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Operator’s Manual

RRX35/45, RDX30, RSX40/50

Electric Stand-Up Rider Truck

Effective Serial Number R_X0027091001

The operator must read and understand this manual before operating this truck.

WARNING Keep this OPERATOR’S MANUAL with unit at all times in place provided when not in use.

WARNING DO NOT operate this equipment unless all factory installed guards and shields are properly secured in place.

Part no: 306754-000 Return

Date: June 01, 1998

Part no: 306754-000

Date: June 01, 1998

Operator’s warning

IMPORTANT NOTICE

This is the “SAFETY ALERT SYMBOL”. This symbol is used to call your attention to items or operations that could be dangerous to you or other persons using this equipment. Please read these messages carefully. It is essential that you read the instructions and safety regulations before you attempt to assemble or use this truck.

Before operating the truck:

1. The operator must be instructed on safe and correct use of this truck.

2. The operator must read and understand the Operator's Manual for this truck.

BEFORE OPERATING TRUCK STUDY OPERATOR’S MANUAL SAFETY MESSAGES. READ ALL SAFETY DECALS ON TRUCK. CLEAR THE AREA OF OTHER PERSONS.

LEARN AND PRACTICE USE OF CONTROLS BEFORE OPERATING.

IT IS YOUR RESPONSIBILITY TO UNDERSTAND AND FOLLOW MANUFACTURER'S INSTRUCTIONS ON TRUCK OPERATION AND TO OBSERVE PERTINENT LAWS AND REGULATIONS. OPERATOR MANUALS, PARTS MANUALS, AND REPAIR MANUALS MAY BE OBTAINED FROM YOUR EQUIPMENT DEALER.

WARNING INJURY OR DEATH TO YOU OR OTHER

PERSONNEL COULD OCCUR IF YOU DO NOT FOLLOW THESE INSTRUCTIONS AND MESSAGES.

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PERSONNEL COULD OCCUR IF YOU DO NOT FOLLOW THESE INSTRUCTIONS AND MESSAGES.

Foreword

It is important that you read and understand this Operator’s Manual for your own safety and the safety of those who work with you!

Before you start to use this truck it is of extreme importance that you have read the contents of the entire Operator’s Manual to be able to use the truck in a safe and efficient manner.

This Operator’s Manual contains information on how you should use the truck and how to keep the truck in a safe condition by following daily service routines.

Only personnel that have been trained as a truck operator, for this type of truck, are permitted to use this truck.

It is your employer’s responsibility to ensure that you have been trained to use your truck safely. Contact your supervisor if you feel uncertain about how to use this truck.

Always follow the warnings given in this Operator’s Manual and on the truck to avoid accidents.

The following warning is provided pursuant to California Health & Safety Code Sections 25249.5 et. seq.

California Proposition 65

This product contains and emits chemicals known to the State of California to cause cancer, birth defects and other reproductive harm.

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Table of Contents

Safety regulations ............................................................. 5 Warning symbols.............................................................. 5 Prohibitory symbols .......................................................... 6 General safety regulations ............................................... 7

Safety regulations............................................................. 5 Warning symbols.............................................................. 5 Prohibitory symbols .......................................................... 6 General safety regulations ............................................... 7

Warning and information signs ...................................... 17

Presentation of truck ....................................................... 19 Application areas for BT’s trucks..................................... 19 Prohibited applications for BT’s trucks ............................ 19 Truck data ....................................................................... 20 Truck battery demensions .............................................. 21 RRX35 Truck dimensions................................................ 22 RRX45 Truck dimensions................................................ 23 RDX30 Truck dimensions................................................ 24 RSX40 Truck dimensions................................................ 25 RSX50 Truck dimensions................................................ 26 Data plate ........................................................................ 27 U.L. Construction type..................................................... 28

Presentation of main components ................................. 29

Controls and instruments ............................................... 31 Emergency stop .............................................................. 31 Key switch ....................................................................... 32 Horn control..................................................................... 32 Travel speed / direction selector ..................................... 32 Steering wheel................................................................. 33 Hydraulic controls............................................................ 34 Display............................................................................. 36 Switches: Lamps and fans .............................................. 38 Preset height (option) ...................................................... 39 Controls for control console position ............................... 46 Brake pedal ..................................................................... 47 Height indicator (option) .................................................. 48

Warning codes ................................................................. 49

Error codes ....................................................................... 52 3 Return

Error codes....................................................................... 52 3

Table of Contents

Driving............................................................................... 55 Starting the truck ............................................................. 55 Braking ............................................................................ 57 Steering ........................................................................... 58 Parking the truck ............................................................. 59

Driving ...............................................................................55 Starting the truck..............................................................55 Braking.............................................................................57 Steering............................................................................58 Parking the truck ..............................................................59

Transporting loads .......................................................... 60 General............................................................................ 60 Collecting a load.............................................................. 63 Leaving a load ................................................................. 64

Transporting loads ...........................................................60 General ............................................................................60 Collecting a load ..............................................................63 Leaving a load..................................................................64

Battery............................................................................... 65 Type of battery ................................................................ 65 Changing the battery ....................................................... 65 Charging the battery........................................................ 67 Battery maintenance ....................................................... 70

Battery ...............................................................................65 Type of battery .................................................................65 Changing the battery........................................................65 Charging the battery ........................................................67 Battery maintenance ........................................................70

Daily service/safety checks ............................................ 72

Daily service/safety checks .............................................72

Maintenance ..................................................................... 74 General............................................................................ 74 Safety regulations with maintenance work ...................... 74 Cleaning and washing ..................................................... 78 Maintenance chart........................................................... 79 Lubrication chart.............................................................. 83 Oil and grease specification ............................................ 84

Maintenance ......................................................................74 General ............................................................................74 Safety regulations with maintenance work.......................74 Cleaning and washing......................................................78 Maintenance chart ...........................................................79 Lubrication chart ..............................................................83 Oil and grease specification.............................................84

Transport and storing the truck ..................................... 85 The truck’s dimensions and weight as standard ............. 85 Lifting the truck ................................................................ 87 Towing and transporting a disabled truck........................ 88 Storing the truck .............................................................. 89 Starting after a period of disuse ...................................... 89

Transport and storing the truck ......................................85 The truck’s dimensions and weight as standard ..............85 Lifting the truck.................................................................87 Towing and transporting a disabled truck ........................88 Storing the truck...............................................................89 Starting after a period of disuse .......................................89

Recycling/discarding....................................................... 90 Discarding the battery ..................................................... 90 Scrapping the truck ......................................................... 90

Recycling/discarding........................................................90 Discarding the battery ......................................................90 Scrapping the truck ..........................................................90

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Safety regulations Warning symbols

Always follow the warnings given in this Instruction Manual and on the truck to avoid accidents from occurring.

Warning levels

Warning texts are given in four levels and provide information on the risks, describe the consequences, and instruct how to avoid accidents.

DANGER

Warns that an accident will occur if you do not follow the instructions. The consequences are serious personal injury or possibly death, and/or extremely large material damage.

WARNING

Warns that an accident can occur if the instructions are not followed. The consequences are serious personal injury or possibly death, and/or large material damage.

CAUTION

Warns that an accident can occur if the instructions are not followed. The consequences are personal injury and/or material damage.

NOTE!

Marks the risk of a crash/breakdown if the instructions are not followed.

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Marks the risk of a crash/breakdown if the instructions are not followed.

Safety regulations Prohibitory symbols

Prohibitory symbols

NO SMOKING

If smoking occurs in situations where a restriction against smoking is stated, a serious accident can occur.

OPEN FLAMES PROHIBITED If open flames are used in situations where open flames are prohibited, a serious accident can occur.

GENERAL PROHIBITION If the prohibition is ignored, a serious accident can occur.

Ordinance symbols

If smoking occurs in situations where a restriction against smoking is stated, a serious accident can occur.

OPEN FLAMES PROHIBITED If open flames are used in situations where open flames are prohibited, a serious accident can occur.

GENERAL PROHIBITION If the prohibition is ignored, a serious accident can occur.

Ordinance symbols

SAFETY SHOES

When the directive for safety shoes is given, safety shoes shall always be worn to avoid personal injury.

PROTECTIVE GLASSES When the directive for protective glasses is given, protective glasses shall always be worn to avoid personal injury.

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Safety regulations

When the directive for safety shoes is given, safety shoes shall always be worn to avoid personal injury.

PROTECTIVE GLASSES When the directive for protective glasses is given, protective glasses shall always be worn to avoid personal injury.

Safety regulations

These warnings are NOT meant to be a complete list, and only the operator's intelligence, good sense, and care of unit will assure that most hazards will be avoided. Refer to ASME B56.1 for further operator's information.

General safety regulations

Control

•

Always carry out the daily service before the truck is used. The working order of all safety equipment, guards and safety switches should be checked before you use the truck. Such safety equipment must not be disengaged or removed.

•

The battery must be secured in its intended compartment. The battery shall have a weight that corresponds with the value stated on the truck’s data plate.

•

The battery must be secured in its intended compartment. The battery shall have a weight that corresponds with the value stated on the truck’s data plate.

•

Read the nameplates. Do not operate the truck if there are any differences between the data stated on the nameplate and the truck.

•

Read the nameplates. Do not operate the truck if there are any differences between the data stated on the nameplate and the truck.

•

The truck must not be used if it is damaged or has faults that affect safety or its safe use. The truck may not be used if it has been repaired, modified or adjusted unless it has been checked and approved by personnel authorized by BT.

•

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Safety regulations

General safety regulations

Operating the truck

•

The truck is designed and produced to be your tool when transporting goods to locations.

•

The truck is designed and produced to be your tool when transporting goods to locations.

•

If the truck is to be used in cold storage environments the truck must be especially built for this type of use.

•

If the truck is to be used in cold storage environments the truck must be especially built for this type of use.

•

It is not permitted to use the truck for other purposes than it has been designed and produced for, e.g. the following applications:

•

It is not permitted to use the truck for other purposes than it has been designed and produced for, e.g. the following applications:

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In areas where the atmosphere contains gases that can cause fires or explosions.

As a towing truck for trailers.

To tow other trucks.

To transport/lift passengers.

Safety regulations

General safety regulations

Operator’s responsibility

•

The truck shall only be driven by personnel that have been specially trained and that have permission to drive the truck.

•

The truck shall only be driven by personnel that have been specially trained and that have permission to drive the truck.

•

The truck shall only be driven with care, good judgement and in a responsible manner.

•

The truck shall only be driven with care, good judgement and in a responsible manner.

•

Each country (state) has its own safety regulations. It is the operator’s obligation to know and follow these. This also applies to local regulations and for different types of handling. If the recommendations in this manual deviate from your country’s (state), the local safety regulations should be followed.

•

The truck should be insured in accordance with local directives and laws where the truck is used.

•

The truck should be insured in accordance with local directives and laws where the truck is used.

•

Any accidents or near accidents (incidents) must be reported to your supervisor.

•

Any accidents or near accidents (incidents) must be reported to your supervisor.

•

The truck shall only be driven with care, good judgment and in a responsible manner.

•

The truck shall only be driven with care, good judgment and in a responsible manner.

•

Local regulations regarding personal safety equipment shall be followed.

•

Local regulations regarding personal safety equipment shall be followed.

•

The truck should not be driven with oily hands or oily shoes due to the risk of slipping.

•

The truck should not be driven with oily hands or oily shoes due to the risk of slipping.

•

DO NOT place any part of body between moving and stationary objects.

•

DO NOT place any part of body between moving and stationary objects.

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Safety regulations

General safety regulations

Working area

•

If there are marked truck routes these shall be used.

•

If there are marked truck routes these shall be used.

•

The truck should only be driven on dry clean surface. Do not operate on wet, oily surfaces.

•

The truck should only be driven on dry clean surface. Do not operate on wet, oily surfaces.

•

The truck should only be driven on hard and even surfaces, e.g. concrete or asphalt.

•

The truck should only be driven on hard and even surfaces, e.g. concrete or asphalt.

•

Ensure that the floor where the truck is to be used has sufficient load bearing capacity for total weight of the truck including the maximum load.

•

Ensure that the floor where the truck is to be used has sufficient load bearing capacity for total weight of the truck including the maximum load.

•

Take special care if there are protruding parts from racks, shelves or walls that can cause injury or damage the truck.

•

Take special care if there are protruding parts from racks, shelves or walls that can cause injury or damage the truck.

•

It’s forbidden for persons to be present in the area around the truck when there is a risk of personal injury, e.g. areas that can be reached by falling goods, lowering or falling lifting devices or in the truck’s maneuvering area.

•

Grades, ramps or inclines: This truck is designed for use on level floor operation. If it is necessary to operate on grade, ramp or incline refer to ASME B56.1 for requirements.

•

Grades, ramps or inclines: This truck is designed for use on level floor operation. If it is necessary to operate on grade, ramp or incline refer to ASME B56.1 for requirements.

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Safety regulations

General safety regulations

Driving and conduct while driving

•

Always drive the truck from the normal operator position.

•

Always drive the truck from the normal operator position.

•

Always drive the truck in a responsible manner and with full control. Sudden starts and braking as well as cornering at high speed should be avoided.

•

Always drive the truck in a responsible manner and with full control. Sudden starts and braking as well as cornering at high speed should be avoided.

•

Drive at a reduced speed on inclines. Drive the truck straight up and down on inclines. It is not permitted to turn the truck on an incline.

•

Drive at a reduced speed on inclines. Drive the truck straight up and down on inclines. It is not permitted to turn the truck on an incline.

•

Reduce the speed if the surface is slippery to prevent the truck from sliding or overturning.

•

Reduce the speed if the surface is slippery to prevent the truck from sliding or overturning.

•

Adapt your speed to the driving conditions, both to pedestrians and other trucks in the working area. Reduce speed when the line of vision is limited and when pedestrians or other vehicles can be encountered.

•

Pay particular attention to other personnel as well as fixed and moving objects within the working area and thereby avoid accidents.

•

Pay particular attention to other personnel as well as fixed and moving objects within the working area and thereby avoid accidents.

•

Always be prepared to stop if other personnel are in the working area.

•

Always be prepared to stop if other personnel are in the working area.

•

Keep a safe distance from all vehicles ahead.

•

Keep a safe distance from all vehicles ahead.

•

Always keep a safe distance from the edges of loading bays and loading ramps. Be attentive to marked risk areas.

•

Always keep a safe distance from the edges of loading bays and loading ramps. Be attentive to marked risk areas.

•

Sound the horn when overtaking other vehicles and when the attention of other personnel is required.

•

Sound the horn when overtaking other vehicles and when the attention of other personnel is required.

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Safety regulations

•

Always give way to a loaded truck at junctions and in confined aisles.

•

Always give way to a loaded truck at junctions and in confined aisles.

•

Never allow passengers to ride on the truck.

•

Never allow passengers to ride on the truck.

•

Never drive with any part of your body outside of the operator position.

•

Never drive with any part of your body outside of the operator position.

•

Before the truck is driven over a loading ramp ensure that the ramp is correctly secured and has the necessary load bearing capacity. Drive slowly and carefully across the ramp.

•

Before the truck is driven over a loading ramp ensure that the ramp is correctly secured and has the necessary load bearing capacity. Drive slowly and carefully across the ramp.

•

When the truck is driven on to another vehicle, make sure the vehicle is stable and that the brakes have been applied correctly and wheels chocked.

•

When the truck is driven on to another vehicle, make sure the vehicle is stable and that the brakes have been applied correctly and wheels chocked.

•

Before you drive the truck into an elevator, ensure that the elevator is approved for the total weight of the truck, the load, operator and any other passengers in the elevator. Enter with the load first. No other personnel should be in the elevator when the load or truck enters or leaves.

•

When the load impairs the line of vision, always drive with the load to the rear.

•

When the load impairs the line of vision, always drive with the load to the rear.

•

DO NOT run over loose objects, uneven surfaces or other obstructions on roadway surfaces.

•

DO NOT run over loose objects, uneven surfaces or other obstructions on roadway surfaces.

•

DO NOT smoke while working around truck.

•

DO NOT smoke while working around truck.

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Safety regulations

General safety regulations

Handling loads

•

Drive with care when collecting or leaving a load.

•

Drive with care when collecting or leaving a load.

•

Only drive with the forks lifted when collecting or leaving a load. Keep a safe distance from persons in the immediate area.

•

Only drive with the forks lifted when collecting or leaving a load. Keep a safe distance from persons in the immediate area.

•

Only handle loads that are within the truck’s permitted lifting capacity. The length and width of the forks shall be adapted to the load’s shape and dimensions.

•

Only handle loads that are within the truck’s permitted lifting capacity. The length and width of the forks shall be adapted to the load’s shape and dimensions.

•

Only handle loads that are stable and arranged in a safe manner.

•

Only handle loads that are stable and arranged in a safe manner.

•

Particular care should be exercised when handling long and high loads.

•

Particular care should be exercised when handling long and high loads.

•

Make sure that the truck is equipped with a suitable load support when handling high loads.

•

Make sure that the truck is equipped with a suitable load support when handling high loads.

•

Watch so that overhead obstructions such as lights, pipes, sprinkler systems, etc. are NOT contacted.

•

Watch so that overhead obstructions such as lights, pipes, sprinkler systems, etc. are NOT contacted.

•

The load shall Only be lifted vertically and NEVER drugged or pushed horizontally.

•

The load shall Only be lifted vertically and NEVER drugged or pushed horizontally.

•

The load shall be transported with bottom of load and forks as low as possible.

•

The load shall be transported with bottom of load and forks as low as possible.

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Safety regulations

General safety regulations

Parking the truck

•

Always park in designated areas if available.

•

Always park in designated areas if available.

•

Never leave the truck parked with the key still in the key switch.

•

Never leave the truck parked with the key still in the key switch.

•

Never park the truck on an incline.

•

Never park the truck on an incline.

•

Never park the truck so that it obstructs emergency exits.

•

Never park the truck so that it obstructs emergency exits.

•

Never park the truck so that it obstructs traffic or work.

•

Never park the truck so that it obstructs traffic or work.

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Safety regulations

General safety regulations

Handling the battery

•

Always handle the battery and its connections with care. Read and follow the instructions for changing or recharging the battery carefully. See chapter Battery.

•

Always handle the battery and its connections with care. Read and follow the instructions for changing or recharging the battery carefully. See chapter Battery.

•

Always wear protective glasses when working with the battery.

•

Always wear protective glasses when working with the battery.

•

Make sure the battery in the truck is of a weight that corresponds with the information on the truck’s data plate.

•

Make sure the battery in the truck is of a weight that corresponds with the information on the truck’s data plate.

•

Make sure the battery is secured in its compartment.

•

Make sure the battery is secured in its compartment.

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Safety regulations

General safety regulations

Maintenance and repair

Maintenance instructions should be followed to prevent faults and accidents. See the chapter covering Maintenance. Only qualified and trained personnel are permitted to maintain, adjust or repair the truck.

All replacement parts shall be BT approved spare parts.

Modifications and additions which affect capacity and safe operation shall not be performed by the customer or user without manufacturers prior written approval. Capacity, operation, and maintenance instruction plate, tags, or decals shall be changed accordingly.

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Warning and information signs

The figure shows the position and significance of the signs location on the truck.

1. Hydraulic controls: lift, reach, tilt, and sideshifter.

2. List of warnings.

3. Pinch points: Do not reach through uprights.

4. Do not walk under an elevated load.

5. U.L. listed.

6. Truck data plate.

1 3

KEEP HANDS CLEAR

4 2

BREAKING THESE RULES MAY CAUSE SERIOUS OR FATAL INJURY TO YOURSELF AND OTHERS READANDUNDERSTANDALLWARNINGSANDOPERATINGINSTRUCTIONS INTHEOPERATOR'SMANUALBEFOREOPERATINGTHISTRUCK. ONLYAUTHORIZEDANDTRAINEDOPERATORSARETOOPERATETHIS MACHINE.

MAKEASAFETYCHECKBEFOREOPERATINGTHETRUCKANDDONOT

OPERATEIFINNEEDOFREPAIRSORMAINTENANCE. MAINTENANCEISTOBEPERFORMEDBYAUTHORIZEDPERSONNELONLY.

TRUCKLOADLIMITEDTONAMEPLATECAPACITY.

MOVELONG,WIDEORHIGHLOADSCAREFULLY.SECUREPALLETOR

CARTWITHPALLETCLAMP.DONOTMOVEUNSTABLELOADS. LOOKWHEREYOUDRIVE.WATCHOUTFOROBSTRUCTIONS.MAKE

SUREALLPEOPLEARECLEAROFMACHINE. THISMACHINEISDESIGNEDFORSMOOTHANDLEVELFLOOR

OPERATION.

LOWERFORKSTOFLOORANDTURNOFFKEYPRIORTOLEAVINGTRUCK.

ADDITIONALOPERATOR'SMANUALSANDOPERATINGDECALSCANBE OBTAINEDFROMYOURDEALERORTHEPRIME-MOVERCO.MUSCATINE,

IOWA52761-0879.

OPERATEIFINNEEDOFREPAIRSORMAINTENANCE.

MAINTENANCEISTOBEPERFORMEDBYAUTHORIZEDPERSONNELONLY. TRUCKLOADLIMITEDTONAMEPLATECAPACITY.

MOVELONG,WIDEORHIGHLOADSCAREFULLY.SECUREPALLETOR

CARTWITHPALLETCLAMP.DONOTMOVEUNSTABLELOADS.

LOOKWHEREYOUDRIVE.WATCHOUTFOROBSTRUCTIONS.MAKE SUREALLPEOPLEARECLEAROFMACHINE.

THISMACHINEISDESIGNEDFORSMOOTHANDLEVELFLOOR

OPERATION. LOWERFORKSTOFLOORANDTURNOFFKEYPRIORTOLEAVINGTRUCK.

ADDITIONALOPERATOR'SMANUALSANDOPERATINGDECALSCANBE

OBTAINEDFROMYOURDEALERORTHEPRIME-MOVERCO.MUSCATINE,

IOWA52761-0879.

OPERATEIFINNEEDOFREPAIRSORMAINTENANCE.

MAINTENANCEISTOBEPERFORMEDBYAUTHORIZEDPERSONNELONLY. TRUCKLOADLIMITEDTONAMEPLATECAPACITY.

MOVELONG,WIDEORHIGHLOADSCAREFULLY.SECUREPALLETOR CARTWITHPALLETCLAMP.DONOTMOVEUNSTABLELOADS.

LOOKWHEREYOUDRIVE.WATCHOUTFOROBSTRUCTIONS.MAKE

SUREALLPEOPLEARECLEAROFMACHINE.

THISMACHINEISDESIGNEDFORSMOOTHANDLEVELFLOOR

OPERATION.

LOWERFORKSTOFLOORANDTURNOFFKEYPRIORTOLEAVINGTRUCK. ADDITIONALOPERATOR'SMANUALSANDOPERATINGDECALSCANBE

OBTAINEDFROMYOURDEALERORTHEPRIME-MOVERCO.MUSCATINE,

IOWA52761-0879.

OPERATEIFINNEEDOFREPAIRSORMAINTENANCE. MAINTENANCEISTOBEPERFORMEDBYAUTHORIZEDPERSONNELONLY.

TRUCKLOADLIMITEDTONAMEPLATECAPACITY.

MOVELONG,WIDEORHIGHLOADSCAREFULLY.SECUREPALLETOR CARTWITHPALLETCLAMP.DONOTMOVEUNSTABLELOADS.

LOOKWHEREYOUDRIVE.WATCHOUTFOROBSTRUCTIONS.MAKE

SUREALLPEOPLEARECLEAROFMACHINE.

THISMACHINEISDESIGNEDFORSMOOTHANDLEVELFLOOR OPERATION.

LOWERFORKSTOFLOORANDTURNOFFKEYPRIORTOLEAVINGTRUCK.

ADDITIONALOPERATOR'SMANUALSANDOPERATINGDECALSCANBE

ADDITIONALOPERATOR'SMANUALSANDOPERATINGDECALSCANBE 29287-00

29287-00

Inches Serial Number

Model

Truck Wt. Less Batt. (Lbs.)

Battery Wt., Max. (Lbs.)

Cap. (Lbs.)

Inches C

Serial Number

Model

Truck Wt. Less Batt. (Lbs.)

Battery Wt., Min. (Lbs.)

Battery Wt., Max. (Lbs.)

Use UL Class DC Voltage

Type

Battery Type

Cap. (Lbs.)

Mast Serial Number

Attachment

DC Voltage

Max. ° Back Tilt

Type

Battery Type

Max. Amp. Hours

Mast Serial Number

Attachment

Max. ° Back Tilt

Truck as rated at factory conforms to requirements of Part III of ASME B561-1993 306040-000

BT Prime-Mover, Inc.

Muscatine, IA 52761

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Battery Wt., Min. (Lbs.)

Use UL Class Max. Amp. Hours

Warning and information signs

Warning decals

Clean or replace all safety and instruction decals that cannot be read.

When you clean decals use only a cloth, soap, and water. DO NOT use solvent, gasoline, etc.

You must replace a decal if the decal is damaged, missing, or cannot be read.

If a decal is on a part that is replaced, make sure you install a new decal on the new part. New warning decals can be obtained from your BT dealer at NO charge.

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Presentation of truck

BT’s truck program is intended for handling pallets indoors or alternatively other types of loads using other load carriers. This truck is operated in a standing position. This BT’s truck has available different outrigger widths, lifting heights, and lifting capacities. Refer to the truck’s data plate for this information.

The trucks are equipped with either 24 or 36 Volt electrical system. The travel and lifting speeds are transistor controlled to provide smooth operations. In addition, the travel function and the different hydraulic functions have additional controls which further enhance these features. Different speeds and steering can be set using parameters to give the best possible individual settings for the functions.

Application area for BT’s trucks

BT’s trucks are solely designed and manufactured to handle goods. The truck should be fitted with the appropriate accessories relevant to the application.

Prohibited applications for BT’s truck

The trucks are designed for handling goods indoors. It is not permitted to use the trucks for other purposes including the following:

In areas that contain gases which can cause fires or explosions

As a towing truck for trailers

To tow other trucks

To transport/lift passengers

To drive on gravel or grass

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Presentation of truck

Truck data

The table provides information regarding some technical data which is of value with daily use of the truck.

Truck type

RRX35/45

Operating speed without load, 24 Volt Operating speed without load, 36 Volt

6.0 mph [9.65 km/h] 6.5 mph [10.46 km/h]

Operating speed without load, 24 Volt Operating speed without load, 36 Volt

6.0 mph [9.65 km/h] 6.5 mph [10.46 km/h]

Operating speed with classified load, 24 Volt Operating speed with classified load, 36 Volt

5.5 mph [8.85 km/h] 6.0 mph [9.65 km/h]

Operating speed with classified load, 24 Volt Operating speed with classified load, 36 Volt

5.5 mph [8.85 km/h] 6.0 mph [9.65 km/h]

Maximum operating gradient with load, %

Continuous noise level. dB (A)

<80

Continuous noise level. dB (A)

<80

Truck type

RDX30

Truck type

RDX30

Operating speed without load, 36 Volt

6.5 mph [10.46 km/h]

Operating speed without load, 36 Volt

6.5 mph [10.46 km/h]

Operating speed with classified load, 36 Volt

6.0 mph [9.65 km/h]

Operating speed with classified load, 36 Volt

6.0 mph [9.65 km/h]

Maximum operating gradient with load, %

Continuous noise level. dB (A)

<80

Continuous noise level. dB (A)

<80

Truck type

RSX40/50

Truck type

RSX40/50

Operating speed without load, 24 Volt Operating speed without load, 36 Volt

6.0 mph [9.65 km/h] 6.5 mph [10.46 km/h]

Operating speed without load, 24 Volt Operating speed without load, 36 Volt

6.0 mph [9.65 km/h] 6.5 mph [10.46 km/h]

Operating speed with classified load, 24 Volt Operating speed with classified load, 36 Volt

5.5 mph [8.85 km/h] 6.0 mph [9.65 km/h]

Operating speed with classified load, 24 Volt Operating speed with classified load, 36 Volt

5.5 mph [8.85 km/h] 6.0 mph [9.65 km/h]

Maximum operating gradient with load, %

Continuous noise level. dB (A)

<80

Continuous noise level. dB (A)

<80

The truck’s lifting capacity, lifting height and weight can be found on the truck’s data plate.

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Presentation of truck Truck battery dimensions

Truck battery dimensions

Important

Use only batteries that meet the following specifications:

Compartment Size: Minimum Maximum Deep (14.5 in. [368.3 mm])13.7 in. [348 mm] 14.2 in. [361 mm] Deep (16.5 in. [419.1 mm])15.9 in. [404 mm] 16.4 in. [417 mm] Deep (21.0 in. [533.4 mm])20.4 in. [518 mm] 20.9 in. [531 mm] Wide 38.2 in. [970 mm] 38.7 in. [983 mm] Height 31.5 in. [800 mm] 32.0 in. [813 mm] Battery Weight (Consult Data plate on truck)

For smaller industrial battery sizes, provide blocking to restrain the battery from moving not more than 0.5 in. [12.7 mm] in any horizontal direction.

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Presentation of truck

RRX35 Truck dimensions

The diagrams below shows external dimensions for RRX35.

RRX35 Dimensions

RRX35

14.5 in. [368.9 mm] Battery

16.5 in. [419.1 mm] Battery

40.5 in. [1028.7 mm]

40.5 in. [1029 mm]

89/95 in. [2260.6/2413 mm]

l1 Truck length less forks

70.14 in. [1781.5 mm]

72.14 in. [1832.4 mm]

Y Wheel base

55.45 in. [1408.4 mm]

Turning radius

67.05 in. [1703.1 mm]

b1 Chassis width h6 Height over head

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Dimensions

14.5 in. [368.9 mm] Battery

16.5 in. [419.1 mm] Battery

40.5 in. [1028.7 mm]

40.5 in. [1029 mm]

89/95 in. [2260.6/2413 mm]

l1 Truck length less forks

70.14 in. [1781.5 mm]

72.14 in. [1832.4 mm]

57.45 in. [1459.2 mm]

Y Wheel base

55.45 in. [1408.4 mm]

57.45 in. [1459.2 mm]

69.05 in. [1753.9 mm]

Turning radius

67.05 in. [1703.1 mm]

69.05 in. [1753.9 mm]

b1 Chassis width h6 Height over head

Presentation of truck

RRX45 Truck dimensions

The diagrams below shows external dimensions for RRX45.

Y l1

RRX45 Dimensions

RRX45

16.5 in. [419.1 mm] Battery

21.0 in. [533.4 mm] Battery

40.5 in. [1028.7 mm]

40.5 in. [1029 mm]

89/95 in. [2260.6/2413 mm]

l1 Truck length less forks

74.64 in. [1895.86 mm]

76.64 in. 1946.66 mm]

Y Wheel base

59.95 in. [1522.73 mm]

Turning radius

69.48 in. 1764.79 mm]

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b1 Chassis width h6 Height over head

Dimensions

16.5 in. [419.1 mm] Battery

21.0 in. [533.4 mm] Battery

40.5 in. [1028.7 mm]

40.5 in. [1029 mm]

89/95 in. [2260.6/2413 mm]

l1 Truck length less forks

74.64 in. [1895.86 mm]

76.64 in. 1946.66 mm]

61.95 in. [1573.53 mm]

Y Wheel base

59.95 in. [1522.73 mm]

61.95 in. [1573.53 mm]

71.48 in. [1815.59 mm]

Turning radius

69.48 in. 1764.79 mm]

71.48 in. [1815.59 mm]

b1 Chassis width h6 Height over head

Presentation of truck

RDX30 Truck dimensions

The diagrams below shows external dimensions for RDX30.

Y l1

RDX30 Dimensions

RDX30

16.5 in. [419.1 mm] Battery

21.0 in. [533.4 mm] Battery

40.5 in. [1028.7 mm]

40.5 in. [1029 mm]

89/95 in. [2260.6/2413 mm]

l1 Truck length less forks

74.64 in. [1895.86 mm]

76.64 in. 1946.66 mm]

Y Wheel base

59.95 in. [1522.73 mm]

Turning radius

69.48 in. 1764.79 mm]

b1 Chassis width h6 Height over head

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Dimensions

16.5 in. [419.1 mm] Battery

21.0 in. [533.4 mm] Battery

40.5 in. [1028.7 mm]

40.5 in. [1029 mm]

89/95 in. [2260.6/2413 mm]

l1 Truck length less forks

74.64 in. [1895.86 mm]

76.64 in. 1946.66 mm]

61.95 in. [1573.53 mm]

Y Wheel base

59.95 in. [1522.73 mm]

61.95 in. [1573.53 mm]

71.48 in. [1815.59 mm]

Turning radius

69.48 in. 1764.79 mm]

71.48 in. [1815.59 mm]

b1 Chassis width h6 Height over head

Presentation of truck

RSX40 Truck dimensions

The diagrams below shows external dimensions for RSX40.

Y l1

RSX40 Dimensions

RSX40

14.5 in. [368.9 mm] Battery

16.5 in. [419.1 mm] Battery

40.5 in. [1028.7 mm]

40.5 in. [1029 mm]

89/95 in. [2260.6/2413 mm]

l1 Truck length less forks

70.14 in. [1781.5 mm]

72.14 in. [1832.4 mm]

Y Wheel base

55.45 in. [1408.4 mm]

Turning radius

67.05 in. [1703.1 mm]

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b1 Chassis width h6 Height over head

Dimensions

14.5 in. [368.9 mm] Battery

16.5 in. [419.1 mm] Battery

40.5 in. [1028.7 mm]

40.5 in. [1029 mm]

89/95 in. [2260.6/2413 mm]

l1 Truck length less forks

70.14 in. [1781.5 mm]

72.14 in. [1832.4 mm]

57.45 in. [1459.2 mm]

Y Wheel base

55.45 in. [1408.4 mm]

57.45 in. [1459.2 mm]

69.05 in. [1753.9 mm]

Turning radius

67.05 in. [1703.1 mm]

69.05 in. [1753.9 mm]

b1 Chassis width h6 Height over head

Presentation of truck

RSX50 Truck dimensions

The diagrams below shows external dimensions for RSX50.

Y l1

RSX50 Dimensions

RSX50

14.5 in. [368.9 mm] Battery

16.5 in. [419.1 mm] Battery

40.5 in. [1028.7 mm]

40.5 in. [1029 mm]

89/95 in. [2260.6/2413 mm]

l1 Truck length less forks

70.14 in. [1781.5 mm]

72.14 in. [1832.4 mm]

Y Wheel base

55.45 in. [1408.4 mm]

Turning radius

67.05 in. [1703.1 mm]

b1 Chassis width h6 Height over head

Return

Dimensions

14.5 in. [368.9 mm] Battery

16.5 in. [419.1 mm] Battery

40.5 in. [1028.7 mm]

40.5 in. [1029 mm]

89/95 in. [2260.6/2413 mm]

l1 Truck length less forks

70.14 in. [1781.5 mm]

72.14 in. [1832.4 mm]

57.45 in. [1459.2 mm]

Y Wheel base

55.45 in. [1408.4 mm]

57.45 in. [1459.2 mm]

69.05 in. [1753.9 mm]

Turning radius

67.05 in. [1703.1 mm]

69.05 in. [1753.9 mm]

b1 Chassis width h6 Height over head

Presentation of truck

Data plate

Know the rated capacity on the data plate and understand areas 1 through 13 as shown in the illustration.

1 Truck model number 2 Truck serial number 3 Weight less battery 4 Maximum battery weight 5 Minimum battery weight 6 Truck voltage DC 7 Battery type UL class 8 Battery maximum AMP hours 9 Truck type 10 Mast serial number 11 Attachment 12 Maximum degree rear tilt 13 Truck capacity

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Presentation of truck

U.L. Construction type

Know the U.L. construction type of this truck and make certain that trucks of this type may be operated in restricted areas before you enter. Never take an unauthorized truck in restricted or hazardous areas.

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Presentation of main components

Hydraulic valve: The valves are located to provide easy access.

Battery: 24/36V with different capacities and weights.

Recharge connector: The battery is recharged through the battery connection.

Hydraulic unit: Pump motor and pump are an integrated unit

Drive unit with brakes: Drive motor, gears drive wheel and electrical brake combined in the drive unit.

Electrical steering: A servo steer motor drives a gear ring enabling the drive unit to be rotated through 360 degree in either direction.

Data plate: With data designation, manufacturing number, year of manufacture, service weight, battery weight, classified lifting capacity, battery voltage and manufacturer.

Cover: Easily removed to provide good access for servicing.

Pedal: Brake pedal.

10 Control console: The control console can be adjusted to a suitable height and angle to obtain a comfortable working position. The steering, hydraulic functions, horn, park bake, preset height, travel direction, key switch and any extra hydraulic functions are all controlled from this console. The position of the console maybe set in 1 of 3 positions.

11 Instrument panel: This provides information on the truck’s running hours, time display, error codes, travel direction, parking brake, steering angle and battery status.

12 Mast: The mast is clear view model.

13 Electronics: All the electronics are collected in a protected compartment.

14 Control circuit fuse: 15A, BT part number 122308-150

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Presentation of main components

15 Steering circuit fuse: 30A, BT part number 122308-300

16 Drive motor fuse: 250A, BT part number 305656-000

17 Pump motor fuse: 425A, 24V BT part number 305656-002 355A, 36V BT part number 305656-001

18 Right foot pedal

19 Emergency stop The emergency stop switch will stop all control functions.

16 17 8

9 18

14 15

13 30

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7 9 18

14 15

13 30

16 17 8

Controls and instruments

Guards and shields have been provided on unit for your protection.

Warning

DO NOT operate this equipment unless all factory installed guards and shields are properly secured in place.

Warning

DO NOT operate this equipment unless all factory installed guards and shields are properly secured in place.

Decals are also provided to warn of potential danger as well as to display special operating procedures

Warning Read and observe all warnings on this unit

before operating it.

Emergency Stop

The truck is fitted with an emergency stop (red in color), which is located on the right side of truck above the battery connectors.

Pressing the emergency stop will cut the power supply in the event of:

• •

An accident. Emergency situation, risk of an accident.

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• •

An accident. Emergency situation, risk of an accident.

Controls and instruments Steering wheel

Reach Tilt

lift & lower

Controls and instruments

Sideshifter Horn switch

Key switch

Steering wheel

Reach Tilt

lift & lower

Horn switch

Key switch

Travel speed / direction selector Spinner

Light & fan switches

Sideshifter

Travel speed / direction selector Spinner

Light & fan switches

Key switch

The main power switch for the control current.

When key switch is turned to the OFF position the power is OFF and display lamp is not light (however, there is still voltage to some parts of the electronics).

When key switch is turned to the ON position the display will light and current is fed to all electronic components.

Horn control

The horn sounds as long as the switch is pressed.

Travel speed / direction selector

After key switch is in the on position and start-up has been done the truck’s direction must be selected. To select the direction, press the travel speed / direction selector to the left, the direction default is forks first. The indicator arrow light will glow in the direction of travel. Pressing the switch again will select the other direction of travel.

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Controls and instruments

To move the truck in the direction you selected. Press travel speed / direction selector to the right. The more you press the faster travel.

This truck is equipped with 360 degree steering. To reverse direction, after stopping travel speed, the steering wheel can be rotated to the other direction and speed increased.

Plug braking function can be done by pressing the travel speed / direction selector to the left to reverse direction. To increase braking speed move the travel speed / direction sector switch back to the right to increase braking speed.

Steering wheel

The steering characteristics are progressive. This means the higher the driving speed the lower the steering speed (sensitivity is reduced). When driving slowly you do not need to turn the steering wheel as many turns as when driving at a higher speed, to turn the truck.

The steering characteristics can be adapted to the operator’s experience and requirements. The steering sensitivity progressiveness can be increased or decreased if necessary. Contact a trained service technician.

This truck is equipped with 360 degree steering which allows you to rotate steering wheel to the direction you wish to travel.

When driven at high speed (long distance transport, etc.) it is easiest to steer the truck by using the tip of the fingers on the steering hub.

When driving slowly and turning the truck, the wheel can be turned quicker using the spinner. Lost stability. Warning The truck can overturn and the load fall if you turn the steering quickly at high speed. Only steer with the finger tips on the steering hub when driving at high speed.

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Controls and instruments Hydraulic controls

On the control console there are a maximum of four levers that control hydraulic functions.

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Controls and instruments

Function

Lever A

Lower forks

Lift forks

Lever B

Reach carriage out

Reach carriage in

Lever C

Fork tilt down

Fork tilt up

Lever D

Sideshifter right

Sideshifter left

Lowering the forks and another function can be used together. When the lever B, C, or D are used and the forks lift is started, the fork lift function will disengage the other functions.

Note. No hydraulic functions can be used if the key switch is in the OFF position or if the operator is not in the operator’s compartment.

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Controls and instruments Display

1/2

I H G F E

A. Direction indicator

When selecting the direction of travel an arrow will light indicating the selected direction.

B. Time display

A digital clock indicates the actual time.

C. Display of hourmeter reading/error code

A character display (C) indicates hours and error codes. When the time meter reading is displayed the indicator window (E) is light. The time displayed is as follows.

Character

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Time

Character

Time

Key time

Total running time

Drive motor time

Pump motor time

Controls and instruments

When the warning/error codes are displayed the indicating window (G) will be light. A character E/C will be displayed in the left hand side of the character window and the error code in the right hand side. The meaning of the codes is explained in section Warning codes and/or Error codes.

D. Battery guard

The battery guard indicates the current charge status of the truck’s battery.

Full charge battery

1/2

Half charged battery

1/2

Half charged battery

Discharged battery

The battery guard has an integrated cut-out function that cuts out the truck’s lift function when a predetermined charge level has been reached. This prevents overloading the battery and increases the operating economy of the truck. When the battery has reached a charge level equivalent to 70 percent discharge a warning signal is given as a flashing lights. A further 10 percent of the battery’s capacity can then be used before the battery guard cuts out the lift function.

F. Parameter control

When checking the set parameters the indicator window (F) will light.

H. Parking brake indicator

The indicator window is light when the parking brake is applied.

I. Extra indicator window

This light indicates that either the brake pedal or platform switch has not been successfully engaged while selecting a hydraulic function. The indicator is also light if the truck is driven without both feet on floor.

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Controls and instruments

J. Drive wheel indicator

The position of the wheel and the truck’s direction of travel are indicated by one of the arrows in the diagram. When the opposite direction is selected without changing the position of the drive wheel the opposite arrow will light.

Switches: Lamps and fans

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Controls and instruments

Preset height (option)

By using the height preset function the operator can lift and lower the forks to a maximum of 69 different programmable levels within the main lift zone.

Based on height settings the mast lifting and lowering will stop at the required fork level. Collecting or leaving the load takes place manually.

The correct height for picking or leaving the pallet is requested/programmed through the keyboard. The selected fork level can be read from the display. Which also indicates any error codes.

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Controls and instruments Symbol

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Function

Controls and instruments Symbol

Function

Numerical push-buttons for setting height levels.

For control of the required height level, while driving.

STOP During automatic mode height levels that have been incorrectly entered can be deleted, cuts programming and causes a stop due to an error.

Save “LEAVE level” when programming.

Save “COLLECT level” when programming.

LOAD Push button to indicate that the operator has a load on the forks when starting.

Push button to access programming routines.

Display for indicating height levels and error codes.

Controls and instruments

Programming

•

Press the button PROG briefly to enter the programming mode. The LED in the button lights and the display reads PL00. You can program new lifting heights, modify or remove programmed height positions.

Programming a level

Programming of lift heights can only take place within the staging zone, above initial lift (freelift).

Forks not horizontal.

Warning Forks not horizontal.

Warning The load can slide off the forks or

The load can slide off the forks or catch on the rack. When the load is lifted or lowered the forks should always be positioned horizontally. The forks and load must be positioned completely clear of the racking and other obstructions before lifting and lowering begins.

catch on the rack. When the load is lifted or lowered the forks should always be positioned horizontally. The forks and load must be positioned completely clear of the racking and other obstructions before lifting and lowering begins. “Collection level”

“Collection level”

•

Press the PROG button briefly. State the required level (e.g. 1+5=level 15). The numbers are shown on the display.

•

Press the PROG button briefly. State the required level (e.g. 1+5=level 15). The numbers are shown on the display.

•

Lift the forks to the required level and press the COLLECT button. The LED flashes.

•

Lift the forks to the required level and press the COLLECT button. The LED flashes.

“Leaving level”

•

Pick-up the load and wait three seconds. Lift the forks just enough so that the pallet can be removed from the rack. Ensure that there is sufficient space (maximum of 5.9 in. [149.9 mm]) for safe handling.

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Controls and instruments

•

Now press the LEAVE button and both LEDs for collecting and leaving will start to flash.

•

Now press the LEAVE button and both LEDs for collecting and leaving will start to flash.

•

Press the PROG button until both the LEDs go out and the display indicates PL00, storing information.

•

Press the PROG button until both the LEDs go out and the display indicates PL00, storing information.

•

Repeat from the first point to program more levels.

•

Repeat from the first point to program more levels.

•

Press STOP to return to the display mode.

•

Press STOP to return to the display mode.

Erasing programmed levels

•

Lower the forks to the free lift zone when programmed lifting heights are to be erased.

•

Lower the forks to the free lift zone when programmed lifting heights are to be erased.

•

Enter the programming mode and state the required level (e.g. 1+5=level 15). The number is shown on the display.

•

Enter the programming mode and state the required level (e.g. 1+5=level 15). The number is shown on the display.

•

Press the COLLECT button (the LED flashes) and press the LEAVE button (both LEDs start to flash).

•

Press the COLLECT button (the LED flashes) and press the LEAVE button (both LEDs start to flash).

•

Press the PROG button until both LEDs stop flashing and the display shows PL00 to erase the memory.

•

Press the PROG button until both LEDs stop flashing and the display shows PL00 to erase the memory.

•

Repeat the process for other heights you wish to delete.

•

Repeat the process for other heights you wish to delete.

•

Press the STOP button to return to the display mode.

•

Press the STOP button to return to the display mode.

Automatic operations

There are two different automatic operating modes, one where the forks are raised/lowered to required level without a load and the other with a load.

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Controls and instruments

Collecting a load

•

State the required height level using buttons 0-9, (e.g. 1 +2=level 12). The display will show LE12.

•

State the required height level using buttons 0-9, (e.g. 1 +2=level 12). The display will show LE12.

•

Raise/lower the forks until they are automatically stopped by the electronics. If the wrong direction is chosen no raise/lower movement will take place. The electronics expects the correct direction to be selected.

•

When the forks stop and the COLLECT, LED comes ON, the forks can be maneuvered in under the load.

•

When the forks stop and the COLLECT, LED comes ON, the forks can be maneuvered in under the load.

Forks not horizontal.

Warning The load can slide off the forks or

•

Lift the forks until they are automatically stopped by the electronics and the LED LEAVE comes ON.

•

Lift the forks until they are automatically stopped by the electronics and the LED LEAVE comes ON.

•

Move the load from the rack. When the work cycle has been completed the LEDs will go OUT.

•

Move the load from the rack. When the work cycle has been completed the LEDs will go OUT.

Leaving a load

•

Press the LOAD button (the LED now comes ON).

•

Press the LOAD button (the LED now comes ON).

•

State the required height level using buttons 0-9, (e.g. 5=level 05). The display will show LE05.

•

State the required height level using buttons 0-9, (e.g. 5=level 05). The display will show LE05.

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Controls and instruments

•

When the forks stop and the LEAVE, LED comes ON, the forks can be maneuvered out from under the load.

•

When the forks stop and the LEAVE, LED comes ON, the forks can be maneuvered out from under the load.

Forks not horizontal.

Warning The load can slide off the forks or

•

Lower the forks until they are automatically stopped by the electronics and the COLLECT, LED comes ON.

•

Lower the forks until they are automatically stopped by the electronics and the COLLECT, LED comes ON.

•

Remove the forks from the rack. When the work cycle has been completed the LEDs will go OUT.

•

Remove the forks from the rack. When the work cycle has been completed the LEDs will go OUT.

Control

•

Return

Press the button INFO to check the required “collect/leave level”. The value will be shown for 3 seconds on the display.

Controls and instruments Error Codes Error Code

Remark

Err 1

The requested height level is not programmed or is incorrect.

Err 1

The requested height level is not programmed or is incorrect.

Err 2

The forks have stopped outside of the tolerance area (P5).

Err 2

The forks have stopped outside of the tolerance area (P5).

Err 9

Incorrect values stated when programming.

Err 9

Incorrect values stated when programming.

Err flashes

Communication error between the preset height and the truck computer.

Err flashes

Communication error between the preset height and the truck computer.

•

Four lines light up when started. This indicates that no communication has been established between the preset height and the main electronics. These go out when contact between the two units has been established.

•

Four points are light in the display when the forks are in the free lift zone.

•

Four points are light in the display when the forks are in the free lift zone.

•

If the points flash, this indicates that the reference switch was active when the truck was started, e.g. the forks were over the free lift zone. If the points still flash the preset mast height could be set to “0”, or when the forks are lowered there can be a fault in the wiring or the reference height switch can be faulty.

•

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Controls and instruments

Controls for control console position

The control console is adjustable to provide a comfortable operating position.

•

Loosen knob (A) and the entire control console can be adjusted to a suitable height.

•

Loosen knob (A) and the entire control console can be adjusted to a suitable height.

•

Loosen knob (B) and the entire control console can be tilted to a suitable position.

•

Loosen knob (B) and the entire control console can be tilted to a suitable position.

•

DO NOT forget to tighten knobs (A) and (B) after adjusting.

•

DO NOT forget to tighten knobs (A) and (B) after adjusting.

A B

NOTE: Overloading the mounting. Do not use the control console as a handle when entering or leaving the operators compartment.

Warning Loose control console.

You can lose control of the truck if the control console is not tightly mounted. Tighten the knob and move the locking lever to its rear position after adjusting.

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NOTE: Overloading the mounting. Do not use the control console as a handle when entering or leaving the operators compartment.

Warning Loose control console.

You can lose control of the truck if the control console is not tightly mounted. Tighten the knob and move the locking lever to its rear position after adjusting. 46

Controls and instruments

Brake pedal

•

To release the parking brakes depress the brake pedal with your left foot.

•

To release the parking brakes depress the brake pedal with your left foot.

•

To apply the proportional brake lift the brake pedal until the desired level of braking is felt. An emergency stop can be made by fully raising the brake pedal quickly.

•

To apply the proportional brake lift the brake pedal until the desired level of braking is felt. An emergency stop can be made by fully raising the brake pedal quickly.

Warning Risk of crushing exists if any part of

the body is outside of the operator’s compartment. Always have your whole body inside the operator’s compartment.

Warning Risk of crushing exists if any part of

the body is outside of the operator’s compartment. Always have your whole body inside the operator’s compartment.

This truck is also equipped with a plug braking function. This method involves simply reversing the travel control to opposite direction without applying the brake. This will cause the truck to come to a stop smoothly.

Brake pedal

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Brake pedal

Controls and instruments

Height indicator (option)

On machines with a higher lifting height there is an optional display that indicates the actual position of the forks above the free lift zone.

Height indicator

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Height indicator

Warning codes

Character

Error

Character

Error

Warning

When an error occurs a buzzer will sound and a code is displayed during a 10 second period on the right hand side of the character window (C).

If the error remains after 1 minute the warning and buzzer will be reactivated for a further 2 second period.

This process continues until the fault is corrected, however, the truck can be driven with all functions as set out in the warning table.

The error is also indicated in the indicator window (G). Ignoring error indications. Warning Truck safety in jeopardy. Always contact a service technician before the truck is used again after an error code has been displayed.

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I H G F E 49

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I H G F E 49

Warning codes Error No.

Error Code Name

Pump Chopper Limit

Steer Chopper Limit

Wheel Indicator Error

Height Indicator Error

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Warning codes Error No.

Error Code Name

Pump Chopper Limit

Steer Chopper Limit

Wheel Indicator Error

Height counter error

Height Indicator Error

Height counter error

Pump Brush Error

Worn Pump motor brush

Pump Brush Error

Worn Pump motor brush

Drive Brush Error

Worn drive motor brush

Drive Brush Error

Worn drive motor brush

Nov Ram Error

Control Module internal error

Nov Ram Error

Control Module internal error

Default Par

Pump Voltage Error

Lift Pot Z Error

Lift pot not centered at key on time

Lift Pot Z Error

Lift pot not centered at key on time

Tilt Pot Z Error

Tilt pot not centered at key on time

Tilt Pot Z Error

Tilt pot not centered at key on time

Reach Pot Z Error

Reach pot not centered at key on time

Reach Pot Z Error

Reach pot not centered at key on time

Sideshfter Pot Z Error

Sideshfter pot not centered at key on time

Sideshifter Pot Z Error

Sideshfter pot not centered at key on time

Bat Measure Error

Low battery voltage detected

Bat Measure Error

Low battery voltage detected

O Lift Error

Shorted or opened lift valve output

O Lift Error

Shorted or opened lift valve output

O Tilt Error

Shorted or opened tilt valve output

O Tilt Error

Shorted or opened tilt valve output

O Direction A Error

Shorted or opened direction A valve output

O Direction A Error

Shorted or opened direction A valve output

O Direction B Error

Shorted or opened direction B valve output

O Direction B Error

Shorted or opened direction B valve output

O Sideshfter Error

Shorted or opened sideshfter valve output

O Sideshifter Error

Shorted or opened sideshfter valve output

O Spare In Error

Unused output/input

O Spare In Error

Unused output/input

O Spare Out Error

Unused output

O Spare Out Error

Unused output

O Reach In Error

Shorted or opened reach in valve output

O Reach In Error

Shorted or opened reach in valve output

O Reach Out Error

Shorted or opened reach out valve output

O Reach Out Error

Shorted or opened reach out valve output

Comment

Steer chopper current limit

Comment

Steer chopper current limit

Warning codes Error No.

Error Code Name

Comment

O Lower Prop Error

Warning codes Error No.

Error Code Name

Comment

Shorted or opened lowering proportional valve output

O Lower Prop Error

Shorted or opened lowering proportional valve output

O Forward Contactor Error

Shorted or opened forward contactor output

O Forward Contactor Error

Shorted or opened forward contactor output

O Backward Contactor Error

Shorted or opened backward contactor output

O Backward Contactor Error

Shorted or opened backward contactor output

Lift Pot Error

Shorted or opened lift potentiometer input

Lift Pot Error

Shorted or opened lift potentiometer input

Tilt Pot Error

Shorted or opened tilt potentiometer input

Tilt Pot Error

Shorted or opened tilt potentiometer input

Reach Pot Error

Shorted or opened reach potentiometer input

Reach Pot Error

Shorted or opened reach potentiometer input

Sideshifter Pot Error

Shorted or opened sadist potentiometer input

Sideshfter Pot Error

Shorted or opened sadist potentiometer input

Pot Ref Error

Potentiometer supply voltage

Pot Ref Error

Potentiometer supply voltage

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Error codes

Error codes Character

Error

Character

Error

When an error occurs a buzzer will sound at the same time as an error code is displayed on the right hand side of the character window (C). The buzzer will sound until the key switch is turned off.

If the error remains when the key is turned on again the buzzer will sound and the error code displayed.

The truck cannot be used when the Error Codes listed on the next page are displayed in the character window (C).

The error is also indicated in the window (G). Ignoring error indications. Warning Truck safety in jeopardy. Always contact a service technician before the truck is used again after an error code has been displayed.

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I H G F E 52

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I H G F E 52

Error codes

Error No.

Error codes

Error Code Name

Comment

Error No.

100

Pump Temperature Error

Pump chopper over or under temperature

101

Pump Current Error

102

Drive Chopper Error

110

Error Code Name

Comment

100

Pump Temperature Error

Pump chopper over or under temperature

101

Pump Current Error

Drive chopper internal error

102

Drive Chopper Error

Drive chopper internal error

P Brake Pot Ref Error

Pedal/parking brake potentiometer supply voltage

110

P Brake Pot Ref Error

Pedal/parking brake potentiometer supply voltage

111

P Brake Pot Error

Pedal/parking brake potentiometer adjustment or failure

111

P Brake Pot Error

Pedal/parking brake potentiometer adjustment or failure

112

P Brake Switch Error

Pedal/parking brake switch adjustment or failure

112

P Brake Switch Error

Pedal/parking brake switch adjustment or failure

113

P Brake Out Error

Shorted or open parking brake output

113

P Brake Out Error

Shorted or open parking brake output

115

Speed Sensor Error

Drive motor speed sensor failure

115

Speed Sensor Error

Drive motor speed sensor failure

116

Direction Sensor Error

Drive motor direction sensor failure

116

Direction Sensor Error

Drive motor direction sensor failure

117

Reversing Signal Error

Drive chopper reversing signal failure

117

Reversing Signal Error

Drive chopper reversing signal failure

120

Steer Data Error

Control module internal error

120

Steer Data Error

Control module internal error

121

Steer Chopper Error

Steer chopper error

121

Steer Chopper Error

Steer chopper error

122

Steer Temperature Error

Steer chopper over temperature

122

Steer Temperature Error

Steer chopper over temperature

123

Steer Volt Error

123

Steer Volt Error

124

Steer Current Error

124

Steer Current Error

125

Steer Tacho Error

Steer tacho error

125

Steer Tacho Error

Steer tacho error

126

Steer Connection Error

Opened steer motor output - motor or connection failure

126

Steer Connection Error

Opened steer motor output - motor or connection failure

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Error codes

Error No.

Error Code Name

Comment

Error No.

Error Code Name

Comment

127

Steer Comm Error

Control module internal error

127

Steer Comm Error

Control module internal error

130

Slave Comm Error

Control module internal error

130

Slave Comm Error

Control module internal error

131

Security Rel Error 1

Security relay error 1

131

Security Rel Error 1

Security relay error 1

132

Steer Power Error

Steer chopper supply voltage under voltage

132

Steer Power Error

Steer chopper supply voltage under voltage

133

Security Rel Error

Security relay error 2

133

Security Rel Error

Security relay error 2

140

Check Sum Error

Control module internal error

140

Check Sum Error

Control module internal error

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Driving

Starting the truck

•

Make sure the emergency stop is not pressed in.

•

Make sure the emergency stop is not pressed in.

•

When key switch is turn ON the electrical controller will run a self check. One check is to see if the floor switch is functioning correctly. This is done by checking the right floor switch with no weight on it, resulting in an open switch. If a weight is found (closed switch) no hydraulic function will be allowed. After the checks have been performed the right foot must be returned to the floor. If not, the triangle on display will flash until this is done.

•

Turn the key switch to the ON position (making sure your right foot is off the floor for about 2-3 seconds). The instrument lighting should come on.

•

Turn the key switch to the ON position (making sure your right foot is off the floor for about 2-3 seconds). The instrument lighting should come on.

•

Make sure the battery indicator indicates a sufficient charge level (1/2-1).

•

Make sure the battery indicator indicates a sufficient charge level (1/2-1).

NOTE: Low charge level. Prolonged operation with a low battery charge level can result in damage to the battery. Do not drive without first recharging the battery.

•

Place your foot on the brake pedal to release brake.

Warning Risk of crushing exists if any part of the

body is outside of the operator’s compartment. Always have your whole body inside the operator’s compartment.

•

Select the travel direction.

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body is outside of the operator’s compartment. Always have your whole body inside the operator’s compartment.

• 55

Place your foot on the brake pedal to release brake.

Select the travel direction. 55

Driving Warning Function failure.

Warning Function failure.

Warning Dangerous driving.

Safety can be jeopardized. Always complete the daily operator’s checks before starting the day’s work.

Accidents can occur. Always drive with care, good judgment and responsibility.

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Driving

Safety can be jeopardized. Always complete the daily operator’s checks before starting the day’s work.

Accidents can occur. Always drive with care, good judgment and responsibility.

Driving

Braking

The brakes are applied when pedal is in the normal position (raised). Depressing pedal releases brake and closes a switch in control circuit that allows operation of truck. The brake and brake interlock switch should always be checked prior to operation of truck.

Brake pedal

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Brake pedal

Driving

Steering

The steering impulses are transmitted to an electric steering motor mounted in the motor compartment. The steering motor moves the transmission by means of gears.

The steering characteristics are progressive, this means that the required steering response on the drive wheel is dependent on the speed of the truck. When driving slowly, a small number of turns to the steering gives the same response as a large number of turns when driving faster.

The drive wheel has no end limit position, which gives the possibility of steering through 360 degree.

The steering characteristics can be adapted to the operator’s experience and requirements. The steering sensitivity, progressiveness can be increased or decreased if necessary. Contact a trained service technician.

When driving slowly and turning the truck, the wheel can be turned more quickly using the spinner.

•

When driving at high speed (long transport, etc.) steer the truck by using the tips of your fingers on steering hub. Lost stability.

•

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When driving at high speed (long transport, etc.) steer the truck by using the tips of your fingers on steering hub. Lost stability.

Warning The truck can overturn and the load fall if

you turn the steering quickly at high speed. Only steer with the finger tips on the steering hub when driving at high speed.

If the truck gets caught against an obstacle, use normal steering force to steer truck free. Try to free truck by carefully driving forwards and backwards while moving the steering wheel.

•

If the truck gets caught against an obstacle, use normal steering force to steer truck free. Try to free truck by carefully driving forwards and backwards while moving the steering wheel.

Driving

Risk of slipping.

Warning You can lose control of the truck if your

hands or shoes are oily. Always dry your hands and shoes before driving.

Parking the truck

•

Stop the truck carefully and make sure that all motion has stopped.

•

Stop the truck carefully and make sure that all motion has stopped.

•

Retract the reach.

•

Retract the reach.

•

Lower the forks to the floor.

•

Lower the forks to the floor.

•

Apply the parking brake by releasing the brake pedal. The parking brake is automatically applied.

•

Apply the parking brake by releasing the brake pedal. The parking brake is automatically applied.

•

Turn the key switch to the OFF position and remove key.

•

Turn the key switch to the OFF position and remove key.

use. Warning Unauthorized Accidents can happen. Always remove key from the key switch when truck is left unattended.

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Unauthorized use.

Warning Accidents can happen. Always remove key from the key switch when truck is left unattended.

Transporting loads

General

The weight of the load should be within the truck’s permitted lifting capacity. See the truck’s data plate.

Warning Risk of overturning.

The lifting capacity is reduced if additional equipment is attached to the truck. Always check the truck’s overall lifting capacity.

•

Only handle loads that are stable and arranged safely. Take particular care when handling high and long loads.

•

Only handle loads that are stable and arranged safely. Take particular care when handling high and long loads.

•

Always drive with the forks tilted back, at floor level and with the reach fully retracted except when leaving and collecting loads.

•

Always drive with the forks tilted back, at floor level and with the reach fully retracted except when leaving and collecting loads.

•

Always drive with the forks fully lowered except when collecting or leaving a load.

•

Always drive with the forks fully lowered except when collecting or leaving a load.

•

Adjust distance between forks to the width of the load.

•

Adjust distance between forks to the width of the load.

stability. Warning Lost High loads can fall when cornering at high

speed or cause tipover. Drive slowly and carefully when cornering and travel with loads in lowered position.

Protruding loads.

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Protruding loads.

Warning The load can collide with personnel, fixed

or moving objects. A truck with a protruding load requires more room when cornering.

Transporting loads

with reach extended. Warning Driving This will cause excessive wear and

maintenance. Always drive with the reach in the fully retracted position.

NOTE: Increased machine width. The outriggers can collide with fixed objects. A truck with wide outriggers requires a greater operating area.

•

Drive the truck with the load trailing, when the load impairs the line of vision.

•

Drive the truck with the load trailing, when the load impairs the line of vision.

•

If necessary, when the operator’s vision is impaired, ask someone to direct operations so that transportation can take place without the risk of causing personal injury or material damage.

•

If necessary, when the operator’s vision is impaired, ask someone to direct operations so that transportation can take place without the risk of causing personal injury or material damage.

•

Drive the truck at a reduced speed when driving on inclines. Always drive with the load uppermost on the incline. Drive straight up and down the incline. It is not permitted to turn the truck on an incline.

•

of overturning. Warning Risk A loaded truck can

overturn when attempting to turn on an incline. Never turn a loaded truck on an incline.

Increased braking distance.

•

Increased braking distance.

Warning The braking distance is increased when

traveling downhill. Drive at a reduced speed, use the truck’s motor brake.

Before the truck is driven into an elevator, ensure that the elevator is certified for the overall load (the weight of the

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•

Before the truck is driven into an elevator, ensure that the elevator is certified for the overall load (the weight of the 61

Transporting loads

•

truck, the load and the operator). When entering an elevator the load goes first not the driver. There must be no personnel in the elevator when entering or exiting.

Warning An overloaded elevator can fall out of

Risk of overloading the elevator.

Warning An overloaded elevator can fall out of

control down the elevator shaft. Always check the capacity of the elevator before driving in with the truck.

Before you drive the truck over a loading ramp, ensure that the ramp is correctly secured and that it has the necessary load bearing capacity. The truck should be driven slowly and carefully across the ramp and at a safe distance from the edges. Risk of tipping.

Warning The truck can tip over. Always check the ramp’s load bearing capacity and that it is secured correctly. Drive at a safe distance from the edges.

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Transporting loads

Risk of overloading the elevator.

•

Warning The truck can tip over. Always check the ramp’s load bearing capacity and that it is secured correctly. Drive at a safe distance from the edges.

Transporting loads

Collecting a load

Instructions on the use of the preset height feature can be found in section, Control and Instruments.

•

Slow down and position the truck carefully in front of the rack.

•

Slow down and position the truck carefully in front of the rack.

•

Lift the forks to the required position.

•

Lift the forks to the required position.

•

Drive the truck forward. Extend the reach so that the forks go as far under the load as possible.

•

Drive the truck forward. Extend the reach so that the forks go as far under the load as possible.

Warning Forks not horizontal.

•

Lift the forks so that the load is lifted free.

•

Lift the forks so that the load is lifted free.

•

Tilt the forks as far as necessary for the load to be stable.

•

Tilt the forks as far as necessary for the load to be stable.

•

Retract the reach and reverse the truck so that the load clears the rack.

•

Retract the reach and reverse the truck so that the load clears the rack.

•

Lower the load to floor level and drive carefully away from the rack.

•

Lower the load to floor level and drive carefully away from the rack.

CAUTION Lost stability

Lifting a loaded pallet when truck is still moving can result in load falling off the pallet. Never lift a load if truck is moving.

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CAUTION Lost stability

Lifting a loaded pallet when truck is still moving can result in load falling off the pallet. Never lift a load if truck is moving. 63

Transporting loads

Leaving a load

•

Slow down and position truck carefully in front of rack.

•

Slow down and position truck carefully in front of rack.

•

Lift forks to required lifting position.

•

Lift forks to required lifting position.

•

Drive truck forward, tilt forks to the horizontal position and extend the reach so that load goes on rack load carrier.

•

Drive truck forward, tilt forks to the horizontal position and extend the reach so that load goes on rack load carrier.

Warning Forks not horizontal.

•

Lower the forks so that they clear the load.

•

Lower the forks so that they clear the load.

•

Retract the reach and reverse the truck.

•

Retract the reach and reverse the truck.

•

Lower forks to floor level and drive carefully away from the rack. Start slowly and then increase the speed.

•

Lower forks to floor level and drive carefully away from the rack. Start slowly and then increase the speed.

CAUTION Lost stability

Lowering a loaded pallet when truck is still moving can result in load falling off the pallet. Never lower a load if truck is moving.

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CAUTION Lost stability

Lowering a loaded pallet when truck is still moving can result in load falling off the pallet. Never lower a load if truck is moving.

Battery

Type of battery

•

Check that the battery used in this truck is the correct voltage as shown on the truck’s data plate. Use a traction battery having a weight within the minimum/maximum values stated on the data plate.

Changing the battery

•

Only replace the battery with a battery of the same weight as the original. The battery weight affects the truck’s stability and its braking capacity. Information on the lowest permitted battery weight can be found on the truck’s data plate. WARNING Risk of moving the center of gravity. A battery weight that is too low gives impaired stability and braking capacity. The battery weight must be in accordance with the information on the truck’s data plate.

When changing the battery proceed as follows:

•

Park truck at battery removal station.

•

Park truck at battery removal station.

•

Turn OFF key and remove.

•

Turn OFF key and remove.

•

Push the emergency disconnect button to the OFF position to stop hourmeter from running.

•

Push the emergency disconnect button to the OFF position to stop hourmeter from running.

•

Disconnect the battery connector from the battery.

•

Disconnect the battery connector from the battery.

•

Remove battery stops.

•

Remove battery stops.

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Battery

•

Slide out the discharged/old battery, then slide in the new battery.

•

Slide out the discharged/old battery, then slide in the new battery.

•

Connect battery and truck connectors.

•

Connect battery and truck connectors.

•

Connect the battery connector and truck connector.

•

Connect the battery connector and truck connector.

WARNING Risk of short-circuiting. The cables can be damaged and cause a short-circuit. Ensure the battery cables are not crushed.

•

Push the emergency disconnect button to the ON position.

•

Push the emergency disconnect button to the ON position.

•

Install battery stops.

•

Install battery stops.

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WARNING Falling battery. If the truck should tip over the battery can fall out if the battery stops have not been installed. Make sure the battery stops have been installed.

WARNING Falling battery. When charging the battery, it can be dropped. Always lift battery using an approved lifting device, and use a battery yoke intended for the battery.

Battery

Charging the battery

General prohibition

When recharging the battery it is absolutely forbidden to smoke or use an open flame.

Use an automatic charger intended for recharging traction batteries.

The charger must have an automatic maintenance charging feature for a certain period after the main charging period has been completed. This eliminates the risk of over charging the battery and the need to monitor the charging procedure is reduced to a minimum.

The charger shall have a minimum charging current of:

Battery (Ah)

Charger (A)

Battery (Ah)

Charger (A)

300-480

50-70

300-480

50-70

480-730

80-110

480-730

80-110

730-900

130-150

730-900

130-150

WARNING Corrosive acid. The battery fluid contains sulfuric acid. Fluid spilled on skin should be rinsed OFF immediately. Wash thoroughly with soap and water. If the fluid has come into contact with the eyes, wash the eyes immediately using an eye shower. Contact a doctor.

ALWAYS WEAR PROTECTIVE GLASSES AND PROTECTIVE GLOVES WHEN CHECKING THE BATTERY.

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Battery

Pre-charging

•

Park the truck in the assigned charging area.

•

Park the truck in the assigned charging area.

•

Ensure nothing prevents ventilation above the battery.

•

Ensure nothing prevents ventilation above the battery.

•

Turn key switch to the OFF position.

•

Turn key switch to the OFF position.

•

Remove the battery connector from the truck’s connector.

•

Remove the battery connector from the truck’s connector.

•

Make sure the battery charger is switched OFF.

•

Make sure the battery charger is switched OFF.

•

Connect the battery connector to charger connector.

•

Connect the battery connector to charger connector.

•

Never connect charger connector to truck connector.

•

Never connect charger connector to truck connector.

•

Switch ON the battery charger.

•

Switch ON the battery charger.

WARNING During the charging process oxygen and hydrogen gases are always formed in the battery. Short circuits, open flames, and sparks in the vicinity of the battery can cause an EXPLOSION. Always switch OFF the charger current BEFORE removing the battery connector. Provide good ventilation, especially if the battery is recharged in a confined area.

During charging

•

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After approximately ten minutes make sure that the ammeter indicates a normal reading and that the control lamp is ON. 68

Battery

After charging

•

Make sure that the ammeter indicates an insignificant or no reading and that maintenance charge lamp is ON, if equipped.

•

Make sure that the ammeter indicates an insignificant or no reading and that maintenance charge lamp is ON, if equipped.

•

Switch OFF the charger.

•

Switch OFF the charger.

•

Disconnect the battery connector from charger connector.

•

Disconnect the battery connector from charger connector.

CAUTION

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Risk of short circuiting. The terminals can otherwise be damaged inside and result in a subsequent short circuit. Do not pull the cables to disconnect from the charger.

CAUTION

Risk of short circuiting. The terminals can otherwise be damaged inside and result in a subsequent short circuit. Do not pull the cables to disconnect from the charger.

Battery

Battery maintenance

Carry out battery maintenance after recharging.

ALWAYS WEAR PROTECTIVE GLASSES AND PROTECTIVE GLOVES WHEN CHECKING THE BATTERY.

Each week:

•

Remove all cell caps. NOTE! This does not apply to batteries with level caps or central filling.

•

Check the fluid level in the cells and note any cells that consume more than a normal amount of fluid.

•

Check the fluid level in the cells and note any cells that consume more than a normal amount of fluid.

•

Fill using distilled water. The fluid level should be 1/4 in. (10-15 mm) above the cell plates.

•

Fill using distilled water. The fluid level should be 1/4 in. (10-15 mm) above the cell plates.

•

Refit all of the cell caps.

•

Refit all of the cell caps.

•

Rinse off and dry the battery.

•

Rinse off and dry the battery.

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Battery

Each month:

•

Measure the temperature in one of the center cells immediately after charging. The temperature should not exceed 122°F [50°C.]

•

Measure the temperature in one of the center cells immediately after charging. The temperature should not exceed 122°F [50°C.]

•

Measure the density of the battery fluid using an acid tester. Hold the acid tester absolutely vertical and extract sufficient fluid so that the hydrometer float moves freely.

•

Measure the density of the battery fluid using an acid tester. Hold the acid tester absolutely vertical and extract sufficient fluid so that the hydrometer float moves freely.

•

Adjust specific gravity with temperatures based on the chart below.

•

Adjust specific gravity with temperatures based on the chart below.

Temperature

Gravity

Temperature

Gravity

77°F [25.2°C]

1.280

77°F [25.2°C]

1.280

WARNING Battery manufactories maintenance and charging procedures must be followed. Battery acid is very corrosive and must be immediately cleaned up after spillage.

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WARNING Battery manufactories maintenance and charging procedures must be followed. Battery acid is very corrosive and must be immediately cleaned up after spillage.

Daily service/safety checks

•

The operator is responsible for the daily service and care of the truck.

•

The operator is responsible for the daily service and care of the truck.

•

Carry out the daily service at the start of the day or shift, before the truck is used. The daily service is a simple safety and function control as set in the check list below.

•

Carry out the daily service at the start of the day or shift, before the truck is used. The daily service is a simple safety and function control as set in the check list below.

•

You need no tools to carry out the service checks.

•

You need no tools to carry out the service checks.

•

If you fail to carry out the daily service, the safety and reliability of the truck can be affected.

•

If you fail to carry out the daily service, the safety and reliability of the truck can be affected.

Warning Never neglect the daily service and safety checks. Serious accidents can occur. Always report any faults or damage to your supervisor without delay. Never use a truck that does not function properly.

Check points

Action

Check points

Action

Hydraulic system

Check for oil leakage, hoses and floor

Hydraulic system

Check for oil leakage, hoses and floor

Lifting device

Check for damage, noise function

Lifting device

Check for damage, noise function

Battery

Check acid level, charge and condition (see battery maintenance)

Battery

Check acid level, charge and condition (see battery maintenance)

Battery cables and connections

Check for breakage cutting or damage

Battery cables and connections

Check for breakage cutting or damage

Battery stops

Check for located correctly

Battery stops

Check for located correctly

Chassis

Check for damage, remove dirt and debris

Chassis

Check for damage, remove dirt and debris

Overhead guard & safety guards

Check for damage, ensure placement

Overhead guard & safety guards

Check for damage, ensure placement

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Daily service/safety checks

Check points

Action

Check points

Action

Drive unit

Inspect abnormal noises and leakage

Drive unit

Inspect abnormal noises and leakage

Wheels

Check for damage, remove oil, metal chips and debris

Wheels

Check for damage, remove oil, metal chips and debris

Brake pedal

Check its function

Brake pedal

Check its function

Direction / accelerator

Check its function

Direction / accelerator

Check its function

Control console

Check its locking mechanism

Control console

Check its locking mechanism

Hydraulic function

Check its function

Hydraulic function

Check its function

Control functions

Check its function

Control functions

Check its function

Parking brake

Check its function

Parking brake

Check its function

Horn

Check its function

Horn

Check its function

Running time

Inform your supervisor if your truck is ready for a schedule maintenance check. See “Maintenance” chapter.

Running time

Inform your supervisor if your truck is ready for a schedule maintenance check. See “Maintenance” chapter.

Emergency stop

Check its function

Emergency stop

Check its function

Steering

Check its function

Steering

Check its function

Special equipment

Your truck may have been fitted with optional or special equipment that requires routine check to ensure safe operation consult with your supervisor and your BT representative about routine checks

Special equipment

Your truck may have been fitted with optional or special equipment that requires routine check to ensure safe operation consult with your supervisor and your BT representative about routine checks

If any of the function fail to operate properly, inform your supervisor or maintenance personal to have the truck repaired.

Warning DO NOT continue to operate the truck when it is not functioning properly.

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If any of the function fail to operate properly, inform your supervisor or maintenance personal to have the truck repaired.

DO NOT continue to operate the truck

Warning when it is not functioning properly.

Maintenance

General

•

Ensure the truck is given a regular maintenance service after every 500 driving hours. The truck’s safety, efficiency and service life is dependent on the service and maintenance it is given.

•

Ensure the truck is given a regular maintenance service after every 500 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.

•

Only use BT approved spare parts when service and repair work are carried out.

•

BT recommends that you contact your BT representative to setup a service and maintenance agreement to ensure your truck’s operating economy and safety.

•

BT recommends that you contact your BT representative to setup a service and maintenance agreement to ensure your truck’s operating economy and safety.

Safety regulations with maintenance work

•

Only personnel that have been trained in the service and repair of this type of truck are authorized to carry out service and repair work.

•

Only personnel that have been trained in the service and repair of this type of truck are authorized 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.

•

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 service clean. Oil or water makes the floor slippery.

•

Keep the area where you carry out service clean. Oil or water makes the floor slippery.

•

Never wear loose objects or jewelry when working on the truck.

•

Never wear loose objects or jewelry when working on the truck.

Short-circuiting/Burns.

•

Short-circuiting/Burns.

Warning When working with the truck’s electrical

system, short circuiting/burns can occur if a metal object comes into contact with live electrical connections. Remove watches, ring or other types of metal jewelry.

Always switch OFF the truck’s power supply before opening the covers on the drive unit or electrical systems. 74 Return

•

Always switch OFF the truck’s power supply before opening the covers on the drive unit or electrical systems. 74

Maintenance

•

Always disconnect the battery by pulling out the battery connector when carrying out maintenance work on the truck unless otherwise stated in this publication or the Service Manual.

•

Always disconnect the battery by pulling out the battery connector when carrying out maintenance work on the truck unless otherwise stated in this publication or the Service Manual.

•

Relieve the system pressure slowly before starting work on the truck’s hydraulic systems.

•

Relieve the system pressure slowly before starting work on the truck’s hydraulic systems.

•

Use paper or a rigid sheet of cardboard when checking for oil leakage. Never use your hand.

•

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. of burns. Warning Risk Hot transmission and hydraulic oil Let the truck cool before changing the oil.

•

Bear in mind that the oil in the transmission or the hydraulic system can be hot. of burns. Warning Risk Hot transmission and hydraulic oil Let the truck cool before changing the oil.

•

Only fill the hydraulic system with new clean oil. Oil should meet BT cleanliness specification 12-00-002. Contact your BT representative for assistance or more information. hydraulic system can be damaged. Warning The 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 regulations.

•

Store and dispose of changed oil in accordance with local regulations.

•

Do not dump solvents, which are used for cleaning/ washing, into drains that are not intended for this purpose. Follow the local regulations that apply for disposal.

•

Do not dump solvents, which are used for cleaning/ washing, into drains that are not intended for this purpose. Follow the local regulations that apply for disposal.

•

When working underneath the truck, support the truck on trestle-blocks. Risk of crushing. Warning A badly supported truck can fall. Never work under a truck that is not supported on trestle-blocks and secured by a lifting device.

•

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Maintenance

Maintenance work that can be carried out by you

The Daily service/Safety checks as set out in the check list.

Maintenance points with intervals 1 day, 1 week, and 1 month as set out in the Maintenance chart may be carried out by the driver without more knowledge than that provided by the Operator’s Manual.

Other maintenance points as set out in the Maintenance chart may only be carried out by personnel who have completed maintenance training for this type of truck.

Maintenance work that may be carried out by trained maintenance personnel

All maintenance points as set out in the Maintenance chart.

If you are uncertain regarding working procedures, consult the Service Manual for the truck.

Other service and repair work

•

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In addition to the maintenance points in the Maintenance chart, all service and repair work should be carried out by personnel with special training for this type of truck.

Maintenance

Cleaning and washing

General

Cleaning and washing of the truck is important to ensure the truck will operate safely and 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 battery connector. Do not spray water directly into the electrical compartments of the truck.

External cleaning

•

Remove debris, etc. from the wheels daily.

•

Remove debris, etc. from the wheels daily.

•

Use a degreasing concentration.

•

Use a degreasing concentration.

•

Rinse off loose grime using warm water.

•

Rinse off loose grime using warm water.

agent,

diluted

suitable

agent,

diluted

suitable

NOTE: Mechanical components can be damaged. After washing, the truck should be lubricated as set out in the chapter Maintenance and Lubrication chart.

Cleaning the motor compartment

•

Cover the electric motors, electrical compartments, connectors, and valves before washing.

•

Cover the electric motors, electrical compartments, connectors, and valves before washing.

•

Clean carefully using the minimum of water and detergent. Never pressure wash or steam clean in the compartments.

•

Clean carefully using the minimum of water and detergent. Never pressure wash or steam clean in the compartments.

Return

Maintenance

NOTE: Risk of short-circuiting. The electrical system can be damaged. Electrical components must not be cleaned with a high pressure washing unit.

•

Clean the motor compartment using a degreasing agent, diluted to a suitable concentration.

•

Clean the motor compartment using a degreasing agent, diluted to a suitable concentration.

•

Rinse off loose grime using warm water.

•

Rinse off loose grime using warm water.

Electrical components

•

Blow electric motors dry using compressed air.

Warning Compressed air used for cleaning

•

MUST be reduced to less than 30 p.s.i., and then only with effective chipguarding and personal protective equipment. Clean the electrical panels, electronic boards, contacts, connector, solenoid valves, etc. using a damp cloth and a cleaning agent. Do not spray or pressure wash in the compartment.

Blow electric motors dry using compressed air.

Warning Compressed air used for cleaning

•

NOTE: Risk of short circuiting. Electrical components can be damaged. Do not break the warranty seal on the electronic board.

Return

Maintenance

Maintenance chart

PM Interval:

A=5 Hours or 1 Day

E=500 Hours or 6 Months

A=5 Hours or 1 Day

E=500 Hours or 6 Months

B=20 Hours or 1 Week

F=1000 Hours or 12 Months

B=20 Hours or 1 Week

F=1000 Hours or 12 Months

C=80 Hours or 1 Month

G=3000 Hours or 36 Months

C=80 Hours or 1 Month

G=3000 Hours or 36 Months

D=250 Hours or 3 Months No.

Action

1.0

Chassis

1.1

Check door lock

1.2

D=250 Hours or 3 Months No.

Action

1.0

Chassis

1.1

Check door lock

Check wear on battery stop

1.2

Check wear on battery stop

1.3

Check for damage and crack formation

1.3

Check for damage and crack formation

1.4

Check outriggers mounting

1.4

Check outriggers mounting

2.0

Motors

2.0

Motors

2.1

Check for loose connections

2.1

Check for loose connections

2.2

Clean motor

2.2

Clean motor

2.3

Check mounting bolts

2.3

Check mounting bolts

2.4

Check for abnormal bearing noise.

2.4

Check for abnormal bearing noise.

2.5

Brush wear

2.5

Brush wear

3.0

Drive unit

3.0

Drive unit

3.1

Check for leakage

3.1

Check for leakage

3.2

Check oil level

3.2

Check oil level

3.3

Check for noises

3.3

Check for noises

3.4

Check the mounting on support

3.4

Check the mounting on support

4.0

Wheels

4.0

Wheels

4.1

Remove string & debris

4.1

Remove string & debris

4.2

Check drive wheel wear and nuts

4.2

Check drive wheel wear and nuts

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Maintenance No.

Action

No.

Action

4.3

Check that the support arm wheels rotate and axles are fitted correctly

4.3

Check that the support arm wheels rotate and axles are fitted correctly

4.4

Check support arm wheel for wear

4.4

Check support arm wheel for wear

4.5

Dismantle and lubricate the support wheel bearing

4.5

Dismantle and lubricate the support wheel bearing

5.0

Brake

5.0

Brake

5.1

Clean

5.1

Clean

5.2

Check for wear to the brake discs

5.2

Check for wear to the brake discs

5.3

Check for play in released position

5.3

Check for play in released position

5.4

Check brake wires for wear

5.4

Check brake wires for wear

6.0

Electrical panel

6.0

Electrical panel

6.1

Clean and check the mounting

6.1

Clean and check the mounting

6.2

Tighten cable connections

6.2

Tighten cable connections

6.3

Check contactor points

6.3

Check contactor points

6.4

Check the contactor’s movement

6.4

Check the contactor’s movement

7.0

Battery

7.0

Battery

7.1

Check the electrolyte level 1/4 in. [10-15 mm] above cell plate

7.1

Check the electrolyte level 1/4 in. [10-15 mm] above cell plate

7.2

Check the connections on battery, truck and charger

7.2

Check the connections on battery, truck and charger

7.3

Check cell and pole guard

7.3

Check cell and pole guard

7.4

Check the fluid density and temperature

7.4

Check the fluid density and temperature

7.5

Check power cables are not cut or frayed

7.5

Check power cables are not cut or frayed

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Maintenance

Maintenance No.

Action

No.

Action

8.0

Hydraulic system

8.0

Hydraulic system

8.1

Check hoses and couplings for leakage

8.1

Check hoses and couplings for leakage

8.2

Check pipes and hoses for wear

8.2

Check pipes and hoses for wear

8.3

Check the tank for leakage and its mountings

8.3

Check the tank for leakage and its mountings

8.5

Check oil level

8.5

Check oil level

8.6

Change oil

8.6

Change oil

9.0

Cylinders

9.0

Cylinders

9.1

Check for leakage

9.1

Check for leakage

9.2

Check the mountings

9.2

Check the mountings

10.0

Mast and reach carriage

10.0

Mast and reach carriage

10.1

Check for damage and cracks

10.1

Check for damage and cracks

10.2

Check mast mounting bolt torque

10.2

Check mast mounting bolt torque

10.3

Check for play on the rollers

10.3

Check for play on the rollers

10.4

Check the electrical limit switch function

10.4

Check the electrical limit switch function

10.5

Check for wear and stretch on the chains and sheaves

10.5

Check for wear and stretch on the chains and sheaves

10.6

Check hoses and couplings for leakage cuts and other damage

10.6

Check hoses and couplings for leakage cuts and other damage

10.7

Check for wear to the forks and other lifting devices

10.7

Check for wear to the forks and other lifting devices

11.0

Control console

11.0

Control console

11.1

Check the mounting and control console locking mechanism

11.1

Check the mounting and control console locking mechanism

11.2

Check the micro switches and hydraulic function

11.2

Check the micro switches and hydraulic function

Return

Maintenance B

X X

Maintenance No.

Action

12.0

Pedal

12.1

Check the pedal function

13.0

Emergency stop switch

13.1

Check the emergency stop switch

Maintenance B

No.

Action

12.0

Pedal

12.1

Check the pedal function

13.0

Emergency stop switch

13.1

Check the emergency stop switch

12 1

1 4

Return

10 11

Maintenance

Lubrication chart

Lubrication chart Interval/Running hours

Pos No.

Service point

Wheel bearings

Mast beam

Interval/Running hours

Pos No.

Service point

Wheel bearings

Mast beam

Reach rails

Lifting chains

Side movement

Hydraulic system

Travel brake

Drive gear

Hinges

Steering bearings

Gear ring

Mast chain sheaves

Mast cable sheaves

Lubricant 500h

L=Lubrication

Return

1000h

3000h L

C=Check

O=Oil change

Lubricant 500h

L=Lubrication

1000h

3000h L

C=Check

O=Oil change

Maintenance

Approved Oils and Grease

Specification Pos. Lubricant

Specification

Above

Below

Application

23°F [-5°C]

5°F [-15°C]

area

Tex. Ref. C & Tex. Ref. C & Tex. Ref. C & C #880 C #880 C #880

Grease

Hydraulic oil

Transmission SAE 80w/90 oil

Sunoco TH

Pos. Lubricant

Bearings and bushings

Grease

Above

Below

Application

23°F [-5°C]

5°F [-15°C]

area

Tex. Ref. C & Tex. Ref. C & Tex. Ref. C & C #880 C #880 C #880

ATF

Texaco 15

Hydraulic system

Hydraulic oil

SAE 80w/90

ATF

Gears

Transmission SAE 80w/90 oil

Sunoco TH

Bearings and bushings

ATF

Texaco 15

Hydraulic system

SAE 80w/90

ATF

Gears

Motor oil

SAE 40

SAE5w-20

Chains

Motor oil

SAE 40

SAE5w-20

Chains

Grease

Molykote 200025

Mast rails Sideshifter

Grease

Molykote 200025

Mast rails Sideshifter

Grease

49670-00

Mast rails Sideshifter

Grease

49670-00

Mast rails Sideshifter

Oil should meet BT cleanliness specification 12-00-002. Contact your BT representative for assistance or more information.

3 5

9 10

7 1

Return

Lubrication chart location points

Transporting and storing the truck

The truck’s dimensions and weight as standard

NOTE! The truck’s dimensions and weight can vary with different accessories.

The RRX35/RSX40 truck’s dimensions and weight

14.5 in. [368.3 mm]

Battery Width Height, truck without mast/OHG

16.5 in. [419.1 mm]

53.5 in. [1351.3 mm]

14.5 in. [368.3 mm]

Battery Width Height, truck without mast/OHG

16.5 in. [419.1 mm]

53.5 in. [1351.3 mm]

Height, dependent on mast

89 in. - 119 in. [2260.6 mm - 3022.6 mm]

Height, dependent on mast

89 in. - 119 in. [2260.6 mm - 3022.6 mm]

Width, dependent on outrigger

40.6 in. - 61.0 in. [1031.2 mm - 1549.4 mm]

Width, dependent on outrigger

40.6 in. - 61.0 in. [1031.2 mm - 1549.4 mm]

Length excl. forks

70.5 in. [1760.7 mm]

72.14 in. [1832.36 mm]

Minimum battery weight

1600 lb [726.4 kg]

2000 lb [908 kg]

Service weight without battery

5400 lb and UP 2451.6 kg and UP]

The RRX45/RSX50 truck’s dimensions and weight 16.5 in. [419.1 mm]

Battery Width Height, truck without mast/OHG

21.0 in. [533.4 mm]

53.5 in. [1351.3 mm]

Length excl. forks

70.5 in. [1760.7 mm]

72.14 in. [1832.36 mm]

Minimum battery weight

1600 lb [726.4 kg]

2000 lb [908 kg]

Service weight without battery

5400 lb and UP 2451.6 kg and UP]

The RRX45/RSX50 truck’s dimensions and weight 16.5 in. [419.1 mm]

Battery Width Height, truck without mast/OHG

21.0 in. [533.4 mm]

53.5 in. [1351.3 mm]

Height, dependent on mast

95 in. - 172 in. [2413 mm - 4368.8 mm]

Height, dependent on mast

95 in. - 172 in. [2413 mm - 4368.8 mm]

Width, dependent on outrigger

40.6 in. - 61.0 in. [1031.2 mm - 1549.4 mm]

Width, dependent on outrigger

40.6 in. - 61.0 in. [1031.2 mm - 1549.4 mm]

Return

Transporting and storing the truck

The RRX35/RSX40 truck’s dimensions and weight

Battery Width Length excl. forks Minimum battery weight Service weight without battery

14.5 in. [368.3 mm]

16.5 in. [419.1 mm]

74.64 in. [1895.86 mm]

76.64 in. [1946.66 mm]

Length excl. forks

2000 lb [908 kg]

2400 lb [1089.6 kg]

Minimum battery weight

5400 lb and UP 2451.6 kg and UP]

The RDX30 truck’s dimensions and weight 16.5 in. [419.1 mm]

Battery Width Height, truck without mast/OHG

21.0 in. [533.4 mm]

53.5 in. [1351.3 mm]

Battery Width

Service weight without battery

14.5 in. [368.3 mm]

16.5 in. [419.1 mm]

74.64 in. [1895.86 mm]

76.64 in. [1946.66 mm]

2000 lb [908 kg]

2400 lb [1089.6 kg]

5400 lb and UP 2451.6 kg and UP]

The RDX30 truck’s dimensions and weight 16.5 in. [419.1 mm]

Battery Width Height, truck without mast/OHG

21.0 in. [533.4 mm]

53.5 in. [1351.3 mm]

Height, dependent on mast

95 in. - 172 in. [2413 mm - 4368.8 mm]

Height, dependent on mast

95 in. - 172 in. [2413 mm - 4368.8 mm]

Width, dependent on outrigger

40.6 in. - 61.0 in. [1031.2 mm - 1549.4 mm]

Width, dependent on outrigger

40.6 in. - 61.0 in. [1031.2 mm - 1549.4 mm]

Length excl. forks

74.64 in. [1895.86 mm]

76.64 in. [1946.66 mm]

Length excl. forks

74.64 in. [1895.86 mm]

76.64 in. [1946.66 mm]

Minimum battery weight

2400 lb [1089.6 kg]

2600 lb [1180.4 mm]

Minimum battery weight

2400 lb [1089.6 kg]

2600 lb [1180.4 mm]

Service weight without battery

Return

5400 lb and UP 2451.6 kg and UP]

Service weight without battery

5400 lb and UP 2451.6 kg and UP]

Transporting and storing the truck

Lifting the truck

•

Lift the truck from the marked lifting points when lifting using a lifting device. Risk of overturning.

Warning The truck can overturn if lifted from the

wrong lifting points. Always lift the truck from the marked lifting points.

of overturning. Warning Risk The truck can overturn if lifted incorrectly.

Always lift the truck secured to, and with the center of gravity between, the lifting truck’s forks.

Return

Transporting and storing the truck Towing and transporting a disabled truck Warning

DO NOT tow a disabled truck

It is not recommended to tow a disabled lift truck.

Return

Transporting and storing the truck Towing and transporting a disabled truck Warning

DO NOT tow a disabled truck

It is not recommended to tow a disabled lift truck.

Transporting and storing the truck

Storing the truck

Take the following action if the truck is not used for one week or more:

Battery

•

Recharge the battery fully and carry out usual battery maintenance.

•

Recharge the battery fully and carry out usual battery maintenance.

•

Maintenance charge the battery every 3rd month and check the fluid level.

•

Maintenance charge the battery every 3rd month and check the fluid level.

Hydraulic system

•

Change the oil in the hydraulic system when stored for periods longer then 1 year, see the oil specification in the section Maintenance and lubrication chart.

Drive unit

•

Block up the truck’s drive section to take the load off the drive wheel and load wheels when storing for periods longer than one week.

Starting after a period of disuse

•

Before the truck is put into operation after a period of disuse it should undergo a function and safety check as stated in the section, Daily service/safety checks.

•

Before the truck is put into operation after a period of disuse it should undergo a function and safety check as stated in the section, Daily service/safety checks.

•

When stored for a period greater then 3 months, carry out preventive maintenance as stated in the instructions, 500 hours interval.

•

When stored for a period greater then 3 months, carry out preventive maintenance as stated in the instructions, 500 hours interval.

Return

Recyling/Discarding

Batteries are hazardous to the environment and should be returned to the manufacturer for recycling.

Discarding the battery

When the working life of the battery in the truck is at an end (change to a new battery) or if the entire truck is to be scrapped special regard to environmental risks shall be taken when disposing/recycling batteries.

Spent batteries shall be returned /sent to the manufacturer of the battery or its representatives (see the label on the battery) for disposal/recycling. You can also return batteries to your local BT representative who will then return the battery to the manufacturer.

Scrapping the truck

The truck consists of parts that contain recyclable metals and plastics. Below is a list of those materials used in the truck’s sub-systems.

Chassis

Return

Chassis

Steel

Chassis

Steel

Mast

Steel

Mast

Steel

Instrument panels

Polypropylene

Instrument panels

Polypropylene

Drive unit

Steel and cast material

Drive unit

Steel and cast material

Bushings

Iron/copper

Bushings

Iron/copper

Finish

Epoxy-polyester

Finish

Epoxy-polyester

Wheels

Polyurethane

Wheels

Polyurethane

Recyling/Discarding

Hydraulic system

Recyling/Discarding

Hydraulic system

Oil tank

Polyethylene

Oil tank

Polyethylene

Pump unit

Steel and aluminium

Pump unit

Steel and aluminium

Hoses

Rubber and steel

Hoses

Rubber and steel

Cylinders

Steel

Cylinders

Steel

Electrical system

Cables

Copper cores with PVC sheaths

Cables

Copper cores with PVC sheaths

Electronic board

Reinforced fiberglass circuit board laminate

Electronic board

Reinforced fiberglass circuit board laminate

Motors

Steel and copper

Motors

Steel and copper

Return

BT Prime-Mover, Inc., 3305 N. Highway 38 Muscatine, Iowa 52761-8800 U.S.A Tel (319) 262-7700 • Fax (319) 262-7600

Return

BT Prime-Mover, Inc., 3305 N. Highway 38 Muscatine, Iowa 52761-8800 U.S.A Tel (319) 262-7700 • Fax (319) 262-7600