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OPERATOR'S MANUAL

Manual Number 9308 Manual Part Number 301363-000 RR-45Z ELECTRIC REACH TRUCK

RR-45Z

Keep this OPERATOR'S MANUAL with unit at all times in the place provided.

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

ISSUED AUGUST 1993

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RR-45Z

ISSUED AUGUST 1993

IMPORTANT NOTICE

This is the industry's "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 unit.

BEFORE OPERATING THE UNIT:

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

2. The operator must read and understand the OPERATOR'S MANUAL for this unit.

BEFORE OPERATING UNIT STUDY OPERATOR'S MANUAL SAFETY MESSAGES. READ ALL SAFETY DECALS ON UNIT. 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 MACHINE OPERATION AND TO OBSERVE PERTINENT LAWS AND REGULATIONS. OPERATOR MANUALS, PARTS MANUALS, AND REPAIR MANUALS MAY BE OBTAINED FROM YOUR EQUIPMENT DEALER.

INJURY OR DEATH TO YOU OR OTHER PERSONNEL WILL OCCUR IF YOU DO NOT FOLLOW THESE INSTRUCTIONS AND MESSAGES.

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FOREWORD

Federal and State laws require that operators be completely trained in the safe operations of lift trucks.

Before you start operating this lift truck, make sure that you understand all driving procedures. It is important to operate your lift truck safely and efficiently.

This manual will help you learn how to operate your lift truck. This manual describes the controls, special features and the functions of each control.

This manual is not a training manual. It is a guide to help authorized operators safely operate a lift truck. Illustrations in this manual show the operator correct procedures for checking, starting, operating, and stopping the lift truck.

This lift truck is built to take hard work but not abuse. This lift truck is built to be dependable, but, as with any lift truck, it is only as efficient as the operator and the persons responsible for maintaining it.

DO NOT make any repairs to this unit unless you have been trained in lift truck repair procedures authorized by your employer.

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TABLE OF CONTENTS NAME

PAGE #

Operator's Warning Foreword Table of contents Drive safely Introduction To New BT Prime-Mover Owners Preliminary Service Right, Left, Front, Back Operator Operating practices Warnings (Fast Reference) Data plate and Decals Controls and Equipment Before Operation Inspection Operation First Time Operation Stopping Unit Operation Parking Load Operations Transporting the Unit Battery Retainment/Care Specifications and lubrications Service intervals Field Modifications

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TABLE OF CONTENTS

1 2 3 4 5 5 6 6 7 8-14 15-16 17-23 24-35 36-42 43-46 43 43 44 47 48-49 50 51-52 53 54 55

NAME

PAGE #

1 2 3 4 5 5 6 6 7 8-14 15-16 17-23 24-35 36-42 43-46 43 43 44 47 48-49 50 51-52 53 54 55

DRIVE SAFELY

BEFORE YOU OPERATE THIS INDUSTRIAL TRUCK, READ AND UNDERSTAND THE INSTRUCTIONS, SIGNS AND MESSAGES IN THIS MANUAL AND ON THE UNIT.

INJURY OR DEATH TO YOU OR OTHER PERSONNEL WILL OCCUR IF YOU DO NOT FOLLOW THESE INSTRUCTIONS AND MESSAGES.

STAY ALERT!

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INTRODUCTION

The operator should read this manual thoroughly so that the important facts about this unit and the contents of the manual are known. The safety of the operator and the reliability and performance of this unit will be determined by the knowledge of the contents of this manual.

Each section of this manual is clearly identified and is divided into smaller sections. The TABLE OF CONTENTS can be used to find the information that is needed.

The model number and serial number for this unit are stamped on the data plate, see the section called "DATA PLATE AND DECALS" for location and description of plate.

Some figures may show door(s), guard(s), or shield(s) opened/removed. BE SURE that all door(s), guard(s), or shield(s) are in their position BEFORE machine is operated.

TO NEW BT PRIME-MOVER OWNERS:

Our Company would like to take this opportunity to thank you for joining (or rejoining) the increasingly large community of companies and individuals finding profit in the use of BT PRIMEMOVER equipment.

The BT PRIME-MOVER unit which you have just purchased was carefully designed and manufactured to ensure minimum cost, maximum reliability, and easy service. Extensive testing and high standards of quality control assure that these standards are maintained.

To keep your BT PRIME-MOVER unit in good condition the periodic maintenance and lubrication must be followed.

BT PRIME-MOVER units are also backed by a network of dealers who were chosen for their experience and reliability. They will assist you in keeping your BT PRIME-MOVER unit in peak operating condition.

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PRELIMINARY SERVICE Examine your BT Prime-Mover uni t carefully to det ermine whet her or not it has been dam aged i n shipment . Any dam age shoul d be i mmedi ately repor ted to the t rans por tation c ompany .

Shippi ng dam age c oul d af fect the safety of oper ation of the uni t, it shoul d not be oper ated unt il the dam age has been r epai red and any dam age par ts repl aced.

QUALIFIED The new uni t shoul d be c hec ked out by a TECHNICIAN. An arrival and pr e-del ivery chec klist is at the THE PRIME-MOVER DEALERSHIP this sheet is to be r eturned to validat e war rant y and t o assure that the us er has received a qual ity BT Prime-Mover pr oduc t ready to do i ts job.

QUALIFIED The new uni t shoul d be c hec ked out by a TECHNICAN. An arrival and pr e-del ivery chec klist is at the THE PRIME-MOVER DEALERSHIP this sheet is to be returned t o validat e war rant y and t o assure that the us er has received a qual ity BT Prime-Mover pr oduc t ready to do i ts job.

This OPERATORS MANUAL m ust be k ept wi th this uni t. If a repl acement manual is needed, pl ease cont act your BT PRIMEMOVER deal er or THE PRIME-MOVER Co. factor y and a no charge replacement will b e sent.

A par ts manual has been pr ov ided wi th the machine. Addi tional copi es are availabl e at a small char ge.

Chec k the trans mission oi l level and hy dr aul ic oi l level bef or e oper ation. Chec k to det ermine that the bat tery is adequat ely char ged, pr oper ly installed and c onnec ted.

RIGHT, LEFT, FRONT, AND REAR SIDES

Right and l eft hand, when us ed in this manual , indi cate the r ight and l eft sides of uni t as seen f rom oper ator 's pos ition.

A. B. C. D.

Right Side Rear Lef t Side Front

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Right Side Rear Lef t Side Front

OPERATOR

There are certain hazards that cannot be avoided solely by mechanical means in the everyday use of material handling trucks. Only the intelligence, good sense and care of the operator, along with proper maintenance, will assure that the trucks are operated properly. It is important to have trained, reliable personnel operating your units. If at any time the operator finds that the unit is not performing properly, he should discontinue operation of the truck and report the condition to his supervisor for correction.

Travel in a direction of maximum visibility. This unit has been designed for level floor operation and should be operated in accordance with instructions.

Operate the machine from the operator's position after assuring that the operation will not endanger the operator or any other person. Do not operate a truck in hazardous areas. Make sure that the forks and/or load have clearance to lower and do not "hang-up".

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OPERATING PRACTICES

Your safety and the safety of those around you depends upon your using care and judgement in the operation of this equipment. Know the positions and functions of all controls before attempting to operate.

Read this manual completely and make sure you understand the controls. Make sure you understand, for example, the characteristics of speed, stability, brakes, speed limit switch, and steering of this unit. If you have any questions, contact your local BT Prime-Mover dealer.

The operating rules in this manual do not replace any other rules or laws of safety that are used in your area. The operating rules listed below are not in order of importance but are all to be learned and used in your area. Make sure that your truck has correct equipment according to these rules or laws.

IMPORTANT:

Always install new decals if old decals cannot be read. When parts that have decals are replaced, make sure to install new decals with the new parts. You can get new warning decals from your BT Prime-Mover dealer at no charge.

BE SURE YOU HAVE CHECKED AND UNDERSTAND THE FUNCTION OF ALL CONTROLS BEFORE STARTING TO WORK.

OPERATING RULES AND INSTRUCTIONS

OPERATOR QUALIFICATIONS

Only trained and authorized operators shall be permitted to operate a powered industrial truck. Operators of powered industrial trucks shall be qualified as to vision, auditory, physical, and mental ability to operate the equipment.

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DATA PLATE AND DECALS

KEEP WINDSHIELD CLEAN

ALWAYS keep the windshield clean.

DO NOT reach through uprights to clean other side of glass.

KEEP HANDS CLEAR

The KEEP HANDS CLEAR decals are located on the uprights.

DO NOT reach into or climb on the uprights. Personal injury will result if any part of your body is put between the moving parts of the rails, chains, sheaves, forks, carriage, and other parts of the uprights.

KEEP AWAY FROM FORKS

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KEEP AWAY FROM FORKS

The KEEP AWAY FROM FORKS decal is located on the lift cylinder in the operator's view.

DO NOT ride on or stand under forks or attachments.

make ALWAYS sure forks or attachments are in the locked position. The forks or attachment can fall and cause INJURY OR DEATH.

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DATA PLATE AND DECALS

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. See your BT Prime-Mover dealer for new decals. New warning decals can be obtained from your BT PRIME-MOVER DEALER at NO charge.

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CONTROLS AND EQUIPMENT

MULTI-FUNCTION CONTROL HANDLE

Reach Control - Reach function is controlled by actuation of upper push button.

Selector Switch - Selector switch is located on lower side of control handle this allows operator to select desired operational mode of lower switch. Operational mode is indicated by illuminated indicator lights. Actuation of this switch allows selection of either tilt or sideshift function.

Tilt Control - With tilt mode selected, (tilt indicator illuminated), tilt function is controlled by actuation of lower push button.

Sideshift Control - With sideshift mode selected, (sideshift indicator illuminated), sideshift function is controlled by actuation of lower push button.

Horn Button - The horn button is red in color and is located on the MULTI-Function control handle for fast operation with thumb. The horn must work when button is pressed. If horn does not function, report the failure and have it repaired before the unit is put into operation.

23A

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CONTROLS AND EQUIPMENT

DASH DISPLAY

The dash display is a four segment light emitting diode (LED) display that displays the status codes, hourmeter readings, and battery discharge indication from the controller.

Checking Hourmeter reading 1. Turn on the key switch. 2. The display is hourmeter LED reading. 3. The display is lit for 5 seconds after key is ON.

Checking Battery condition reading. (BDI) 1. Turn on the key switch. 2. Depress foot brake pedal and hold down. 3. The display is percent of battery discharge. The battery condition is displayed anytime unit is in the operating mode.

Checking Status Code reading. (wrench) 1. Turn on the Key switch. 2. The display is a status code for failure with unit.

The dash display is physically located in the dash below the key switch.

DASH DISPLAY

25A

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CONTROLS AND EQUIPMENT

DASH DISPLAY

The following status codes are items that operator should check. If any other status codes appears your BT PRIME-MOVER DEALER should be contacted to solve problem.

Status Code -01 Indicates that brake foot switch is not closed. Make sure the brake pedal is depressed.

Status Code -02 Indicates forward switch was closed before the key switch or brake switch was closed. With key switch on and brake foot switch is pressed; return directional switch to neutral then select direction.

Status Code -03 Indicates rearward switch was closed before the key switch or brake switch was closed. With key switch on and brake switch is pressed; return directional switch to neutral then select direction.

Status Code -04 Indicates forward or rearward switch was closed before the key switch or brake switch was closed. Status code will change to -03 if rearward directional switch or -02 if forward directional switch is closed.

Status Code -05 Indicates brake foot switch is not closed. brake foot switch is closed.

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25B

Make sure

25B

Make sure

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BEFORE OPERATION INSTRUCTION

MULTI-FUNCTION CONTROL HANDLE

33. REACH EXTENSION: Push down on upper right push button to actuate reach extension switch. Switch must return to the up or "OFF" position when released. The switch must work when pressed. If switch does not work or does not return to the OFF Position, report the failure and have it repaired before the unit is put into operation. Note forks travel distance is forward of outriggers when fully extended.

34. REACH RETRACTION: Push down on upper left push button to actuate reach retraction switch. Switch must return to the up or "OFF" position when released. The switch must work when pressed. If switch does not work or does not return to the OFF Position, report the failure and have it repaired before the unit is put into operation. Note forks travel distance is forward of outriggers when fully extended. Make sure the reach mechanism is clear of foreign materials before retracting the forks.

35. Release the MULTI-FUNCTION control handle. It must return to the OFF Position. If handle does not return report the failure and have it repaired before the unit is put into operation.

35A. SELECTOR SWITCH: Selector switch when pressed must illuminate one of the two functions (tilt or sideshift). If switch does not work or if light does not illuminate report the failure and have it repair before the unit is put into operation.

36. TILT DOWN: After selecting tilt mode (tilt indicator illuminated). Push down on lower right push button to tilt the carriage forward and lower the fork tips. Switch must return to the up or "OFF" position when released. The switch must work when pressed. If switch does not work or does not return to the OFF Position, report the failure and have it repaired before the unit is put into operation.

37. TILT UP: After selecting tilt mode (tilt indicator illuminated). Push down on lower push button to tilt the carriage backwards and raise the fork tips. Switch must return to the up or "OFF" position when released. The switch must work when pressed. If switch does not work or does not return to the OFF Position, report the failure and have it repaired before the unit is put into operation.

34A

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BEFORE OPERATION INSTRUCTION

MULTI-FUNCTION CONTROL HANDLE

38. SIDESHIFT RIGHT: After selecting sideshift mode (Sideshift indicator illuminated). Push down on lower right push button to move the carriage and forks to the RIGHT . Switch must return to the up or "OFF" position when released. The switch must work when pressed. If switch does not work or does not return to the OFF Position, report the failure and have it repaired before the unit is put into operation.

39. SIDESHIFT LEFT: After selecting sideshift mode (Sideshift indicator illuminated). Push down on lower left push button to move the carriage and forks to the LEFT . Switch must return to the up or "OFF" position when released. The switch must work when pressed. If switch does not work or does not return to the OFF Position, report the failure and have it repaired before the unit is put into operation.

35A

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BEFORE OPERATION INSPECTION

• Inspect unit and look for damage and leakage. if any DO NOT operate unit it is repaired.

• Inspect hydraulic system. Look for leakage around filter, hoses, fittings, and pumps.

• Inspect steering linkage for looseness or lack of lubrication.

• Inspect drive unit. Look for leakage.

• Inspect speed limit switch on upright. Make sure roller is against upright rail.

• Remove battery retainers and inspect the battery connector. Check the condition of electrical cables and wiring and make a report of all worn or cracked cables. Reinstall the battery retainers.

• Inspect all wheels for flat spots or pieces of material missing from tires.

• Enter the operator's compartment and check condition of the overhead guard. If it has damage, report it to your supervisor.

• Make sure the operator's manual is at hand.

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BEFORE OPERATION INSPECTION

• Inspect the lift forks for cracks, breaks, bending, and wear. The forks, surfaces should be level and even with each other.

• Look at condition of lift chains, hoses, sheaves, and retainers.

• Inspect the forks, latches. Make sure they are not damaged or broken, operate freely and lock correctly.

• Check condition of load backrest extension.

• Be sure it is correctly positioned and secured.

• Remove blocks from wheels and carefully enter operator's compartment.

Use caution not to step on brake pedal when entering as this will release brake and cause unit to roll if parked on an incline.

• Connect the battery to unit (if disconnected), and turn the key switch to the ON position.

• Check the operation of the hourmeter.

• Check the charge condition of the battery. If gauge shows reading in the red area, have battery charged before operating.

• Press horn button to check function. If horn dose not function, report the failure and have it repaired before the unit is put into operation.

• Before operating unit, look in all directions to make sure your path of travel is clear.

• Put your foot on the brake pedal and press down. This will release the brake and make electrical power available to drive motor.

• Turn steering crank unit steering is in the desired direction of travel.

• FORWARD: Put a firm grip on the directional control handle with your hand. Twist it forward (away from you) slowly.

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BEFORE OPERATION INSPECTION

The unit must move slowly in a forward direction. Twist the handle more to increase speed. Unit should accelerate smoothly to maximum speed as handle is twisted. Return the handle to NEUTRAL position and slowly remove your foot from the brake pedal to stop.

• Rearward: Put a firm grip on the directional control handle with your right hand. Twist it rearward (towards you) slowly. The unit must move slowly in a rearward direction. Twist the handle more to increase speed. Unit should accelerate smoothly to maximum speed as handle is twisted. Return the handle to NEUTRAL position and slowly remove your foot from the brake pedal to stop.

Brake action should be smooth and stop unit in a normal distance. Note any unusual brake operation.

Braking can also be done using PLUG BRAKING for information on this see the section on PLUG BRAKING in this manual.

• To RAISE FORKS make sure there is enough overhead clearance. Put a firm grip on the directional control handle with your right hand. Raise (up) it slowly. The forks must lift slowly. Raise the handle more to increase lifting speed. Forks should lift smoothly to maximum speed. To stop upward movement, slowly lower the handle, and forks will hold position.

• To LOWER FORKS make sure there nothing under forks. Put a firm grip on the directional control handle with your right hand. Lower (down) it slowly. The forks must lower slowly. Lower the handle more to increase lowering speed. Forks should lower smoothly to maximum speed. To stop downward movement, slowly raise the handle, and forks will hold position.

Both lifting and lowering should be a smooth movement. Make sure unit can travel while lifting and lowering a load.

• Pushing down on the emergency disconnect handle will disconnect all electrical power to the unit. To operate unit after pressing the emergency disconnect, it is necessary to push battery connectors back together.

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BEFORE OPERATION INSPECTION

• Check steering crank while unit is moving. Turn the steering crake fully left and then right. Steering crank should turn smoothly without binding or any loss of steering control.

• Check operation of flashing light if equipped. The warning light should illuminate when key switch is in the ON position and brake pedal is pressed.

• Carefully read the decals at auxiliary control lever showing tilt, reach, and sideshifter instructions.

• Make sure the area in front of forks is clear before extending forks.

REACH EXTENTION:

MULTI-LEVER CONTROL HANDLE Push lever forward (no side movement) for reach extention. Note forks travel distance is forward of outriggers when fully extended.

MULTI-FUNCTION CONTROL HANDLE Push down on upper right push button to actuate reach extension switch. Switch must return to the up or "OFF" position when released. The switch must work when pressed. If switch does not work or does not return to the OFF Position, report the failure and have it repaired before the unit is put into operation. Note forks travel distance is forward of outriggers when fully extended.

REACH RETRACTION:

MULTI-LEVER CONTROL HANDLE Pull lever rearward (no side movement) for reach retraction. Make sure the mechanism is clear of foreign materials before retracting the forks.

MULTI-FUNCTION CONTROL HANDLE Push down on upper left push button to actuate reach retraction switch. Switch must return to the up or "OFF" position when released. The switch must work when pressed. If switch does not work or does not return to the OFF Position, report the failure and have it repaired before the unit is put into operation. Note forks travel

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BEFORE OPERATION INSPECTION

distance is forward of outriggers when fully extended. Make sure the reach mechanism is clear of foreign materials before retracting the forks.

MULTI-LEVER CONTROL HANDLE Release the auxiliary control lever. It should return to the neutral position.

MULTI-FUNCTION CONTROL HANDLE Release the control handle. It must return to the OFF Position. If handle does not return report the failure and have it repaired before the unit is put into operation.

SELECTOR SWITCH: Selector switch when pressed must illuminate one of the two functions (tilt or sideshift). If switch does not work or if light does not illuminate report the failure and have it repair before the unit is put into operation.

TILT DOWN:

MULTI-LEVER CONTROL HANDLE Push auxiliary control lever to left and forward. This will tilt the carriage forward and lower the fork tips.

MULTI-FUNCTION CONTROL HANDLE After selecting tilt mode (tilt indicator illuminated). Push down on lower right push button to tilt the carriage forward and lower the fork tips. Switch must return to the up or "OFF" position when released. The switch must work when pressed. If switch does not work or does not return to the OFF Position, report the failure and have it repaired before the unit is put into operation.

TILT UP:

MULTI-LEVER CONTROL HANDLE Push auxiliary control lever to left and rearward. This will tilt the carriage backwards and raise the fork tips.

MULTI-FUNCTION CONTROL HANDLE After selecting tilt mode (tilt indicator illuminated). Push down on lower push button to tilt the carriage backwards and raise the fork tips. Switch must return to the up or

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BEFORE OPERATION INSPECTION "OFF" position when released. The switch must work when pressed. If switch does not work or does not return to the OFF Position, report the failure and have it repaired before the unit is put into operation. SIDESHIFTER RIGHT:

MULTI-LEVER CONTROL HANDLE If this unit has sideshifter, push auxiliary control lever to the right and forward. This will move carriage and forks to the right.

MULTI-FUNCTION CONTROL HANDLE After selecting sideshift mode (Sideshift indicator illuminated). Push down on lower right push button to move the carriage and forks to the RIGHT . Switch must return to the up or "OFF" position when released. The switch must work when pressed. If switch does not work or does not return to the OFF Position, report the failure and have it repaired before the unit is put into operation.

SIDESHIFTER LEFT:

MULTI-LEVER CONTROL HANDLE If this unit has sideshifter, push auxiliary control lever to the right and backwards. This will move carriage and forks to the left.

MULTI-FUNCTION CONTROL HANDLE After selecting sideshift mode (Sideshift indicator illuminated). Push down on lower left push button to move the carriage and forks to the LEFT . Switch must return to the up or "OFF" position when released. The switch must work when pressed. If switch does not work or does not return to the OFF Position, report the failure and have it repaired before the unit is put into operation.

• NO SIDESHIFT: If this unit has no sideshifter, pushing auxiliary control lever to the right and forward will extend the reach and pushing auxiliary control lever to the right and backwards will retract the reach. Note see reach extention and retraction for futher information.

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BEFORE OPERATION INSPECTION

• Repeat these movements several times to become familiar with auxiliary controls lever action.

Report any erratic movement of carriage or forks and any unusual noise or vibration that might indicate a problem.

• If SCR system dose not operate properly, turn key switch OFF and ON (this will reset controls).

• Turn key switch to OFF position and remove, and place in a designated area.

• DO NOT forget to block wheels to prevent accidental roll.

• Before leaving unit, make a final check to be sure the unit is properly parked and can be left safely in this location.

• If the unit is to be left in a parked position for an extended period, disconnect the battery, put chocks at the wheels, and remove the key.

• Make sure OPERATOR'S MANUAL is returned to the proper position.

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OPERATION

STOPPING UNIT

1. Move direction control handle to "NEUTRAL" position. 2. Relaese brake pedal to stop unit movement. 3. Push down on lower control button to lower forks to floor. 4. Turn key switch to "OFF" position and remove key, 5. Make sure that all motion has stopped and exit operator's compartment with key.

FIRST TIME OPERATION

Be sure that the area being used for test running is clear of spectators and obstructions. Operate unit with empty forks.

Smoothest and most efficient unit operation is achieved while being operated at half speed to full speed. Only attempt full speed after familiarizing yourself with steering and directional controls.

Operation of full speed should only be attempted after complete familiarity with all operations. ALWAYS exercise caution and good judgement while running this equipment.

NOTE: To prolong component life, avoid "jackrabbit" starts, stops, and forceful steering control movements.

If the battery was disconnected and removed, first turn key switch to the OFF position. Reinstall battery and reconnect battery connector to unit.

BRAKING - STOPPING MOTION

When the direction control lever is moved to "NEUTRAL" position, all POWERED movement is stopped. To stop all movement, gradually and deliberately move steering control handle to one of two positions, fully raised or fully lowered.

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LOAD OPERATIONS

There are certain hazards that cannot be avoided solely by mechanical means in the everyday use of material handling trucks. Only the intelligence, good sense and care of the operator, along with proper maintenance will assure that the unit is operated properly. It is important to have trained, reliable personnel operating your unit. If, at any time the operator finds that the unit is not performing properly, operation should be discontinue and condition be reported to the operator's supervisor for correction.

There are certain hazards that cannot be avoided solely by mechanical means in the everyday use of material handling trucks. Only the intelligence, good sense and care of the operator, along with proper maintenance will assure that the unit is operated properly. It is important to have trained, reliable personnel operating your unit. If, at any time the operator finds that the unit is not performing properly, he should discontinue operation and report the condition to his supervisor for correction.

Move and transport materials that have been properly and evenly loaded in as low a position as possible. Travel in a direction of maximum visibility.

This information does not include all possible conditions you can find. The purpose of this information is to give you the basic information you need to operate the unit.

If you are a new operator learning about this unit, operate in a clear area at slow speed.

SAFETY WHEN YOU WORK

Be a careful operator, you can prevent accidents.

Read the following information:

Before you operate the unit, check steering control, brake, instruments, and equipment hydraulic controls. If you know there is a malfunction, a missing part, or a part that needs adjustment, stop unit immediately and correct problem. Continued operation during these conditions can cause an accident or injury.

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43A

OPERATION

Connect the battery, if not connected.

Remove blocks from drive wheel and carefully enter operator's compartment.

Remember that pressing down on the brake pedal will release the brake, and this should be avoided until ready to move unit.

Turn the key to the ON position.

Smoothly and gently pull back on TILT auxiliary control lever to raise fork tips from floor.

Gently pull up on direction control handle to raise forks 3-4 inches above the floor.

Look in all directions to make sure that your path to travel is clear.

Put your left foot on the brake pedal and press down. This will release the brake and make power available to the drive motor.

Put a firm grip on the directional control handle with your hand and slowly twist it in the direction you want to travel.

This unit is equipped with a plugging feature (see "STEERING AND BRAKE CONTROLS" in Section "CONTROLS AND EQUIPMENT" for proper operation) which means that you need not brake to a complete stop to change directions. Use the direction/speed control handle to change direction

10. Always be alert for pedestrians, other vehicles or obstacles in your path of travel.

11. Remember to enter loads slowly and squarely.

Load should be centered and forks should be near outside edges. 44

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Load should be centered and forks should be near outside edges. 44

OPERATION

12. Adjust forks by lifting forks lock lever and sliding forks to the desired position.

13. Remember to lower lever to lock forks securely in notch on top of fork bar.

14. Before forks are raised, make sure there is enough overhead clearance. Put a firm grip on the directional control handle with your hand. Raise (UP) it slowly. Raise the handle more to increase lifting speed. Forks should lift smoothly to maximum speed.

To stop upward movement, release or slowly lower the handle, and forks will hold position.

15. Remember that load should be lowered to position near floor; the carriage should be tilted back to cradle and load when traveling.

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OPERATION

16. Use minimum forward and reverse tilt when stacking and unstacking loads.

NEVER tilt load forward unless it is over stack or at low lift height.

17. Be constantly alert for unusual or erratic operations.

Report any malfunction immediately so that adjustments or repairs may be made by thoroughly trained and qualified personnel.

18. Push the emergency disconnect handle if you have and emergency while the unit is in operation.

This will disconnect all electrical power and stop unit operation except for lower control circuit.

19. To operate the unit after pressing the emergency disconnect, it is necessary to push the battery connections back together.

20. Remember, DO NOT travel with reach extended.

21. Make sure OPERATOR'S instruction manual is returned to the case and storage box.

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PARKING 1. Park unit in desgnated parking areas ONLY . Make sure unit dose NOT block fire aisles, fire equipment, stairways, or walkways.

2. Lower forks fully.

3. Push forward on TILT auxiliary control lever tp put fork tips on floor.

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

5. Carefully dismount from unit.

6. Remember to block wheels securely to prevent accidental roll.

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LOAD OPERATIONS

There are certain hazards that cannot be avoided solely by mechanical means in the everyday use of material handling trucks. Only the intelligence, good sense and care of the operator, along with proper maintenance will assure that the unit is operated properly. It is important to have trained, reliable personnel operating your unit. If, at any time the operator finds that the unit is not performing properly, operation should be discontinue and condition be reported to the operator's supervisor for correction.

There are certain hazards that cannot be avoided solely by mechanical means in the everyday use of material handling trucks. Only the intelligence, good sense and care of the operator, along with proper maintenance will assure that the unit is operated properly. It is important to have trained, reliable personnel operating your unit. If, at any time the operator finds that the unit is not performing properly, he should discontinue operation and report the condition to his supervisor for correction.

Move and transport materials that have been properly and evenly loaded in as low a position as possible. Travel in a direction of maximum visibility.

This information does not include all possible conditions you can find. The purpose of this information is to give you the basic information you need to operate the unit.

If you are a new operator learning about this unit, operate in a clear area at slow speed.

SAFETY WHEN YOU WORK

Be a careful operator, you can prevent accidents.

Read the following information:

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LOAD OPERATIONS Always lower the forks to enter pallet, and tilt load toward load backrest. Lower the forks to enter pallet. This action can be done by two means: (1) extending the reach, or (2) driving unit forward. Driving unit forward only works if pallet is not wider then the outriggers (loadwheels) or if pallet is above outriggers height. Extending the reach and then lifting is the most common way of entering pallets. After pallet has been entered, lift and tilt pallet slowly towards load backrest to lift tips of forks only high enough to clear floor and not to block operator's view. This action is done to prevent pallet from catching on floor when transporting material. Gradually rotate direction control lever in the direction you with to travel, Slowly increase speed to mach speed of traffic and control. Travel slowly around corners and pedestrians (For further safety instructions, see Safety and Warning Instructions). DO NOT travel with reach extended.

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TRANSPORTING THE UNIT

Never drive unit from one job site to the next if any streets or highways are to be used.

Use steel ramps when backing the unit on to a trailer. Chain and block the unit securely in place.

When transporting a disabled unit, always release brake. Otherwise, brake damage can result.

Before putting unit on a trailer, remove all ice, oil, and grease from trailer and ramp.

When transporting unit on a trailer, be sure to drive on and off squarely so as not to drive off the side of trailer and tip unit.

Secure truck transporting.

battery

securely

before

battery

securely

before

Know your regulations and laws of safety in each area that you operate a unit. Make sure that both your trailer and unit are equipped with the necessary safety equipment.

1. Place blocks at front and rear of each trailer wheel.

2. Move unit slowly onto ramps and trailer.

3. Lower unit forks to trailer floor.

4. Stop unit and remove key. (See stopping instructions in this manual.)

5. Place blocks at front and rear of each tire on unit.

6. Connect chains to front and rear of unit.

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BATTERY RETAINMENT/CARE

DO NOT allow alkaline solution to fall in the Battery Cell. This will result in a dead or weak cell.

IF ACID contacts your skin, eyes, or clothing, flush the area immediately with large amounts of water and contact a physician.

DO NOT attempt to recharge a frozen Battery; this may cause it to rupture or explode. DO NOT attempt to recharge the Battery in an area of sparks or near an open flame.

This unit uses a 24/36 volt wet cell Battery.

Proper care and servicing of the battery is vital to assure satisfactory operation and lift of your BT Prime-Mover electric truck. Battery acid is, of course, extremely corrosive and should be kept off or washed off the machine as any spillage occurs. The battery should always be kept in a charged state. An overly discharged battery will cause a number of operational difficulties in any electric truck. The battery charge should be checked first if any electrical difficulties occur.

In cases of a battery not taking a charge, make sure that the charger is being attached to the battery connector and not to the connector on the unit. A battery which does not take a proper charge should be referred to the battery manufacturer's representative for service.

IMPORTANT

Use only batteries that meet the following specifications: Use only batteries that meet the following specifications: Voltage 24/36 24/36 36 Minimum Battery Weight (consult nameplate on unit) Maximum Battery Weight (consult nameplate on unit) Compartment Size 14½"Deep 16½"Deep 21"Deep 38¾"Wide 38¾"Wide 38¾"Wide 32" High 32" High 32" High

For other industrial battery sizes, provide blocking to restrain the battery from moving not more than .50 inches or 12.7 mm in any horizontal direction.

Voltage 24/36 24/36 36 Minimum Battery Weight (consult nameplate on unit) Maximum Battery Weight (consult nameplate on unit) Compartment Size 14½"Deep 16½"Deep 21"Deep 38¾"Wide 38¾"Wide 38¾"Wide 32" High 32" High 32" High

For other industrial battery sizes, provide blocking to restrain the battery from moving not more than .50 inches or 12.7 mm in any horizontal direction. 51

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BATTERY RETAINMENT/CARE

Make sure that battery retainers are installed before operating unit.

BATTERY SERVICE

DO NOT SERVICE BATTERY UNLESS YOU ARE TRAINED AND AUTHORIZED BATTERY ACID CAN CAUSE SEVERE BURNS AND INJURY OR DEATH.

ADDING WATER

On a routine basis after every 50 hours of operation, remove the Battery Vent Caps and inspect the Electrolyte level. The water in the Electrolyte Solution evaporates at high temperatures or with excessive charging rates. The level should be to the bottom of the Filler Neck, if NOT , replenish to the proper level with distilled water.

CLEANING TERMINALS & CABLE CONNECTIONS

The top of the Battery MUST BE KEPT CLEAN . Tighten the Vent Caps and clean the Battery with a brush dipped in an alkaline solution (ammonia or baking soda and water). After the foaming has stopped, flush top of Battery with clear water. If Terminals and Cable clamps are corroded, disconnect the Cables and clean them with the same alkaline solution.

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SPECIFICATIONS AND LUBRICATIONS AMP Hours Battery Pack

Consult nameplate on unit

SPECIFICATIONS AND LUBRICATIONS AMP Hours Battery Pack

Consult nameplate on unit

Oil Capacity in Transmission 2.5 Quarts[2.37l] or to bottom of the fluid fill hole in the transmission. Fluid Type Dexron II

Oil capacity in Hydraulic Reservoir Fluid

Drive Motor Diameter

6.5 Gallons [24.61 l] SUNVIS 832 (cold storage) Dexron II 7.18" (182.3)

Grease Type

Tex. Ref. C and C #880

NOTE: Dexron II that meets or exceeds Allison C-3 or Caterpillar T0-2 specifications.

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Drive Motor Diameter

6.5 Gallons [24.61 l] SUNVIS 832 (cold storage) Dexron II 7.18" (182.3)

Grease Type

Tex. Ref. C and C #880

NOTE: Dexron II that meets or exceeds Allison C-3 or Caterpillar T0-2 specifications.

SERVICE INTERVALS

100 HOURS OR MONTHLY

1. Check machine operation; all functions and safety switches 2. Clean with compressed air 3. Check hydraulic fluid level. 4. Check brake fluid level. 5. Service all grease fittings 6. Check transmission oil level. 7. Inspect all tires and wheels 8. Clean and lubricate lift chains 9. Clean lift chain adjustment 10. Lubricate steering knob, brake pedal shaft, lift handle and tilt lever. 11. Check brake adjustment and brake pedal linkage stopping distance 12. Inspect fittings and valves for leaks 13. Inspect for loose and missing parts 14. Inspect wiring 15. Inspect contractor tips for pitting 16. Lubricate door hinges

500 HOURS OR SEMI-ANNUAL

1. Change hydraulic oil filter. 2. Clean and lubricate battery rollers. 3. Clean battery and machine.

1000 HOURS OR ANNUAL

1. Steam clean machine. 2. Drain, flush and refill gear case. 3. Drain, flush and refill hydraulic reservoir. 4. Clean hydraulic reservoir outlet screen. 5. Clean hydraulic pressure relief setting. 6. Inspect condition of lift chains. 7. Inspect motors; brushes (length) and commutator. 8. Check mast and carriage-lube, adjust, and shim as needed.

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FIELD MODIFICATIONS

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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THE PRIME-MOVER CO. 3000 NORTH US HIGHWAY 61 MUSCATINE, IOWA 52761-5810

PROUDLY Made in AMERICA

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