

OM S6.0 6210
Valve block
Version no T-code
001 355,356
1.1. Komponents and descriptions

J

Y30 Solinoid valve Closes by cabin lift Connects both hydrau-
lic pumps when lifting
the cabin
Y34 Solinoid valve Fork lift Soft opening/closing
valve
Y41 Solinoid valve Fork lowering Soft opening/closing
valve
Y69 Solinoid valve Control valve cabin lift Soft opening/closing
valve
Y70 Solinoid valve Cabin lowering Soft opening/closing
valve
H Port for cabin lift
I Port for initial lift
M Port for measuring of hydraulic
pressure
P1 Inlet pump no 1
P2 Inlet pump no 2
T Return pipe
3 Pressure Open by overload 140 Bar
relief valve
6 Emergency Emergency lowering, cabin
lowering
valve

OM S6.0 6210
Valve block
Version no T-code
001 355,356
2. Valves
Here is a description of the individual valves in the valve
block. See also C-code 6000.
2.1. By-pass valveY30
The by-pass valve Y30 is a two-position magnetic valve with

spring loaded return to its neutral position.
The valve is used to connect and disconnect the second of
the twin pumps of the hydraulic system at different lifting func-
tions.
When the valve is in-active (not the position of the picture),
lifting of the forks, the oil flows from pump no 1 at the “P”-port
to the Tank port.
When the valve is activated (the position of the picture), lifting
of the cabin, the piston is drawn by the magnet to open the
channel from the “P”-port to the the “A”-port.

OM S6.0 6210
Valve block
Version no T-code
001 355,356
2.2. Directional valves Y34, Y41, Y69 and

Y70.
The directional valves operates in pairs, Y34/Y41 at fork

lift/loweting and Y69/Y70 at cabin lift/lowering.
The valves are of the “soft” opening/closing type, meaning
that the valve piston opens and reduces the oil flow gradually,
to obtain a smooth start and stop of the lift/lower motion.
2.3. Pressure relief valve
The pressure relief valve is the safety valve of the hydraulic

system, to prevent high oil pressure.
Warning
Too high hydralic pressure.
Ejection of hydraulic oil.
Never change the adjustment of the pressure relief valve
without using a pressure gauge connected to the
measuring port of the valve block. The pressure must not
be adjusted higher than what is specified according to the
technical data of this truck type.

OM S6.0 6210
Valve block
Version no T-code
001 355,356
2.3.1. Adjustment
• Connect the pressure gauge to the port “M” on the valve
block.
• Remove the cover cap of the adjustment screw.
• Lift the fork to mechanical stop and check the reading of
the gauge.
• Turn the adjustment screw clockwise to increase the pres-
sure or counter clockwise to reduce the pressure.
• Stop the adjustment when the reading of the pressure
gauge shows 140 bar.
• Fit the cover cap and tighten firmly.
2.4. Emergency lowering valve
The emergency lowering valve shall only be used to lower the

cabin if the lift/lowering function have lost its power supply
when the cabin is in a raised position.
• Loosen the inner locking nut.
• Open the valve by turning the outer nut counter clockwise.
The lowering speed will vary depending on how much the
valve is opened. The lowering speed can not exceed 0,4
m/s.
• When the cabin has reached its lowest position, close the
valve completely and lock it with the locking nut.

OM S6.0 6210
Valve block
Version no T-code
001 355,356

OM S7 7120
Main lift chain system
ITS S Blom 001 355, 356,457, 458

T- Model Machine no. Remarks

code
355 OM 0.85, 0.85 C all
356 OM 0.85 W all
457 OMC all
458 OMCW all
1 General
Applies to all machines with a mast.
NOTE!
On machines with T-code 407 RR B7-B8/15, 408 RR B7C-B8C/15,
413 RR E7-E8/15 and 414 RR E7C-E8C the chains should be
replaced every 2.5 years.
2 Checking the chain setting

The lift chains must be adjusted at regular periods due to stretching,
see below. The chain setting is checked during servicing as set out
in the maintenance schedule.
Any adjustment is made with the chain mounting bolts.
Adjust the fork height according to C code 7100, 7420, 7700 and
7800 as applicable.
Service Manual 2002-12-02 English 1 (8)

OM S7 7120
Version no T-code
001 355, 356,457, 458
3 Chain inspection
The chains are exposed to two types of wear, outline wear and
stretching. Wear to the bolts and disc holes is caused by stretching.
The chains are also affected by the environment they are used in.
3.1 Noise
If lubrication has been insufficient there will be metallic friction on the
chain and this will result in noise.
The chain should be replaced.
3.2 Surface rust

Surface rust is easy to recognize as the chain will be reddish brown.
Deep-seated rust has generally started and the chain has impaired
strength.
The chain should be replaced
3.3 Rusty links

Fretting corrosion results in a reddish brown powder being visible by
the outer discs. It can also appear as if the chain is bleeding when
lubricated.
3.4 Stiff links

If it is not possible to pull out the chain to its normal position this can
be because of link rust or seizing.

OM S7 7120
Version no T-code
001 355, 356,457, 458
3.5 Bolt rotation

Bolt rotation can be a phenomenon of stiff links. The fault is easy to
see when comparing with a new chain.
The chain should be replaced
.
3.6 Loose bolts

If a bolt is loose it will protrude from the side of the chain, which is
due to a stiff link or bolt rotation.

OM S7 7120
Version no T-code
001 355, 356,457, 458
3.7 Outline wear
H2 H3
P = Pitch
H2 = Nominal disc height.
H3 = Minimum disc height.
A new lift chain has a specific nominal disc height, defined as H2 in

the figure. As the truck is used the lift chain wears radically, on the
side that runs over the chain sprocket. The minimum disc height is
define as H3 in the figure and denotes the minimum permitted value
of the disc height.
Maximal permitted outline wear is 5% of the height H2. If a lift
chain reaches the maximum level of wear, the chain should be
replaced.
The nominal and minimum disc heights for respective lift chains are
stated in the table in the chapter “Stretching”.

OM S7 7120
Version no T-code
001 355, 356,457, 458
3.8 Stretching
The amount of stretch on a lift chain is measured on the part of the
chain that runs over the chain sprocket. The amount of stretch may,
at the most, be 2% on the most worn section of the chain. Measure-
ment is suitably made over 300-1000 mm of the chain.
The nominal and maximum permitted chain lengths for lift chains
are stated in the table below.
Type of Nominal Minimum Pitch P Nominal chain Maximum permit-

chain disc height disc height (mm) length for 20/30/ ted chain length for
H2 ( mm) H3 (mm) 50 discs (mm) 20/30/50 discs (mm)
3/4”, 2x3 17.8 16.9 19.05 381/572/953 389/583/972
3/4”, 3x4 17.8 16.9 19.05 381/572/953 389/583/972
3/4”, 4x6 17.8 16.9 19.05 381/572/953 389/583/972
1”, 4x4 23,6 22,4 25,4 508/762/1270 518/777/1295
1”, 6x6 23,6 22,4 25,4 508/762/1270 518/777/1295
Wear to the bolts and around the holes on the discs are a reason
why the chain stretches. The chain should be replaced if stretch-
ing is more than 2%.
3.9 Damage
The chain should be replaced if damaged in any way.

OM S7 7120
Version no T-code
001 355, 356,457, 458
3.10 Damaged discs

If a disc has broken on the chain, this can be due to overloading or
corrosion.
3.11 Damaged bolts

It can be difficult to discover whether a bolt has broken. It can appear
as bolt rotation and/or that the outer disc is loose.
3.12 Dirty chain

If a chain is very dirty it is first and foremost recommended that it is
replaced. It can also be dismantled and cleaned as set out in the
chapter “Cleaning”.
4 Cleaning
If a chain is very dirty it is recommended that it is replaced.
Dirty chains should be cleaned before they are lubricated, e.g. by
washing with solvent such as diesel or petrol.
The chain should be blown dry using compressed air and lubricated
directly after cleaning
NOTE!
Exercise care with degreasing agent as these can contain abra-
sives.

OM S7 7120
Version no T-code
001 355, 356,457, 458
5 Lubrication
Mineral and synthetic oils can be used to relubricate Rexnord
chains.
NOTE!
Lubricant must not contain substances such as molybdenum
disulphide, PTFE or the like.
A lift chain should be offloaded from the weight of the fork carriage
(hanging free) when lubricated.
• Lubrication intervals:
- 500 hours with normal operations
- 100 hours when driving in rugged environments such as cold
stores and corrosive environments.
The chains are sprayed with lubricant. Note the entire chain must be
lubricated, even the fastening bolts. It is especially important that the
part of the chain which runs over the chain sprocket is well lubricat-
ed.
The lubricate must comply with the viscosity demands at respective
temperatures as set out in the table below. The following lubricants
are recommended:
Ambient Viscosity Recommended Products*
temperature class
> - 40°C VG 15 Klüberoil 4UH 1-15, Klüber
< - 30°C Lubrication
> - 30°C VG 68 Klüberoil 4UH 1-68N, Klüber
< + 5°C Lubrication
Anticorit LBO 160 TT, Fuchs
DEA
> + 5°C VG 150 Klüberoil 4UH 1-150N, Klüber
< + 45°C Lubrication
Anticorit LBO 160, Fuchs DEA
Rexoil, Rexnord Kette
>+ 45°C VG 220 Klüberoil 4UH 1-220N, Klüber
<+ 80°C Lubrication
* Equivalent products from another manufacturer may be used.
NOTE!
Do not use a special rust protective agent to prevent
rust on the lift chains.
These agents impair the lubrication of the chains. Regular lubri-
cation is the best method to prevent rust attack.

OM S7 7120
Version no T-code
001 355, 356,457, 458

OM S7 7310
Lift cylinder
SSD K.Hallman 001 355,356,457,458
Lift cylinder

355 OM 287595AA-
356 OMW 287595AA-
457 OMC 307476AA-
458 OMCW 307476AA-
1. General
There are two lift cylinders in the mast, of the type single acting
telescopic cylinders.
Each cylinder is fitted with a lowering brake valve to prevent
the cab from falling in the event of a ruptured hose.
The cylinders have an integrated damping piston that automat-
ically slows the cab’s lowering speed just before the bottom
position.
The table of essential tools for assembling and dismantling is
presented below.
2. Tools
Tool Note
number
08-15366 Assembling the piston rod seal on 08-15367
08-15367 Assembling the piston rod seal on the
piston
08-15368 Assembling the collar on 08-15369
08-15369 Assembling the collar on 08-15370
08-15370 Assembling the collar on piston rod
08-15393 Pipe wrench
08-15400 Assembling the lowering brake valve

OM S7 7310
Lift cylinder
Version no T-code
001 355,356,457,458
3. Lift cylinder
3.1. Dismantling/assembling the cylinder

from/in the mast
3.1.1. Dismantling
• Lift up the cage approx. 400-500 mm and block under the
inner guide.
• Loosen the piston rod’s mounting bolt 1 on the inner guide.
• Press down the lowering button for the cab so that the
hydraulic system becomes depressurised.
• At the same time as the lowering button is pressed, press
the piston rod into the cylinder so that the piston rod
releases from the guide pin 2.
• Cut the ties holding the cable harness and the return oil
hose. Dismantle the return oil hose from the connection on
the cylinder.
• Loosen the hydraulic pipe from the cylinder.
• Loosen the cylinder’s lower mounting bolt 3 from the mast
frame.
• Dismantle the cylinder support 4.
• Lift out the cylinder from the mast.
• Save the shims, 5, fitted the cylinder.

OM S7 7310
Lift cylinder
Version no T-code
001 355,356,457,458
3.1.2. Assembling
• Place the cylinder in position in the mast. Make sure the
guide pin centres in its hole.
• Place the shims, 5, in position under the cylinder.
NOTE!
Make sure the shims are placed on the same side as they
were originally fitted if both cylinders are dismantled.
• Fit the cylinder support 4 to support the cylinder during the
rest of the assembly procedure.
• Fit the cylinder’s lower mounting bolt 3. Do not tighten the
bolt fully.
• Connect the hydraulic pipe to the cylinder.
• Use the machine’s hydraulic system to move the cylinder
piston/pistons towards the inner guide’s top beam. make
sure to guide the guide pin/pin in its hole.
Warning!
Pinch risk.
Exercise great care when carrying out this stage of the
assembly to avoid pinch injuries to your hands/fingers.
• Fit the cylinder’s upper mounting bolt 1.

• Tighten the cylinder’s mounting bolts 1, 3 to 86.9 Nm.
• Adjust the cylinder support, 4, against the cylinder.
• Lift up the cage and remove the material used to block up
the truck under the inner guide.
• Check the adjustment of the lifting chains and that the
mast lifts straight. See C-code 7120.

OM S7 7310
Lift cylinder
Version no T-code
001 355,356,457,458
3.2. Dismantling the cylinder

• Secure the bottom insert 7 in a vice and let the top section
rest against, e.g. a cradle so that the cylinder rests horizon-
tally.
• Knock the top sleeve 1 and the cylinder lightly with a rub-
ber mallet, you may to need to heat this carefully.
• Unscrew the top sleeve 1 using the pipe wrench 08-15393.
• Carefully remove the piston from the cylinder so that the
threads are not damaged. Place the piston rod on a soft,
clean surface so that it is not damaged.
• Knock out the top sleeve 1 with a rubber mallet.
3.3. Dismantling the piston rod seals,

guide ring, guide ring holder and locking
ring from the lift cylinder
• Remove the locking ring 6.
• Pry off the piston rod seal 5.
• Dismantle the guide ring holder 3.
• Pry off the guide ring 4 from the holder 3.
• Remove the locking ring 2.

OM S7 7310
Lift cylinder
Version no T-code
001 355,356,457,458
3.4. Assembling the locking ring, piston

rod seal, guide ring and guide ring holder
in the lift cylinder
• Fit the locking ring 2 on the piston rod using the tools
08-15368, 08-15369 and 08-15370.
• Fit the guide ring 4 on the guide ring holder 3.
• Fit the guide ring holder 3 on the piston rod.
• Place the assembly tool 08-15367 on the piston rod.
• Place the piston rod seal 5 on the assembly tool 08-15366.
• Fit the piston rod seal 5 on the piston rod.
• Fit the locking ring 6.
3.5. Dismantling and assembling the low-

ering brake valve
• Dismantling and assembling of the lowering brake valve 4
is carried out using the tool 08-15400.
3.6. Assembling the cylinder

• Use assembly tool 08-15364 when you insert the piston
rod in the cylinder.
• Remove the assembly sleeve 08-15364.
• Fit the top sleeve 1 on the piston rod using a rubber mallet.
• Screw the top sleeve in the cylinder a few turns.
• Apply the flange seal FD 1042 on threads.
• Tighten using hook wrench 08-15391.
NOTE!
The flange seal takes 4 hours to dry, the cylinder must not
be used before this.

OM S7 7310
Lift cylinder
Version no T-code
001 355,356,457,458

OM S
Extra equipment – 9500
ITS K-G Andersson
1. Dry powder extinguisher

The truck is equipped with a fire extinguisher/powder extinguisher.
The following information and instructions can be read on the extin-
guisher — follow the instructions carefully.
2 kg ABC Powder
13A 89BC
The letters signify:
A: Wood, paper, textiles
B: Liquids, oils
C: Gases
Extinguishing agent: Prestolit Ultra
Propellant:Nitrogen 15 bar
Functional range: -30° C to +60° C
CE-0409
The digits 13 and 89 represent the fire extinguisher’s capacity for
fires involving the specified materials.
In the event of fire, the powder extinguisher

should be employed as follows:
1. Remove the safety catch.
2. Aim the nozzle at the base of the flames
3. Press the handle down

OM S
ITS K-G Andersson
1.1. Regular checks of the powder extin-

guisher – truck driver
The following points can be found on the powder extinguisher and
these can also be found in the driver’s manual for the truck.
• Check regularly that the pressure gauge indicator is in the green
field. If the indicator is in the red field, the apparatus is useless
and must be recharged.
• Recharge the extinguisher immediately after use. Contact an au-
thorised service company.
• Make sure that the extinguisher is checked once a year by a qual-
ified service engineer (from an authorised service company for
fire protection) and that a workshop review is carried out every 10
years.
Only material/parts approved by the manufacturer may be used.
1.2. Inspection of powder extinguisher in

service inspection of the truck
The powder extinguisher must be checked once a year in connec-
tion with servicing of the truck.
• Check that the pressure gauge indicator is in the green field. If the
indicator is in the red field, the apparatus is useless and must be
recharged.
• Check that the powder extinguisher is intact and in working order
and is in the correct location in the truck.
• If the extinguisher does not appear to function satisfactorily, make
sure that an authorised service company is contacted.

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What modifications were made to the OME truck?

What modifications were made to the OME truck?

Master Service Manual

Ring binder number: Part number: 153875-040

This notification contains supplementary information about the fol-

T code Model Product number Date of Chapter

This page is intentionally left blank

1- Modification of the OME truck

1.1 Software package update – 5710

Valid from serial number:

T-code Model Serial No Notes

Section C-code T-code Document Issued

© BT Industries AB Service Manual 2005-11-08 English 1 (2)

Section C-code T-code Document Issued

2 (2) Service Manual 2005-11-08 English

Technical service data

T-code Model Serial No Notes

© BT Industries AB Service Manual 2005-11-08 English 1 (6)

© BT Industries AB Service Manual 2005-11-08 English 3 (6)

4 (6) Service Manual 2005-11-08 English

© BT Industries AB Service Manual 2005-11-08 English 5 (6)

6 (6) Service Manual 2005-11-08 English

1. Safety regulations with

© BT Products AB Service Manual 2005-11-08 English 1 (6)

• Always disconnect the battery by pulling out the emer-

2 (6) Service Manual 2005-11-08 English

2. Cleaning and washing

2.1. External cleaning

2.2. Cleaning the motor compartment

© BT Products AB Service Manual 2005-11-08 English 3 (6)

2.3. Electrical components

3. Safe lifting of the truck

4 (6) Service Manual 2005-11-08 English

4. Information plates, only Japan

5 (6) Service Manual 2005-11-08 English

6 (6) Service Manual 2005-11-08 English

T-code Model Serial No Notes

Pos. Work to carry out

© BT Industries AB Service Manual 2005-11-08 English 1 (8)

Pos. Work to carry out

2 (8) Service Manual 2005-11-08 English

Pos. Work to carry out

© BT Industries AB Service Manual 2005-11-08 English 3 (8)

Pos. Work to carry out

4 (8) Service Manual 2005-11-08 English

© BT Industries AB Service Manual 2005-11-08 English 5 (8)

Item Service point Intervall/Running Lubricant Volume

6 (8) Service Manual 2005-11-08 English

© BT Industries AB Service Manual 2005-11-08 English 7 (8)

8 (8) Service Manual 2005-11-08 English

Oil and grease specification

T-code Model Serial No Notes

Lubri- Type of Specification To be

© BT Industries AB Service Manual 1998-07-09 English 1 (2)

2 (2) Service Manual 1998-07-09 English

Oil and grease specification

T-code Model Serial No Notes