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CSX10/20/30/40 BT Prime-Mover

Operator’s Manuals 304953-000 1996_July 304953-000 1996_October 304953-000 1997_October 304953-000 1998_October 304953-001 2001_December 304953-002 2002_July

Return BT Prime-Mover, Inc., 3305 N. Highway 38, Muscatine, Iowa 52761-8800 U.S.A. Tel (563) 262-7700 • Fax (563) 262-7600

070302

Operator’s Manual

CSX

Electric Straddle Stacker Truck

Effective Serial Number CSX__25268001

The operator must read and understand this manual before operating this truck. Keep this OPERATOR’S MANUAL with unit at all times in place provided when not in use.

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

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

Part no: 304953-000 Return

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

Date: October 1996

Part no: 304953-000

Date: October 1996

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 SAFELY 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.

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

NAME

PAGE #

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 Data plate and Decals Controls and Equipment Before Operation Inspection Stopping Unit Parking Battery Retainment/Care Specifications and lubrications Service intervals Field Modifications Recycling/Discarding

1 2 3 4 5 5 6 6 7 8-13 14-17 18-24 25-28 29 30 31-32 33 34 35 36-37

This unit is designed under ANSI B56.1.

For additional operating instructions see ANSI B56.1 “OPERATING SAFETY RULES AND PRACTICES”.

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DRIVE SAFELY

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 enhanced 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 correct 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 Prime-Mover 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 planned 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 unit carefully to determine whether or not it has been damaged in shipment. Any damage should be immediately reported to the transportation company.

Shipping damage could affect the safety of operation of the unit, it should not be operated until the damage has been repaired and any damage parts replaced.

The new unit should be checked out by a QUALIFIED TECHNICIAN. An arrival and pre-delivery checklist is at the BT Prime-Mover dealership. This form is to be returned to validate warranty and to assure that the user has received a quality BT Prime-Mover product ready to do its job.

This Operator’s Manual must be kept with this unit. If a replacement manual is needed, please contact your BT PrimeMover dealer or BT Prime-Mover Inc., factory and a no charge replacement will be sent.

A parts manual has been provided with the machine. Additional copies are available at a small charge.

Check oil levels before operation. Check that the battery is adequately charged, properly installed and connected.

RIGHT, LEFT, FRONT, AND REAR SIDES

Right and left hand, when used in this manual, indicate the right and left sides of unit as seen from operator's position.

A. Right Side B. Rear C. Left Side D. Front

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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.

The proper operator position for this truck is shown and described below.

Proper operation of this unit is with forks trailing when possible. Steering the truck is easier with the forks trailing. Always look in the direction of travel.

When forks are first to enter a confined area or elevator or on an incline, keep both hands on control handle. Keep both hands within the handle guard and always look in the direction of travel.

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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, 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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OPERATING PRACTICES

! ! !

! !

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Avoid loose clothing, particularly cuffs and scarves. Know what safety equipment is required on this truck and use it. A hard hat, safety glasses, reflector-type vest, respirators, and ear plugs are some of the types of equipment you may need. DO NOT rush. Know the hand signals used on this job and who has responsibility for signaling. Safeguard the pedestrians at all times. DO NOT drive a truck up to anyone standing in front of a bench or other fixed object. DO NOT allow anyone to stand or pass under the elevated portion of any truck, whether loaded or empty. PASSENGERS MUST NOT be permitted to ride. When operator is away from truck, the load-engaging means shall be lowered, controls neutralized, and brake set to prevent movement. DO NOT place any part of body between moving and stationary or outside running lines of truck. Use caution when making a right or left turn into an aisle. Remember rear wheels do not follow turn path of front wheel. When making a turn allow for “corner-cutting” of trailers. Safeguard co-workers from truck operational hazards when their assistance is required to perform a task. ALWAYS LOOK IN DIRECTION OF TRAVEL, especially when reversing. 9

! ! !

! !

OPERATING PRACTICES

When A Powered Industrial Truck Is To Be Left Unattended

OPERATING PRACTICES

When A Powered Industrial Truck Is To Be Left Unattended

Completely stop truck in a clear, authorized area.

Lower load-engaging means to the floor.

Place directional controls in neutral.

Apply the brake.

Turn key switch to OFF and disconnect battery connectors.

If truck must be left on an incline, block wheels.

Maintain a safe distance from the edge of docks and platforms when operating powered industrial trucks. DO NOT use powered industrial trucks while on any elevated dock or platform to move freight cars.

ELEVATING PERSONNEL: This truck was not designed for elevating personnel. Refer to ANSI B56.1 for elevating personnel requirements.

Care shall be taken that overhead installations such as lights, pipes, sprinkler systems, etc. are not contacted.

A load backrest extension shall be used when necessary to guard against the load, or part of it, falling toward the operator.

NEVER get ON or OFF a moving truck.

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OPERATING PRACTICES

WHEN A POWERED INDUSTRIAL TRUCK IS TRAVELING:

! Local safety regulations must always be followed. Know and

understand the traffic flow patterns of your job.

! Yield right of way to pedestrians.

! DO NOT pass another truck traveling in the same direction

at intersections, blind spots or other dangerous locations.

! Slow down and sound the audible warning device(s) at

cross aisles and other locations where vision is blocked. If the load being carried blocks any view, ask for assistance so the load can be moved without any danger to personal or property.

! Keep a clear view of the path of travel, and observe for

traffic personnel and safe clearances.

! GRADES, RAMPS, OR INCLINES; This unit is designed for

level floor operation. If it is necessary to operate on a grade, ramp, or incline refer to ANSI B56.1 for requirements.

! Under all travel conditions this unit shall be operated at a

speed that will permit it to be brought to a stop in a safe manner.

! Carry your load low so you have maximum stability while

still maintaining ground clearance. ! Make start, stops, turns or direction reversals in a smooth

manner so as not to shift load and/or overturn truck.

still maintaining ground clearance. ! Make start, stops, turns or direction reversals in a smooth

manner so as not to shift load and/or overturn truck.

! DO NOT indulge in stunt driving or horseplay.

! Slow down for wet and slippery floors.

! Before driving over a dockboard or bridgeplate, be sure that

it is properly secured. Drive carefully and slowly across the dockboard or bridgeplate and never exceed its rated capacity.

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OPERATING PRACTICES

! Before the truck is driven into an elevator, the operator must

! Trucks shall enter confined areas with load end forward.

! Avoid running over loose objects, uneven surfaces or other

! While negotiating turns, reduce speed, steer in a smooth

! Report any defect in unit noted during operation.

! Observe instruments and gauges frequently to determine if

! DO NOT permit riders on unit.

! Understand unit limitations and keep unit under control.

! Understand unit limitations

! Remember to enter load slowly and squarely. Load should

! Handle only stable and properly arranged loads. Off-center

! Handle only loads within the capacity of the unit as rated on

! Handle long and wide loads exceeding the dimensions used

! The load shall only be lifted vertically and never dragged

! The load shall be transported with the bottom of load and

make sure that the elevator is certificated for that particular load. When entering an elevator the load goes first not the driver. There must be no personnel in the elevator when the load is entering or being removed.

obstructions on roadway surface.

motion. Except when maneuvering at a very low speed, turn the steering at a moderate even rate.

they are operating properly.

Maintain a safe distance from the truck ahead, and keep the truck under control at all times.

be centered.

loads must be handled with extra caution. nameplate.

to establish truck capacity with extra caution. Stability and maneuverability may be adversely affected. horizontally.

forks as low as possible.

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obstructions on roadway surface.

motion. Except when maneuvering at a very low speed, turn the steering at a moderate even rate.

they are operating properly.

and keep unit under control. Maintain a safe distance from the truck ahead, and keep the truck under control at all times.

be centered.

loads must be handled with extra caution. nameplate.

to establish truck capacity with extra caution. Stability and maneuverability may be adversely affected. horizontally.

forks as low as possible.

OPERATING PRACTICES

OPERATOR PRECHECKS AND INSPECTION

! Before

each shift (every 8 hours) it is the operator's responsibility to carry out the following checks and inspections before beginning truck operation.

! ! ! ! ! !

Tires Warning and safety Devices Battery Brake Steering Mechanism Couplers

! Horn ! Reverser ! Proper operation of truck

each shift (every 8 hours) it is the operator's responsibility to carry out the following checks and inspections before beginning truck operation.

! ! ! ! ! !

Tires Warning and safety Devices Battery Brake Steering Mechanism Couplers

! Horn ! Reverser ! Proper operation of truck

If the truck is found to be in need of repair or in any way unsafe, or contributes to an unsafe condition, the matter shall be reported immediately to the designated authority, and the truck shall NOT be operated until it has been restored to proper operating condition.

! DO NOT make repairs or adjustments unless specifically

authorized to do so.

! DO NOT use open flames when checking electrolyte level in

battery

! DO NOT use open flames when checking electrolyte level in

battery

! DO NOT adjust unit with any parts moving.

! DO NOT smoke while working around truck.

! Block securely with drive tire off of floor when working under

truck, and on drive unit or electrical controls. ! DO NOT attempt repairs you do not understand. There is no

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truck, and on drive unit or electrical controls. ! DO NOT attempt repairs you do not understand. There is no

disgrace in asking for help.

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 ANSI B56.1 for further operator's information.

DATA PLATE AND DECALS

Know the rated capacity on the data plate and understand areas 1 through 14 as shown in the illustration.

1. Truck model number 2. Truck serial number 3. Truck weight less battery 4. Maximum battery weight 5. Minimum battery weight 6. Truck voltage 7. Truck type 8. Battery type 9. Battery maximum AMP hours 10. Mast Serial number 11. Attachment 12 Load wheel tread width (in.) (NOT USED on this model) The distance between outrigger centers at ground level. 13. Maximum Degree rear tilt 14. Truck capacity

This data plate is located in the electrical compartment access shield. Knowing the model and serial numbers for this unit is very helpful when ordering service parts. For further information and specifications on this unit or any other, contact your BT Prime-Mover dealer.

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DATA PLATE AND DECALS

KEEP WINDSHIELD CLEAN

ALWAYS keep the windshield clean.

DO NOT reach thought 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.

DO NOT ride on or stand under forks or attachments.

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

DATA PLATE AND DECALS

OPERATING WARNINGS

The OPERATING WARNINGS decal is located in front of battery box on right hand side. This decal describes basic warnings for safe operation of this unit. Carefully read the decal and make sure you understand the warning instructions.

Breaking these rules may cause serious or fatal injury to yourself or others

Read and understand all warnings and operating instructions in the operator's manual before operating this truck.

Only authorized and trained operators are to operate this machine.

Keep feet clear of drive wheel and lowering frame.

Make a safty check before operating the truck and do not operate if in need of repairs or maintenance.

Maintenance is to be performed by authorized personnel only.

This machine is designed of level floors and normal industrial operations.

Additional operator's manuals can be obtained from your dealer or BT Prime-Mover, Inc., Muscatine, IA 52761.

305955-000

RAISE AND LOWER DECAL

This decal is located to the right and below the manual raise and lower control lever.

This decal is used to help you to remember just where the raise and lower control lever is and how it functions.

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DATA PLATE AND DECALS

TILT/AUXILIARY CONTROL DECALS

The tilt/auxiliary control decal is located to the right and below the manual tilt/auxiliary control lever.

This decal is used to help you to remember the auxiliary functions and there locations.

The decal shown is the standard decal with tilt control only. The decal on your truck may look different and have different functions. Carefully read the decal on your truck to make sure you understand the auxiliary control lever and the functions.

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

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

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.

Read and observe all warnings on this unit before operating it.

THE CONTROL HANDLE

The control handle is used to provide brake, direction, speed, lift/lower, horn, and reverser control of the machine.

The Control Handle

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CONTROLS AND EQUIPMENT

RAISE SWITCH

The lift (raising forks) is controlled by pushing down on the raise bar. The forks will continue to raise as long as the bar is depressed or until the lift stops are reached. Releasing the bar will automatically stop the lift.

LOWER SWITCH

The lower (lowering forks) is controlled by pushing down on the lower bar. The forks will continue to lower as long as the bar is depressed or until the lowering stops are reached. Releasing the bar will automatically stop the lowering.

HORN SWITCH

The horn is activated by pushing down on the horn bar located on top the steering control handle.

REVERSER SWITCH

The end of the control handle is provided with a red automatic reversing switch which causes the truck to travel in the rearward (FORK) direction when activated. Its function is to prevent the operator from being pinched between the handle and obstruction when traveling in the forward direction.

DIRECTION AND SPEED

The truck is available with either a thumb control or twist grip speed and direction control. Rotating either control in the forward or rearward direction will select the direction of travel. The truck speed will progressively increase as the control is rotated. Reversing the control can be used to quickly decrease speed or brake the truck.

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CONTROLS AND EQUIPMENT

COMPONENT IDENTIFICATION

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

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Drive Unit Steering Control Handle Load Backrest Battery Compartment Forks Load Wheels Directional Control Lever Reverser Switch Lift/Lower Mast Control Lever Tilt/Auxiliary Control Lever Operator’s Manual Pocket 20

CONTROLS AND EQUIPMENT

KEY SWITCH

A KEY SWITCH is provided to prevent unauthorized use of this unit. The key switch is located on the control panel cover.

The key switch has two (2) positions: OFF and ON.

1. OFF POSITION: Turning the key to “OFF” will stop all electrical power from going to the control circuit from battery.

2. ON POSITION: Turn the key to “ON” to check function of hourmeter and battery discharge indicator. The key switch must be in this position to provide power to the control circuit when unit is operated.

EMERGENCY DISCONNECT BUTTON

The emergency disconnect button will cut off all electrical power to unit when pushed. To reset emergency disconnect button turn key switch OFF position, repair emergency, push emergency disconnect button on. The emergency disconnect button is red in color and is physically located on dash next to key switch.

Key Switch

Battery Discharge Indicator/Hourmeter Dash Display

Emergency Disconnect Switch

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Battery Discharge Indicator/Hourmeter Dash Display

Emergency Disconnect Switch

Dash Panel Layout

CONTROLS AND EQUIPMENT

BRAKE CONTROL

The brakes are applied when steering control handle is in the “BRAKE” (fully raised or fully lowered) position. Moving the steering control handle to the middle of its travel releases brake and closes a switch in control circuit that allows operation of unit.

The brake and brake interlock switch must always be checked prior to operation of unit.

BRAKING USING PLUGGING FUNCTION

As stated above “BRAKE CONTROL” the truck can be brought to a stop by using the steering control handle brake (emergency use). An equally acceptable method of stopping the truck's travel is by using the “plugging” function (normal use). This method involves reversing the travel control to the opposite direction without using the steering control handle brake. This will cause the truck to come to a stop smoothly.

When using the “PLUGGING BRAKE” the operator may regulate, within the programmed capabilities, the severity of the “plugging” force and the stopping distance. For the lightest “plugging” force, and the longest stopping distance, the travel control should be operated only to the “creep” position in the opposite direction. For the strongest “plugging” power, and the shortest distance, the travel control should be operated to full speed in the opposite direction.

As the truck comes to a full stop the operator may choose to continue holding the control in the opposite direction and thus start the truck moving in that direction, or the operator may release the steering control handle and allow the truck to come to a complete halt. Releasing the steering control handle brake will allow the parking brake to be automatically applied.

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CONTROLS AND EQUIPMENT

BATTERY DISCHARGE INDICATOR/HOURMETER DASH DISPLAY

HOURMETER (optional)

The hourmeter is provided to indicate the number of hours the unit has operated. The hourmeter is physically located on the dash next to key switch.

BATTERY DISCHARGE INDICATOR/HOURMETER (optional)

This dash display is a two segment display that indicates the percentage of battery discharge and hourmeter. The hourmeter and battery condition can be read anytime the key is in the on position. The dash display is physically located on the dash next to key switch.

BDI/HOURMETER WITH LIFT INTERRUPT (optional)

This dash display has hourmeter and battery discharge indicator along with lift interrupt function. This gauge has a ten-LED multicolored display. One LED is illuminated at a time, beginning with a green LED at the far right position. As the battery is drained of charge, the display moves one position to the left at a time. The first five LEDs are green, the next three are amber, and the last two are red. When the display moves to the ninth position from the right, the LED will go “ON” and “OFF”. This position corresponds to a battery that is approximately 70% discharged. The next position is the tenth, or last, LED (red). This LED will flash alternately with the ninth LED. This corresponds to approximately 80% discharged. At this point, lift interrupt occurs. The dash display is physically located on the dash next to key switch.

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CONTROLS AND EQUIPMENT

AUXILIARY HYDRAULIC CONTROL LEVERS

The auxiliary hydraulic control levers are controlled by pushing or pulling the control levers. The auxiliary hydraulic control levers are used for lift/lower and optional controls. The levers are located on top and to the right side of electrical dash panel.

Lift/lower Control

The Lift/lower is controlled by pushing lever forward to lower the mast and pulling back to lift. The speed of lift/lowering can be controlled by the degree of movement of lever.

Tilt/Auxiliary Control

The Tilt is controlled by pushing lever forward to lower fork tips and pulling back the lever to raise fork tips. The speed of tilt can be controlled by the degree of movement of lever.

Sideshifter/Auxiliary Control (optional)

The Sideshifter is controlled by depressing and holding the sideshifter function button on side of auxiliary control lever and moving lever. Pulling lever will move forks Right and pushing will move forks Left. The speed of Sideshifter can be controlled by the degree of movement of lever.

Lift/lower Control Lever

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Auxiliary Hydraulic Control Lever

Lift/lower Control Lever

Auxiliary Hydraulic Control Lever

BEFORE OPERATION INSPECTION

Before operating and attempting to operate unit review warnings and controls section of this manual. Know how to stop unit before operating.

If the truck is found to be in need of repair, or in any way unsafe, or contributes to an unsafe condition, the matter shall be reported immediately to the designated authority; and the truck shall not be operated until it has been restored to proper operating condition.

Check the complete truck daily or at the beginning of each shift.

If, during operation, the truck develops problems, the matter shall be reported immediately to the designated authority, and the truck shall not be operated until it has been restored to proper operating condition.

! Inspect unit and look for damage and leakage. If any, DO

! Inspect hydraulic system. Look for leakage around hoses,

NOT operate unit until it is repaired.

fittings, and pump.

NOT operate unit until it is repaired.

fittings, and pump.

! Inspect

! Inspect drive unit. Look for leakage.

! Inspect all wheels for flat spots or pieces of material missing

! Inspect

! Make sure the Operator's Manual is in compartment and

! Inspect the frame for cracks, breaks, bending and wear.

! Check condition of load backrest (optional). Be sure it is

steering for looseness or binding and lack of lubrication.

from tires.

the battery connectors. Check the condition of electrical cables and wiring and make a report of all worn or cracked cables. tethered to machine.

correctly positioned and secured.

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steering for looseness or binding and lack of lubrication.

from tires.

the battery connectors. Check the condition of electrical cables and wiring and make a report of all worn or cracked cables. tethered to machine.

correctly positioned and secured.

BEFORE OPERATION INSPECTION

! Inspect forks latches. Make sure they are NOT damaged or

! Adjust forks by lifting fork lock lever and sliding forks to the

broken, operate freely and lock correctly.

desired position.

broken, operate freely and lock correctly.

desired position.

! Remember to lower lever to lock forks securely in notch on

top of fork bar.

! Remember to lower lever to lock forks securely in notch on

top of fork bar.

! Look

! Connect the battery to unit (if disconnected), and turn the

! Check

! Press horn button to check horn function. If horn does not

! Before operating unit, look in all directions to make sure

at condition of lift chains, hoses, sheaves, and retainers. key switch to the “ON” position.

the operation of the Battery Discharge Indicator (BDI)/hourmeter. function, report the failure and have it repaired before the unit is put into operation. your path of travel is clear.

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at condition of lift chains, hoses, sheaves, and retainers. key switch to the “ON” position.

the operation of the Battery Discharge Indicator (BDI)/hourmeter. function, report the failure and have it repaired before the unit is put into operation. your path of travel is clear.

BEFORE OPERATION INSPECTION

! Turn steering control handle until steering is in the desired

direction of travel.

! Put your hands on the steering control handle and pull down

partially. This will release the brake and make power available to drive motor.

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

REARWARD TRAVEL: Put a firm grip on the directional control handle and rotate backward slowly. The unit must move slowly in a rearward direction. Rotate the handle more to increase speed. Unit should accelerate smoothly to maximum speed as handle is rotated. Direction controls MUST automatically return to the NEUTRAL position when released. Position and raise control handle fully up or fully down to stop unit using the parking brake.

! FORWARD TRAVEL: Put a firm grip on the directional

control handle and rotate forward slowly. The unit must move slowly in a forward direction. Rotate the handle more to increase speed. Unit should accelerate smoothly to maximum speed as handle is rotated. Direction controls MUST automatically return to the NEUTRAL position when released. Position and raise control handle fully up or fully

! This unit is equipped with a PLUGGING FEATURE. 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 action should be smooth and stop unit in a normal

distance. Report any unusual brake operation.

! Check steering control handle while truck is moving. Turn

the steering handle fully left and then right. Steering control handle should turn smoothly without binding or any loss of steering control.

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BEFORE OPERATION INSPECTION

! To RAISE forks, push down on the raise control bar with

The raise bar is physically located on top of the steering control handle for ease or operation when needed.

! To LOWER forks, push down on the lower control bar with

The lower bar is physically located on top of the steering control handle for ease of operation when needed.

your thumb or fingers. The forks will continue to raise as long as the bar is depressed or until the lifting stops are reached. Releasing the bar will automatically stop the raising.

your thumb or fingers. The forks will continue to lower as long as the bar is depressed or until the lowering stops are reached. Releasing the bar will automatically stop the lowering

your thumb or fingers. The forks will continue to raise as long as the bar is depressed or until the lifting stops are reached. Releasing the bar will automatically stop the raising.

your thumb or fingers. The forks will continue to lower as long as the bar is depressed or until the lowering stops are reached. Releasing the bar will automatically stop the lowering

! Both

! Use minimum forward and reverse tilt when stacking and

! Make sure Operator's Manual is returned to the case and

lifting and lowering of forks should be a smooth movement. unstacking loads.

storage box.

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lifting and lowering of forks should be a smooth movement. unstacking loads. storage box.

OPERATION

STOPPING UNIT

1. Rotate direction control to the “NEUTRAL” position.

2. Raise steering control handle fully to stop unit's movement.

3. Push down on lower control button to lower forks to floor.

4. Make sure that all motion has stopped.

5. Turn key switch to “OFF” position and remove key.

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PARKING 1. Park units in designated parking areas only. Make sure unit does not block fire aisles, fire equipment, stairways or walkways.

2. Lower forks fully.

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

4. Remember to block drive wheel securely to prevent accidental roll.

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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 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 that 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:

VOLTAGE Minimum Battery Weight Maximum Battery Weight

24 (consult nameplate on unit) (consult nameplate on unit)

For other industrial battery sizes, provide blocking to restrain the battery from moving not more than 0.50 inches or 12.7 mm in any horizontal direction.

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BATTERY RETAINMENT/CARE

When removing battery out top of battery compartment the control handle must be rotated fully to clear battery.

BATTERY SERVICE

DO NOT SERVICE BATTERY UNLESS YOU ARE TRAINED AND AUTHORIZED BATTERY ACID CAN CAUSE SEVERE

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.

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

Oil Capacity in Transmission .8 Quart [.75 l] or to bottom of the fluid fill hole in the transmission.

Transmission Fluid Type

Greater then 5°F SAE 80W-90 Less then 5°F ATF Dexron III

Oil capacity in Hydraulic Reservoir 2.9 Gl.[11 l] Fluid Greater then 5°F Sunoco TH Less then 5°F ATF Dexron III

Lift chains

Greater then 5°F SAE 40W Less then 5°F SAE 20W

Grease Type

Tex. Ref. C and C #880

Greater then 5°F SAE 40W Less then 5°F SAE 20W

Grease Type

Tex. Ref. C and C #880

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

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SERVICE INTERVALS

200 HOURS OR MONTHLY

! Check condition of battery charge. ! Visually inspect for leaks, loose,

2000 HOURS OR ANNUAL

! Clean battery and machine. ! Drain, flush, and refill transmission gear case. ! Drain, flush, and refill hydraulic reservoir.

missing, or damaged parts. ! Check all operating functions and adjustments. ! Check hydraulic fluid level. ! Check transmission oil level. ! Lubricate all grease fittings. ! Inspect power cables and control wiring. ! Clean with compressed air. ! Inspect motor brushes.

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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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RECYCLING/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 Prime-Mover representative who will then take care of returning 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

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Chassis

Steel

Chassis

Steel

Mast

Steel

Mast

Steel

Battery cover

Steel

Battery cover

Steel

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

RECYCLING/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

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RECYCLING/DISCARDING

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

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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

Operator’s Manual

CSX

Electric Straddle Stacker Truck

Effective Serial Number CSX__25268001

The operator must read and understand this manual before operating this truck. Keep this OPERATOR’S MANUAL with unit at all times in place provided when not in use.

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

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

Part no: 304953-000 Return

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

Date: October 1996

Part no: 304953-000

Date: October 1996

IMPORTANT NOTICE

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 SAFELY DECALS ON UNIT. CLEAR THE AREA OF OTHER PERSONS.

LEARN AND PRACTICE USE OF CONTROLS BEFORE OPERATING.

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.

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

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

NAME

PAGE #

NAME

PAGE #

1 2 3 4 5 5 6 6 7 8-13 14-17 18-24 25-28 29 30 31-32 33 34 35 36-37

This unit is designed under ANSI B56.1.

For additional operating instructions see ANSI B56.1 “OPERATING SAFETY RULES AND PRACTICES”.

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DRIVE SAFELY

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

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 correct position BEFORE machine is operated.

TO NEW BT PRIME-MOVER OWNERS:

To keep your BT Prime-Mover unit in good condition the planned maintenance and lubrication must be followed.

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PRELIMINARY SERVICE

Examine your BT Prime-Mover unit carefully to determine whether or not it has been damaged in shipment. Any damage should be immediately reported to the transportation company.

Shipping damage could affect the safety of operation of the unit, it should not be operated until the damage has been repaired and any damage parts replaced.

A parts manual has been provided with the machine. Additional copies are available at a small charge.

Check oil levels before operation. Check that the battery is adequately charged, properly installed and connected.

RIGHT, LEFT, FRONT, AND REAR SIDES

Right and left hand, when used in this manual, indicate the right and left sides of unit as seen from operator's position.

A. Right Side B. Rear C. Left Side D. Front

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OPERATOR

The proper operator position for this truck is shown and described below.

Proper operation of this unit is with forks trailing when possible. Steering the truck is easier with the forks trailing. Always look in the direction of travel.

When forks are first to enter a confined area or elevator or on an incline, keep both hands on control handle. Keep both hands within the handle guard and always look in the direction of travel.

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OPERATING PRACTICES

IMPORTANT:

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

OPERATING RULES AND INSTRUCTIONS

OPERATOR QUALIFICATIONS

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OPERATING PRACTICES

OPERATOR TRAINING An effective operator training program should center around user company's policies, operating conditions and trucks. The program should be presented completely to all new operators and not condensed for those claiming previous experience. OPERATOR RESPONSIBILITY Powered industrial truck operators shall abide by the following rules and practices. l Avoid loose clothing, particularly cuffs and scarves. l Know what safety equipment is required on this truck and use it. A hard hat, safety glasses, reflector-type vest, respirators, and ear plugs are some of the types of equipment you may need. l DO NOT rush. l Know the hand signals used on this job and who has responsibility for signaling. l Safeguard the pedestrians at all times. DO NOT drive a truck up to anyone standing in front of a bench or other fixed object. l DO NOT allow anyone to stand or pass under the elevated portion of any truck, whether loaded or empty. l PASSENGERS MUST NOT be permitted to ride. l When operator is away from truck, the load-engaging means shall be lowered, controls neutralized, and brake set to prevent movement. l DO NOT place any part of body between moving and stationary or outside running lines of truck. l Use caution when making a right or left turn into an aisle. Remember rear wheels do not follow turn path of front wheel. When making a turn allow for “corner-cutting” of trailers.

Safeguard co-workers from truck operational hazards when their assistance is required to perform a task. l ALWAYS LOOK IN DIRECTION OF TRAVEL, especially when reversing. Return

Safeguard co-workers from truck operational hazards when their assistance is required to perform a task. l ALWAYS LOOK IN DIRECTION OF TRAVEL, especially when reversing. 9

OPERATING PRACTICES

When A Powered Industrial Truck Is To Be Left Unattended

OPERATING PRACTICES

When A Powered Industrial Truck Is To Be Left Unattended

Completely stop truck in a clear, authorized area.

Lower load-engaging means to the floor.

Place directional controls in neutral.

Apply the brake.

Turn key switch to OFF and disconnect battery connectors.

If truck must be left on an incline, block wheels.

ELEVATING PERSONNEL: This truck was not designed for elevating personnel. Refer to ANSI B56.1 for elevating personnel requirements.

Care shall be taken that overhead installations such as lights, pipes, sprinkler systems, etc. are not contacted.

A load backrest extension shall be used when necessary to guard against the load, or part of it, falling toward the operator.

NEVER get ON or OFF a moving truck.

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OPERATING PRACTICES

WHEN A POWERED INDUSTRIAL TRUCK IS TRAVELING:

l Local safety regulations must always be followed. Know and

understand the traffic flow patterns of your job.

l Yield right of way to pedestrians.

l DO NOT pass another truck traveling in the same direction

at intersections, blind spots or other dangerous locations.

l Slow down and sound the audible warning device(s) at

cross aisles and other locations where vision is blocked. If the load being carried blocks any view, ask for assistance so the load can be moved without any danger to personal or property.

l Keep a clear view of the path of travel, and observe for

traffic personnel and safe clearances.

l GRADES, RAMPS, OR INCLINES; This unit is designed for

level floor operation. If it is necessary to operate on a grade, ramp, or incline refer to ANSI B56.1 for requirements.

l Under all travel conditions this unit shall be operated at a

speed that will permit it to be brought to a stop in a safe manner.

l Carry your load low so you have maximum stability while

still maintaining ground clearance. l Make start, stops, turns or direction reversals in a smooth

manner so as not to shift load and/or overturn truck.

still maintaining ground clearance. l Make start, stops, turns or direction reversals in a smooth

manner so as not to shift load and/or overturn truck.

l DO NOT indulge in stunt driving or horseplay.

l Slow down for wet and slippery floors.

l Before driving over a dockboard or bridgeplate, be sure that

it is properly secured. Drive carefully and slowly across the dockboard or bridgeplate and never exceed its rated capacity.

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OPERATING PRACTICES

l Before the truck is driven into an elevator, the operator must

l Trucks shall enter confined areas with load end forward.

l Avoid running over loose objects, uneven surfaces or other

l While negotiating turns, reduce speed, steer in a smooth

l Report any defect in unit noted during operation.

l Observe instruments and gauges frequently to determine if

l DO NOT permit riders on unit.

l Understand unit limitations and keep unit under control.

l Remember to enter load slowly and squarely. Load should

l Handle only stable and properly arranged loads. Off-center

l Handle only loads within the capacity of the unit as rated on

l Handle long and wide loads exceeding the dimensions used

l The load shall only be lifted vertically and never dragged

l The load shall be transported with the bottom of load and

obstructions on roadway surface.

motion. Except when maneuvering at a very low speed, turn the steering at a moderate even rate.

they are operating properly.

Maintain a safe distance from the truck ahead, and keep the truck under control at all times.

be centered.

loads must be handled with extra caution. nameplate.

to establish truck capacity with extra caution. Stability and maneuverability may be adversely affected. horizontally.

forks as low as possible.

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obstructions on roadway surface.

motion. Except when maneuvering at a very low speed, turn the steering at a moderate even rate.

they are operating properly.

Maintain a safe distance from the truck ahead, and keep the truck under control at all times.

be centered.

loads must be handled with extra caution. nameplate.

to establish truck capacity with extra caution. Stability and maneuverability may be adversely affected. horizontally.

forks as low as possible.

OPERATING PRACTICES

OPERATOR PRECHECKS AND INSPECTION

l Before

each shift (every 8 hours) it is the operator's responsibility to carry out the following checks and inspections before beginning truck operation.

l l l l l l

Tires Warning and safety Devices Battery Brake Steering Mechanism Couplers

l Horn l Reverser l Proper operation of truck

each shift (every 8 hours) it is the operator's responsibility to carry out the following checks and inspections before beginning truck operation.

l l l l l l

Tires Warning and safety Devices Battery Brake Steering Mechanism Couplers

l Horn l Reverser l Proper operation of truck

l DO NOT make repairs or adjustments unless specifically

authorized to do so.

l DO NOT use open flames when checking electrolyte level in

battery

l DO NOT use open flames when checking electrolyte level in

battery

l DO NOT adjust unit with any parts moving.

l DO NOT smoke while working around truck.

l Block securely with drive tire off of floor when working under

truck, and on drive unit or electrical controls. l DO NOT attempt repairs you do not understand. There is no

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truck, and on drive unit or electrical controls. l DO NOT attempt repairs you do not understand. There is no

disgrace in asking for help.

DATA PLATE AND DECALS

Know the rated capacity on the data plate and understand areas 1 through 14 as shown in the illustration.

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DATA PLATE AND DECALS

KEEP WINDSHIELD CLEAN

ALWAYS keep the windshield clean.

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

KEEP HANDS CLEAR

The KEEP HANDS CLEAR decals are located on 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.

DO NOT ride on or stand under forks or attachments.

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

DATA PLATE AND DECALS

OPERATING WARNINGS

Breaking these rules may cause serious or fatal injury to yourself or others

Read and understand all warnings and operating instructions in the operator's manual before operating this truck.

Only authorized and trained operators are to operate this machine.

Keep feet clear of drive wheel and lowering frame.

Make a safty check before operating the truck and do not operate if in need of repairs or maintenance.

Maintenance is to be performed by authorized personnel only.

This machine is designed of level floors and normal industrial operations.

Additional operator's manuals can be obtained from your dealer or BT Prime-Mover, Inc., Muscatine, IA 52761.

305955-000

RAISE AND LOWER DECAL

This decal is located to the right and below the manual raise and lower control lever.

This decal is used to help you to remember just where the raise and lower control lever is and how it functions.

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DATA PLATE AND DECALS

TILT/AUXILIARY CONTROL DECALS

The tilt/auxiliary control decal is located to the right and below the manual tilt/auxiliary control lever.

This decal is used to help you to remember the auxiliary functions and there locations.

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.

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CONTROLS AND EQUIPMENT

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

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.

Read and observe all warnings on this unit before operating it.

THE CONTROL HANDLE

The control handle is used to provide brake, direction, speed, lift/lower, horn, and reverser control of the machine.

The Control Handle

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CONTROLS AND EQUIPMENT

RAISE SWITCH

LOWER SWITCH

HORN SWITCH

The horn is activated by pushing down on the horn bar located on top the steering control handle.

REVERSER SWITCH

DIRECTION AND SPEED

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CONTROLS AND EQUIPMENT

COMPONENT IDENTIFICATION

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

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CONTROLS AND EQUIPMENT

KEY SWITCH

A KEY SWITCH is provided to prevent unauthorized use of this unit. The key switch is located on the control panel cover.

The key switch has two (2) positions: OFF and ON.

1. OFF POSITION: Turning the key to “OFF” will stop all electrical power from going to the control circuit from battery.

EMERGENCY DISCONNECT BUTTON

Key Switch

Battery Discharge Indicator/Hourmeter Dash Display

Emergency Disconnect Switch

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Battery Discharge Indicator/Hourmeter Dash Display

Emergency Disconnect Switch

Dash Panel Layout

CONTROLS AND EQUIPMENT

BRAKE CONTROL

The brake and brake interlock switch must always be checked prior to operation of unit.

BRAKING USING PLUGGING FUNCTION

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CONTROLS AND EQUIPMENT

BATTERY DISCHARGE INDICATOR/HOURMETER DASH DISPLAY

HOURMETER (optional)

The hourmeter is provided to indicate the number of hours the unit has operated. The hourmeter is physically located on the dash next to key switch.

BATTERY DISCHARGE INDICATOR/HOURMETER (optional)

BDI/HOURMETER WITH LIFT INTERRUPT (optional)

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CONTROLS AND EQUIPMENT

AUXILIARY HYDRAULIC CONTROL LEVERS

Lift/lower Control

The Lift/lower is controlled by pushing lever forward to lower the mast and pulling back to lift. The speed of lift/lowering can be controlled by the degree of movement of lever.

Tilt/Auxiliary Control

The Tilt is controlled by pushing lever forward to lower fork tips and pulling back the lever to raise fork tips. The speed of tilt can be controlled by the degree of movement of lever.

Sideshifter/Auxiliary Control (optional)

Lift/lower Control Lever

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Auxiliary Hydraulic Control Lever

Lift/lower Control Lever

Auxiliary Hydraulic Control Lever

BEFORE OPERATION INSPECTION

Before operating and attempting to operate unit review warnings and controls section of this manual. Know how to stop unit before operating.

Check the complete truck daily or at the beginning of each shift.

l Inspect unit and look for damage and leakage. If any, DO

l Inspect hydraulic system. Look for leakage around hoses,

NOT operate unit until it is repaired.

fittings, and pump.

NOT operate unit until it is repaired.

fittings, and pump.

l Inspect

l Inspect drive unit. Look for leakage.

l Inspect all wheels for flat spots or pieces of material missing

l Inspect

l Make sure the Operator's Manual is in compartment and

l Inspect the frame for cracks, breaks, bending and wear.

l Check condition of load backrest (optional). Be sure it is

steering for looseness or binding and lack of lubrication.

from tires.

the battery connectors. Check the condition of electrical cables and wiring and make a report of all worn or cracked cables.

tethered to machine.

correctly positioned and secured.

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steering for looseness or binding and lack of lubrication.

from tires.

the battery connectors. Check the condition of electrical cables and wiring and make a report of all worn or cracked cables. tethered to machine.

correctly positioned and secured.

BEFORE OPERATION INSPECTION

l Inspect forks latches. Make sure they are NOT damaged or

l Adjust forks by lifting fork lock lever and sliding forks to the

broken, operate freely and lock correctly.

desired position.

broken, operate freely and lock correctly.

desired position.

l Remember to lower lever to lock forks securely in notch on

top of fork bar.

l Remember to lower lever to lock forks securely in notch on

top of fork bar.

l Look

l Connect the battery to unit (if disconnected), and turn the

l Check

l Press horn button to check horn function. If horn does not

l Before operating unit, look in all directions to make sure

at condition of lift chains, hoses, sheaves, and retainers. key switch to the “ON” position.

the operation of the Battery Discharge Indicator (BDI)/hourmeter.

function, report the failure and have it repaired before the unit is put into operation. your path of travel is clear.

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at condition of lift chains, hoses, sheaves, and retainers. key switch to the “ON” position.

the operation of the Battery Discharge Indicator (BDI)/hourmeter.

function, report the failure and have it repaired before the unit is put into operation. your path of travel is clear.

BEFORE OPERATION INSPECTION

l Turn steering control handle until steering is in the desired

direction of travel.

l Put your hands on the steering control handle and pull down

partially. This will release the brake and make power available to drive motor.

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

l FORWARD TRAVEL: Put a firm grip on the directional

l This unit is equipped with a PLUGGING FEATURE. 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.

l Brake action should be smooth and stop unit in a normal

distance. Report any unusual brake operation.

l Check steering control handle while truck is moving. Turn

the steering handle fully left and then right. Steering control handle should turn smoothly without binding or any loss of steering control.

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BEFORE OPERATION INSPECTION

l To RAISE forks, push down on the raise control bar with

The raise bar is physically located on top of the steering control handle for ease or operation when needed.

l To LOWER forks, push down on the lower control bar with

The lower bar is physically located on top of the steering control handle for ease of operation when needed.

your thumb or fingers. The forks will continue to raise as long as the bar is depressed or until the lifting stops are reached. Releasing the bar will automatically stop the raising.

your thumb or fingers. The forks will continue to lower as long as the bar is depressed or until the lowering stops are reached. Releasing the bar will automatically stop the lowering

your thumb or fingers. The forks will continue to raise as long as the bar is depressed or until the lifting stops are reached. Releasing the bar will automatically stop the raising.

your thumb or fingers. The forks will continue to lower as long as the bar is depressed or until the lowering stops are reached. Releasing the bar will automatically stop the lowering

l Both

l Use minimum forward and reverse tilt when stacking and

l Make sure Operator's Manual is returned to the case and

lifting and lowering of forks should be a smooth movement. unstacking loads. storage box.

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lifting and lowering of forks should be a smooth movement. unstacking loads. storage box.

OPERATION

STOPPING UNIT

1. Rotate direction control to the “NEUTRAL” position.

2. Raise steering control handle fully to stop unit's movement.

3. Push down on lower control button to lower forks to floor.

4. Make sure that all motion has stopped.

5. Turn key switch to “OFF” position and remove key.

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PARKING 1. Park units in designated parking areas only. Make sure unit does not block fire aisles, fire equipment, stairways or walkways.

2. Lower forks fully.

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

4. Remember to block drive wheel securely to prevent accidental roll.

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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 volt wet cell Battery.

IMPORTANT:

Use only batteries that meet the following specifications:

VOLTAGE Minimum Battery Weight Maximum Battery Weight

24 (consult nameplate on unit) (consult nameplate on unit)

For other industrial battery sizes, provide blocking to restrain the battery from moving not more than 0.50 inches or 12.7 mm in any horizontal direction.

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BATTERY RETAINMENT/CARE

When removing battery out top of battery compartment the control handle must be rotated fully to clear battery.

BATTERY SERVICE

DO NOT SERVICE BATTERY UNLESS YOU ARE TRAINED AND AUTHORIZED BATTERY ACID CAN CAUSE SEVERE

ADDING WATER

TERMINALS & CABLE CONNECTIONS

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SPECIFICATIONS AND LUBRICATIONS

Oil Capacity in Transmission .8 Quart [.75 l] or to bottom of the fluid fill hole in the transmission.

Transmission Fluid Type

Greater then 5°F SAE 80W-90 Less then 5°F ATF Dexron III

Oil capacity in Hydraulic Reservoir 2.9 Gl.[11 l] Fluid Greater then 5°F Sunoco TH Less then 5°F ATF Dexron III

Lift chains

Greater then 5°F SAE 40W Less then 5°F SAE 20W

Grease Type

Tex. Ref. C and C #880

Greater then 5°F SAE 40W Less then 5°F SAE 20W

Grease Type

Tex. Ref. C and C #880

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

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SERVICE INTERVALS

200 HOURS OR MONTHLY

l Check condition of battery charge. l Visually inspect for leaks, loose,

missing, or damaged parts. l Check all operating functions and adjustments. l Check hydraulic fluid level. l Check transmission oil level. l Lubricate all grease fittings. l Inspect power cables and control wiring. l Clean with compressed air. l Inspect motor brushes.

2000 HOURS OR ANNUAL

l Clean battery and machine. l Drain, flush, and refill transmission gear case. l Drain, flush, and refill hydraulic reservoir.

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FIELD MODIFICATIONS

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RECYCLING/DISCARDING

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

Discarding the battery

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

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Chassis

Steel

Chassis

Steel

Mast

Steel

Mast

Steel

Battery cover

Steel

Battery cover

Steel

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

RECYCLING/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

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RECYCLING/DISCARDING

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

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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

Operator’s Manual

CSX

Electric Counter Balanced Stacker Truck

Effective Serial Number CSX__27290001

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 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: 304953-000 Return

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

Date: October 17, 1997

Part no: 304953-000

Date: October 17, 1997

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

Operator’s warning ........................................................... 1

Foreword............................................................................ 2

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..................................... 20 Prohibited applications for BT’s trucks ............................ 20 Truck data ....................................................................... 21 CSX truck dimensions ..................................................... 22 Data plate ........................................................................ 23 U.L. construction type...................................................... 24

Presentation of truck ....................................................... 19 Application areas for BT’s trucks..................................... 20 Prohibited applications for BT’s trucks ............................ 20 Truck data ....................................................................... 21 CSX truck dimensions ..................................................... 22 Data plate........................................................................ 23 U.L. construction type...................................................... 24

Presentation of main components ................................. 25

Controls and instruments ............................................... 28 Control handle ................................................................. 28 Control for raising the forks ............................................. 29 Control for lowering the forks .......................................... 29 Travel direction selector and speed control..................... 30 Horn................................................................................. 30 Reverser switch............................................................... 31 Steering Control Handle/Brake Control ........................... 32 Braking using plugging function ...................................... 33 Key switch (toggle switch) ............................................... 34 Emergency disconnect switch ......................................... 34 BDI/Hourmeter with travel interrupt ................................. 35 Battery discharge indicator (BDI) .................................... 35 Hourmeter ....................................................................... 36 Control for Lift/Lower Control .......................................... 37 Control for Tilt/Auxiliary Control....................................... 37 Control for Sideshifter/Auxiliary Control (optional) .......... 37

Controls and instruments ............................................... 28 Control handle................................................................. 28 Control for raising the forks ............................................. 29 Control for lowering the forks .......................................... 29 Travel direction selector and speed control..................... 30 Horn ................................................................................ 30 Reverser switch............................................................... 31 Steering Control Handle/Brake Control ........................... 32 Braking using plugging function ...................................... 33 Key switch (toggle switch)............................................... 34 Emergency disconnect switch ......................................... 34 BDI/Hourmeter with travel interrupt ................................. 35 Battery discharge indicator (BDI) .................................... 35 Hourmeter ....................................................................... 36 Control for Lift/Lower Control .......................................... 37 Control for Tilt/Auxiliary Control....................................... 37 Control for Sideshifter/Auxiliary Control (optional) .......... 37

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Table of Contents

Driving............................................................................... 38 Starting the truck ............................................................. 39 Braking ............................................................................ 41 Steering........................................................................... 43 Parking the truck ............................................................. 43

Driving ...............................................................................38 Starting the truck..............................................................39 Braking.............................................................................41 Steering............................................................................43 Parking the truck ..............................................................43

Transporting loads .......................................................... 44 General............................................................................ 44 Collecting a load.............................................................. 47 Leaving a load................................................................. 48

Transporting loads ...........................................................44 General ............................................................................44 Collecting a load ..............................................................47 Leaving a load..................................................................48

Battery............................................................................... 49 Type of battery ................................................................ 49 Changing the battery ....................................................... 49 Charging the battery........................................................ 53 Battery maintenance ....................................................... 56

Battery ...............................................................................49 Type of battery .................................................................49 Changing the battery........................................................49 Charging the battery ........................................................53 Battery maintenance ........................................................56

Daily service/safety checks ............................................ 56

Daily service/safety checks .............................................56

Maintenance ..................................................................... 60 General............................................................................ 60 Safety regulations with maintenance work ...................... 60 Cleaning and washing ..................................................... 64 Maintenance chart........................................................... 66 Lubrication chart.............................................................. 70 Oil and grease specification ............................................ 71

Maintenance ......................................................................60 General ............................................................................60 Safety regulations with maintenance work.......................60 Cleaning and washing......................................................64 Maintenance chart ...........................................................66 Lubrication chart ..............................................................70 Oil and grease specification.............................................71

Transport and storing the truck ..................................... 72 The truck’s dimensions and weight as standard ............. 72 Lifting the truck................................................................ 72 Towing and transporting a disabled truck........................ 73 Storing the truck .............................................................. 74 Starting after a period of disuse ...................................... 74

Transport and storing the truck ......................................72 The truck’s dimensions and weight as standard ..............72 Lifting the truck.................................................................72 Towing and transporting a disabled truck ........................73 Storing the truck...............................................................74 Starting after a period of disuse .......................................74

Recycling/discarding....................................................... 75 Discarding the battery ..................................................... 75 Scrapping the truck ......................................................... 75

Recycling/discarding........................................................75 Discarding the battery ......................................................75 Scrapping the truck ..........................................................75

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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 severe 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 severe 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:

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.

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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.

•

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 a dry, clean surface. Do not operate on wet, oily surfaces.

•

The truck should only be driven on a 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 is 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 a 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 a 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.

•

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 manufacturer’s 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. List of warnings 2. Signal/Horn 3. Hydraulic controls: Raising 4. Hydraulic controls: Lowering 5. No Riding decal 6. Decal: Tilt Forks 7. Pinch points: Do not reach through uprights. 8. Do not walk under an elevated load. 9. Decal: Mast Raise/Lower 10. Warning decal: No Step, or No Standing, or No Riding 11. Truck data plate 12. U.L. listed

2 3 4

1 12

10 Return

10 17

9 17

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 by a walking operator. This BT truck has available different fork lengths and mast heights. Refer to the truck’s data plate for this information.

The truck has a maximum lifting capacity of 4000 lb. Refer to the truck’s data plate for this information on lifting capacities.

The trucks are equipped with a 24 volt electrical system. The travel speeds are regulated by means of a transistor controller to provide gentle control of acceleration and speed while operating.

The forks are raised by means of a hydraulic unit. The control of the lift is done electrically with the push button on the steering arm. Control of the speed and positioning of the forks when stacking are done with the mechanical valve lever of the truck.

The trucks can be fitted with different accessories including sideshifter, warning light, hourmeter/battery indicator, and BDI with lift interrupt. The trucks can be specially equipped to work in cold conditions.

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Presentation of truck

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 trucks

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

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Do not use in areas that contain gases which can cause fires or explosions

Do not use as a towing truck for trailers

Do not use to tow other trucks

Do not use to transport/lift passengers

Do not use to drive on gravel or grass

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

CSX

Truck type

CSX

Operating speed without load, mph

3.3

Operating speed without load, mph

3.3

Operating speed with classified load, mph

2.9

Operating speed with classified load, mph

2.9

Maximum operating gradient with load, %

Continuous noise level. dB (A)

<80

Continuous noise level. dB (A)

<80

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

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Presentation of truck

CSX truck dimensions

The following diagrams show external dimensions for CSX trucks.

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Presentation of truck

Data plate

Know the rated capacity on the data plate and understand areas 1 through 14 as shown in the illustration.

1. Truck model number 2. Truck serial number 3. Truck weight less battery 4. Maximum battery weight 5. Minimum battery weight 6. Truck voltage 7. Truck type 8. Battery type 9. Battery maximum AMP hours 10. Mast serial number 11. Attachment 12. Load wheel tread width (in.) (NOT USED on this model) The distance between outrigger centers at ground level. 13. Maximum degree rear tilt 14. 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

1. Steering control handle The truck is to be controlled by the operator with 180 degree steering angle. The brake is applied in the upper and lower position of the steering arm. 2. Data plate Contains type designation, serial number, service weight, battery weight, rated lifting capacity, battery voltage, and manufacturer. 3. Door Swing open which provides good accessibility when servicing. The door can be completely removed from the truck by lifting the door from the hinges. 4. Gauge Combined hourmeter/battery indicator, hourmeter/battery indicator with lift interrupt, or hourmeter only. 5. Hydraulic control (manual valve) For controlling lifting and lowering functions. 6. Hydraulic control (manual valve) For controlling the tilt, and sideshifter function. 7. Hydraulic unit Pump motor, pump, electric valves, and oil tank integrated in a compact unit. 8. Hydraulic electric solenoid valve For controlling lifting and lowering function with electric solenoid valve. 9. Hydraulic manual valves For controlling hydraulic functions with a manual lever on top of truck.

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Presentation of main components

10. Drive unit with brake Fixed drive unit with a spring applied brake, drive motor, gear box, and drive wheel combined into a compact unit. The steering bearings are at the top of the drive unit. 11. Steering pivot point Lubricate pivot point to prevent stiff steering. 12. Electric panel 24 volt electrical system. Vehicle speed is regulated by means of a transistor controller. 13. Circuit breaker 12A, BT Control circuit breaker part number 301889-000. 300A, BT Pump circuit breaker part number 25094-04. 150A, BT Drive circuit breaker part number 307601-000 needs two. 14. Mast Covered by a finger protection which covers the operator’s normal range of reach from the operating position. 15. Load wheel Lubricate load wheels to prevent wheels from locking up. 16. Battery 24 volt with different capacities and weights. 17. Reverser switch The function is to prevent the operator from being pinched between the handle and an obstruction when traveling in the forward direction. 18. Horn switch The horn sounds to warn others of your position. 19. Fork raise switch The forks will raise when switch is pressed or until lift stops are reached. 20. Fork lower switch The forks will lower when switch is pressed or until lower stops are reached.

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Presentation of main components

21. Travel speed / direction selection To select direction rotate in the direction you wish to move. The further in that direction you rotate the faster you move. 22. Key switch (toggle switch) Shuts off electrical power to control system. 23. Emergency stop switch The emergency stop switch will stop all control functions.

17 14

21 9

9 22

1 12 13

23 3

3 10

10 15 8

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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.

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.

Control handle

The control handle is used to provide hand brake, direction, speed, and horn on this machine. Fork Lower Switch Fork Raise

Switch

Switch Steering Control Handle

Horn Switch

Steering Control Handle Horn Switch

Rearward

Directional Controls Return

Forward

Rearward

Directional Controls 29

Forward

Controls and instruments

Control for raising the forks

The control button activates a micro switch to start the pump motor with lifting.

The diagram illustrates the controls as seen from the operator’s position. Lift the forks by pressing ‘A’.

NOTE! The forks cannot be raised with the key switch in position O.

Control for lowering the forks

NOTE! The forks cannot be raised with the key switch in position O.

Control for lowering the forks E

Lower the forks by pressing ‘E’. The lowering speed of the forks is controlled by a flow control valve. NOTE! The forks cannot be lowered with the key switch in position O.

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Lower the forks by pressing ‘E’. The lowering speed of the forks is controlled by a flow control valve. NOTE! The forks cannot be lowered with the key switch in position O.

Controls and instruments Travel direction selector and speed control

Select the travel direction by rotating ‘R’ in the required direction. The speed is controlled variably based on the position of the lever.

This truck is equipped with a thumb control and optional picking knob for speed and direction control. Rotating control in the forward or rearward direction will select that direction of travel. The truck speed will progressively increase as the control is rotated. Reversing the control can be used to quickly decrease speed or brake the truck.

Horn

The horn sounds as long as the button is pressed.

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The horn sounds as long as the button is pressed.

Controls and instruments Reverser switch

Reverser Switch

The end of the control handle is equipped with a red automatic reversing switch which causes the truck to travel in the rearward direction when activated. Its function is to prevent the operator from being pinched between the handle and obstruction when traveling in the forward direction.

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Controls and instruments Steering control handle/brake control

B1 F

Operate the truck with the steering control handle in the center range, F.

The brake is activated mechanically by the steering control handle/brake control. The brake is applied in two ranges, B1 and B2.

Parking brake (B1):

The arm automatically returns to position B1 when released.

Travel brake (B2):

Apply the brake by pushing the steering control handle downwards.

The brake function should always be checked before using this unit.

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Controls and instruments

Braking using plugging function

This unit is equipped with a PLUG BRAKING FEATURE. This method involves simply reversing the travel control to the opposite direction without applying the brake. This will cause the truck to come to a stop smoothly.

As the truck comes to a full stop the operator may choose to continue holding the controls in the opposite direction and thus start the truck moving in that direction, or the operator may release the handle and allow the truck to come to a complete halt. Releasing the steering control handle will allow the parking brake to become automatically applied.

THE CONTROL HANDLE MUST NOT BE PLACED IN THE BRAKE POSITION DURING THE PLUG BRAKING OPERATION.

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When using the plug braking the operator may regulate, within the programmed capabilities, the severity of the plugging force and the stopping distance. For the lightest plugging force, and the longest stopping distance, the travel control should be operated only to the creep position in the opposite direction. For the strongest plugging power, and the shortest distance, the travel control should be operated to full speed in the opposite direction. Plug braking may be regulated with the control handle at any point between the creep position and full speed.

Controls and instruments Key Switch

Battery Discharge Indicator/Hourmeter Dash Display

Emergency Disconnect Switch

Dash Panel Layout

Controls and instruments Key Switch

Battery Discharge Indicator/Hourmeter Dash Display

Emergency Disconnect Switch

Dash Panel Layout

Key switch (toggle switch)

A key switch is provided to prevent unauthorized use of this unit. The key switch is located on the control panel cover.

The key switch has two (2) positions: OFF and ON.

1. Off Position: Turning the key to “OFF” will stop all electrical power from going to the control circuit from the battery.

2. On Position: Turn the key to “ON” to check function of the hourmeter and battery discharge indicator. The key switch must be in this position to provide power to the control circuit when unit is operated.

Emergency disconnect switch

The emergency disconnect switch will cut off all electrical power to the unit when pushed. To reset the emergency disconnect switch turn key switch to OFF position, repair emergency, push emergency disconnect switch on. The emergency disconnect button is physically located on the dash next to the key switch.

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Controls and instruments

BDI/hourmeter with travel interrupt

Fully-charged battery

1/2

Half-charged battery

1/2

Half-charged battery

Discharged battery

The battery indicator shows the actual charge level of the truck’s battery.

The battery indicator has an integrated travel interrupt that disables the truck’s travel function when a preset discharge level is reached. This prevents damage to the battery and increases the running economy of the truck. When the battery has reached a charge level equivalent to 70 percent discharge a warning signal is given by a flashing light. A further 10 percent of the battery’s capacity can be used before the battery indicator interrupts the lifting function.

The hourmeter displays the time the drive motor is operating.

Battery discharge indicator (BDI)

The battery discharge indicator (BDI) is used to indicate the degree the battery has been drained of charge. The BDI is to be read when unit is at rest with the key switch “ON” and with NO motors running.

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Controls and instruments

Hourmeter

The hourmeter displays the time the drive motor and/or the pump motor are operating.

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Controls and instruments

Auxiliary Hydraulic Control Levers

Lift/Lower Control Lever

Auxiliary Hydraulic Control Lever

Control for Lift/Lower Control

The Lift/Lower is controlled by pushing lever forward to lower the mast and pulling back to lift. The speed of lift/lowering can be controlled by the degree of movement of lever.

Control for Tilt/Auxiliary Control

The Tilt is controlled by pushing lever forward to lower fork tips and pulling back the lever to raise fork tips. The speed of tilt can be controlled by the degree of movement of lever.

Control for Sideshifter/Auxiliary Control (optional)

The Sideshifter is controlled by depressing and holding the sideshifter function button on side of auxiliary control lever and moving lever. Pulling lever will move forks Right and pushing will move forks Left. The speed of sideshifter can be controlled by the degree of movement of lever.

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Driving

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.

The proper operator position for this truck is shown and described below.

Proper operation of this unit is with forks trailing when possible. Steering the truck is easier with the forks trailing. Always look in the direction of travel.

When forks are first to enter a confined area or elevator or on an incline keep both hands on control handle. Keep both hands within the handle guard and always look in the direction of travel.

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Driving

Starting the truck

Ensure the battery connector is connected to the truck.

Turn the key switch to position I. The instrument lighting comes on.

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

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.

Move the control handle to the drive position (F). The parking brake is released when the control handle is moved to the drive position (F).

Move the travel direction selector/speed control in the desired direction.

WARNING Function failure. Safety can be jeopardized. Always check the following safety functions before starting the day’s work. Return

WARNING Function failure. Safety can be jeopardized. Always check the following safety functions before starting the day’s work. 39

Driving

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Driving

- That the horn functions correctly.

- That the steering functions correctly.

- That the brakes function correctly.

Start gently by accelerating slowly until you reach the desired speed.

WARNING Dangerous driving. Accidents can occur. Always drive with care, good judgement, and responsibility as set out in the general safety guidelines.

Driving

Braking

Braking B1

2 B2

By moving the arm to the B2 position you will apply the travel brake. When you release the tiller arm it automatically returns to the parking brake position (B1).

This unit is equipped with a PLUG BRAKING FEATURE. 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.

THE CONTROL HANDLE MUST NOT BE PLACED IN THE BRAKE POSITION DURING THE “PLUG BRAKING” OPERATION.

When using the “plug braking” the operator may regulate, within the programmed capabilities, the severity of the “plugging” force and the stopping distance. For the lightest

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When using the “plug braking” the operator may regulate, within the programmed capabilities, the severity of the “plugging” force and the stopping distance. For the lightest 41

Driving “plugging” force, and the longest stopping distance, the travel control should be operated only to the “creep” position in the opposite direction. For the strongest “plugging” power, and the shortest distance, the travel control should be operated to full speed in the opposite direction. Plug braking may be regulated with the control handle at any point between the “creep” position and full speed.

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Driving

Steering

Steer by means of the control handle.

If the truck gets caught against an obstacle do not use more force to steer than used when steering the truck under normal conditions. When this occurs try to free the truck by carefully driving forwards and backwards and at the same time carefully moving the control handle.

WARNING Risk of slipping. 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 and disengage the travel direction selector.

Release the control handle. The handle will return automatically to the parking brake position and the brakes are applied.

Turn the key switch to the O position.

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

WARNING Unauthorized use. Accidents can happen. Always remove the key switch when the truck is left unattended. 43

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.

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

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

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WARNING Lost stability. 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.

WARNING Protruding loads. The load can collide with personnel, fixed or moving objects. A truck with a protruding load requires more room when cornering.

Transporting loads

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.

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.

DO NOT use the truck on grades, ramps, or inclines.

Before the truck is driven into an elevator ensure that the elevator is approved for the overall load (the truck’s weight and the load). Enter with the load first. DO NOT permit other personnel to be in the elevator while entering or leaving.

WARNING Risk of overturning. A loaded truck can overturn when attempting to turn on an incline. Never turn a loaded truck on an incline.

WARNING Increased braking distance. The braking distance is increased when traveling downhill. Drive at a reduced speed using the truck’s motor brake.

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Transporting loads

WARNING Risk of overloading the elevator. 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. WARNING Risk of tipping. 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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WARNING Risk of overloading the elevator. 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. •

Transporting loads

Collecting a load

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

Lift the forks to the required position.

Drive the truck forward so that the forks are positioned in the center and as far as possible under the load.

Lift the forks so that the load is lifted free of the rack.

Reverse the truck so that the load clears 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. Ÿ

Start slowly and then increase the speed.

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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. Ÿ

Start slowly and then increase the speed.

Transporting loads

Leaving a load

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

Lift the load to the required lifting position.

Drive the truck forward so that the load is positioned correctly on the rack.

Lower the forks so that they clear the load.

Reverse the truck.

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

NOTE! Forks not horizontal. The load can slide off the forks or catch on the rack. When the load is left or collected the forks should always be positioned horizontally. •

Drive carefully away from the load. Start slowly and then increase the speed. 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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NOTE! Forks not horizontal. The load can slide off the forks or catch on the rack. When the load is left or collected the forks should always be positioned horizontally. •

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. 54

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.

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Daily service/safety checks 2

Daily service/safety checks

2 6

6 16

6 4 5 19

10 11

12 13

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

Check points

Action

Direction / accelerator

Check its function

Reverser switch

3 4

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4 5 19

Item #

WARNING DO NOT continue to operate the truck when it is not functioning properly. Item #

Check points

Action

Direction / accelerator

Check its function

Reverser switch

Check its function

Horn

Check its function

Horn

Check its function

Handle steering

Check its function

Handle steering

Check its function

Daily service/safety checks Item #

Check points

Action

Parking brake

Daily service/safety checks Item #

Check points

Action

Check its function

Parking brake

Check its function

Hydraulic function

Check its function

Hydraulic function

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.

Hydraulic system

Check for oil leakage, hoses, and floor

Hydraulic system

Check for oil leakage, hoses, and floor

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

Chassis

Check for damage, remove dirt and debris

Chassis

Check for damage, remove dirt and debris

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

Fork carriage

Check the locking and for damage and wear

Fork carriage

Check the locking and for damage and wear

Lifting device

Check for damage and alignment of forks

Lifting device

Check for damage and alignment of forks

Hydraulic cylinder

Check for damage and leakage

Hydraulic cylinder

Check for damage and leakage

Key switch (toggle)

Check its function

Key switch (toggle)

Check its function

Emergency stop switch

Check its function

Emergency stop switch

Check its function

Covers / guards

Check for damage, ensure placement

Covers / guards

Check for damage, ensure placement

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

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Daily service/safety checks

Special equipment

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

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Maintenance

General information

•

Under normal conditions 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 set up a service and maintenance agreement to ensure your truck’s operating economy and safety.

•

BT recommends that you contact your BT representative to set up 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.

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Maintenance

WARNING Short-circuiting/burns. 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, rings, 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.

•

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

•

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.

•

Bear in mind that the oil in the transmission or the hydraulic system can be hot.

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

•

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

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WARNING Risk of burns. 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. 63

Maintenance

WARNING The hydraulic system can be damaged. If 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.

•

When working underneath the truck support the truck on trestle-blocks.

WARNING Risk of crushing. A badly supported truck can fall. Never work under a truck that is not supported on trestle-blocks and secured by a lifting device.

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WARNING Risk of crushing. A badly supported truck can fall. Never work under a truck that is not supported on trestle-blocks and secured by a lifting device.

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

•

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.

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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 the truck is important to ensure the truck will operate safely and reliably.

•

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 agent diluted to a suitable concentration.

•

Use a degreasing agent diluted to a suitable concentration.

•

Rinse off loose grime using warm water.

•

Rinse off loose grime using warm water.

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

•

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Cover the electric motors, electrical compartments, connectors, and valves before washing. 66

Maintenance •

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

Maintenance •

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

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 psi, and then only with effective chip-guarding and personal protective equipment.

•

Clean the electrical panels, electronic boards, contacts, connector, solenoid valves, etc. using a damp cloth and a cleaning agent.

•

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.

•

Do not spray or pressure wash in the compartment.

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

Return

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

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

No.

Action

1.0

Chassis

1.1

Check that the truck’s data plate is legible

1.1

Check that the truck’s data plate is legible

1.2

Check the cover screws

1.2

Check the cover screws

1.3

Check door lock

1.3

Check door lock

1.4

Check for damage and crack formation

1.4

Check for damage and crack formation

1.5

Check fork frame mounting

1.5

Check fork frame 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

Check brush wear

2.5

Check 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 and debris

4.1

Remove string and debris

4.2

Check all wheels for wear

4.2

Check all wheels for wear

4.3

Check that all wheels rotate and axles are fitted correctly

4.3

Check that all wheels rotate and axles are fitted correctly

4.4

Check all wheels for loose screws

4.4

Check all wheels for loose screws

4.5

Grease load wheel bearings

4.5

Grease load wheel bearings

Return

Maintenance No.

Action

No.

Action

4.6

Grease caster and caster wheels

4.6

Grease caster and caster wheels

4.7

Dismantle and lubricate all wheel bearings.

4.7

Dismantle and lubricate all wheel bearings.

5.0

Brake

5.0

Brake

5.1

Clean

5.1

Clean

5.2

Check shoes and discs for wear

5.2

Check shoes and discs for wear

5.3

Check correct clearance brake

5.3

Check correct clearance brake

5.4

Check brake operation

5.4

Check brake operation

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 tips

6.3

Check contactor tips

6.4

Check the contactor tips for free movements

6.4

Check the contactor tips for free movements

6.5

Check all cable insulation for damage

6.5

Check all cable insulation for damage

7.0

Electronic card

7.0

Electronic card

7.1

Check for connections in harness connectors

7.1

Check for connections in harness connectors

8.0

Electronic control system

8.0

Electronic control system

8.1

Check key switch (toggle)

8.1

Check key switch (toggle)

8.2

Check brake switch

8.2

Check brake switch

8.3

Check control wiring harness for proper routing

8.3

Check control wiring harness for proper routing

9.0

Battery

9.0

Battery

9.1

Check electrolyte level, 1/2 -5/8 in. (10-15mm above cell plate)

9.1

Check electrolyte level, 1/2 -5/8 in. (10-15mm above cell plate)

9.2

Check the connections on battery, truck, and charger

9.2

Check the connections on battery, truck, and charger

9.3

Check all cells and pole guards

9.3

Check all cells and pole guards

9.4

Check the fluid density and temperature

9.4

Check the fluid density and temperature

9.5

Check power cables are not cut or frayed

9.5

Check power cables are not cut or frayed

Return

Maintenance B

X X

Maintenance No.

Action

No.

Action

10.0

Hydraulic system

10.0

Hydraulic system

10.1

Check hoses and connections for leakage

10.1

Check hoses and connections for leakage

10.2

Check hoses for wear and damage

10.2

Check hoses for wear and damage

10.3

Check oil tank for cracks, leaks, and mounting

10.3

Check oil tank for cracks, leaks, and mounting

10.4

Check oil level

10.4

Check oil level

10.5

Change oil

10.5

Change oil

11.0

Cylinders

11.0

Cylinders

11.1

Check for leakage

11.1

Check for leakage

11.2

Check the mountings

11.2

Check the mountings

12.0

Mast carriage

12.0

Mast carriage

12.1

Check for damage and cracks

12.1

Check for damage and cracks

12.2

Check mast mounting bolts torque

12.2

Check mast mounting bolts torque

12.3

Check for play on rollers

12.3

Check for play on rollers

12.4

Check the electrical limit switch function

12.4

Check the electrical limit switch function

12.5

Check for wear and stretch on the chains and sheaves

12.5

Check for wear and stretch on the chains and sheaves

12.6

Check hoses and couplings for leakage, cuts, and other damage

12.6

Check hoses and couplings for leakage, cuts, and other damage

12.7

Check for wear to the forks and other lifting devices

12.7

Check for wear to the forks and other lifting devices

12.8

Lube all grease fittings

12.8

Lube all grease fittings

13.0

Controls

13.0

Controls

13.1

Check handle mounting

13.1

Check handle mounting

13.2

Check the handle brake switch

13.2

Check the handle brake switch

13.3

Check travel direction/speed control

13.3

Check travel direction/speed control

13.4

Check horn button function

13.4

Check horn button function

13.5

Check hydraulic button functions

13.5

Check hydraulic button functions

13.6

Check the reverser switch

13.6

Check the reverser switch

13.7

Check hydraulic manual control lever functions

13.7

Check hydraulic manual control lever functions

Return

Maintenance B

Maintenance No.

Action

14.0

Gauge

14.1

Check dash display

15.0

Brake levers

15.1

Check parking brake lever

15.2

Check that the control handle returns to the upright position with parking brake applied

16.0

Emergency stop switch

16.1

Check the emergency stop switch

Maintenance B

No.

Action

14.0

Gauge

14.1

Check dash display

15.0

Brake levers

15.1

Check parking brake lever

15.2

Check that the control handle returns to the upright position with parking brake applied

16.0

Emergency stop switch

16.1

Check the emergency stop switch

14 15

6 7

14 15

6 7 16

16 2

3 4

4 2

Return

13 11

Maintenance chart

Maintenance

Lubrication chart

Lubrication chart Interval/Running hours

Pos No.

Service point

Wheel bearings

Hydraulic system

Parking brake

Drive gear

Hinges

Steering bearings

Gear ring

500h

L=Lubrication

Return

Service point

Wheel bearings

Hydraulic system

Parking brake

Drive gear

Hinges

Steering bearings

Gear ring

1000h

3000h L

C=Check

Interval/Running hours

Pos No.

Lubricant

O=Oil change

Lubricant 500h

L=Lubrication

1000h

3000h L

C=Check

A B

O=Oil change

Maintenance

Approved Oils and Grease Pos. Lubricant

Approved Oils and Grease

Specification > 5°F-15°C

< 5°F-15°C

Application <-10°F-23°C

Pos. Lubricant

Specification > 5°F-15°C

area

< 5°F-15°C

Application <-10°F-23°C

area

Grease

Tex. Ref. C & Tex. Ref. C & Tex. Ref. C & Bearings and C #880 C #880 C #880 bushings

Grease

Tex. Ref. C & Tex. Ref. C & Tex. Ref. C & Bearings and C #880 C #880 C #880 bushings

Hydraulic oil

Sunoco TH

C D

Sunoco TH

Texaco 15

Hydraulic system

Hydraulic oil

Transmission SAE 80W/90 oil

SAE 75W

Gears

Motor oil

SAE5W-20

Hinges

SAE 40

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

Sunoco TH

Texaco 15

Hydraulic system

Transmission SAE 80W/90 oil

SAE 75W

Gears

Motor oil

SAE5W-20

Hinges

SAE 40

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

C A D

Return

A D

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.

Truck’s dimensions and weight

Height

60 in. (1524 mm)

Height

60 in. (1524 mm)

Width

37.4 in. (950 mm)

Width

37.4 in. (950 mm)

Length

52.0 in. (1320 mm)

Length

52.0 in. (1320 mm)

Minimum battery weight

950 lb to 1200 lb

Minimum battery weight

950 lb to 1200 lb

Lifting the truck

•

Return

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

WARNING Risk of overturning. The truck can overturn if lifted from the wrong lifting points. Always lift the truck from the marked lifting points.

WARNING Risk of overturning. 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.

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

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

Recycling/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

Steel

Chassis

Steel

Battery cover

Steel

Battery cover

Steel

Mast

Steel

Mast

Steel

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

Return

Recyling/Discarding

Hydraulic system

Oil tank

Polythene

Oil tank

Polythene

Pump unit

Steel and aluminium

Pump unit

Steel and aluminium

Hoses

Rubber and steel

Hoses

Rubber and steel

Cylinders

Steel

Cylinders

Steel

Electrical system

Return

Recyling/Discarding

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

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

Operator’s Manual

CSX

Electric Counter Balanced Stacker Truck

Effective Serial Number CSX__27290001 - UP

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 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: 304953-000 Return

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

Date: October 20, 1998

Part no: 304953-000

Date: October 20, 1998

Operator’s warning

IMPORTANT NOTICE

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.

WARNING INJURY OR DEATH

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

Return

WARNING INJURY

OR DEATH TO YOU OR OTHER 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.

Return

Table of Contents

Operator’s warning ........................................................... 1

Foreword............................................................................ 2

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

Presentation of truck ....................................................... 19 Application areas for BT’s trucks ..................................... 20 Prohibited applications for BT’s trucks ............................ 20 Truck data ....................................................................... 21 CSX truck dimensions ..................................................... 22 Data plate ........................................................................ 23 U.L. construction type...................................................... 24

Presentation of truck ....................................................... 19 Application areas for BT’s trucks..................................... 20 Prohibited applications for BT’s trucks ............................ 20 Truck data ....................................................................... 21 CSX truck dimensions..................................................... 22 Data plate ........................................................................ 23 U.L. construction type...................................................... 24

Presentation of main components ................................. 25

Controls and instruments ............................................... 28 Control handle ................................................................. 28 Control for raising the forks ............................................. 29 Control for lowering the forks .......................................... 29 Travel direction selector and speed control..................... 30 Horn ................................................................................ 30 Reverser switch............................................................... 31 Steering Control Handle/Brake Control ........................... 32 Braking using plugging function ...................................... 33 Key switch (toggle switch) ............................................... 34 Emergency disconnect switch ......................................... 34 BDI/Hourmeter with travel interrupt ................................. 35 Battery discharge indicator (BDI) .................................... 35 Hourmeter ....................................................................... 36 Control for Lift/Lower Control .......................................... 37 Control for Tilt/Auxiliary Control....................................... 37 Control for Sideshifter/Auxiliary Control (optional) .......... 37

Return

Table of Contents

Driving............................................................................... 38 Starting the truck ............................................................. 39 Braking ............................................................................ 41 Steering ........................................................................... 43 Parking the truck ............................................................. 43

Driving ............................................................................... 38 Starting the truck.............................................................. 39 Braking............................................................................. 41 Steering............................................................................ 43 Parking the truck .............................................................. 43

Transporting loads .......................................................... 44 General............................................................................ 44 Collecting a load.............................................................. 47 Leaving a load ................................................................. 48

Transporting loads ........................................................... 44 General ............................................................................ 44 Collecting a load .............................................................. 47 Leaving a load.................................................................. 48

Battery............................................................................... 49 Type of battery ................................................................ 49 Changing the battery....................................................... 49 Charging the battery........................................................ 53 Battery maintenance ....................................................... 56

Battery ............................................................................... 49 Type of battery ................................................................. 49 Changing the battery........................................................ 49 Charging the battery ........................................................ 53 Battery maintenance ........................................................ 56

Daily service/safety checks ............................................ 56

Daily service/safety checks ............................................. 56

Maintenance ...................................................................... 60 General ............................................................................ 60 Safety regulations with maintenance work....................... 60 Cleaning and washing...................................................... 64 Maintenance chart ........................................................... 66 Lubrication chart .............................................................. 70 Oil and grease specification............................................. 71

Transport and storing the truck ..................................... 72 The truck’s dimensions and weight as standard ............. 72 Lifting the truck ................................................................ 72 Towing and transporting a disabled truck........................ 73 Storing the truck .............................................................. 74 Starting after a period of disuse ...................................... 74

Transport and storing the truck ...................................... 72 The truck’s dimensions and weight as standard .............. 72 Lifting the truck................................................................. 72 Towing and transporting a disabled truck ........................ 73 Storing the truck............................................................... 74 Starting after a period of disuse ....................................... 74

Recycling/discarding ....................................................... 75 Discarding the battery ..................................................... 75 Scrapping the truck ......................................................... 75

Recycling/discarding........................................................ 75 Discarding the battery ...................................................... 75 Scrapping the truck .......................................................... 75

Return

Safety regulations Warning symbols

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

Return

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. Return

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

General safety regulations

Control

•

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.

•

Return

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:

Return

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.

•

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.

•

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.

Return

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 a dry, clean surface. Do not operate on wet, oily surfaces.

•

The truck should only be driven on a 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.

•

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

Return

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.

•

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.

Return

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.

•

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 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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NEVER

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

All replacement parts shall be BT approved spare parts.

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Warning and information signs

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

2 3 4

1 12

10 Return

10 17

9 17

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

The truck has a maximum lifting capacity of 4000 lb. Refer to the truck’s data plate for this information on lifting capacities.

The trucks are equipped with a 24 volt electrical system. The travel speeds are regulated by means of a transistor controller to provide gentle control of acceleration and speed while operating.

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Presentation of truck

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 trucks

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

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Do not use in areas that contain gases which can cause fires or explosions

Do not use as a towing truck for trailers

Do not use to tow other trucks

Do not use to transport/lift passengers

Do not use to drive on gravel or grass

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

CSX

Truck type

CSX

Operating speed without load, mp

3.3

Operating speed without load, mph

3.3

Operating speed with classified load, mp

2.9

Operating speed with classified load, mph

2.9

Maximum operating gradient with load, %

Continuous noise level. dB (A)

<80

Continuous noise level. dB (A)

<80

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

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Presentation of truck

CSX truck dimensions

The following diagrams show external dimensions for CSX trucks.

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Presentation of truck

Data plate

Know the rated capacity on the data plate and understand areas 1 through 14 as shown in the illustration.

1. Truck model number 2. Truck serial number 3. Truck weight less battery 4. Maximum battery weight 5. Minimum battery weight 6. Truck voltage 7. Truck type 8. Battery type 9. Battery maximum AMP hours 10. Mast serial number 11. Attachment 12. Load wheel tread width (in.) (NOT USED on this model) The distance between outrigger centers at ground level. 13. Maximum degree rear tilt 14. Truck capacity

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Presentation of truck

U.L. construction type

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Presentation of main components

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Presentation of main component

Presentation of main components

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Presentation of main components

17 14

21 9

9 22

1 12 13

23 3

3 10

10 15 8

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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.

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.

Control handle

The control handle is used to provide hand brake, direction, speed, and horn on this machine. Fork Lower Switch Fork Raise

Switch

Switch Steering Control Handle

Horn Switch

Steering Control Handle Horn Switch

Rearward

Directional Controls Return

Forward

Rearward

Directional Controls 28

Forward

Controls and instruments

Control for raising the forks

The control button activates a micro switch to start the pump motor with lifting.

The diagram illustrates the controls as seen from the operator’s position. Lift the forks by pressing ‘A’.

NOTE! The forks cannot be raised with the key switch in position O.

Control for lowering the forks

NOTE! The forks cannot be raised with the key switch in position O.

Control for lowering the forks E

Lower the forks by pressing ‘E’. The lowering speed of the forks is controlled by a flow control valve. NOTE! The forks cannot be lowered with the key switch in position O.

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Lower the forks by pressing ‘E’. The lowering speed of the forks is controlled by a flow control valve. NOTE! The forks cannot be lowered with the key switch in position O.

Controls and instruments Travel direction selector and speed control

Select the travel direction by rotating ‘R’ in the required direction. The speed is controlled variably based on the position of the lever.

Horn

The horn sounds as long as the button is pressed.

Return

The horn sounds as long as the button is pressed.

Controls and instruments Reverser switch

Reverser Switch

Return

Controls and instruments Steering control handle/brake control

B1 F

Operate the truck with the steering control handle in the center range, F.

The brake is activated mechanically by the steering control handle/brake control. The brake is applied in two ranges, B1 and B2.

Parking brake (B1):

The arm automatically returns to position B1 when released.

Travel brake (B2):

Apply the brake by pushing the steering control handle downwards.

The brake function should always be checked before using this unit.

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Controls and instruments Braking using plugging function

•

THE CONTROL HANDLE MUST NOT BE PLACED IN THE BRAKE POSITION DURING THE PLUG BRAKING OPERATION. •

Return

THE CONTROL HANDLE MUST NOT BE PLACED IN THE BRAKE POSITION DURING THE PLUG BRAKING OPERATION. •

When using the plug braking the operator may regulate, within the programmed capabilities, the severity of the plugging force and the stopping distance. For the lightest plugging force, and the longest stopping distance, the travel control should be operated only to the creep position plugging in the opposite direction. For the strongest power, and the shortest distance, the travel control should be operated to full speed in the opposite direction. Plug braking may be regulated with the control handle at any point between the creep position and full speed.

Controls and instruments Key Switch

Battery Discharge Indicator/Hourmeter Dash Display

Emergency Disconnect Switch

Dash Panel Layout

Controls and instruments Key Switch

Battery Discharge Indicator/Hourmeter Dash Display

Emergency Disconnect Switch

Dash Panel Layout

Key switch (toggle switch)

A key switch is provided to prevent unauthorized use of this unit. The key switch is located on the control panel cover.

The key switch has two (2) positions: OFF and ON.

1. Off Position: Turning the key to “OFF” will stop all electrical power from going to the control circuit from the battery.

Emergency disconnect switch

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Controls and instruments

BDI/hourmeter with travel interrupt

Fully-charged battery

1/2

Half-charged battery

1/2

Half-charged battery

Discharged battery

The battery indicator shows the actual charge level of the truck’s battery.

The hourmeter displays the time the drive motor is operating.

Battery discharge indicator (BDI)

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Controls and instruments

Hourmeter

The hourmeter displays the time the drive motor and/or the pump motor are operating.

Return

Controls and instruments

Auxiliary Hydraulic Control Levers

Lift/Lower Control Lever

Auxiliary Hydraulic Control Lever

Control for Lift/Lower Control

The Lift/Lower is controlled by pushing lever forward to lower the mast and pulling back to lift. The speed of lift/lowering can be controlled by the degree of movement of lever.

Control for Tilt/Auxiliary Control

The Tilt is controlled by pushing lever forward to lower fork tips and pulling back the lever to raise fork tips. The speed of tilt can be controlled by the degree of movement of lever.

Control for Sideshifter/Auxiliary Control (optional)

The Sideshifter is controlled by depressing and holding the sideshifter function button on side of auxiliary control lever and moving lever. Pulling lever will move forks Right and pushing will move forks Left. The speed of sideshifter can be controlled by the degree of movement of lever.

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Driving

The proper operator position for this truck is shown and described below.

Proper operation of this unit is with forks trailing when possible. Steering the truck is easier with the forks trailing. Always look in the direction of travel.

When forks are first to enter a confined area or elevator or on an incline keep both hands on control handle. Keep both hands within the handle guard and always look in the direction of travel.

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Driving

Starting the truck

•

Ensure the battery connector is connected to the truck.

•

Ensure the battery connector is connected to the truck.

•

Turn the key switch to position I. The instrument lighting comes on.

•

Turn the key switch to position I. The instrument lighting comes on.

•

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

•

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

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.

•

Move the control handle to the drive position (F). The parking brake is released when the control handle is moved to the drive position (F).

•

Move the control handle to the drive position (F). The parking brake is released when the control handle is moved to the drive position (F).

•

Move the travel direction selector/speed control in the desired direction.

•

Move the travel direction selector/speed control in the desired direction.

WARNING Function failure. Safety can be jeopardized. Always check the following safety functions before starting the day’s work. Return

WARNING Function failure. Safety can be jeopardized. Always check the following safety functions before starting the day’s work. 39

Driving

•

Return

Driving

- That the horn functions correctly.

- That the steering functions correctly.

- That the brakes function correctly.

Start gently by accelerating slowly until you reach the desired speed.

•

Start gently by accelerating slowly until you reach the desired speed.

WARNING Dangerous driving. Accidents can occur. Always drive with care, good judgement, and responsibility as set out in the general safety guidelines.

Driving

Braking

Braking B1

2 B2

•

By moving the arm to the B2 position you will apply the travel brake. When you release the tiller arm it automatically returns to the parking brake position (B1).

•

By moving the arm to the B2 position you will apply the travel brake. When you release the tiller arm it automatically returns to the parking brake position (B1).

•

THE CONTROL HANDLE MUST NOT BE PLACED IN THE BRAKE POSITION DURING THE “PLUG BRAKING” OPERATION.

•

When using the “plug braking” the operator may regulate, within the programmed capabilities, the severity of the “plugging” force and the stopping distance. For the lightest

Return

When using the “plug braking” the operator may regulate, within the programmed capabilities, the severity of the “plugging” force and the stopping distance. For the lightest 41

Return

Driving

Steering

•

Steer by means of the control handle.

•

Steer by means of the control handle.

•

WARNING Risk of slipping. 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 and disengage the travel direction selector.

•

Stop the truck and disengage the travel direction selector.

•

Release the control handle. The handle will return automatically to the parking brake position and the brakes are applied.

•

Release the control handle. The handle will return automatically to the parking brake position and the brakes are applied.

•

Turn the key switch to the O position.

•

Turn the key switch to the O position.

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

WARNING Unauthorized use. Accidents can happen. Always remove the key switch when the truck is left unattended. 43

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.

•

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.

•

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.

Return

WARNING Lost stability. 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.

WARNING Protruding loads. The load can collide with personnel, fixed or moving objects. A truck with a protruding load requires more room when cornering.

Transporting loads

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.

•

DO NOT use the truck on grades, ramps, or inclines.

•

DO NOT use the truck on grades, ramps, or inclines.

•

WARNING Risk of overturning. A loaded truck can overturn when attempting to turn on an incline. Never turn a loaded truck on an incline.

WARNING Increased braking distance. The braking distance is increased when traveling downhill. Drive at a reduced speed using the truck’s motor brake.

Return

Transporting loads

WARNING Risk of overloading the elevator. 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. •

Return

WARNING Risk of overloading the elevator. 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. •

Transporting loads

Collecting a load

•

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 so that the forks are positioned in the center and as far as possible under the load.

•

Drive the truck forward so that the forks are positioned in the center and as far as possible under the load.

•

Lift the forks so that the load is lifted free of the rack.

•

Lift the forks so that the load is lifted free of the rack.

•

Reverse the truck so that the load clears the rack.

•

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. •

Start slowly and then increase the speed.

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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. •

Start slowly and then increase the speed.

Transporting loads

Leaving a load

•

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 load to the required lifting position.

•

Lift the load to the required lifting position.

•

Drive the truck forward so that the load is positioned correctly on the rack.

•

Drive the truck forward so that the load is positioned correctly on the rack.

•

Lower the forks so that they clear the load.

•

Lower the forks so that they clear the load.

•

Reverse the truck.

•

Reverse the truck.

•

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

•

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

NOTE! Forks not horizontal. The load can slide off the forks or catch on the rack. When the load is left or collected the forks should always be positioned horizontally. •

Return

NOTE! Forks not horizontal. The load can slide off the forks or catch on the rack. When the load is left or collected the forks should always be positioned horizontally. •

Battery

Type of battery

•

Changing the battery

•

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.

Return

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.

Return

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 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

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.

During charging

•

Return

After approximately ten minutes make sure that the ammeter indicates a normal reading and that the control lamp is ON. 52

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

Return

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.

Return

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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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.

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Daily service/safety checks 2

Daily service/safety checks

2 6

6 16

6 4 5 19

10 11

12 13

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

Check points

Action

Direction / accelerator

Check its function

Reverser switch

3 4

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4 5 19

Item #

WARNING DO NOT continue to operate the truck when it is not functioning properly. Item #

Check points

Action

Direction / accelerato

Check its function

Reverser switch

Check its function

Horn

Check its function

Horn

Check its function

Handle steerin

Check its function

Handle steering

Check its function

Daily service/safety checks Item #

Check points

Action

Parking brake

Daily service/safety checks Item #

Check points

Action

Check its function

Parking brak

Check its function

Hydraulic function

Check its function

Hydraulic function

Check its function

Running tim

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

Running time

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

Hydraulic system

Check for oil leakage, hoses, and floor

Hydraulic system

Check for oil leakage, hoses, and floor

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

Chassis

Check for damage, remove dirt and debris

Chassis

Check for damage, remove dirt and debris

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 an connections

Check for breakage, cutting, or damag

Fork carriag

Check the locking and for damag and wear

Fork carriage

Check the locking and for damage and wear

Lifting device

Check for damage and alignment of forks

Lifting device

Check for damage and alignment of forks

Hydraulic cylinder

Check for damage and leakage

Hydraulic cylinder

Check for damage and leakage

Key switch (toggle)

Check its function

Key switch (toggle)

Check its function

Emergency stop switch

Check its function

Emergency stop switch

Check its function

Covers / guards

Check for damage, ensure placement

Covers / guards

Check for damage, ensure placement

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

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Daily service/safety checks

Special equipment

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

Return

Maintenance

General information

•

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 set up a service and maintenance agreement to ensure your truck’s operating economy and safety.

•

BT recommends that you contact your BT representative to set up 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.

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Maintenance

•

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

•

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

•

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.

•

Bear in mind that the oil in the transmission or the hydraulic system can be hot.

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

•

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

Return

WARNING Risk of burns. 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. 61

Maintenance

WARNING The hydraulic system can be damaged. If 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.

•

When working underneath the truck support the truck on trestle-blocks.

WARNING Risk of crushing. A badly supported truck can fall. Never work under a truck that is not supported on trestle-blocks and secured by a lifting device.

Return

WARNING Risk of crushing. A badly supported truck can fall. Never work under a truck that is not supported on trestle-blocks and secured by a lifting device.

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

•

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.

Return

•

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 the truck is important to ensure the truck will operate safely and reliably.

•

Carry out general cleaning and washing weekly.

External cleaning

•

Remove debris, etc. from the wheels daily.

•

Remove debris, etc. from the wheels daily.

•

Use a degreasing agent diluted to a suitable concentration.

•

Use a degreasing agent diluted to a suitable concentration.

•

Rinse off loose grime using warm water.

•

Rinse off loose grime using warm water.

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

•

Return

Cover the electric motors, electrical compartments, connectors, and valves before washing. 64

Maintenance •

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

Maintenance •

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

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

•

Clean the electrical panels, electronic boards, contacts, connector, solenoid valves, etc. using a damp cloth and a cleaning agent.

•

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.

•

Do not spray or pressure wash in the compartment.

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

Return

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

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

No.

Action

1.0

Chassis

1.0

Chassis

1.1

Check that the truck’s data plate is legible

1.1

Check that the truck’s data plate is legible

1.2

Check the cover screws

1.2

Check the cover screws

1.3

Check door lock

1.3

Check door lock

1.4

Check for damage and crack formation

1.4

Check for damage and crack formation

1.5

Check fork frame mounting

1.5

Check fork frame 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

Check brush wear

2.5

Check 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 and debris

4.1

Remove string and debris

4.2

Check all wheels for wear

4.2

Check all wheels for wear

4.3

Check that all wheels rotate and axles are fitted correctly

4.3

Check that all wheels rotate and axles are fitted correctly

4.4

Check all wheels for loose screws

4.4

Check all wheels for loose screws

4.5

Grease load wheel bearings

4.5

Grease load wheel bearings

Return

Maintenance No.

Action

No.

Action

4.6

Grease caster and caster wheels

4.6

Grease caster and caster wheels

4.7

Dismantle and lubricate all wheel bearings.

4.7

Dismantle and lubricate all wheel bearings.

5.0

Brake

5.0

Brake

5.1

Clean

5.1

Clean

5.2

Check shoes and discs for wear

5.2

Check shoes and discs for wear

5.3

Check correct clearance brake

5.3

Check correct clearance brake

5.4

Check brake operation

5.4

Check brake operation

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 tips

6.3

Check contactor tips

6.4

Check the contactor tips for free movements

6.4

Check the contactor tips for free movements

6.5

Check all cable insulation for damage

6.5

Check all cable insulation for damage

7.0

Electronic card

7.0

Electronic card

7.1

Check for connections in harness connectors

7.1

Check for connections in harness connectors

8.0

Electronic control system

8.0

Electronic control system

8.1

Check key switch (toggle)

8.1

Check key switch (toggle)

8.2

Check brake switch

8.2

Check brake switch

8.3

Check control wiring harness for proper routing

8.3

Check control wiring harness for proper routing

9.0

Battery

9.0

Battery

9.1

Check electrolyte level, 1/2 -5/8 in. (10-15mm above cell plate)

9.1

Check electrolyte level, 1/2 -5/8 in. (10-15mm above cell plate)

9.2

Check the connections on battery, truck, and charger

9.2

Check the connections on battery, truck, and charger

9.3

Check all cells and pole guards

9.3

Check all cells and pole guards

9.4

Check the fluid density and temperature

9.4

Check the fluid density and temperature

9.5

Check power cables are not cut or frayed

9.5

Check power cables are not cut or frayed

Return

Maintenance B

X X

Maintenance No.

Action

No.

Action

10.0

Hydraulic system

10.0

Hydraulic system

10.1

Check hoses and connections for leakage

10.1

Check hoses and connections for leakage

10.2

Check hoses for wear and damage

10.2

Check hoses for wear and damage

10.3

Check oil tank for cracks, leaks, and mounting

10.3

Check oil tank for cracks, leaks, and mounting

10.4

Check oil level

10.4

Check oil level

10.5

Change oil

10.5

Change oil

11.0

Cylinders

11.0

Cylinders

11.1

Check for leakage

11.1

Check for leakage

11.2

Check the mountings

11.2

Check the mountings

12.0

Mast carriage

12.0

Mast carriage

12.1

Check for damage and cracks

12.1

Check for damage and cracks

12.2

Check mast mounting bolts torque

12.2

Check mast mounting bolts torque

12.3

Check for play on rollers

12.3

Check for play on rollers

12.4

Check the electrical limit switch function

12.4

Check the electrical limit switch function

12.5

Check for wear and stretch on the chains and sheaves

12.5

Check for wear and stretch on the chains and sheaves

12.6

Check hoses and couplings for leakage, cuts, and other damage

12.6

Check hoses and couplings for leakage, cuts, and other damage

12.7

Check for wear to the forks and other lifting devices

12.7

Check for wear to the forks and other lifting devices

12.8

Lube all grease fittings

12.8

Lube all grease fittings

13.0

Controls

13.0

Controls

13.1

Check handle mounting

13.1

Check handle mounting

13.2

Check the handle brake switch

13.2

Check the handle brake switch

13.3

Check travel direction/speed control

13.3

Check travel direction/speed control

13.4

Check horn button function

13.4

Check horn button function

13.5

Check hydraulic button functions

13.5

Check hydraulic button functions

13.6

Check the reverser switch

13.6

Check the reverser switch

13.7

Check hydraulic manual control lever functions

13.7

Check hydraulic manual control lever functions

Return

Maintenance B

Maintenance No.

Action

14.0

Gauge

14.1

Check dash display

15.0

Brake levers

15.1

Check parking brake lever

15.2

Check that the control handle returns to the upright position with parking brake applied

16.0

Emergency stop switch

16.1

Check the emergency stop switch

Maintenance B

No.

Action

14.0

Gauge

14.1

Check dash display

15.0

Brake levers

15.1

Check parking brake lever

15.2

Check that the control handle returns to the upright position with parking brake applied

16.0

Emergency stop switch

16.1

Check the emergency stop switch

14 15

6 7

14 15

6 7 16

16 2

3 4

4 2

Return

13 11

Maintenance chart

Maintenance

Lubrication chart

Lubrication chart Interval/Running hours

Pos No.

Service point

Wheel bearings

Hydraulic system

Parking brake

Drive gear

Hinges

Steering bearings

Gear ring

500h

L=Lubrication

Return

Service point

Wheel bearings

Hydraulic system

Parking brake

Drive gear

Hinges

Steering bearings

Gear ring

1000h

3000h L

C=Check

Interval/Running hours

Pos No.

Lubricant

O=Oil change

Lubricant 500h

L=Lubrication

1000h

3000h L

C=Check

A B

O=Oil change

Maintenance

Approved Oils and Grease Pos. Lubricant

Approved Oils and Grease

Specification > 5°F-15°

< 5°F-15°C

Application <-10°F-23°C

Pos. Lubricant

Specification > 5°F-15°C

area

< 5°F-15°C

Application <-10°F-23°C

area

Grease

Tex. Ref. C & Tex. Ref. C & Tex. Ref. C & Bearings and C #880 C #880 C #880 bushings

Grease

Tex. Ref. C & Tex. Ref. C & Tex. Ref. C & Bearings and C #880 C #880 C #880 bushings

Hydraulic oil

Sunoco TH

C D

Sunoco TH

Texaco 15

Hydraulic system

Hydraulic oil

Transmission SAE 80W/90 oil

SAE 75

Gears

Motor oil

SAE5W-20

Hinges

SAE 40

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

Sunoco TH

Texaco 15

Hydraulic system

Transmission SAE 80W/90 oil

SAE 75W

Gears

Motor oil

SAE5W-20

Hinges

SAE 40

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

C A D

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A D

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.

Truck’s dimensions and weight

Height

60 in. (1524 mm)

Height

60 in. (1524 mm)

Width

37.4 in. (950 mm)

Width

37.4 in. (950 mm)

Length

52.0 in. (1320 mm)

Length

52.0 in. (1320 mm)

Minimum battery weight

950 lb to 1200 lb

Minimum battery weight

950 lb to 1200 lb

Lifting the truck

•

Return

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

WARNING Risk of overturning. The truck can overturn if lifted from the wrong lifting points. Always lift the truck from the marked lifting points.

WARNING Risk of overturning. 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.

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

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

Recycling/Discarding

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

Discarding the battery

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

Chassi

Steel

Chassis

Steel

Battery cover

Steel

Battery cover

Steel

Mast

Steel

Mast

Steel

Drive unit

Steel and cast material

Drive unit

Steel and cast material

Bushings

Iron/copper

Bushings

Iron/coppe

Finish

Epoxy-polyester

Finish

Epoxy-polyester

Wheels

Polyurethane

Wheels

Polyurethane

Return

Recyling/Discarding

Hydraulic system

Oil tank

Polythene

Oil tank

Polythene

Pump unit

Steel and aluminium

Pump unit

Steel and aluminium

Hoses

Rubber and stee

Hoses

Rubber and steel

Cylinders

Steel

Cylinders

Stee

Electrical system

Return

Recyling/Discarding

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

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

Front Cover

Operator’s Manual

CSX10/20/30/40

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

WARNING Read and observe all warnings on this unit

WARNING DO NOT operate this equipment unless all

factory installed guards and shields are properly secured in place.

Electric Counter Balanced Stacker Truck Effective Serial Number CSX__31339001

before operating it.

Part no: 304953-001

Return

Date: December 15, 2001

Electric Counter Balanced Stacker Truck Effective Serial Number CSX__31339001

before operating it.

Part no: 304953-001

Date: December 15, 2001

AllReturn Rights Reserved.

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.

! WARNING

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 SERVICE MANUALS MAY BE OBTAINED FROM YOUR EQUIPMENT DEALER.

Operator’s Warning

INJURY OR DEATH TO YOU OR OTHER WARNING PERSONNEL COULD OCCUR IF YOU DO NOT FOLLOW THESE INSTRUCTIONS AND MESSAGES. 3 Return

INJURY OR DEATH TO YOU OR OTHER WARNING PERSONNEL COULD OCCUR IF YOU DO NOT FOLLOW THESE INSTRUCTIONS AND MESSAGES. 3

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.

Foreword

Return

Foreword

Standard Compliance

This truck complies with the following standards and regulation in effect on the date the truck was manufactured:

•

American Society of Mechanical Engineers (ASME) B56.1

•

American Society of Mechanical Engineers (ASME) B56.1

•

Underwriters Laboratory (UL) # 583

•

Underwriters Laboratory (UL) # 583

•

Occupational Safety and Health Administration (OSHA) 29 C.F.R. Section 1910.178

•

Occupational Safety and Health Administration (OSHA) 29 C.F.R. Section 1910.178

Return

Table of Contents

Operator’s Warning ..................................................................... 3

Operator’s Warning ......................................................................3

Before operating the truck: ....................................................................3

Foreword ...................................................................................... 4

Foreword .......................................................................................4

Standard Compliance ............................................................................5

Safety regulations symbols........................................................ 9

Safety regulations symbols.........................................................9

Warning symbols ...................................................................................9 Warning levels...................................................................................9 Prohibitory symbols .............................................................................10 Ordinance symbols ..............................................................................10 General safety regulations...................................................................11 Control.............................................................................................11 Operating the truck..........................................................................12 Operator’s responsibility..................................................................13 Working area...................................................................................14 Driving and conduct while driving....................................................15 Handling loads ................................................................................18 Parking the truck .............................................................................19 Handling the battery ........................................................................20 Maintenance and repair ..................................................................21

Warning and information decals.............................................. 22

Warning and information decals...............................................22

Warning decals ...............................................................................23

Presentation of truck................................................................. 24

Presentation of truck..................................................................24

Application area for BT Prime-Mover’s trucks ................................25 Prohibited applications for BT Prime-Mover’s trucks......................25 Truck data .......................................................................................26 Truck battery dimensions ................................................................27 CSX-10 truck dimensions................................................................28 CSX-20 truck dimensions................................................................29 CSX-30 truck dimensions................................................................30 CSX-40 truck dimensions................................................................31 Data plate........................................................................................32 U.L. construction type .....................................................................33

Presentation of main components........................................... 34

Presentation of main components............................................34

Controls and instruments......................................................... 37

Controls and instruments..........................................................37

Control handle .....................................................................................37 Control for raising the forks .............................................................38 Control for lowering the forks ..........................................................38 Travel direction selector and speed control ....................................39 Horn ................................................................................................39

Return

Table of Contents

Reverser switch .............................................................................. 40 Steering control handle/brake control............................................. 41 Braking using plugging function...................................................... 42 Dash Controls ..................................................................................... 43 Key switch (Toggle switch) ............................................................. 43 Master control on/off switch............................................................ 43 Key switch (Toggle switch) ............................................................. 43 BDI/hourmeter with lift interrupt ...................................................... 44 Battery discharge indicator (BDI).................................................... 44 Hourmeter....................................................................................... 45 Emergency battery disconnect............................................................ 46 Mast Function Control Lever ............................................................... 47 Control for Raise/Lower using control lever.................................... 47 Fork Function Control Levers.............................................................. 48 Control for Tilt/Auxiliary Control...................................................... 48 Control for Sideshifter/Auxiliary Control (optional).......................... 48

Reverser switch.............................................................................. 40 Steering control handle/brake control............................................. 41 Braking using plugging function ..................................................... 42 Dash Controls ..................................................................................... 43 Key switch (Toggle switch)............................................................. 43 Master control on/off switch............................................................ 43 Key switch (Toggle switch)............................................................. 43 BDI/hourmeter with lift interrupt...................................................... 44 Battery discharge indicator (BDI) ................................................... 44 Hourmeter ...................................................................................... 45 Emergency battery disconnect............................................................ 46 Mast Function Control Lever............................................................... 47 Control for Raise/Lower using control lever ................................... 47 Fork Function Control Levers.............................................................. 48 Control for Tilt/Auxiliary Control...................................................... 48 Control for Sideshifter/Auxiliary Control (optional) ......................... 48

Driving ........................................................................................ 49

Driving .........................................................................................49

Driving ................................................................................................. 49 Braking the Truck ........................................................................... 52 Steering the Truck .......................................................................... 53 Parking the Truck ........................................................................... 54

Driving................................................................................................. 49 Braking the Truck ........................................................................... 52 Steering the Truck .......................................................................... 53 Parking the Truck ........................................................................... 54

Transporting loads .................................................................... 55

Transporting loads .....................................................................55

General Information........................................................................ 55 Collecting a load ............................................................................. 58 Leaving a load ................................................................................ 59

General Information........................................................................ 55 Collecting a load............................................................................. 58 Leaving a load ................................................................................ 59

Battery ........................................................................................ 60

Battery .........................................................................................60

Type of battery................................................................................ 60 Changing the battery ...................................................................... 60 Charging the battery ........................................................................... 62 General prohibition ......................................................................... 62 Pre-charging ................................................................................... 63 During charging .............................................................................. 63 After charging ................................................................................. 64 Battery maintenance....................................................................... 65 Each week: ..................................................................................... 65 Each month: ................................................................................... 66

Type of battery ............................................................................... 60 Changing the battery ...................................................................... 60 Charging the battery ........................................................................... 62 General prohibition ......................................................................... 62 Pre-charging................................................................................... 63 During charging .............................................................................. 63 After charging ................................................................................. 64 Battery maintenance ...................................................................... 65 Each week:..................................................................................... 65 Each month: ................................................................................... 66

Daily service/safety checks ...................................................... 67

Daily service/safety checks .......................................................67

Daily service/safety checks drawing............................................... 68 Special equipment .......................................................................... 69

Daily service/safety checks drawing............................................... 68 Special equipment.......................................................................... 69

Return

Table of Contents

Maintenance............................................................................... 70

Maintenance................................................................................70

General information.........................................................................70 Safety regulations with maintenance work ......................................70 Maintenance that can be carried out by driver ................................73 Maintenance that may be carried out by trained maintenance personnel ........................................................................................73 Other service and repair work .........................................................73 Cleaning and washing .........................................................................74 General ...........................................................................................74 External cleaning.............................................................................74 Cleaning the motor compartment....................................................74 Electrical components .....................................................................75 Maintenance chart ...............................................................................76 Lubrication chart ..................................................................................80 Approved Oils and Grease Chart.........................................................81

General information.........................................................................70 Safety regulations with maintenance work......................................70 Maintenance that can be carried out by driver ................................73 Maintenance that may be carried out by trained maintenance personnel ........................................................................................73 Other service and repair work .........................................................73 Cleaning and washing .........................................................................74 General ...........................................................................................74 External cleaning.............................................................................74 Cleaning the motor compartment....................................................74 Electrical components .....................................................................75 Maintenance chart ...............................................................................76 Lubrication chart ..................................................................................80 Approved Oils and Grease Chart ........................................................81

Transporting and storing the truck.......................................... 83

Transporting and storing the truck...........................................83

Truck’s dimensions and weight as standard ...................................83 Towing and transporting a disabled truck ............................................84 Storing the truck...................................................................................85 Battery.............................................................................................85 Hydraulic system .............................................................................85 Drive unit .........................................................................................85 Starting after a period of disuse...........................................................86

Truck’s dimensions and weight as standard ...................................83 Towing and transporting a disabled truck ............................................84 Storing the truck ..................................................................................85 Battery.............................................................................................85 Hydraulic system.............................................................................85 Drive unit .........................................................................................85 Starting after a period of disuse...........................................................86

APPENDIX A - Selected OSHA Regulations............................ 87

APPENDIX A - Selected OSHA Regulations.............................87

Index ........................................................................................... 91

Index ............................................................................................91

Return

Safety regulations Warning symbols

Safety regulations symbols

Always follow the warnings given in this Operator’s 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 severe 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 severe 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 an accident or breakdown if the instructions are not followed.

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Marks the risk of an accident or 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

General safety regulations

Control

•

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.

•

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 data plate(s). Do not operate the truck if there are any differences between the data stated on the data plate and the truck.

•

Read the data plate(s). Do not operate the truck if there are any differences between the data stated on the data plate and the truck.

•

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 Prime-Mover.

•

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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.

•

Never allow anyone to stand or walk under any elevated portion of this truck.

•

Never allow anyone to stand or walk under any elevated portion of this truck.

•

It is not permitted to use the truck for other purposes than it has been designed and produced for such as the following applications:

•

It is not permitted to use the truck for other purposes than it has been designed and produced for such as the following applications:

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.

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Safety regulations

General safety regulations

Operator’s responsibility

•

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

•

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

•

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

•

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

•

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

•

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

•

Local regulations regarding personal safety equipment shall be followed.

•

Local regulations regarding personal safety equipment shall be followed.

•

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

•

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.

•

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

•

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

•

Truck should only be driven on hard and even surfaces, for example concrete or asphalt.

•

Truck should only be driven on hard and even surfaces, for example 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 is forbidden for persons to be present in the area around the truck when there is a risk of personal injury, that is 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 a grade, ramp, or incline on all grades, the truck shall be operated with load-engaging means downgrade. If load restricts visibility or requires the load backrest to retain the load, travel with the load upgrade, with the operator position off to one side.

•

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

•

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

•

Always drive with the forks fully lowered except when a load is collected or left.

•

Always drive with the forks fully lowered except when a load is collected or left.

•

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

•

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. 15 Return

•

Sound the horn when overtaking other vehicles and when the attention of other personnel is required. 15

•

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 truck.

•

Never allow passengers to ride on 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.

•

Keep hands and feet clear of controls other than those in use.

•

Keep hands and feet clear of controls other than those in use.

•

Lift and lower with caution. Make sure there are no obstructions under, or in the path of, the lifting mechanism.

•

Lift and lower with caution. Make sure there are no obstructions under, or in the path of, the lifting mechanism.

•

Make sure the lifting mechanism is operating smoothly.

•

Make sure the lifting mechanism is operating smoothly.

•

Whenever truck is driven ON and OFF semi-trailers not coupled to a tractor, supports may be needed to prevent upending or corner dipping.

•

Whenever truck is driven ON and OFF semi-trailers not coupled to a tractor, supports may be needed to prevent upending or corner dipping.

•

Before 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 ramp.

•

Before 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 ramp.

•

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

•

When truck is driven on to another vehicle make sure the other 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 elevator with load first. No other personnel should be in the elevator when the load or truck enters or leaves.

•

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 elevator with load first. No other personnel should be in the elevator when the load or truck enters or leaves.

•

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 or use open flame while working around the truck.

•

DO NOT smoke or use open flame while working around the truck.

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Safety regulations

•

DO NOT BYPASS LIMIT SWITCHES. Doing so will result in server INJURY OR DEATH.

•

DO NOT BYPASS LIMIT SWITCHES. Doing so will result in server INJURY OR DEATH.

•

Look in the direction of travel and keep a clear view of the path of travel.

•

Look in the direction of travel and keep a clear view of the path of travel.

•

Slow down and sound your horn at cross aisles and wherever vision is obstructed.

•

Slow down and sound your horn at cross aisles and wherever vision is obstructed.

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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, see truck’s data plate. 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, see truck’s data plate. 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.

•

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 dragged or pushed horizontally.

•

The load shall Only be lifted vertically and NEVER dragged 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.

•

Always park with the load carrier fully lowered and the brake applied and secured.

•

Always park with the load carrier fully lowered and the brake applied and secured.

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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” on page 60.

•

Always handle the battery and its connections with care. Read and follow the instructions for changing or recharging the battery carefully. See chapter “Battery” on page 60.

•

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” on page 70. Only qualified and trained personnel are permitted to maintain, adjust, or repair the truck.

All replacement parts shall be BT Prime-Mover approved spare parts.

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Warning and information decals

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

Warning and information decals

2 3 4

KEEP HANDS CLEAR

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10 22

1 12

KEEP HANDS CLEAR

9 22

Warning and information 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. New warning decals can be obtained from your BT Prime-Mover Dealer at NO charge.

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Presentation of truck

BT Prime-Mover truck is designed for handling pallets indoors. The CSX trucks are operated by a walking operator. This BT Prime-Mover truck has available different fork lengths and lifting capacities. Refer to the truck’s data plate for this information.

CSX10 truck has a maximum lifting capacity of 1000 lb [543 kg].

CSX20 truck has a maximum lifting capacity of 2000 lb [907 kg] and is rated with a battery type rating of “EE” only.

CSX30 truck has a maximum lifting capacity of 3000 lb [1361 kg] and is rated with a battery type rating of “EE” only.

CSX40 truck has a maximum lifting capacity of 4000 lb [1814 kg] and is rated with a battery type rating of “EE” only.

Refer to the truck’s data plate for information on lifting capacities.

The CSX trucks are equipped with a 24 volt electrical system. The travel speeds are regulated by means of a transistor controller to provide gentle control of acceleration and speed while operating.

The forks are raised by means of a hydraulic pump unit. The control of the lift is done electrically with the push button on the steering arm. Control of the speed and positioning of the forks when stacking are done with the mechanical valve lever of the truck.

The trucks can be fitted with different accessories including sideshifter, warning light, hourmeter/battery indicator, and BDI with lift interrupt. The truck can also be fitted with plated axles and low temperature oil for use in cool and humid conditions.

Presentation of truck

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Presentation of truck

Application area for BT Prime-Mover’s trucks

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

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 Prime-Mover’s trucks

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

Do not use in areas that contain gases which can cause fires or explosions

Do not use as a towing truck for trailers

Do not use to tow other trucks

Do not use to transport/lift passengers

Do not use 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 data

CSX10/20/30/40 1000/2000/3000/4000 lb (453/907/1361/1814 kg)

Maximum load capacity

100 -189 inch [2540 - 4800 mm]

Lift height Operating speed Service weight

Empty

3.3 mph [5.3 kph]

Loaded

2.9 mph [4.7 kph]

Without battery

3780/4610/5985 lb [1715/2091/2715 kg]

With battery

4730/5560/7195 lb [2145/2522/3264 kg]

Truck data

CSX10/20/30/40 1000/2000/3000/4000 lb (453/907/1361/1814 kg)

Maximum load capacity

100 -189 inch [2540 - 4800 mm]

Lift height Operating speed Service weight

Empty

3.3 mph [5.3 kph]

Loaded

2.9 mph [4.7 kph]

Without battery

3780/4610/5985 lb [1715/2091/2715 kg]

With battery

4730/5560/7195 lb [2145/2522/3264 kg]

The truck’s lifting capacity 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 CSX10 Deep 7.6 in. [3193 mm] 8.1 in. [206 mm] Wide 31.3 in. [795 mm] 31.8 in. [807 mm] Battery Weight (Consult Data plate on truck)

CSX20-40 Deep Wide Battery Weight

12.5 in. [317 mm] 13 in. [330 mm] 31.3 in. [795 mm] 31.8 in. [807 mm] (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

CSX-10 truck dimensions

The following diagrams show external dimensions for CSX-10 trucks in its standard design.

O R

M K

Overall Lowered Height

H G

34.1 in. (886 mm)

11.7 in. (297 mm)

34.1 in. (886 mm)

11.7 in. (297 mm)

32.3 in. (820 mm)

2.1 in. (53 mm)

32.3 in. (820 mm)

2.1 in. (53 mm)

4 in. (101 mm)

32.5 in. (8.25 mm)

4 in. (101 mm)

32.5 in. (8.25 mm)

41.7 in. (1059 mm)

16.2°

41.7 in. (1059 mm)

16.2°

2 in. (50 mm)

10.5°

2 in. (50 mm)

10.5°

8.1 in. (205 mm)

67°

8.1 in. (205 mm)

67°

49.8 in. (1264 mm)

12.5°

49.8 in. (1264 mm)

12.5°

30.0 in. (762 mm)

55.6 in. (1412 mm)

30.0 in. (762 mm)

55.6 in. (1412 mm)

9 in. (228 mm)

59.5 in. (1511 mm)

9 in. (228 mm)

59.5 in. (1511 mm)

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Overall Lowered Height

Presentation of truck

CSX-20 truck dimensions

The following diagrams show external dimensions for CSX-20 trucks in its standard design.

C A

O R Q N

M K

Overall Lowered Height

R Q N

H G

34.1 in. (886 mm)

9.7 in. (246 mm)

34.1 in. (886 mm)

9.7 in. (246 mm)

32.3 in. (820 mm)

2.1 in. (53 mm)

32.3 in. (820 mm)

2.1 in. (53 mm)

4 in. (101 mm)

32.5 in. (8.25 mm)

4 in. (101 mm)

32.5 in. (8.25 mm)

56.7 in. (1440 mm)

16.2°

56.7 in. (1440 mm)

16.2°

2 in. (50 mm)

10.5°

2 in. (50 mm)

10.5°

8.1 in. (205 mm)

67°

8.1 in. (205 mm)

67°

64.8 in. (1645 mm)

12.5°

64.8 in. (1645 mm)

12.5°

47 in. (1193 mm)

55.6 in. (1412 mm)

47 in. (1193 mm)

55.6 in. (1412 mm)

13.3 in. (337 mm)

59.5 in. (1511 mm)

13.3 in. (337 mm)

59.5 in. (1511 mm)

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Overall Lowered Height

Presentation of truck

CSX-30 truck dimensions

The following diagrams show external dimensions for CSX-30 trucks in its standard design.

C A

O R Q N

M K

Overall Lowered Height

R Q N

H G

34.1 in. (886 mm)

9.7 in. (246 mm)

34.1 in. (886 mm)

9.7 in. (246 mm)

32.3 in. (820 mm)

2.1 in. (53 mm)

32.3 in. (820 mm)

2.1 in. (53 mm)

4 in. (101 mm)

32.5 in. (8.25 mm)

4 in. (101 mm)

32.5 in. (8.25 mm)

62 in. (1574 mm)

16.2°

62 in. (1574 mm)

16.2°

2 in. (50 mm)

10.5°

2 in. (50 mm)

10.5°

8.1 in. (205 mm)

67°

8.1 in. (205 mm)

67°

70.1 in. (1780 mm)

12.5°

70.1 in. (1780 mm)

12.5°

52.3 in. (1328 mm)

55.6 in. (1412 mm)

52.3 in. (1328 mm)

55.6 in. (1412 mm)

13.3 in. (337 mm)

59.5 in. (1511 mm)

13.3 in. (337 mm)

59.5 in. (1511 mm)

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Overall Lowered Height

Presentation of truck

CSX-40 truck dimensions

The following diagrams show external dimensions for CSX-40 trucks in its standard design.

C A

O R Q N

M K

Overall Lowered Height

R Q N

H G

34.1 in. (886 mm)

9.7 in. (246 mm)

34.1 in. (886 mm)

9.7 in. (246 mm)

32.3 in. (820 mm)

2.1 in. (53 mm)

32.3 in. (820 mm)

2.1 in. (53 mm)

4 in. (101 mm)

32.5 in. (8.25 mm)

4 in. (101 mm)

32.5 in. (8.25 mm)

68.3 in. (1734 mm)

16.2°

68.3 in. (1734 mm)

16.2°

2 in. (50 mm)

10.5°

2 in. (50 mm)

10.5°

8.3 in. (210 mm)

67.0°

8.3 in. (210 mm)

67.0°

76.6 in. (1945 mm)

12.5°

76.6 in. (1945 mm)

12.5°

58.6 in. (1488 mm)

55.6 in. (1412 mm)

58.6 in. (1488 mm)

55.6 in. (1412 mm)

13.5 in. (342 mm)

59.5 in. (1511 mm)

13.5 in. (342 mm)

59.5 in. (1511 mm)

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Overall Lowered Height

Presentation of truck

Data plate

Know the rated capacity on the data plate and understand areas 1 through 15 as shown in the illustration.

1. Truck model number 2. Truck serial number 3. Truck capacity 4. Battery type 5. Truck voltage 6. Truck weight less battery 7. Truck type 8. Battery hour rating 9. Battery maximum AMP hours 10. Minimum battery weight 11. Maximum battery weight 12. Mast serial number 13. Attachment 14. Load wheel tread width (NOT USED on this model) The distance between outrigger centers at ground level. 15. Maximum degree rear tilt

3 6

4 8

9 12

10 13

8 15

9 12

7 11

10 13

This data plate is located in the electrical compartment access shield. Knowing the model and serial numbers for this unit is very helpful when ordering repair parts. For further information and specifications on this unit, or any other, contact your BT Prime-Mover dealer.

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Presentation of truck

U.L. construction type

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Presentation of main components

10. Drive unit with brake Fixed drive unit with a spring applied brake, drive motor,

1. Steering control handle The truck is to be controlled by the operator with 180 degree steering angle. The brake is applied in the upper and lower position of the steering arm. 2. Data plate Contains type designation, serial number, service weight, battery weight, rated lifting capacity, battery voltage, and manufacturer. See “Data plate” on page 32. 3. Door Swing open which provides good accessibility when servicing. The door can be completely removed from the truck by lifting the door from the hinges. 4. Gauge Combined hourmeter/battery indicator, hourmeter/battery indicator with lift interrupt, or hourmeter only. 5. Hydraulic control (manual valve) For controlling lifting and lowering functions. 6. Hydraulic control (manual valve) (Not on CSX-10) For controlling the tilt, and sideshifter function. 7. Hydraulic unit Pump motor, pump, electric valves, and oil tank integrated in a compact unit. 8. Hydraulic electric solenoid valve For controlling lifting and lowering function with electric solenoid valve. 9. Hydraulic manual valves For controlling hydraulic functions with a manual lever on top of truck. 10. Drive unit with brake Fixed drive unit with a spring applied brake, drive motor,

Presentation of main components

4. Gauge Combined hourmeter/battery indicator, hourmeter/battery indicator with lift interrupt, or hourmeter only. 5. Hydraulic control (manual valve) For controlling lifting and lowering functions. 6. Hydraulic control (manual valve) (Not on CSX-10) For controlling the tilt, and sideshifter function. 7. Hydraulic unit Pump motor, pump, electric valves, and oil tank integrated in a compact unit. 8. Hydraulic electric solenoid valve For controlling lifting and lowering function with electric solenoid valve. 9. Hydraulic manual valves For controlling hydraulic functions with a manual lever on top of truck.

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Presentation of main components

gear box, and drive wheel combined into a compact unit. The steering bearings are at the top of the drive unit. 11. Steering pivot point Lubricate pivot point to prevent stiff steering. 12. Electric panel 24 volt electrical system. Vehicle speed is regulated by means of a transistor controller. 13. Circuit breaker Control 12A, part number 301889-000. Pump 300A, part number 25094-04. Drive 105A, part number 307601-001 (CSX10/20) 150A, part number 307601-000 requires 2. (CSX30/40) 14. Mast Covered by a finger protection which covers the operator’s normal range of reach from the operating position. 15. Load wheel Lubricate load wheels to prevent wheels from locking up. 16. Battery 24 volt with different capacities and weights. 17. Reverser switch The function is to prevent the operator from being pinched between the handle and an obstruction when traveling in the forward direction. 18. Horn switch The horn sounds to warn others of your position. 19. Fork raise switch The forks will raise when switch is pressed or until lift stops are reached.

20. Fork lower switch The forks will lower when switch is pressed or until lower

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Presentation

Presentation of main components

stops are reached. 21. Travel speed / direction selection To select direction rotate in the direction you wish to move. The further in that direction you rotate the faster you move. 22. Key switch (toggle switch) Shuts off electrical power to control system. 23. Master control on/off switch The stop switch will stop all control functions. 24. Emergency battery disconnect Pulling the battery connector will shut off all electrical power to the truck.

17 14

19 20

9 22

4 0

1 / 2

1 12 13

9 22

6 0

OFF

1 / 2

1 12 13

5 6

OFF

23 3

3 10

15 8

16 7

Presentation of main components drawing 36 Return

16 7

Presentation of main components drawing 36

Controls and instruments

Guards and shields have been provided on the truck for your protection.

DO NOT operate this truck unless all factory

Warning installed guards and shields are properly

Controls and instruments

Warning installed guards and shields are properly

DO NOT operate this truck unless all factory

secured in place.

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

and observe all warnings on this unit Warning Read before operating it.

Control handle

The control handle is used to provide hand brake, direction, speed, and horn on this truck.

Fork Raise Switch

Fork Lower Switch

Fork Raise Switch

Fork Lower Switch

Steering Control Handle Horn Switch

Rearward

Directional Controls

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Forward

Rearward

Directional Controls

Forward

Controls and instruments Control for raising the forks

The control button activates a micro switch to start the pump motor with lifting.

The diagram illustrates the controls as seen from the operator’s position. Lift the forks by pressing ‘A’.

NOTE! The forks cannot be raised with the key switch in position O. Control for lowering the forks

Lower the forks by pressing ‘E’. The lowering speed of the forks is controlled by a flow control valve. NOTE! The forks cannot be lowered with the key switch in position O.

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Lower the forks by pressing ‘E’. The lowering speed of the forks is controlled by a flow control valve. NOTE! The forks cannot be lowered with the key switch in position O.

Controls and instruments Travel direction selector and speed control

Select the travel direction by rotating ‘R’ in the required direction. The speed is controlled variably based on the position of the lever.

Horn

The horn sounds as long as the button is pressed.

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The horn sounds as long as the button is pressed.

Controls and instruments Reverser switch

Reverser Switch

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Controls and instruments Steering control handle/brake control

B1 F

Operate the truck with the steering control handle in the center range, F.

The brake is activated mechanically by the steering control handle/brake control. The brake is applied in two ranges, B1 and B2.

Parking brake (B1):

The arm automatically returns to position B1 when released.

Travel brake (B2):

Apply the brake by pushing the steering control handle downwards.

The brake function should always be checked before using this unit.

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Controls and instruments

Braking using plugging function

•

The truck is equipped with plug braking. This method involves reversing the travel control to the opposite direction without applying the brake causing the truck to decelerate smoothly. The operator may choose to continue holding the controls in the opposite direction. This will start the truck moving in that direction or the operator may release the handle and allow the truck to come to a complete halt. Releasing the steering control handle will allow the parking brake to become automatically applied.

THE CONTROL HANDLE MUST NOT BE PLACED IN THE BRAKE POSITION DURING THE PLUG BRAKING OPERATION.

•

When using plug braking the operator may regulate, within the programmed capabilities, the severity of the plugging force and distance travelled during plugging. For the lightest plugging force, and the longest distance, the travel control should be operated only to the creep position in the opposite direction. For the strongest plugging power, and the shortest distance, the travel control should be operated to full speed in the opposite direction. Plug braking may be regulated with the control handle at any point between the creep position and full speed.

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Controls and instruments Dash Controls

Battery Discharge Indicator/Hourmeter Dash Display

Key Switch Off Master Control On/Off Switch

Battery Discharge Indicator/Hourmeter Dash Display

Key Switch Off Master Control On/Off Switch

Dash Panel Layout

Key switch (Toggle switch)

A key switch is provided to prevent unauthorized use of this unit. The key switch is located on the control panel cover.

The key switch has two (2) positions: OFF and ON.

1. Off Position: Turning the key to “OFF” will stop all electrical power from going to the control circuit from the battery.

Master control on/off switch

The master control on/off switch will cut off electrical power to the control functions on the truck when pushed. To reset switch turn key switch to OFF position, repair, push switch on. The master control on/off switch is physically located on the opposite side of the dash from the key switch.

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Controls and instruments

BDI/hourmeter with lift interrupt

Fully-charged battery

1/2

Half-charged battery

1/2

Half-charged battery

Discharged battery

The battery indicator shows the actual charge level of the truck’s battery.

The battery indicator has an integrated lift interrupt that disables the truck’s lift function when a preset discharge level is reached. This prevents damage to the battery and increases the running economy of the truck. When the battery has reached a charge level equivalent to 70 percent discharge a warning signal is given by a flashing light. A further 10 percent of the battery’s capacity can be used before the battery indicator interrupts the lifting function.

The hourmeter displays the time the drive motor is operating.

Battery discharge indicator (BDI)

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Controls and instruments

Hourmeter

The hourmeter displays the time the drive motor and/or the pump motor are operating.

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Controls and instruments

Emergency battery disconnect

In an emergency, first push the master control on/off switch to OFF this will disable all controls under normal circumstances. Then disconnect the battery connector, this will cut all electrical power to the truck. Perform all repairs before using and reconnecting battery after emergency.

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Controls and instruments

Mast Function Control Lever

The mast function control lever is controlled by pushing or pulling the control lever. The mast function control lever is used to raise/lower the fork height on mast. The lever is located on top and to the right side of electrical dash panel.

Mast Function Control Lever

Control for Raise/Lower using control lever

The Raise/Lower is controlled by pushing lever forward to lower the fork height on mast and pulling back to raise. The speed of raising/lowering can be controlled by the degree of movement of lever.

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Controls and instruments

Fork Function Control Levers

The fork control lever is controlled by pushing or pulling the control lever. The fork control lever is used for sideshifter control, and an auxiliary functions. The lever is located on top and to the right side of electrical dash panel.

Auxiliary Hydraulic Control Lever

Control for Tilt/Auxiliary Control

The Tilt is controlled by pushing lever forward to lower fork tips and pulling back the lever to raise fork tips. The speed of tilt can be controlled by the degree of movement of lever.

Control for Sideshifter/Auxiliary Control (optional)

The Sideshifter is controlled by depressing and holding the sideshifter function button on side of auxiliary control lever and moving lever. Pulling lever will move forks Right and pushing will move forks Left. The speed of sideshifter can be controlled by the degree of movement of lever.

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Driving

The proper operator position for this truck is shown and described below.

Proper operation of this unit is with forks trailing when possible. Steering the truck is easier with the forks trailing. Always look in the direction of travel.

When forks are first to enter a confined area or elevator or on an incline keep both hands on control handle. Keep both hands within the handle guard and always look in the direction of travel.

Driving

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Driving

Starting the Truck

•

Ensure battery connector is connected to truck.

•

Ensure battery connector is connected to truck.

•

Master control on/off switch is in the on position. Turn key switch to position I. The instrument lighting comes on.

•

Master control on/off switch is in the on position. Turn key switch to position I. The instrument lighting comes on.

•

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

•

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

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 battery.

•

Move the control handle to the drive position (F). The parking brake is released when the control handle is moved to the drive position (F).

•

Move the control handle to the drive position (F). The parking brake is released when the control handle is moved to the drive position (F).

•

Move the travel direction selector/speed control in the desired direction.

•

Move the travel direction selector/speed control in the desired direction.

failure. Warning Function Safety can be jeopardized. Always check the following safety functions before starting the day’s work.

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failure. Warning Function Safety can be jeopardized. Always check the following safety functions before starting the day’s work. 50

Driving

•

Driving

- Horn functions correctly.

- Steering functions correctly.

- Brakes function correctly.

Start gently by accelerating slowly until the desired speed is reached. Dangerous driving.

Warning Accidents can occur. Always drive with care, good judgement and responsibility as set out in the general safety guidelines.

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•

Start gently by accelerating slowly until the desired speed is reached. Dangerous driving.

Warning Accidents can occur. Always drive with care, good judgement and responsibility as set out in the general safety guidelines.

Driving

Braking the Truck

Braking the Truck B1

2 B2

•

Brake by moving the arm to the B2 position will apply the travel brake. Release of the tiller arm automatically returns it to the parking brake position (B1).

•

Brake by moving the arm to the B2 position will apply the travel brake. Release of the tiller arm automatically returns it to the parking brake position (B1).

•

THE CONTROL HANDLE MUST NOT BE PLACED IN THE BRAKE POSITION DURING THE PLUG BRAKING OPERATION.

•

Driving

shortest distance, the travel control should be operated to full speed in the opposite direction. Plug braking may be regulated with the control handle at any point between the creep position and full speed.

Steering the Truck

•

Steer by means of the control handle.

•

Steer by means of the control handle.

•

Risk of slipping.

Warning If hands or shoes are oily there is a risk of

slipping causing loss of control of truck. Always dry hands and shoes before driving.

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Driving

Parking the Truck

•

Stop truck and disengage travel direction selector.

•

Stop truck and disengage travel direction selector.

•

Release steering control handle. The handle will automatically return to the parking brake position and brakes are applied.

•

Release steering control handle. The handle will automatically return to the parking brake position and brakes are applied.

•

Turn key switch to the O position.

•

Turn key switch to the O position.

•

Always remove key from key switch when truck is left unattended.

•

Always remove key from key switch when truck is left unattended.

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Transporting loads

General Information

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

Transporting loads

Risk of overturning.

Warning 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.

•

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.

•

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.

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.

loads. Warning Protruding The load can collide with personnel, fixed or

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

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Transporting loads

NOTE! Increased truck width. The load can collide with fixed objects. A truck with wide loads requires a greater operating area.

•

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.

•

Risk of overturning.

Warning 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 grade. Drive at a reduced speed, using the truck’s motor brake.

of overloading the elevator. Warning Risk 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

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•

Transporting loads

the edges.

Warning Risk of tipping.

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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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

•

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

•

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

•

Lower the forks to the fully down position.

•

Lower the forks to the fully down position.

•

Drive the truck rearward so that the forks are positioned in the center and as far as possible under the load.

•

Drive the truck rearward so that the forks are positioned in the center and as far as possible under the load.

•

Lift the forks so that the load is lifted free of the rack.

•

Lift the forks so that the load is lifted free of the rack.

•

Reverse the truck so that the load clears the rack.

•

Reverse the truck so that the load clears the rack.

•

Lower the load to floor level and drive carefully away from the rack by start slowly and then increase the speed.

•

Lower the load to floor level and drive carefully away from the rack by start slowly and then increase the speed.

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.

Transporting loads

Leaving a load

•

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

•

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

•

Lift the load to the required lifting position.

•

Lift the load to the required lifting position.

•

Drive the truck forward so that the load is positioned correctly on the rack.

•

Drive the truck forward so that the load is positioned correctly on the rack.

NOTE! Forks not horizontal. The load can slide off the forks or catch on the rack. When the load is left or collected the forks should always be positioned horizontally.

•

Lower the forks so that they clear the load.

•

Lower the forks so that they clear the load.

•

Reverse the truck.

•

Reverse the truck.

•

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

•

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

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.

Battery

Type of battery

•

Battery

Changing the battery

•

of moving the center of gravity. Warning Risk 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 master control on/off switch to the OFF position to stop hourmeter from running.

•

Push the master control on/off switch 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.

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

•

Install battery stops.

•

Install battery stops.

•

Push the master control on/off switch to the ON position.

•

Push the master control on/off switch to the ON position.

Falling battery.

Warning 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.

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

Warning When

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

Warning When

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 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

Corrosive acid.

Warning 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.

the charging process oxygen and Warning During 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

•

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

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

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.

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

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Battery

Battery maintenance

Carry out battery maintenance after recharging.

Corrosive acid.

Warning The battery fluid contains sulfuric acid. Fluid

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

manufactures maintenance and Warning Battery charging procedures must be followed.

Battery acid is very corrosive and must be immediately cleaned up after spillage.

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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 shown in the chart.

•

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 shown in the chart.

•

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.

Daily service/safety checks

Never neglect the daily service and safety

Warning 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.

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Never neglect the daily service and safety

Warning 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.

Daily service/safety checks

Daily service/safety checks drawing 2

Daily service/safety checks drawing

2 6

6 16

17 0

1 / 2

4 5 19

1 18

OFF

7 0

1 / 2

4 5 19

1 18

OFF

10 11

12 13

DO NOT continue to operate the truck

Warning when it is not functioning properly. Item #

Check points

Action

Direction / speed control

Warning when it is not functioning properly. Item #

Check points

Action

Check its function

Direction / speed control

Check its function

Reverser switch

Check its function

Reverser switch

Check its function

Horn

Check its function

Horn

Check its function

Handle steering

Check its function

Handle steering

Check its function

Parking brake

Check its function

Parking brake

Check its function

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12 13

Daily service/safety checks Item #

Check points

Action

Hydraulic function

Check its function

Running time

Daily service/safety checks Item #

Check points

Action

Hydraulic function

Check its function

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.

Hydraulic system

Check for oil leakage, hoses, and floor

Hydraulic system

Check for oil leakage, hoses, and floor

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

Chassis

Check for damage, remove dirt and debris

Chassis

Check for damage, remove dirt and debris

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

Fork carriage

Check the locking and for damage and wear

Fork carriage

Check the locking and for damage and wear

Lifting device

Check for damage and alignment of forks

Lifting device

Check for damage and alignment of forks

Hydraulic cylinder

Check for damage and leakage

Hydraulic cylinder

Check for damage and leakage

Key switch (toggle)

Check its function

Key switch (toggle)

Check its function

Master control on/off switch

Check its function

Master control on/off switch

Check its function

Covers / guards

Check for damage, ensure placement

Covers / guards

Check for damage, ensure placement

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

Special equipment

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

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Maintenance

General information

•

Under normal conditions ensure that truck is given a regular maintenance service. See “Maintenance chart” on page 76. The truck’s safety, efficiency, and service life is dependent on the service and maintenance it is given.

•

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

•

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

•

BT Prime-Mover recommends that you contact your BT Prime-Mover representative to set up a service and maintenance agreement to ensure your truck’s operating efficiently and safety.

•

BT Prime-Mover recommends that you contact your BT Prime-Mover representative to set up a service and maintenance agreement to ensure your truck’s operating efficiently and safety.

Maintenance

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.

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Maintenance

Warning Short-circuiting/burns.

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, rings, 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.

•

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

•

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.

•

Bear in mind that the oil in the transmission or the hydraulic system can be hot.

Warning Risk of burns.

Hot transmission and hydraulic oil. Let the truck cool before changing the oil.

•

Only fill the hydraulic system with new clean oil. Oil should meet BT Prime-Mover cleanliness specification 12-00002. Contact your BT Prime-Mover representative for assistance or more information.

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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 Prime-Mover cleanliness specification 12-00002. Contact your BT Prime-Mover representative for assistance or more information. 71

Maintenance

Warning The hydraulic system can be damaged.

If 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 cleaning solution, 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 cleaning solution, 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.

•

When working underneath the truck support the truck on trestle-blocks.

Warning Risk of crushing.

A badly supported truck can fall. Never work under a truck that is not supported on trestle-blocks and secured by a lifting device.

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A badly supported truck can fall. Never work under a truck that is not supported on trestle-blocks and secured by a lifting device.

Maintenance

Maintenance that can be carried out by driver

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 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

•

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.

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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 the truck is important to ensure the truck will operate safely and reliably.

•

Carry out general cleaning and washing weekly.

External cleaning

•

Remove debris, etc. from the wheels daily.

•

Remove debris, etc. from the wheels daily.

•

Use a degreasing agent diluted to a suitable concentration.

•

Use a degreasing agent diluted to a suitable concentration.

•

Rinse off loose grime using warm water.

•

Rinse off loose grime using warm water.

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

Blow electric motors dry using compressed air.

Warning Compressed air used for cleaning MUST be

reduced to less than 30 psi [207 kPa], and then only with effective chip-guarding and personal protective equipment.

•

Clean the electrical panels, electronic boards, contacts, connector, solenoid valves, etc. using a damp cloth and a cleaning agent.

•

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.

•

Do not spray or pressure wash in the compartment.

NOTE! Risk of short-circuiting. Electrical components can be damaged. Do not break warranty seal on electronic components.

Return

NOTE! Risk of short-circuiting. Electrical components can be damaged. Do not break warranty seal on electronic components.

Maintenance

Maintenance chart

PM Interval:

A=8 Hours or 1 Day

E=720 Hours or 6 Months

A=8 Hours or 1 Day

E=720 Hours or 6 Months

B=30 Hours or 1 Week

F=1440 Hours or 12 Months

B=30 Hours or 1 Week

F=1440 Hours or 12 Months

C=120 Hours or 1 Month

G=4320 Hours or 36 Months

C=120 Hours or 1 Month

G=4320 Hours or 36 Months

D=360 Hours or 3 Months

No.

Action

No.

Action

1.0

Chassis

1.0

Chassis

1.1

Check that the truck’s data plate is legible

1.1

Check that the truck’s data plate is legible

1.2

Check the cover screws

1.2

Check the cover screws

1.3

Check door lock

1.3

Check door lock

1.4

Check for damage and crack formation

1.4

Check for damage and crack formation

1.5

Check fork frame mounting

1.5

Check fork frame mounting

1.6

Check wear on battery stop (optional)

1.6

Check wear on battery stop (optional)

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 torque of motor bolts

2.3

Check torque of motor bolts

2.4

Check for abnormal bearing noise

2.4

Check for abnormal bearing noise

2.5

Check brush wear

2.5

Check 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 and debris

4.1

Remove string and debris

4.2

Check all wheels for wear

4.2

Check all wheels for wear

4.3

Check that all wheels rotate and axles are fitted correctly

4.3

Check that all wheels rotate and axles are fitted correctly

4.4

Check all wheels for loose screws

4.4

Check all wheels for loose screws

Return

Maintenance No.

Action

No.

Action

4.5

Grease load wheel bearings

4.5

Grease load wheel bearings

4.6

Grease caster and caster wheels

4.6

Grease caster and caster wheels

4.7

Dismantle and lubricate all wheel bearings.

4.7

Dismantle and lubricate all wheel bearings.

5.0

Brake

5.0

Brake

5.1

Clean dust and debris

5.1

Clean dust and debris

5.2

Check shoes and discs for wear

5.2

Check shoes and discs for wear

5.3

Check correct clearance brake

5.3

Check correct clearance brake

5.4

Check brake operation

5.4

Check brake operation

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 main contactor function

6.3

Check main contactor function

6.4

Check the contactor tips for free movements

6.4

Check the contactor tips for free movements

6.5

Check all cable insulation for damage

6.5

Check all cable insulation for damage

7.0

Electronic card

7.0

Electronic card

7.1

Check for connections in harness connectors

7.1

Check for connections in harness connectors

8.0

Electronic control system

8.0

Electronic control system

8.1

Check key switch (option toggle)

8.1

Check key switch (option toggle)

8.2

Check brake switch

8.2

Check brake switch

8.3

Check control wiring harness for proper routing

8.3

Check control wiring harness for proper routing

9.0

Battery

9.0

Battery

9.1

Check electrolyte level, 1/2 - 5/8 in. [10-15 mm] above cell plate

9.1

Check electrolyte level, 1/2 - 5/8 in. [10-15 mm] above cell plate

9.2

Check the connections on battery, truck, and charger

9.2

Check the connections on battery, truck, and charger

9.3

Check all cells and pole guards

9.3

Check all cells and pole guards

9.4

Check the fluid density and temperature

9.4

Check the fluid density and temperature

9.5

Check power cables are not cut or frayed

9.5

Check power cables are not cut or frayed

Return

Maintenance B

X X X

Maintenance No.

Action

No.

Action

10.0

Hydraulic system

10.0

Hydraulic system

10.1

Check hoses and connections for leakage

10.1

Check hoses and connections for leakage

10.2

Check hoses for wear and damage

10.2

Check hoses for wear and damage

10.3

Check oil tank for cracks, leaks, and mounting

10.3

Check oil tank for cracks, leaks, and mounting

10.4

Check oil level

10.4

Check oil level

10.5

Change oil

10.5

Change oil

11.0

Cylinder

11.0

Cylinder

11.1

Check for leakage

11.1

Check for leakage

11.2

Check the mountings

11.2

Check the mountings

12.0

Lift devices

12.0

Lift devices

12.1

Check for damage and cracks

12.1

Check for damage and cracks

12.2

Check mast mounting bolts torque

12.2

Check mast mounting bolts torque

12.3

Check for play on rollers

12.3

Check for play on rollers

12.4

Check the electrical limit switch function

12.4

Check the electrical limit switch function

12.5

Check for wear and stretch on the chains and sheaves

12.5

Check for wear and stretch on the chains and sheaves

12.6

Check hoses and couplings for leakage, cuts, and other damage

12.6

Check hoses and couplings for leakage, cuts, and other damage

12.7

Check for wear to the forks and other lifting devices

12.7

Check for wear to the forks and other lifting devices

12.8

Lube all grease fittings

12.8

Lube all grease fittings

13.0

Controls

13.0

Controls

13.1

Check handle mounting

13.1

Check handle mounting

13.2

Check the handle brake switch

13.2

Check the handle brake switch

13.3

Check travel direction/speed control

13.3

Check travel direction/speed control

13.4

Check horn button function

13.4

Check horn button function

13.5

Check hydraulic button functions

13.5

Check hydraulic button functions

13.6

Check the handle control switches

13.6

Check the handle control switches

13.7

Check the reverser switch

13.7

Check the reverser switch

Return

Maintenance B

Maintenance No.

Action

13.8

Check hydraulic manual control lever functions

14.0

Gauge

14.1

Check dash display

15.0

Brake lever

15.1

Check parking brake lever

15.2

Check that the control handle returns to the upright position with parking brake applied

16.0

Master control on/off switch

16.1

Check the function of switch

Maintenance B

No.

Action

13.8

Check hydraulic manual control lever functions

14.0

Gauge

14.1

Check dash display

15.0

Brake lever

15.1

Check parking brake lever

15.2

Check that the control handle returns to the upright position with parking brake applied

16.0

Master control on/off switch

16.1

Check the function of switch

1 / 2

14 15 6 7

OFF

16 2

3 4

4 2

Return

6 7

14 15

OFF

13 11

Maintenance

Lubrication chart

Lubrication chart Interval/Running hours

Pos No.

Service point

Wheel bearings

Hydraulic system

Parking brake

Drive gear

Hinges

Steering bearings

Mast

720h

Lubricant

Wheel bearings

Hydraulic system

Parking brake

Drive gear

Hinges

Steering bearings

Mast

C=Check

Service point

O=Oil change

720h

1440h

A B

L=Lubrication

C=Check

O=Oil change

4320h

See “Approved Oils and Grease Chart” on page 81.

4 1

Return

Lubricant

4320h

1440h

L=Lubrication

Interval/Running hours

Pos No.

See “Approved Oils and Grease Chart” on page 81.

6 80

Maintenance

Approved Oils and Grease Chart

Specification Standard & Corrosion Environment

Lubricant

Grease

B Hydraulic oil C

Transmissi on oil

D Motor Oil

Continuous Operation Above 23° F (-5° C)

Specification Standard & Corrosion Environment

Cold Storage Continuous Operation To 5° F (-15° C)

Application area

Lubricant

Intermittent Operation To -13° F (-25° C) Bearings and bushings

Mystik JT-6

Grease

Sunoco TH

ATF

Hydraulic system

B Hydraulic oil

SAE 80

ATF

Gears

#10 W 40

Chains

D Motor Oil

Transmissi on oil

Continuous Operation Above 23° F (-5° C)

Cold Storage Continuous Operation To 5° F (-15° C)

Application area

Intermittent Operation To -13° F (-25° C) Bearings and bushings

Mystik JT-6 Sunoco TH

ATF

Hydraulic system

SAE 80

ATF

Gears

#10 W 40

Chains

Grease

Molykote 200025*

Mast rails, reach, sideshift

Grease

Molykote 200025*

Mast rails, reach, sideshift

Grease

49670-00*

Mast rails, reach, sideshift

Grease

49670-00*

Mast rails, reach, sideshift

* Refer to section 10000 of Parts Book for special lubricants.

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

Environmental Definitions

Standard

Trucks parked outside when not in use and charging and maintenance work

Standard

Trucks parked outside when not in use and charging and maintenance work

Corrosion

Where a damp, wet, or corrosive condition exit

Corrosion

Where a damp, wet, or corrosive condition exit

Return

Maintenance

Environmental Definitions

Continuous Cold Operation

Trucks completely dry prior to entering the continuous stay in the cold store Park inside cold storage for operator breaks Charging and maintenance work done outside cold storage Truck completely dry before returning to continuous cold store

Intermittent Cold Operation

Surface condensation will occur, “wet” trucks should neither remain idle in cold store for longer than 10 minutes nor operate inside cold store for extended periods. Condensation must not be allowed to freeze on truck at any time. Park outside cold store for operator breaks Charging and maintenance work done outside cold store

Freezer Condition

Truck parked inside freezer for operator breaks Trucks stays in freezer during battery charging or change-out If truck is removed from freezer for maintenance work or battery charging, it must be completely dry before reentering the continuous shift in the freezer.

Return

Continuous Cold Operation

Intermittent Cold Operation

Freezer Condition

Transporting and storing the truck

Truck’s dimensions and weight as standard

Transporting and storing the truck

NOTE! The truck’s weights and measurements are only estimates and can very on trucks with different accessories. Consult your truck’s data plate for specific information.

Truck’s dimensions and weight

CSX10

CSX20

CSX30

CSX40

CSX10

CSX20

CSX30

Height (less mast down height)

60 inch [1524 mm]

Height (less mast down height)

60 inch [1524 mm]

Width (Minimum width)

35 inch [889 mm]

Width (Minimum width)

35 inch [889 mm]

50 inch 65 inch 71 inch 77 inch [1955 mm] [1651 mm] [1803 mm] [1955 mm]

Length Minimum battery weight Service weight

Return

Consult data plate on truck 3400 lb [1542 kg]

3780 lb [171 kg]

4610 lb [2091 kg]

5985 lb [2715 kg]

With battery

3990lb [1809kg]

4730 lb [2145 kg]

5560 lb [2522 kg]

7195 lb [3264 kg]

50 inch 65 inch 71 inch 77 inch [1955 mm] [1651 mm] [1803 mm] [1955 mm]

Length Minimum battery weight

Without battery

Service weight

CSX40

Consult data plate on truck

Without battery

3400 lb [1542 kg]

3780 lb [171 kg]

4610 lb [2091 kg]

5985 lb [2715 kg]

With battery

3990lb [1809kg]

4730 lb [2145 kg]

5560 lb [2522 kg]

7195 lb [3264 kg]

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

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.

Return

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.

Transporting and storing the truck

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 “Maintenance chart” on page 76

•

When stored for a period greater then 3 months carry out preventive maintenance as stated in the “Maintenance chart” on page 76

Return

APPENDEX A - Selected OSHA Regulations

APPENDIX A - Selected OSHA Regulations

The use of forklift trucks in the workplace is governed by various regulations. In the United States, the Department of Labor Occupational Safety and Health Administration (OSHA) has issued regulations which cover the majority of workplaces. In addition, several states have implemented regulations which apply instead of the Department of Labor regulations. Check with your local OSHA office or provincial Labor Bureau to confirm which regulations govern your workplace. Because of their wide applicability, this section of your manual lists several parts of the Department of Labor OSHA regulations which may be of particular importance to your workplace. The full text of the Department of Labor regulations may be found in the Code of Department of Labor Regulations at 29 CFR Section 1910.178. The selections cited below and on the next page are followed by a reference to the appropriate subparagraph of the regulations.

•

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 plates, tags or decals shall be changed accordingly. (a) (3)

•

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 plates, tags or decals shall be changed accordingly. (a) (3)

•

The user shall see that all nameplates and markings are in place and are maintained in a legible condition. (a) (6)

•

The user shall see that all nameplates and markings are in place and are maintained in a legible condition. (a) (6)

•

The employer shall ensure that each powered industrial truck operator is competent to operate a powered industrial truck safely, as demonstrated by the successful completion of the training and evaluation specified in this paragraph. (l) (1) (i)

•

Prior to permitting an employee to operate a powered industrial truck (except for training purposes), the employer shall ensure that each operator has successfully completed the training required by this paragraph. (l) (1) (ii)

•

APPENDIX A - Selected OSHA Regulations

Return

APPENDEX A - Selected OSHA Regulations

•

Trainees may operate a powered industrial truck only under the direct supervision of persons who have the knowledge, training, and experience to train operators and evaluate their competence and where such operation does not endanger the trainee or other employees. (l) (2) (i) (A) (B)

•

Training shall consist of a combination of formal instruction (e.g. lecture, discussion, interactive computer learning, videotape, written material), practical training (demonstrations performed by the trainer and practical exercises performed by the trainee), and evaluation of the operator’s performance in the workplace. (l) (2) (B) (ii) (Editorial Note: For required Training program content, refer to (l) (3) (i) (A-M) and (l) (3) (ii) (A-I).)

•

Refresher training, including an evaluation of the effectiveness of that training, shall be conducted as required by paragraph (l) (4) (ii) to ensure that the operator has the knowledge and skills needed to operate the powered industrial truck safely. (l) (4) (i)

•

An evaluation of each powered industrial truck operator’s performance shall be conducted at least once every three years. (l) (4) (iii)

•

An evaluation of each powered industrial truck operator’s performance shall be conducted at least once every three years. (l) (4) (iii)

•

The employer shall certify that each operator has been trained and evaluated as required by this paragraph (l). The certification shall include the name of the operator, the date of the training, the date of the evaluation, and the identity of the person(s) performing the training or evaluation. (l) (6)

•

The employer shall prohibit arms or legs from being placed between the uprights of the mast or outside the running lines of the truck. (m) (4)

•

The employer shall prohibit arms or legs from being placed between the uprights of the mast or outside the running lines of the truck. (m) (4)

Return

APPENDEX A - Selected OSHA Regulations

•

Brakes shall be set and wheel blocks shall be in place to prevent movement of trucks, trailers or railroad cars while loading or unloading. Fixed jacks may be necessary to support a semitrailer when the trailer is not coupled to a tractor. The flooring of trucks, trailers, and railroad cars shall be checked for breaks and weakness before they are driven into. (m) (7)

•

Only approved industrial trucks shall be used in hazardous locations. (m) (11)

•

Only approved industrial trucks shall be used in hazardous locations. (m) (11)

•

All traffic regulations shall be observed, including authorized plant speed limits. A safe distance shall be maintained approximately three truck lengths from the truck ahead, and the truck shall be kept under control at all times. (n) (1)

•

The driver shall be required to slow down and sound the horn at cross aisles and other locations where vision is obstructed. If the load being carried obstructs forward view, the driver shall be required to travel with the load trailing. (n) (4)

•

Under all travel conditions the truck shall be operated at a speed that will permit it to be brought to a stop in a safe manner. (n) (8)

•

Under all travel conditions the truck shall be operated at a speed that will permit it to be brought to a stop in a safe manner. (n) (8)

•

Stunt driving and horseplay shall not be permitted. (n) (9)

•

Stunt driving and horseplay shall not be permitted. (n) (9)

•

If at any time a powered industrial truck is found to be in need of repair, defective, or in any way unsafe, the truck shall be taken out of service until it has been restored to safe operating condition. (p) (1)

•

Any power-operated industrial truck not in safe operating condition shall be removed from service. All repairs shall be made by authorized personnel. (q) (1)

•

Any power-operated industrial truck not in safe operating condition shall be removed from service. All repairs shall be made by authorized personnel. (q) (1)

•

All parts of any such industrial truck requiring replacement shall be replaced only by parts equivalent as to safety with those used in the original design. (q) (5)

•

All parts of any such industrial truck requiring replacement shall be replaced only by parts equivalent as to safety with those used in the original design. (q) (5)

Return

APPENDEX A - Selected OSHA Regulations

•

Industrial trucks shall be examined before being placed in service, and shall not be placed in service if the examination shows any condition adversely affecting the safety of the truck. Such examination shall be made at least daily. Where powered industrial trucks are used on a round-the-clock basis, they shall be examined after each shift. Defects when found shall be immediately reported and corrected. (q) (7)

Return

Index

Appendix A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Application area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Approved Oils and Grease . . . . . . . . . . . . . . . . . . . . . . 81

B Battery After charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Battery maintenance . . . . . . . . . . . . . . . . . . . . . . . . 65 Each month . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Each week . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Changing the battery . . . . . . . . . . . . . . . . . . . . . . . . 60 Charging the battery . . . . . . . . . . . . . . . . . . . . . . . . 62 During charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 General prohibition . . . . . . . . . . . . . . . . . . . . . . . . . 62 Pre-charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Type of battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Battery discharge indicator (BDI) . . . . . . . . . . . . . . . . . . 44 BDI/hourmeter with lift interrupt . . . . . . . . . . . . . . . . . . . 44 Brake Braking using plugging function . . . . . . . . . . . . . . . . 42 Braking the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

C Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58, 59 Cleaning and washing . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Cleaning the motor compartment . . . . . . . . . . . . . . 74 Electrical components . . . . . . . . . . . . . . . . . . . . . . . 75 External cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Control Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Lowering the forks . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Raising the forks . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Reverser switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Steering control handle/brake control . . . . . . . . . . . 41 Travel brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Return

C Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58, 59 Cleaning and washing . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Cleaning the motor compartment . . . . . . . . . . . . . . 74 Electrical components . . . . . . . . . . . . . . . . . . . . . . . 75 External cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Control Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Lowering the forks . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Raising the forks . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Reverser switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Steering control handle/brake control . . . . . . . . . . . 41 Travel brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Index Travel direction selector and speed control . . . . . . . 39 Control handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Controls and instruments . . . . . . . . . . . . . . . . . . . . . . . . 37

D Daily service/safety checks . . . . . . . . . . . . . . . . . . . . . . 67 Special equipment . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Data plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Dimensions CSX-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 CSX-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 CSX-30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 CSX-40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Braking the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Parking the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Starting the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Steering the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

E Emergency battery disconnect . . . . . . . . . . . . . . . . . . . . 36

F Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Fork Function Control Levers . . . . . . . . . . . . . . . . . . . . . 48 Control for Sideshifter/Auxiliary Control (optional) . . 48 Control for Tilt/Auxiliary Control . . . . . . . . . . . . . . . . 48

G General safety regulations . . . . . . . . . . . . . . . . . . . . . . . 12 Maintenance and repair . . . . . . . . . . . . . . . . . . . . . . 21 Operating the truck . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Ordinance symbols . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Parking the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Working area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

H Hourmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Return

D Daily service/safety checks . . . . . . . . . . . . . . . . . . . . . . 67 Special equipment . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Data plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Dimensions CSX-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 CSX-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 CSX-30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 CSX-40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Braking the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Parking the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Starting the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Steering the truck . . . . . . . . . . . . . . . . . . . . . . . . . . 53

E Emergency battery disconnect . . . . . . . . . . . . . . . . . . . 36

F Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Fork Function Control Levers . . . . . . . . . . . . . . . . . . . . 48 Control for Sideshifter/Auxiliary Control (optional) . . 48 Control for Tilt/Auxiliary Control . . . . . . . . . . . . . . . . 48

G General safety regulations . . . . . . . . . . . . . . . . . . . . . . . 12 Maintenance and repair . . . . . . . . . . . . . . . . . . . . . . 21 Operating the truck . . . . . . . . . . . . . . . . . . . . . . . . . 12 Ordinance symbols . . . . . . . . . . . . . . . . . . . . . . . . . 10 Parking the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Working area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

H Hourmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Index

Lubrication chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

M Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Driver maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 73 General information . . . . . . . . . . . . . . . . . . . . . . . . . 70 Maintenance personnel . . . . . . . . . . . . . . . . . . . . . . 73 Safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Maintenance chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Mast Function Control Lever . . . . . . . . . . . . . . . . . . . . . 47 Control for Raise/Lower using control lever . . . . . . . 47

Lubrication chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

NOTE! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38, 50, 56, 59, 61, 64, 65, 74, 75, 83 Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

NOTE! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38, 50, 56, 59, 61, 64, 65, 74, 75, 83 Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Oils and Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 OSHA regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

P Parking the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Presentation of main components . . . . . . . . . . . . . . . . . 34 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Circuit breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Data plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Drive unit with brake . . . . . . . . . . . . . . . . . . . . . . . . 34 Electric panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Fork lower switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Fork raise switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Horn switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Return

Oils and Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 OSHA regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Index Hydraulic control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Hydraulic electric solenoid valve . . . . . . . . . . . . . . . . 34 Hydraulic manual valves . . . . . . . . . . . . . . . . . . . . . . 34 Hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Key switch (toggle switch) . . . . . . . . . . . . . . . . . . . . 36 Load wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Master control on/off switch . . . . . . . . . . . . . . . . . . . 36 Reverser switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Steering control handle . . . . . . . . . . . . . . . . . . . . . . . 34 Steering pivot point . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Travel speed / direction selection . . . . . . . . . . . . . . . 36 Presentation of truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Prohibited applications . . . . . . . . . . . . . . . . . . . . . . . . . . 25

S Safety Symbol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Standard Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Starting the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Steering the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Storing Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Drive unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Starting after a period of disuse . . . . . . . . . . . . . . . . 86 Transporting and storing the truck . . . . . . . . . . . . . . 83 Storing the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Symbols Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 General prohibition . . . . . . . . . . . . . . . . . . . . . . . . . . 10 No Smoking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Note! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Open flames prohibited . . . . . . . . . . . . . . . . . . . . . . . 10 Protective glasses . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Safety Alert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Safety shoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Return

Index Hydraulic control . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Hydraulic electric solenoid valve . . . . . . . . . . . . . . . 34 Hydraulic manual valves . . . . . . . . . . . . . . . . . . . . . 34 Hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Key switch (toggle switch) . . . . . . . . . . . . . . . . . . . . 36 Load wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Master control on/off switch . . . . . . . . . . . . . . . . . . . 36 Reverser switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Steering control handle . . . . . . . . . . . . . . . . . . . . . . 34 Steering pivot point . . . . . . . . . . . . . . . . . . . . . . . . . 35 Travel speed / direction selection . . . . . . . . . . . . . . 36 Presentation of truck . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Prohibited applications . . . . . . . . . . . . . . . . . . . . . . . . . 25

S Safety Symbol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Standard Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Starting the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Steering the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Storing Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Drive unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Starting after a period of disuse . . . . . . . . . . . . . . . . 86 Transporting and storing the truck . . . . . . . . . . . . . . 83 Storing the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Symbols Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 General prohibition . . . . . . . . . . . . . . . . . . . . . . . . . 10 No Smoking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Note! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Open flames prohibited . . . . . . . . . . . . . . . . . . . . . . 10 Protective glasses . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Safety Alert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Safety shoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Index

Towing and transporting a disabled truck . . . . . . . . . . . 84 Transporting loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Collecting a load . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 General Information . . . . . . . . . . . . . . . . . . . . . . . . . 55 Leaving a load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Truck Dimensions and weight chart . . . . . . . . . . . . . . . . . . 83 Truck battery dimensions . . . . . . . . . . . . . . . . . . . . . . . . 27 Truck data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

U U.L. construction type . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Towing and transporting a disabled truck . . . . . . . . . . . 84 Transporting loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Collecting a load . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 General Information . . . . . . . . . . . . . . . . . . . . . . . . . 55 Leaving a load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Truck Dimensions and weight chart . . . . . . . . . . . . . . . . . 83 Truck battery dimensions . . . . . . . . . . . . . . . . . . . . . . . 27 Truck data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

U U.L. construction type . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3, 37, 50, 51, 53, 55, 56, 57, 60, 61, 62, 63, 65, 66, 67, 68, 71, 72, 75, 84 Warning and information signs . . . . . . . . . . . . . . . . . . . 22

Return

Back Cover

BT Prime-Mover, Inc., 3305 N. Highway 38 Muscatine, Iowa 52761-8800 U.S.A. Tel (563) 262-7700 • Fax (563) 262-7600

Return

BT Prime-Mover, Inc., 3305 N. Highway 38 Muscatine, Iowa 52761-8800 U.S.A. Tel (563) 262-7700 • Fax (563) 262-7600

Front Cover

Operator’s Manual

CSX10/20/30/40

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

WARNING Read and observe all warnings on this unit

WARNING DO NOT operate this equipment unless all

factory installed guards and shields are properly secured in place.

Electric Counter Balanced Stacker Truck Effective Serial Number CSX__31339001

before operating it.

Part no: 304953-002

Return

Date: July 01, 2002

before operating it.

Part no: 304953-002

Date: July 01, 2002

Operator’s Warning

IMPORTANT NOTICE

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.

! WARNING

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 SERVICE MANUALS MAY BE OBTAINED FROM YOUR EQUIPMENT DEALER.

Operator ’s Warning

INJURY OR DEATH TO YOU OR OTHER WARNING PERSONNEL COULD OCCUR IF YOU DO NOT FOLLOW THESE INSTRUCTIONS AND MESSAGES. 1 Return

INJURY OR DEATH TO YOU OR OTHER WARNING PERSONNEL COULD OCCUR IF YOU DO NOT FOLLOW THESE INSTRUCTIONS AND MESSAGES. 1

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.

Foreword

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Foreword

Standard Compliance

This truck complies with the following standards and regulation in effect on the date the truck was manufactured:

•

American Society of Mechanical Engineers (ASME) B56.1

•

American Society of Mechanical Engineers (ASME) B56.1

•

Underwriters Laboratory (UL) # 583

•

Underwriters Laboratory (UL) # 583

•

Occupational Safety and Health Administration (OSHA) 29 C.F.R. Section 1910.178

•

Occupational Safety and Health Administration (OSHA) 29 C.F.R. Section 1910.178

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Table of Contents

Operator’s Warning ..................................................................... 1

Operator’s Warning ......................................................................1

Before operating the truck: ....................................................................1

Foreword ...................................................................................... 2

Foreword .......................................................................................2

Standard Compliance ............................................................................3

Safety regulations symbols........................................................ 7

Safety regulations symbols.........................................................7

Warning symbols ...................................................................................7 Warning levels...................................................................................7 Prohibitory symbols ...............................................................................8 Ordinance symbols ................................................................................8 General safety regulations.....................................................................9 Control...............................................................................................9 Operating the truck..........................................................................10 Operator’s responsibility..................................................................11 Working area ...................................................................................12 Driving and conduct while driving....................................................13 Handling loads ................................................................................16 Parking the truck .............................................................................17 Handling the battery ........................................................................18 Maintenance and repair ..................................................................19

Warning symbols ...................................................................................7 Warning levels...................................................................................7 Prohibitory symbols ...............................................................................8 Ordinance symbols ................................................................................8 General safety regulations.....................................................................9 Control...............................................................................................9 Operating the truck..........................................................................10 Operator’s responsibility..................................................................11 Working area...................................................................................12 Driving and conduct while driving....................................................13 Handling loads ................................................................................16 Parking the truck .............................................................................17 Handling the battery ........................................................................18 Maintenance and repair ..................................................................19

Warning and information decals.............................................. 20

Warning and information decals...............................................20

Warning decals ...............................................................................21

Presentation of truck................................................................. 22

Presentation of truck..................................................................22

Application area for BT Prime-Mover’s trucks ................................23 Prohibited applications for BT Prime-Mover’s trucks......................23 Truck data .......................................................................................24 Truck battery dimensions ................................................................25 CSX-10 truck dimensions................................................................26 CSX-20 truck dimensions................................................................27 CSX-30 truck dimensions................................................................28 CSX-40 truck dimensions................................................................29 Data plate ........................................................................................30 U.L. construction type .....................................................................31

Application area for BT Prime-Mover’s trucks ................................23 Prohibited applications for BT Prime-Mover’s trucks......................23 Truck data .......................................................................................24 Truck battery dimensions ................................................................25 CSX-10 truck dimensions................................................................26 CSX-20 truck dimensions................................................................27 CSX-30 truck dimensions................................................................28 CSX-40 truck dimensions................................................................29 Data plate........................................................................................30 U.L. construction type .....................................................................31

Presentation of main components........................................... 32

Presentation of main components............................................32

Controls and instruments......................................................... 35

Controls and instruments..........................................................35

Control handle .....................................................................................35 Control for raising the forks .............................................................36 Control for lowering the forks ..........................................................36 Travel direction selector and speed control ....................................37 Horn ................................................................................................37

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Table of Contents

Reverser switch .............................................................................. 38 Steering control handle/brake control............................................. 39 Braking using plugging function...................................................... 40 Dash Controls ..................................................................................... 41 Key switch (Toggle switch) ............................................................. 41 Master control on/off switch............................................................ 41 Key switch (Toggle switch) ............................................................. 41 BDI/hourmeter with lift interrupt ...................................................... 42 Battery discharge indicator (BDI).................................................... 42 Hourmeter....................................................................................... 43 Emergency battery disconnect............................................................ 44 Mast Function Control Lever ............................................................... 45 Control for Raise/Lower using control lever.................................... 45 Fork Function Control Levers.............................................................. 46 Control for Tilt/Auxiliary Control...................................................... 46 Control for Sideshifter/Auxiliary Control (optional).......................... 46

Reverser switch.............................................................................. 38 Steering control handle/brake control............................................. 39 Braking using plugging function ..................................................... 40 Dash Controls ..................................................................................... 41 Key switch (Toggle switch)............................................................. 41 Master control on/off switch............................................................ 41 Key switch (Toggle switch)............................................................. 41 BDI/hourmeter with lift interrupt...................................................... 42 Battery discharge indicator (BDI) ................................................... 42 Hourmeter ...................................................................................... 43 Emergency battery disconnect............................................................ 44 Mast Function Control Lever............................................................... 45 Control for Raise/Lower using control lever ................................... 45 Fork Function Control Levers.............................................................. 46 Control for Tilt/Auxiliary Control...................................................... 46 Control for Sideshifter/Auxiliary Control (optional) ......................... 46

Driving ........................................................................................ 47

Driving .........................................................................................47

Driving ................................................................................................. 47 Braking the Truck ........................................................................... 50 Steering the Truck .......................................................................... 51 Parking the Truck ........................................................................... 52

Driving................................................................................................. 47 Braking the Truck ........................................................................... 50 Steering the Truck .......................................................................... 51 Parking the Truck ........................................................................... 52

Transporting loads .................................................................... 53

Transporting loads .....................................................................53

General Information........................................................................ 53 Collecting a load ............................................................................. 56 Leaving a load ................................................................................ 57

General Information........................................................................ 53 Collecting a load............................................................................. 56 Leaving a load ................................................................................ 57

Battery ........................................................................................ 58

Battery .........................................................................................58

Type of battery................................................................................ 58 Changing the battery ...................................................................... 58 Charging the battery ........................................................................... 60 General prohibition ......................................................................... 60 Pre-charging ................................................................................... 61 During charging .............................................................................. 61 After charging ................................................................................. 62 Battery maintenance....................................................................... 63 Each week: ..................................................................................... 63 Each month: ................................................................................... 64

Type of battery ............................................................................... 58 Changing the battery ...................................................................... 58 Charging the battery ........................................................................... 60 General prohibition ......................................................................... 60 Pre-charging................................................................................... 61 During charging .............................................................................. 61 After charging ................................................................................. 62 Battery maintenance ...................................................................... 63 Each week:..................................................................................... 63 Each month: ................................................................................... 64

Daily service/safety checks ...................................................... 65

Daily service/safety checks .......................................................65

Daily service/safety checks drawing ............................................... 66 Special equipment .......................................................................... 67

Daily service/safety checks drawing............................................... 66 Special equipment.......................................................................... 67

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Table of Contents

Maintenance............................................................................... 68

Maintenance................................................................................68

General information.........................................................................68 Safety regulations with maintenance work ......................................68 Maintenance that can be carried out by driver ................................71 Maintenance that may be carried out by trained maintenance personnel ........................................................................................71 Other service and repair work .........................................................71 Cleaning and washing .........................................................................72 General ...........................................................................................72 External cleaning.............................................................................72 Cleaning the motor compartment ....................................................72 Electrical components .....................................................................73 Maintenance chart ...............................................................................74 Lubrication chart ..................................................................................78 Approved Oils and Grease Chart.........................................................79

General information.........................................................................68 Safety regulations with maintenance work......................................68 Maintenance that can be carried out by driver ................................71 Maintenance that may be carried out by trained maintenance personnel ........................................................................................71 Other service and repair work .........................................................71 Cleaning and washing .........................................................................72 General ...........................................................................................72 External cleaning.............................................................................72 Cleaning the motor compartment....................................................72 Electrical components .....................................................................73 Maintenance chart ...............................................................................74 Lubrication chart ..................................................................................78 Approved Oils and Grease Chart ........................................................79

Transporting and storing the truck.......................................... 81

Transporting and storing the truck...........................................81

Truck’s dimensions and weight as standard ...................................81 Towing and transporting a disabled truck ............................................82 Storing the truck...................................................................................83 Battery .............................................................................................83 Hydraulic system .............................................................................83 Drive unit .........................................................................................83 Starting after a period of disuse...........................................................84

Truck’s dimensions and weight as standard ...................................81 Towing and transporting a disabled truck ............................................82 Storing the truck ..................................................................................83 Battery.............................................................................................83 Hydraulic system.............................................................................83 Drive unit.........................................................................................83 Starting after a period of disuse...........................................................84

APPENDIX A - Selected OSHA Regulations............................ 85

APPENDIX A - Selected OSHA Regulations.............................85

Index ........................................................................................... 89

Index ............................................................................................89

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Safety regulations Warning symbols

Safety reg ulations symb ols

Always follow the warnings given in this Operator’s 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 severe 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 severe 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 an accident or breakdown if the instructions are not followed.

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Marks the risk of an accident or 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 reduce personal injury.

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

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Safety regulations

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

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

Safety regulations

General safety regulations

Control

•

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.

•

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 data plate(s). Do not operate the truck if there are any differences between the data stated on the data plate and the truck.

•

Read the data plate(s). Do not operate the truck if there are any differences between the data stated on the data plate and the truck.

•

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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.

•

Never allow anyone to stand or walk under any elevated portion of this truck.

•

Never allow anyone to stand or walk under any elevated portion of this truck.

•

It is not permitted to use the truck for other purposes than it has been designed and produced for such as the following applications:

•

It is not permitted to use the truck for other purposes than it has been designed and produced for such as the following applications:

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.

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Safety regulations

General safety regulations

Operator’s responsibility

•

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

•

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

•

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

•

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

•

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

•

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

•

Local regulations regarding personal safety equipment shall be followed.

•

Local regulations regarding personal safety equipment shall be followed.

•

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

•

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.

•

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

•

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

•

Truck should only be driven on hard and even surfaces, for example concrete or asphalt.

•

Truck should only be driven on hard and even surfaces, for example 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.

•

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

•

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

•

Always drive with the forks fully lowered except when a load is collected or left.

•

Always drive with the forks fully lowered except when a load is collected or left.

•

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. 13 Return

•

Sound the horn when overtaking other vehicles and when the attention of other personnel is required. 13

•

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 truck.

•

Never allow passengers to ride on 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.

•

Keep hands and feet clear of controls other than those in use.

•

Keep hands and feet clear of controls other than those in use.

•

Lift and lower with caution. Make sure there are no obstructions under, or in the path of, the lifting mechanism.

•

Lift and lower with caution. Make sure there are no obstructions under, or in the path of, the lifting mechanism.

•

Make sure the lifting mechanism is operating smoothly.

•

Make sure the lifting mechanism is operating smoothly.

•

Whenever truck is driven ON and OFF semi-trailers not coupled to a tractor, supports may be needed to prevent upending or corner dipping.

•

Whenever truck is driven ON and OFF semi-trailers not coupled to a tractor, supports may be needed to prevent upending or corner dipping.

•

Before 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 ramp.

•

Before 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 ramp.

•

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

•

When truck is driven on to another vehicle make sure the other 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 elevator with load first. No other personnel should be in the elevator when the load or truck enters or leaves.

•

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 elevator with load first. No other personnel should be in the elevator when the load or truck enters or leaves.

•

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 or use open flame while working around the truck.

•

DO NOT smoke or use open flame while working around the truck.

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Safety regulations

•

DO NOT BYPASS LIMIT SWITCHES. Doing so will result in server INJURY OR DEATH.

•

DO NOT BYPASS LIMIT SWITCHES. Doing so will result in server INJURY OR DEATH.

•

Look in the direction of travel and keep a clear view of the path of travel.

•

Look in the direction of travel and keep a clear view of the path of travel.

•

Slow down and sound your horn at cross aisles and wherever vision is obstructed.

•

Slow down and sound your horn at cross aisles and wherever vision is obstructed.

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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, see truck’s data plate. 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, see truck’s data plate. 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.

•

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 dragged or pushed horizontally.

•

The load shall Only be lifted vertically and NEVER dragged 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.

•

Always park with the load carrier fully lowered and the brake applied and secured.

•

Always park with the load carrier fully lowered and the brake applied and secured.

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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” on page 58.

•

Always handle the battery and its connections with care. Read and follow the instructions for changing or recharging the battery carefully. See chapter “Battery” on page 58.

•

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” on page 68. Only qualified and trained personnel are permitted to maintain, adjust, or repair the truck.

All replacement parts shall be BT Prime-Mover approved spare parts.

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Warning and information decals

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

Warning and inform atio n decals

2 3 4

KEEP HANDSCLEAR

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10 20

1 12

KEEP HANDSCLEAR

9 20

Warning and information 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. New warning decals can be obtained from your BT Prime-Mover Dealer at NO charge.

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Presentation of truck

CSX10 truck has a maximum lifting capacity of 1000 lb [543 kg].

CSX20 truck has a maximum lifting capacity of 2000 lb [907 kg].

CSX30 truck has a maximum lifting capacity of 3000 lb [1361 kg].

CSX40 truck has a maximum lifting capacity of 4000 lb [1814 kg].

Refer to the truck’s data plate for information on lifting capacities.

The CSX trucks are equipped with a 24 volt electrical system. The travel speeds are regulated by means of a transistor controller to provide gentle control of acceleration and speed while operating.

Presentation of truck

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Presentation of truck

Application area for BT Prime-Mover’s trucks

BT Prime-Mover 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 Prime-Mover’s trucks

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

Do not use in areas that contain gases which can cause fires or explosions

Do not use as a towing truck for trailers

Do not use to tow other trucks

Do not use to transport/lift passengers

Do not use 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 data

CSX10/20/30/40 1000/2000/3000/4000 lb (453/907/1361/1814 kg)

Maximum load capacity

100 -189 inch [2540 - 4800 mm]

Lift height Operating speed Service weight

Empty

3.3 mph [5.3 kph]

Loaded

2.9 mph [4.7 kph]

Without battery

3780/4610/5985 lb [1715/2091/2715 kg]

With battery

4730/5560/7195 lb [2145/2522/3264 kg]

Truck data

CSX10/20/30/40 1000/2000/3000/4000 lb (453/907/1361/1814 kg)

Maximum load capacity

100 -189 inch [2540 - 4800 mm]

Lift height Operating speed Service weight

Empty

3.3 mph [5.3 kph]

Loaded

2.9 mph [4.7 kph]

Without battery

3780/4610/5985 lb [1715/2091/2715 kg]

With battery

4730/5560/7195 lb [2145/2522/3264 kg]

The truck’s lifting capacity 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 CSX10 Deep 7.6 in. [3193 mm] 8.1 in. [206 mm] Wide 31.3 in. [795 mm] 31.8 in. [807 mm] Battery Weight (Consult Data plate on truck)

CSX20-40 Deep Wide Battery Weight

12.5 in. [317 mm] 13 in. [330 mm] 31.3 in. [795 mm] 31.8 in. [807 mm] (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

CSX-10 truck dimensions

The following diagrams show external dimensions for CSX-10 trucks in its standard design.

O R

M K

Overall Lowered Height

H G

34.1 in. (886 mm)

11.7 in. (297 mm)

34.1 in. (886 mm)

11.7 in. (297 mm)

32.3 in. (820 mm)

2.1 in. (53 mm)

32.3 in. (820 mm)

2.1 in. (53 mm)

4 in. (101 mm)

32.5 in. (8.25 mm)

4 in. (101 mm)

32.5 in. (8.25 mm)

41.7 in. (1059 mm)

16.2°

41.7 in. (1059 mm)

16.2°

2 in. (50 mm)

10.5°

2 in. (50 mm)

10.5°

8.1 in. (205 mm)

67°

8.1 in. (205 mm)

67°

49.8 in. (1264 mm)

12.5°

49.8 in. (1264 mm)

12.5°

30.0 in. (762 mm)

55.6 in. (1412 mm)

30.0 in. (762 mm)

55.6 in. (1412 mm)

9 in. (228 mm)

59.5 in. (1511 mm)

9 in. (228 mm)

59.5 in. (1511 mm)

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Overall Lowered Height

Presentation of truck

CSX-20 truck dimensions

The following diagrams show external dimensions for CSX-20 trucks in its standard design.

C A

O R Q N

M K

Overall Lowered Height

R Q N

H G

34.1 in. (886 mm)

9.7 in. (246 mm)

34.1 in. (886 mm)

9.7 in. (246 mm)

32.3 in. (820 mm)

2.1 in. (53 mm)

32.3 in. (820 mm)

2.1 in. (53 mm)

4 in. (101 mm)

32.5 in. (8.25 mm)

4 in. (101 mm)

32.5 in. (8.25 mm)

56.7 in. (1440 mm)

16.2°

56.7 in. (1440 mm)

16.2°

2 in. (50 mm)

10.5°

2 in. (50 mm)

10.5°

8.1 in. (205 mm)

67°

8.1 in. (205 mm)

67°

64.8 in. (1645 mm)

12.5°

64.8 in. (1645 mm)

12.5°

47 in. (1193 mm)

55.6 in. (1412 mm)

47 in. (1193 mm)

55.6 in. (1412 mm)

13.3 in. (337 mm)

59.5 in. (1511 mm)

13.3 in. (337 mm)

59.5 in. (1511 mm)

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Overall Lowered Height

Presentation of truck

CSX-30 truck dimensions

The following diagrams show external dimensions for CSX-30 trucks in its standard design.

C A

O R Q N

M K

Overall Lowered Height

R Q N

H G

34.1 in. (886 mm)

9.7 in. (246 mm)

34.1 in. (886 mm)

9.7 in. (246 mm)

32.3 in. (820 mm)

2.1 in. (53 mm)

32.3 in. (820 mm)

2.1 in. (53 mm)

4 in. (101 mm)

32.5 in. (8.25 mm)

4 in. (101 mm)

32.5 in. (8.25 mm)

62 in. (1574 mm)

16.2°

62 in. (1574 mm)

16.2°

2 in. (50 mm)

10.5°

2 in. (50 mm)

10.5°

8.1 in. (205 mm)

67°

8.1 in. (205 mm)

67°

70.1 in. (1780 mm)

12.5°

70.1 in. (1780 mm)

12.5°

52.3 in. (1328 mm)

55.6 in. (1412 mm)

52.3 in. (1328 mm)

55.6 in. (1412 mm)

13.3 in. (337 mm)

59.5 in. (1511 mm)

13.3 in. (337 mm)

59.5 in. (1511 mm)

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Overall Lowered Height

Presentation of truck

CSX-40 truck dimensions

The following diagrams show external dimensions for CSX-40 trucks in its standard design.

C A

O R Q N

M K

Overall Lowered Height

R Q N

H G

34.1 in. (886 mm)

9.7 in. (246 mm)

34.1 in. (886 mm)

9.7 in. (246 mm)

32.3 in. (820 mm)

2.1 in. (53 mm)

32.3 in. (820 mm)

2.1 in. (53 mm)

4 in. (101 mm)

32.5 in. (8.25 mm)

4 in. (101 mm)

32.5 in. (8.25 mm)

68.3 in. (1734 mm)

16.2°

68.3 in. (1734 mm)

16.2°

2 in. (50 mm)

10.5°

2 in. (50 mm)

10.5°

8.3 in. (210 mm)

67.0°

8.3 in. (210 mm)

67.0°

76.6 in. (1945 mm)

12.5°

76.6 in. (1945 mm)

12.5°

58.6 in. (1488 mm)

55.6 in. (1412 mm)

58.6 in. (1488 mm)

55.6 in. (1412 mm)

13.5 in. (342 mm)

59.5 in. (1511 mm)

13.5 in. (342 mm)

59.5 in. (1511 mm)

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Overall Lowered Height

Presentation of truck

Data plate

Know the rated capacity on the data plate and understand areas 1 through 15 as shown in the illustration.

3 6

4 8

9 12

10 13

8 15

9 12

7 11

10 13

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Presentation of truck

U.L. construction type

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Presentation of main components

1. Steering control handle The truck is to be controlled by the operator with 180 degree steering angle. The brake is applied in the upper and lower position of the steering arm. 2. Data plate Contains type designation, serial number, service weight, battery weight, rated lifting capacity, battery voltage, and manufacturer. See “Data plate” on page 30. 3. Door Swing open which provides good accessibility when servicing. The door can be completely removed from the truck by lifting the door from the hinges. 4. Gauge Combined hourmeter/battery indicator, hourmeter/battery indicator with lift interrupt, or hourmeter only. 5. Hydraulic control (manual valve) For controlling lifting and lowering functions. 6. Hydraulic control (manual valve) (Not on CSX-10) For controlling the tilt, and sideshifter function. 7. Hydraulic unit Pump motor, pump, electric valves, and oil tank integrated in a compact unit. 8. Hydraulic electric solenoid valve For controlling lifting and lowering function with electric solenoid valve. 9. Hydraulic manual valves For controlling hydraulic functions with a manual lever on top of truck. 10. Drive unit with brake Fixed drive unit with a spring applied brake, drive motor,

Presentation of main com ponents

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Presentation of main components

gear box, and drive wheel combined into a compact unit. The steering bearings are at the top of the drive unit.

11. Steering pivot point Lubricate pivot point to prevent stiff steering. 12. Electric panel 24 volt electrical system. Vehicle speed is regulated by means of a transistor controller. 13. Circuit breaker Control 12A, part number 301889-000. Pump 300A, part number 25094-04. Drive 105A, part number 307601-001 (CSX10/20) 150A, part number 307601-000 requires 2. (CSX30/40) 14. Mast Covered by a finger protection which covers the operator’s normal range of reach from the operating position. 15. Load wheel Lubricate load wheels to prevent wheels from locking up. 16. Battery 24 volt with different capacities and weights. 17. Reverser switch The function is to prevent the operator from being pinched between the handle and an obstruction when traveling in the forward direction. 18. Horn switch The horn sounds to warn others of your position. 19. Fork raise switch The forks will raise when switch is pressed or until lift stops are reached. 20. Fork lower switch The forks will lower when switch is pressed or until lower

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Presentation

Presentation of main components

17 14

19 20

9 22

4 0

1/2

1 12 13

1 18

19 20

9 22

4 1 12 13

6 0

O FF

1/2

1 18

5 6

O FF

23 3

3 10

15 8

16 7

Presentation of main components drawing 34 Return

16 7

Presentation of main components drawing 34

Controls and instruments

Guards and shields have been provided on the truck for your protection.

DO NOT operate this truck unless all factory

Warning installed guards and shields are properly

Contro ls an d instruments

Warning installed guards and shields are properly

DO NOT operate this truck unless all factory

secured in place.

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

and observe all warnings on this unit Warning Read before operating it.

Control handle

The control handle is used to provide hand brake, direction, speed, and horn on this truck.

Fork Raise Switch

Fork Lower Switch

Fork Raise Switch

Fork Lower Switch

Steering Control Handle Horn Switch

Rearward

Directional Controls

Return

Forward

Rearward

Directional Controls

Forward

Controls and instruments Control for raising the forks

The control button activates a micro switch to start the pump motor with lifting.

The diagram illustrates the controls as seen from the operator’s position. Lift the forks by pressing ‘A’.

NOTE! The forks cannot be raised with the key switch in position O.

NOTE! The forks cannot be raised with the key switch in position O. Control for lowering the forks

Control for lowering the forks E

Lower the forks by pressing ‘E’. The lowering speed of the forks is controlled by a flow control valve. NOTE! The forks cannot be lowered with the key switch in position O.

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Lower the forks by pressing ‘E’. The lowering speed of the forks is controlled by a flow control valve. NOTE! The forks cannot be lowered with the key switch in position O.

Controls and instruments Travel direction selector and speed control

Select the travel direction by rotating ‘R’ in the required direction. The speed is controlled variably based on the position of the lever.

Horn

The horn sounds as long as the button is pressed.

Return

The horn sounds as long as the button is pressed.

Controls and instruments Reverser switch

Reverser Switch

Return

Controls and instruments Steering control handle/brake control

B1 F

Operate the truck with the steering control handle in the center range, F.

The brake is activated mechanically by the steering control handle/brake control. The brake is applied in two ranges, B1 and B2.

Parking brake (B1):

The arm automatically returns to position B1 when released.

Travel brake (B2):

Apply the brake by pushing the steering control handle downwards.

The brake function should always be checked before using this unit.

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Controls and instruments

Braking using plugging function

•

THE CONTROL HANDLE MUST NOT BE PLACED IN THE BRAKE POSITION DURING THE PLUG BRAKING OPERATION.

•

Return

Controls and instruments Dash Controls

Battery Discharge Indicator/Hourmeter Dash Display

Key Switch Off Master Control On/Off Switch

Battery Discharge Indicator/Hourmeter Dash Display

Key Switch Off Master Control On/Off Switch

Dash Panel Layout

Key switch (Toggle switch)

A key switch is provided to prevent unauthorized use of this unit. The key switch is located on the control panel cover.

The key switch has two (2) positions: OFF and ON.

1. Off Position: Turning the key to “OFF” will stop all electrical power from going to the control circuit from the battery.

Master control on/off switch

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Controls and instruments

BDI/hourmeter with lift interrupt

Fully-charged battery

1/2

Half-charged battery

1/2

Half-charged battery

Discharged battery

The battery indicator shows the actual charge level of the truck’s battery.

The hourmeter displays the time the drive motor is operating.

Battery discharge indicator (BDI)

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Controls and instruments

Hourmeter

The hourmeter displays the time the drive motor and/or the pump motor are operating.

Return

Controls and instruments

Emergency battery disconnect

Return

Controls and instruments

Mast Function Control Lever

Control for Raise/Lower using control lever

The Raise/Lower is controlled by pushing lever forward to lower the fork height on mast and pulling back to raise. The speed of raising/lowering can be controlled by the degree of movement of lever.

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Controls and instruments

Fork Function Control Levers

Auxiliary Hydraulic Control Lever

Control for Tilt/Auxiliary Control

The Tilt is controlled by pushing lever forward to lower fork tips and pulling back the lever to raise fork tips. The speed of tilt can be controlled by the degree of movement of lever.

Control for Sideshifter/Auxiliary Control (optional)

The Sideshifter is controlled by depressing and holding the sideshifter function button on side of auxiliary control lever and moving lever. Pulling lever will move forks Right and pushing will move forks Left. The speed of sideshifter can be controlled by the degree of movement of lever.

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Driving

The proper operator position for this truck is shown and described below.

Proper operation of this unit is with forks trailing when possible. Steering the truck is easier with the forks trailing. Always look in the direction of travel.

When forks are first to enter a confined area or elevator or on an incline keep both hands on control handle. Keep both hands within the handle guard and always look in the direction of travel.

Dr iving

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Driving

Starting the Truck

•

Ensure battery connector is connected to truck.

•

Ensure battery connector is connected to truck.

•

Master control on/off switch is in the on position. Turn key switch to position I. The instrument lighting comes on.

•

Master control on/off switch is in the on position. Turn key switch to position I. The instrument lighting comes on.

•

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

•

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

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 battery.

•

Move the control handle to the drive position (F). The parking brake is released when the control handle is moved to the drive position (F).

•

Move the control handle to the drive position (F). The parking brake is released when the control handle is moved to the drive position (F).

•

Move the travel direction selector/speed control in the desired direction.

•

Move the travel direction selector/speed control in the desired direction.

failure. Warning Function Safety can be jeopardized. Always check the following safety functions before starting the day’s work.

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failure. Warning Function Safety can be jeopardized. Always check the following safety functions before starting the day’s work. 48

Driving

•

Driving

- Horn functions correctly.

- Steering functions correctly.

- Brakes function correctly.

Start gently by accelerating slowly until the desired speed is reached. Dangerous driving.

Warning Accidents can occur. Always drive with care, good judgement and responsibility as set out in the general safety guidelines.

Return

•

Start gently by accelerating slowly until the desired speed is reached. Dangerous driving.

Warning Accidents can occur. Always drive with care, good judgement and responsibility as set out in the general safety guidelines.

Driving

Braking the Truck

Braking the Truck B1

2 B2

•

Brake by moving the arm to the B2 position will apply the travel brake. Release of the tiller arm automatically returns it to the parking brake position (B1).

•

Brake by moving the arm to the B2 position will apply the travel brake. Release of the tiller arm automatically returns it to the parking brake position (B1).

•

THE CONTROL HANDLE MUST NOT BE PLACED IN THE BRAKE POSITION DURING THE PLUG BRAKING OPERATION.

•

Driving

Steering the Truck

•

Steer by means of the control handle.

•

Steer by means of the control handle.

•

Risk of slipping.

Warning If hands or shoes are oily there is a risk of

slipping causing loss of control of truck. Always dry hands and shoes before driving.

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Driving

Parking the Truck

•

Stop truck and disengage travel direction selector.

•

Stop truck and disengage travel direction selector.

•

Release steering control handle. The handle will automatically return to the parking brake position and brakes are applied.

•

Release steering control handle. The handle will automatically return to the parking brake position and brakes are applied.

•

Turn key switch to the O position.

•

Turn key switch to the O position.

•

Always remove key from key switch when truck is left unattended.

•

Always remove key from key switch when truck is left unattended.

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Transporting loads

General Information

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

Tr ansportin g loads

Risk of overturning.

Warning 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.

•

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.

•

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.

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.

loads. Warning Protruding The load can collide with personnel, fixed or

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

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Transporting loads

NOTE! Increased truck width. The load can collide with fixed objects. A truck with wide loads requires a greater operating area.

•

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.

•

Risk of overturning.

Warning 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 grade. Drive at a reduced speed, using the truck’s motor brake.

of overloading the elevator. Warning Risk 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.

Return

•

Transporting loads

the edges.

Warning Risk of tipping.

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.

Return

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

•

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

•

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

•

Lower the forks to the fully down position.

•

Lower the forks to the fully down position.

•

Drive the truck rearward so that the forks are positioned in the center and as far as possible under the load.

•

Drive the truck rearward so that the forks are positioned in the center and as far as possible under the load.

•

Lift the forks so that the load is lifted free of the rack.

•

Lift the forks so that the load is lifted free of the rack.

•

Reverse the truck so that the load clears the rack.

•

Reverse the truck so that the load clears the rack.

•

Lower the load to floor level and drive carefully away from the rack by start slowly and then increase the speed.

•

Lower the load to floor level and drive carefully away from the rack by start slowly and then increase the speed.

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.

Transporting loads

Leaving a load

•

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

•

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

•

Lift the load to the required lifting position.

•

Lift the load to the required lifting position.

•

Drive the truck forward so that the load is positioned correctly on the rack.

•

Drive the truck forward so that the load is positioned correctly on the rack.

NOTE! Forks not horizontal. The load can slide off the forks or catch on the rack. When the load is left or collected the forks should always be positioned horizontally.

•

Lower the forks so that they clear the load.

•

Lower the forks so that they clear the load.

•

Reverse the truck.

•

Reverse the truck.

•

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

•

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

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.

Return

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.

Battery

Type of battery

•

Battery

Check that the battery used in this truck is the correct voltage and type 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

•

of moving the center of gravity. Warning Risk 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 master control on/off switch to the OFF position to stop hourmeter from running.

•

Push the master control on/off switch 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.

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

•

Install battery stops.

•

Install battery stops.

•

Push the master control on/off switch to the ON position.

•

Push the master control on/off switch to the ON position.

Falling battery.

Warning 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.

Falling battery.

Warning 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.

Return

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 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

Corrosive acid.

Warning The battery fluid contains sulfuric acid. Fluid

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.

the charging process oxygen and Warning During hydrogen gases are always formed in the

During charging

•

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

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

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.

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

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Battery

Battery maintenance

Carry out battery maintenance after recharging.

Corrosive acid.

Warning The battery fluid contains sulfuric acid. Fluid

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

manufactures maintenance and Warning Battery charging procedures must be followed.

Battery acid is very corrosive and must be immediately cleaned up after spillage.

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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 shown in the chart.

•

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 shown in the chart.

•

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.

Daily service/safety checks

Never neglect the daily service and safety

Warning 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.

Return

Never neglect the daily service and safety

Warning 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.

Daily service/safety checks

Daily service/safety checks drawing 2

Daily service/safety checks drawing

2 6

6 16

17 0

1/2

4 5 19

OFF

7 0

1/2

4 5 19

OFF

10 11

12 13

DO NOT continue to operate the truck

Warning when it is not functioning properly. Item #

Check points

Action

Direction / speed control

Warning when it is not functioning properly. Item #

Check points

Action

Check its function

Direction / speed control

Check its function

Reverser switch

Check its function

Reverser switch

Check its function

Horn

Check its function

Horn

Check its function

Handle steering

Check its function

Handle steering

Check its function

Parking brake

Check its function

Parking brake

Check its function

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12 13

Daily service/safety checks Item #

Check points

Action

Hydraulic function

Check its function

Running time

Daily service/safety checks Item #

Check points

Action

Hydraulic function

Check its function

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.

Hydraulic system

Check for oil leakage, hoses, and floor

Hydraulic system

Check for oil leakage, hoses, and floor

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

Chassis

Check for damage, remove dirt and debris

Chassis

Check for damage, remove dirt and debris

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

Fork carriage

Check the locking and for damage and wear

Fork carriage

Check the locking and for damage and wear

Lifting device

Check for damage and alignment of forks

Lifting device

Check for damage and alignment of forks

Hydraulic cylinder

Check for damage and leakage

Hydraulic cylinder

Check for damage and leakage

Key switch (toggle)

Check its function

Key switch (toggle)

Check its function

Master control on/off switch

Check its function

Master control on/off switch

Check its function

Covers / guards

Check for damage, ensure placement

Covers / guards

Check for damage, ensure placement

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

Special equipment

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Maintenance

General information

•

Under normal conditions ensure that truck is given a regular maintenance service. See “Maintenance chart” on page 74. The truck’s safety, efficiency, and service life is dependent on the service and maintenance it is given.

•

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

•

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

•

BT Prime-Mover recommends that you contact your BT Prime-Mover representative to set up a service and maintenance agreement to ensure your truck’s operating efficiently and safety.

•

BT Prime-Mover recommends that you contact your BT Prime-Mover representative to set up a service and maintenance agreement to ensure your truck’s operating efficiently and safety.

Mainten ance

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.

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Maintenance

Warning Short-circuiting/burns.

•

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

•

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

•

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.

•

Bear in mind that the oil in the transmission or the hydraulic system can be hot.

Warning Risk of burns.

Hot transmission and hydraulic oil. Let the truck cool before changing the oil.

•

Only fill the hydraulic system with new clean oil. Oil should meet BT Prime-Mover cleanliness specification 12-00002. Contact your BT Prime-Mover representative for assistance or more information.

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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 Prime-Mover cleanliness specification 12-00002. Contact your BT Prime-Mover representative for assistance or more information. 69

Maintenance

Warning The hydraulic system can be damaged.

If 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 cleaning solution, 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 cleaning solution, 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.

•

When working underneath the truck support the truck on trestle-blocks.

Warning Risk of crushing.

A badly supported truck can fall. Never work under a truck that is not supported on trestle-blocks and secured by a lifting device.

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A badly supported truck can fall. Never work under a truck that is not supported on trestle-blocks and secured by a lifting device.

Maintenance

Maintenance that can be carried out by driver

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 that may be carried out maintenance personnel

Maintenance that may maintenance personnel

trained

carried out by trained

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

•

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.

Return

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 the truck is important to ensure the truck will operate safely and reliably.

•

Carry out general cleaning and washing weekly.

External cleaning

•

Remove debris, etc. from the wheels daily.

•

Remove debris, etc. from the wheels daily.

•

Use a degreasing agent diluted to a suitable concentration.

•

Use a degreasing agent diluted to a suitable concentration.

•

Rinse off loose grime using warm water.

•

Rinse off loose grime using warm water.

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.

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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

Blow electric motors dry using compressed air.

Warning Compressed air used for cleaning MUST be

reduced to less than 30 psi [207 kPa], and then only with effective chip-guarding and personal protective equipment.

•

Clean the electrical panels, electronic boards, contacts, connector, solenoid valves, etc. using a damp cloth and a cleaning agent.

•

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.

•

Do not spray or pressure wash in the compartment.

NOTE! Risk of short-circuiting. Electrical components can be damaged. Do not break warranty seal on electronic components.

Return

NOTE! Risk of short-circuiting. Electrical components can be damaged. Do not break warranty seal on electronic components.

Maintenance

Maintenance chart

PM Interval:

A=8 Hours or 1 Day

E=720 Hours or 6 Months

A=8 Hours or 1 Day

E=720 Hours or 6 Months

B=30 Hours or 1 Week

F=1440 Hours or 12 Months

B=30 Hours or 1 Week

F=1440 Hours or 12 Months

C=120 Hours or 1 Month

G=4320 Hours or 36 Months

C=120 Hours or 1 Month

G=4320 Hours or 36 Months

D=360 Hours or 3 Months

No.

Action

1.0

Chassis

1.1

Check that the truck’s data plate is legible

1.2

No.

Action

1.0

Chassis

1.1

Check that the truck’s data plate is legible

Check the cover screws

1.2

Check the cover screws

1.3

Check door lock

1.3

Check door lock

1.4

Check for damage and crack formation

1.4

Check for damage and crack formation

1.5

Check fork frame mounting

1.5

Check fork frame mounting

1.6

Check wear on battery stop (optional)

1.6

Check wear on battery stop (optional)

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 torque of motor bolts

2.3

Check torque of motor bolts

2.4

Check for abnormal bearing noise

2.4

Check for abnormal bearing noise

2.5

Check brush wear

2.5

Check 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 and debris

4.1

Remove string and debris

4.2

Check all wheels for wear

4.2

Check all wheels for wear

4.3

Check that all wheels rotate and axles are fitted correctly

4.3

Check that all wheels rotate and axles are fitted correctly

4.4

Check all wheels for loose screws

4.4

Check all wheels for loose screws

Return

Maintenance No.

Action

No.

Action

4.5

Grease load wheel bearings

4.5

Grease load wheel bearings

4.6

Grease caster and caster wheels

4.6

Grease caster and caster wheels

4.7

Dismantle and lubricate all wheel bearings.

4.7

Dismantle and lubricate all wheel bearings.

5.0

Brake

5.0

Brake

5.1

Clean dust and debris

5.1

Clean dust and debris

5.2

Check shoes and discs for wear

5.2

Check shoes and discs for wear

5.3

Check correct clearance brake

5.3

Check correct clearance brake

5.4

Check brake operation

5.4

Check brake operation

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 main contactor function

6.3

Check main contactor function

6.4

Check the contactor tips for free movements

6.4

Check the contactor tips for free movements

6.5

Check all cable insulation for damage

6.5

Check all cable insulation for damage

7.0

Electronic card

7.0

Electronic card

7.1

Check for connections in harness connectors

7.1

Check for connections in harness connectors

8.0

Electronic control system

8.0

Electronic control system

8.1

Check key switch (option toggle)

8.1

Check key switch (option toggle)

8.2

Check brake switch

8.2

Check brake switch

8.3

Check control wiring harness for proper routing

8.3

Check control wiring harness for proper routing

9.0

Battery

9.0

Battery

9.1

Check electrolyte level, 1/2 - 5/8 in. [10-15 mm] above cell plate

9.1

Check electrolyte level, 1/2 - 5/8 in. [10-15 mm] above cell plate

9.2

Check the connections on battery, truck, and charger

9.2

Check the connections on battery, truck, and charger

9.3

Check all cells and pole guards

9.3

Check all cells and pole guards

9.4

Check the fluid density and temperature

9.4

Check the fluid density and temperature

9.5

Check power cables are not cut or frayed

9.5

Check power cables are not cut or frayed

Return

Maintenance B

X X X

Maintenance No.

Action

10.0

Hydraulic system

No.

Action

10.0

Hydraulic system

10.1

Check hoses and connections for leakage

10.1

Check hoses and connections for leakage

10.2

Check hoses for wear and damage

10.2

Check hoses for wear and damage

10.3

Check oil tank for cracks, leaks, and mounting

10.3

Check oil tank for cracks, leaks, and mounting

10.4

Check oil level

10.4

Check oil level

10.5

Change oil

10.5

Change oil

11.0

Cylinder

11.0

Cylinder

11.1

Check for leakage

11.1

Check for leakage

11.2

Check the mountings

11.2

Check the mountings

12.0

Lift devices

12.0

Lift devices

12.1

Check for damage and cracks

12.1

Check for damage and cracks

12.2

Check mast mounting bolts torque

12.2

Check mast mounting bolts torque

12.3

Check for play on rollers

12.3

Check for play on rollers

12.4

Check the electrical limit switch function

12.4

Check the electrical limit switch function

12.5

Check for wear and stretch on the chains and sheaves

12.5

Check for wear and stretch on the chains and sheaves

12.6

Check hoses and couplings for leakage, cuts, and other damage

12.6

Check hoses and couplings for leakage, cuts, and other damage

12.7

Check for wear to the forks and other lifting devices

12.7

Check for wear to the forks and other lifting devices

12.8

Lube all grease fittings

12.8

Lube all grease fittings

13.0

Controls

13.0

Controls

13.1

Check handle mounting

13.1

Check handle mounting

13.2

Check the handle brake switch

13.2

Check the handle brake switch

13.3

Check travel direction/speed control

13.3

Check travel direction/speed control

13.4

Check horn button function

13.4

Check horn button function

13.5

Check hydraulic button functions

13.5

Check hydraulic button functions

13.6

Check the handle control switches

13.6

Check the handle control switches

13.7

Check the reverser switch

13.7

Check the reverser switch

Return

Maintenance B

Maintenance No.

Action

13.8

Check hydraulic manual control lever functions

14.0

Gauge

14.1

Check dash display

15.0

Brake lever

15.1

Check parking brake lever

15.2

Check that the control handle returns to the upright position with parking brake applied

16.0

Master control on/off switch

16.1

Check the function of switch

Maintenance B

No.

Action

13.8

Check hydraulic manual control lever functions

14.0

Gauge

14.1

Check dash display

15.0

Brake lever

15.1

Check parking brake lever

15.2

Check that the control handle returns to the upright position with parking brake applied

16.0

Master control on/off switch

16.1

Check the function of switch

1/ 2

ON OFF

1/ 2

14 15 6 7

1 18

16 2

3 4

4 2

Return

6 7

14 15 ON OFF

13 11

Maintenance

Lubrication chart

Lubrication chart Interval/Running hours

Pos No.

Service point

Wheel bearings

Hydraulic system

Parking brake

Drive gear

Hinges

Steering bearings

Mast

720h

Lubricant

Wheel bearings

Hydraulic system

Parking brake

Drive gear

Hinges

Steering bearings

Mast

C=Check

Service point

O=Oil change

720h

1440h

A B

L=Lubrication

C=Check

O=Oil change

4320h

See “Approved Oils and Grease Chart” on page 79.

4 1

Return

Lubricant

4320h

1440h

L=Lubrication

Interval/Running hours

Pos No.

See “Approved Oils and Grease Chart” on page 79.

6 78

Maintenance

Approved Oils and Grease Chart

Specification Standard & Corrosion Environment

Lubricant

Continuous Operation Above 23° F (-5° C)

Standard & Corrosion Environment

Cold Storage Continuous Operation To 5° F (-15° C)

Application area

Lubricant

Intermittent Operation To -13° F (-25° C)

Continuous Operation Above 23° F (-5° C)

Cold Storage Continuous Operation To 5° F (-15° C)

Application area

Intermittent Operation To -13° F (-25° C)

Bearings and bushings

Grease

ATF

Hydraulic system

Hydraulic oil

Sunoco TH

ATF

Hydraulic system

ATF

Gears

Transmissi on oil

SAE 80

ATF

Gears

#10 W 40

Chains

D Motor Oil

Grease

Hydraulic oil

Sunoco TH

Transmissi on oil

SAE 80

D Motor Oil

Specification

Mystik JT-6

Bearings and bushings

Mystik JT-6

#10 W 40

Chains

Grease

Molykote 200025*

Mast rails, reach, sideshift

Grease

Molykote 200025*

Mast rails, reach, sideshift

Grease

49670-00*

Mast rails, reach, sideshift

Grease

49670-00*

Mast rails, reach, sideshift

* Refer to section 10000 of Parts Book for special lubricants.

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

Environmental Definitions

Standard

Trucks parked outside when not in use and charging and maintenance work

Standard

Trucks parked outside when not in use and charging and maintenance work

Corrosion

Where a damp, wet, or corrosive condition exit

Corrosion

Where a damp, wet, or corrosive condition exit

Return

Maintenance

Environmental Definitions

Continuous Cold Operation

Intermittent Cold Operation

Freezer Condition

Return

Continuous Cold Operation

Intermittent Cold Operation

Freezer Condition

Transporting and storing the truck

Truck’s dimensions and weight as standard

Tr ansportin g and sto ring the tru ck

NOTE! The truck’s weights and measurements are only estimates and can very on trucks with different accessories. Consult your truck’s data plate for specific information.

Truck’s dimensions and weight

CSX10

CSX20

CSX30

CSX40

CSX10

CSX20

CSX30

Height (less mast down height)

60 inch [1524 mm]

Height (less mast down height)

60 inch [1524 mm]

Width (Minimum width)

35 inch [889 mm]

Width (Minimum width)

35 inch [889 mm]

50 inch 65 inch 71 inch 77 inch [1955 mm] [1651 mm] [1803 mm] [1955 mm]

Length Minimum battery weight Service weight

Return

Consult data plate on truck 3400 lb [1542 kg]

3780 lb [171 kg]

4610 lb [2091 kg]

5985 lb [2715 kg]

With battery

3990lb [1809kg]

4730 lb [2145 kg]

5560 lb [2522 kg]

7195 lb [3264 kg]

50 inch 65 inch 71 inch 77 inch [1955 mm] [1651 mm] [1803 mm] [1955 mm]

Length Minimum battery weight

Without battery

Service weight

CSX40

Consult data plate on truck

Without battery

3400 lb [1542 kg]

3780 lb [171 kg]

4610 lb [2091 kg]

5985 lb [2715 kg]

With battery

3990lb [1809kg]

4730 lb [2145 kg]

5560 lb [2522 kg]

7195 lb [3264 kg]

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

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.

Return

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.

Transporting and storing the truck

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 “Maintenance chart” on page 74

•

When stored for a period greater then 3 months carry out preventive maintenance as stated in the “Maintenance chart” on page 74

Return

APPENDEX A - Selected OSHA Regulations

APPENDIX A - Selected OSHA Regulations

•

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 plates, tags or decals shall be changed accordingly. (a) (3)

•

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 plates, tags or decals shall be changed accordingly. (a) (3)

•

The user shall see that all nameplates and markings are in place and are maintained in a legible condition. (a) (6)

•

The user shall see that all nameplates and markings are in place and are maintained in a legible condition. (a) (6)

•

APPENDIX A - Selected OSHA Regulation s

Return

APPENDEX A - Selected OSHA Regulations

•

An evaluation of each powered industrial truck operator’s performance shall be conducted at least once every three years. (l) (4) (iii)

•

An evaluation of each powered industrial truck operator’s performance shall be conducted at least once every three years. (l) (4) (iii)

•

The employer shall prohibit arms or legs from being placed between the uprights of the mast or outside the running lines of the truck. (m) (4)

•

The employer shall prohibit arms or legs from being placed between the uprights of the mast or outside the running lines of the truck. (m) (4)

Return

APPENDEX A - Selected OSHA Regulations

•

Only approved industrial trucks shall be used in hazardous locations. (m) (11)

•

Only approved industrial trucks shall be used in hazardous locations. (m) (11)

•

Under all travel conditions the truck shall be operated at a speed that will permit it to be brought to a stop in a safe manner. (n) (8)

•

Under all travel conditions the truck shall be operated at a speed that will permit it to be brought to a stop in a safe manner. (n) (8)

•

Stunt driving and horseplay shall not be permitted. (n) (9)

•

Stunt driving and horseplay shall not be permitted. (n) (9)

•

Any power-operated industrial truck not in safe operating condition shall be removed from service. All repairs shall be made by authorized personnel. (q) (1)

•

Any power-operated industrial truck not in safe operating condition shall be removed from service. All repairs shall be made by authorized personnel. (q) (1)

•

All parts of any such industrial truck requiring replacement shall be replaced only by parts equivalent as to safety with those used in the original design. (q) (5)

•

All parts of any such industrial truck requiring replacement shall be replaced only by parts equivalent as to safety with those used in the original design. (q) (5)

Return

APPENDEX A - Selected OSHA Regulations

•

Return

In dex

Index

Appendix A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Application area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Approved Oils and Grease . . . . . . . . . . . . . . . . . . . . . . 79

B Battery After charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Battery maintenance . . . . . . . . . . . . . . . . . . . . . . . . 63 Each month . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Each week . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Changing the battery . . . . . . . . . . . . . . . . . . . . . . . . 58 Charging the battery . . . . . . . . . . . . . . . . . . . . . . . . 60 During charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 General prohibition . . . . . . . . . . . . . . . . . . . . . . . . . 60 Pre-charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Type of battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Battery discharge indicator (BDI) . . . . . . . . . . . . . . . . . . 42 BDI/hourmeter with lift interrupt . . . . . . . . . . . . . . . . . . . 42 Brake Braking using plugging function . . . . . . . . . . . . . . . . 40 Braking the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

C Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56, 57 Cleaning and washing . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Cleaning the motor compartment . . . . . . . . . . . . . . 72 Electrical components . . . . . . . . . . . . . . . . . . . . . . . 73 External cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Control Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Lowering the forks . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Raising the forks . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Reverser switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Steering control handle/brake control . . . . . . . . . . . 39 Travel brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Return

C Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56, 57 Cleaning and washing . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Cleaning the motor compartment . . . . . . . . . . . . . . 72 Electrical components . . . . . . . . . . . . . . . . . . . . . . . 73 External cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Control Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Lowering the forks . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Raising the forks . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Reverser switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Steering control handle/brake control . . . . . . . . . . . 39 Travel brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Index Travel direction selector and speed control . . . . . . . 37 Control handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Controls and instruments . . . . . . . . . . . . . . . . . . . . . . . . 35

D Daily service/safety checks . . . . . . . . . . . . . . . . . . . . . . 65 Special equipment . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Data plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Dimensions CSX-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 CSX-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 CSX-30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 CSX-40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Braking the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Parking the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Starting the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Steering the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

E Emergency battery disconnect . . . . . . . . . . . . . . . . . . . . 34

F Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Fork Function Control Levers . . . . . . . . . . . . . . . . . . . . . 46 Control for Sideshifter/Auxiliary Control (optional) . . 46 Control for Tilt/Auxiliary Control . . . . . . . . . . . . . . . . 46

G General safety regulations . . . . . . . . . . . . . . . . . . . . . . . 10 Maintenance and repair . . . . . . . . . . . . . . . . . . . . . . 19 Operating the truck . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Ordinance symbols . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Parking the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Working area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

H Hourmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Return

D Daily service/safety checks . . . . . . . . . . . . . . . . . . . . . . 65 Special equipment . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Data plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Dimensions CSX-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 CSX-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 CSX-30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 CSX-40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Braking the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Parking the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Starting the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Steering the truck . . . . . . . . . . . . . . . . . . . . . . . . . . 51

E Emergency battery disconnect . . . . . . . . . . . . . . . . . . . 34

F Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Fork Function Control Levers . . . . . . . . . . . . . . . . . . . . 46 Control for Sideshifter/Auxiliary Control (optional) . . 46 Control for Tilt/Auxiliary Control . . . . . . . . . . . . . . . . 46

G General safety regulations . . . . . . . . . . . . . . . . . . . . . . . 10 Maintenance and repair . . . . . . . . . . . . . . . . . . . . . . 19 Operating the truck . . . . . . . . . . . . . . . . . . . . . . . . . 10 Ordinance symbols . . . . . . . . . . . . . . . . . . . . . . . . . 8 Parking the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Working area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

H Hourmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Index

Lubrication chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

M Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Driver maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 71 General information . . . . . . . . . . . . . . . . . . . . . . . . . 68 Maintenance personnel . . . . . . . . . . . . . . . . . . . . . . 71 Safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Maintenance chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Mast Function Control Lever . . . . . . . . . . . . . . . . . . . . . 45 Control for Raise/Lower using control lever . . . . . . . 45

Lubrication chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

NOTE! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36, 48, 54, 57, 59, 62, 63, 72, 73, 81 Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

NOTE! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36, 48, 54, 57, 59, 62, 63, 72, 73, 81 Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Oils and Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 OSHA regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

P Parking the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Presentation of main components . . . . . . . . . . . . . . . . . 32 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Circuit breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Data plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Drive unit with brake . . . . . . . . . . . . . . . . . . . . . . . . 32 Electric panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Fork lower switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Fork raise switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Horn switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

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Oils and Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 OSHA regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Index Hydraulic control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Hydraulic electric solenoid valve . . . . . . . . . . . . . . . . 32 Hydraulic manual valves . . . . . . . . . . . . . . . . . . . . . . 32 Hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Key switch (toggle switch) . . . . . . . . . . . . . . . . . . . . 34 Load wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Master control on/off switch . . . . . . . . . . . . . . . . . . . 34 Reverser switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Steering control handle . . . . . . . . . . . . . . . . . . . . . . . 32 Steering pivot point . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Travel speed / direction selection . . . . . . . . . . . . . . . 34 Presentation of truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Prohibited applications . . . . . . . . . . . . . . . . . . . . . . . . . . 23

S Safety Symbol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Standard Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Starting the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Steering the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Storing Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Drive unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Starting after a period of disuse . . . . . . . . . . . . . . . . 84 Transporting and storing the truck . . . . . . . . . . . . . . 81 Storing the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Symbols Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 General prohibition . . . . . . . . . . . . . . . . . . . . . . . . . . 8 No Smoking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Note! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Open flames prohibited . . . . . . . . . . . . . . . . . . . . . . . 8 Protective glasses . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Safety Alert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Safety shoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Return

Index Hydraulic control . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Hydraulic electric solenoid valve . . . . . . . . . . . . . . . 32 Hydraulic manual valves . . . . . . . . . . . . . . . . . . . . . 32 Hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Key switch (toggle switch) . . . . . . . . . . . . . . . . . . . . 34 Load wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Master control on/off switch . . . . . . . . . . . . . . . . . . . 34 Reverser switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Steering control handle . . . . . . . . . . . . . . . . . . . . . . 32 Steering pivot point . . . . . . . . . . . . . . . . . . . . . . . . . 33 Travel speed / direction selection . . . . . . . . . . . . . . 34 Presentation of truck . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Prohibited applications . . . . . . . . . . . . . . . . . . . . . . . . . 23

S Safety Symbol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Standard Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Starting the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Steering the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Storing Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Drive unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Starting after a period of disuse . . . . . . . . . . . . . . . . 84 Transporting and storing the truck . . . . . . . . . . . . . . 81 Storing the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Symbols Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 General prohibition . . . . . . . . . . . . . . . . . . . . . . . . . 8 No Smoking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Note! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Open flames prohibited . . . . . . . . . . . . . . . . . . . . . . 8 Protective glasses . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Safety Alert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Safety shoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Index

Towing and transporting a disabled truck . . . . . . . . . . . 82 Transporting loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Collecting a load . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 General Information . . . . . . . . . . . . . . . . . . . . . . . . . 53 Leaving a load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Truck Dimensions and weight chart . . . . . . . . . . . . . . . . . . 81 Truck battery dimensions . . . . . . . . . . . . . . . . . . . . . . . . 25 Truck data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

U U.L. construction type . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Towing and transporting a disabled truck . . . . . . . . . . . 82 Transporting loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Collecting a load . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 General Information . . . . . . . . . . . . . . . . . . . . . . . . . 53 Leaving a load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Truck Dimensions and weight chart . . . . . . . . . . . . . . . . . 81 Truck battery dimensions . . . . . . . . . . . . . . . . . . . . . . . 25 Truck data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

U U.L. construction type . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1, 35, 48, 49, 51, 53, 54, 55, 58, 59, 60, 61, 63, 64, 65, 66, 69, 70, 73, 82 Warning and information signs . . . . . . . . . . . . . . . . . . . 20

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Back Cover

BT Prime-Mover, Inc., 3305 N. Highway 38 Muscatine, Iowa 52761-8800 U.S.A. Tel (563) 262-7700 • Fax (563) 262-7600

Return

BT Prime-Mover, Inc., 3305 N. Highway 38 Muscatine, Iowa 52761-8800 U.S.A. Tel (563) 262-7700 • Fax (563) 262-7600