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Operator’s Manual

RTX35/45

Electric Stand-Up Rider Truck

Effective Serial Number RTX3530317001 - UP

1+ 01/2

+01/12

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

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

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

Part no: 310426-000

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Date: November 17, 2000

+01/12

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

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

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

Part no: 310426-000

Date: November 17, 2000

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 REPAIR MANUALS MAY BE OBTAINED FROM YOUR EQUIPMENT DEALER.

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INJURY OR DEATH TO YOU OR OTHER

! WARNING PERSONNEL COULD OCCUR IF YOU DO

NOT FOLLOW THESE INSTRUCTIONS AND MESSAGES.

! WARNING PERSONNEL COULD OCCUR IF YOU DO

Foreword

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

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 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 to 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 are 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.

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

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Table of Contents

Safety Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Safety Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Warning symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Prohibitory symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Ordinance symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 General Safety Regulations . . . . . . . . . . . . . . . . . . . . . . . . .7

Warning symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Prohibitory symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Ordinance symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 General Safety Regulations . . . . . . . . . . . . . . . . . . . . . . . . . 7

Warning and Information Signs . . . . . . . . . . . . . . . . . . . . . .17

Warning and Information Signs . . . . . . . . . . . . . . . . . . . . . . 17

Presentation of Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Presentation of Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Application area for BT Prime-Mover’s trucks . . . . . . . . . .19 Prohibited applications for BT Prime-Mover’s truck . . . . . .19 Truck data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 Truck battery dimensions . . . . . . . . . . . . . . . . . . . . . . . . . .20 RTX35 Truck dimensions . . . . . . . . . . . . . . . . . . . . . . . . .21 RTX45 Truck dimensions . . . . . . . . . . . . . . . . . . . . . . . . .22 Data plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 U.L. Construction type . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Application area for BT Prime-Mover’s trucks . . . . . . . . . . 19 Prohibited applications for BT Prime-Mover’s truck . . . . . . 19 Truck data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Truck battery dimensions . . . . . . . . . . . . . . . . . . . . . . . . . 20 RTX35 Truck dimensions . . . . . . . . . . . . . . . . . . . . . . . . . 21 RTX45 Truck dimensions . . . . . . . . . . . . . . . . . . . . . . . . . 22 Data plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 U.L. Construction type . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Presentation of Main Components . . . . . . . . . . . . . . . . . . .25

Presentation of Main Components . . . . . . . . . . . . . . . . . . . 25

Controls and Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Controls and Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Emergency stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28 Key switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29 Horn control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29 Directional/Speed control handle . . . . . . . . . . . . . . . . . . . .29 Steering wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 Hydraulic controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 Switches: Lamps and fans . . . . . . . . . . . . . . . . . . . . . . . . .34 Brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 Height indicator (option) . . . . . . . . . . . . . . . . . . . . . . . . . . .36

Emergency stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Key switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Horn control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Directional/Speed control handle . . . . . . . . . . . . . . . . . . . . 29 Steering wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Hydraulic controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Switches: Lamps and fans . . . . . . . . . . . . . . . . . . . . . . . . . 34 Brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Height indicator (option) . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Warning/Caution Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

Warning/Caution Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Starting the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44 Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47 Parking the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

Starting the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Parking the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

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Table of Contents

Transporting Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Collecting a load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Leaving a load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Type of battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Changing the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Charging the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 General prohibition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Daily Service/Safety Checks . . . . . . . . . . . . . . . . . . . . . . . . 61

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Safety regulations with maintenance work . . . . . . . . . . . . 63 Cleaning and washing . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Cleaning the motor compartment . . . . . . . . . . . . . . . . . . . 66 Cleaning and washing . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Maintenance chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Lubrication chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Approved oils and grease . . . . . . . . . . . . . . . . . . . . . . . . . 73

Transporting and Storing the Truck . . . . . . . . . . . . . . . . . . 74

The truck’s dimensions and weight as standard . . . . . . . . 74 Lifting the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Towing and transporting a disabled truck . . . . . . . . . . . . . 77 Storing the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Starting after a period of disuse . . . . . . . . . . . . . . . . . . . . 78

The truck’s dimensions and weight as standard . . . . . . . 74 Lifting the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Towing and transporting a disabled truck . . . . . . . . . . . . . 77 Storing the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Starting after a period of disuse . . . . . . . . . . . . . . . . . . . . 78

Recycling/Discarding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Discarding the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Scrapping the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Discarding the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Scrapping the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

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Safety Regulations Warning symbols

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

Warning levels

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

DANGER

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

WARNING

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

CAUTION

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

NOTE!

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

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

Safety Regulations

Prohibitory symbols

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

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

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

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. Contact your authorized BT Prime-Mover dealer.

•

The truck must not be used if it is damaged or has faults that affect safety or its safe use. Contact your authorized BT Prime-Mover dealer.

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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 and from locations.

•

The truck is designed and produced to be your tool when transporting goods to and from 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 purposes other than those for which it was designed and produced. For example, the following applications:

•

It is not permitted to use the truck for purposes other than those for which it was designed and produced. For example, the following applications:

•

Do not operate in areas where the atmosphere contains gases that can cause fires or explosions

•

Do not operate in areas where the atmosphere contains gases that can cause fires or explosions

•

Do not use as a towing truck for trailers

•

Do not use as a towing truck for trailers

•

Do not tow other lift trucks

•

Do not tow other lift trucks

•

Do not transport/lift passengers

•

Do not transport/lift passengers

•

Do not drive on gravel or grass

•

Do not drive on gravel or grass

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Safety Regulations

General Safety Regulations

Operator’s responsibility

•

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

•

The truck shall only be driven by personnel that are specially trained and have authorization 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 those of your country (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 your body between moving and stationary objects.

•

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

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Safety Regulations

General Safety Regulations

Working area

•

If there are marked truck routes, these shall be used.

•

If there are marked truck routes, these shall be used.

•

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

•

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

•

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

•

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

•

Ensure that the floor where the truck is to be used has sufficient load bearing capacity for the 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 the 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, i.e., areas that can be reached by falling goods, lowering or falling lifting devices, or in the truck’s maneuvering area.

•

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

•

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

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Safety Regulations

General Safety Regulations

Driving and conduct while driving

•

Always drive the truck from the normal operator position.

•

Always drive the truck from the normal operator position.

•

Always drive the truck in a responsible manner and with full control. Use caution when starting and braking. Reduce speed when turning corners.

•

Always drive the truck in a responsible manner and with full control. Use caution when starting and braking. Reduce speed when turning corners.

•

Drive at a reduced speed on inclines. Do not turn the truck on an incline.

•

Drive at a reduced speed on inclines. Do not 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. Being aware of your surroundings reduces the risk of accidents.

•

Pay particular attention to other personnel, as well as fixed and moving objects, within the working area. Being aware of your surroundings reduces the risk of 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 nearing other vehicles and when the attention of other personnel is required.

•

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

•

Always yield the right of way to a loaded truck at junctions and in confined aisles.

•

Always yield the right of 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’s compartment.

•

Never drive with any part of your body outside of the operator’s compartment.

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Safety Regulations

•

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 onto another vehicle, make sure the vehicle is stable, the brakes have been applied correctly, and the wheels are chocked.

•

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

•

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

•

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 the truck.

•

DO NOT smoke while working around the 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.

•

When traveling, keep the forks as low as possible. Keep a safe distance from persons in the immediate area.

•

When traveling, keep the forks as low as possible. Keep a safe distance from persons in the immediate area.

•

Only handle loads that are within the truck’s permitted lifting capacity.

•

Only handle loads that are within the truck’s permitted lifting capacity.

•

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 dragged or pushed horizontally.

•

The load shall only be lifted vertically and NEVER dragged or pushed horizontally.

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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 “Battery” on page 54.

•

Always handle the battery and its connections with care. Read and follow the instructions for changing or recharging the battery carefully. See “Battery” on page 54.

•

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

Only qualified and trained personnel are permitted to maintain, adjust, or repair the truck. See “Maintenance” on page 63.

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

Modifications and additions which affect capacity and safe operation shall not be performed by the customer or user without prior written approval of the manufacturer. Consult your BT Prime-Mover dealer. Capacity, operation, and maintenance instruction plate, tags, or decals shall be changed accordingly.

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Warning and Information Signs

Warning and information signs

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

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

2. List of warnings.

3. Pinch points: Do not reach through uprights.

4. Do not walk under an elevated load.

5. U.L. listed.

6. Truck data plate.

1 3 + 1/1 02

3 + 1/21 0

KEEP HANDS CLEAR

+1 01/2

Model

TrckuSerialNumber BatMatxmeiryumWt(.Lbs.)

MBaintimerumyWt(.Lbs).

UBatseteUrLyClTyapse

Max.AmpHr.

Type

Cap.(Lbs.)

LTreusckBaWtt .(.Lbs.) DCVoltage

Attachment

MastSerialNumber

MaBaxck°Tilt B

THANISSIA/OFSRMEKLBF5IT6TR.1INUCEFKFMEEETCTONSOTHREEXCDAETDESOFDEMSANIGUFSPNACETCUIFRECAT.OI NSOF BTPrime-Mvero,nIc. Muscatine, AI 52761

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Inches

HouRrate

+1 01/2

Model

TrckuSerialNumber

TrLeucskBaWtt .(.Lbs.)

MaBatxtmierumyWt(.Lbs.)

MBaintimerumyWt(.Lbs.)

DCVoltage

BatUseterUyLTClypaes

Max.AmpHr.

Type

ANTHISSI/AOFRSMKELBF5IT6TR.1UINCEFKFMEEETCTONSORTHEEXCDAETDESOFDEMSANIGUSPFNACETCUFIRCEAT.OI NSOF

Cap.(Lbs.)

Attachment

MastSeiralNumber

C B

A 310574-000

MaBaxck°Tilt

BTPrime-Mvero,Inc. Muscatine, IA52761

310574-000

Inches

HouRrate

Warning and Information Signs

Warning decals

New warning decals can be obtained at NO charge from your BT Prime-Mover dealer.

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.

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Presentation of Truck

Presentation of truck

BT Prime-Mover trucks are intended for handling pallets indoors. This truck is operated in a standing position. This truck has available different outrigger widths, lifting heights, and lifting capacities. Refer to the truck’s data plate for this information.

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

Application area for BT Prime-Mover’s trucks

BT Prime-Mover’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 Prime-Mover’s truck

Prohibited applications for BT Prime Mover’s truck

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

•

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

•

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

•

Do not use as a towing truck for trailers

•

Do not use as a towing truck for trailers

•

Do not tow other lift trucks

•

Do not tow other lift trucks

•

Do not transport or lift passengers

•

Do not transport or lift passengers

•

Do not drive on gravel or grass

•

Do not drive on gravel or grass

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Presentation of Truck

Truck data

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

Truck type

RTX35/45

Truck type

RTX35/45

Maximum operating speed without load, 24 volt Maximum operating speed without load, 36 volt

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

Maximum operating speed without load, 24 volt Maximum operating speed without load, 36 volt

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

Maximum operating speed with classified load, 24 volt Maximum operating speed with classified load, 36 volt

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

Maximum operating speed with classified load, 24 volt Maximum operating speed with classified load, 36 volt

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

Maximum operating gradient with load, %

5% (See Note)

Continuous noise level. dB (A)

<80

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

Maximum operating gradient with load, %

5% (See Note)

Continuous noise level. dB (A)

<80

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

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

Truck battery dimensions

Important

Use only batteries that meet the following specifications:

Compartment Size: Deep 14.4 inch [365.8 mm] Deep 16.4 inch [416.6 mm] Deep 20.9 inch [530.9 mm] Wide Height Battery Weight

Minimum Maximum 13.7 inch [348 mm] 14.2 inch [361 mm] 15.9 inch [404 mm] 16.4 inch [417 mm] 20.4 inch [518 mm] 20.9 inch [531 mm] 38.2 inch [970 mm] 38.7 inch [983 mm] 31.5 inch [800 mm] 32.0 inch [813 mm] (Consult Data plate on truck)

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

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Presentation of Truck

RTX35 Truck dimensions

The diagrams below shows external dimensions for RTX35.

RTX35 Dimensions

14.4 inch [365.8 mm] Battery

RTX35 16.4 inch [416.6 mm] Battery

Dimensions

14.4 inch [365.8 mm] Battery

16.4 inch [416.6 mm] Battery

b1 Chassis width

40.5 inch [1029 mm]

b1 Chassis width

40.5 inch [1029 mm]

h6 Height overhead

95 inch [2413 mm]

h6 Height over head

95 inch [2413 mm]

l1 Truck length less forks

70.14 inch [1781.5 mm]

72.2 inch [1833.8 mm]

l1 Truck length less forks

70.14 inch [1781.5 mm]

72.2 inch [1833.8 mm]

Y Wheel base

55.45 inch [1408.4 mm]

57.45 inch [1459.2 mm]

Y Wheel base

55.45 inch [1408.4 mm]

57.45 inch [1459.2 mm]

Turning radius

67.05 inch [1703.1 mm]

69.05 inch [1753.9 mm]

Turning radius

67.05 inch [1703.1 mm]

69.05 inch [1753.9 mm]

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Presentation of Truck

RTX45 Truck dimensions

The diagrams below shows external dimensions for RTX45.

Y l1

RTX45 Dimensions

16.4 inch [416.6 mm] Battery

RTX45 20.9 inch [530.9 mm] Battery

Dimensions

16.4 inch [416.6 mm] Battery

20.9 inch [530.9 mm] Battery

b1 Chassis width

40.5 inch [1029 mm]

b1 Chassis width

40.5 inch [1029 mm]

h6 Height over head

95 inch [2413 mm]

h6 Height over head

95 inch [2413 mm]

l1 Truck length less forks

74.64 inch [1895.86 mm]

79.14 inch [2010.16 mm]

l1 Truck length less forks

74.64 inch [1895.86 mm]

79.14 inch [2010.16 mm]

Y Wheel base

59.95 inch [1522.73 mm]

64.45 inch [1637.03 mm]

Y Wheel base

59.95 inch [1522.73 mm]

64.45 inch [1637.03 mm]

Turning radius

69.48 inch [1764.79 mm]

73.98 inch [1879.09 mm]

Turning radius

69.48 inch [1764.79 mm]

73.98 inch [1879.09 mm]

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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. Weight less battery

4. Maximum battery weight

5. Minimum battery weight

6. Truck voltage DC

7. Battery type UL class

8. Battery maximum AMP hours

9. Hour rate

10. Truck type

11. Mast serial number

12. Attachment

13. Maximum degree rear tilt

14. Truck capacity

14. Truck capacity Inches

Inches Model

Truck Serial Number

Cap. (Lbs.)

Battery Wt. Minimum (Lbs.)

Use UL Class Battery Type

6 10

Model

Truck Serial Number

Battery Wt. Maximum (Lbs.)

Type

Truck Wt. Less Batt. (Lbs.)

DC Voltage

Max. Amp Hr.

Hour Rate

Attachment

Mast Serial Number

Battery Wt. Maximum (Lbs.)

Battery Wt. Minimum (Lbs.)

Use UL Class Battery Type

6 Max ° Back Tilt

Type

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Max. Amp Hr.

Hour Rate

Attachment

Mast Serial Number

Max ° Back Tilt

13 B

310574-000

B THIS FORKLIFT TRUCK MEETS OR EXCEEDS DESIGN SPECIFICATIONS OF ANSI/ASME B56.1 IN EFFECT ON THE DATE OF MANUFACTURE.

BT Prime-Mover, Inc. Muscatine, IA 52761

Truck Wt. Less Batt. (Lbs.)

DC Voltage

Cap. (Lbs.)

THIS FORKLIFT TRUCK MEETS OR EXCEEDS DESIGN SPECIFICATIONS OF ANSI/ASME B56.1 IN EFFECT ON THE DATE OF MANUFACTURE.

BT Prime-Mover, Inc. Muscatine, IA 52761

310574-000

Presentation of Truck

U.L. Construction type

Before you enter a restricted or hazardous area, know the U.L. construction type of the truck. Make certain that this type of truck may be operated in restricted areas before entering. Never take an unauthorized truck in restricted or hazardous areas.

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Presentation of Main Components

Presentation of main components

Hydraulic valve: The valves are located to provide easy access. 2 Battery: 24/36V with different capacities and weights. 3 Recharge connector: The battery is recharged through the battery connection. 4 Hydraulic unit: Pump motor and pump are an integrated unit 5 Drive unit with brakes: Drive motor, gears, drive wheel, and electrical brake combined in the drive unit. 6 Electrical steering: A servo steer motor drives a gear ring enabling the drive unit to be rotated through 180 degrees (90 degrees in either direction). 7 Data plate: With data designation, manufacturing number, year of manufacture, service weight, battery weight, classified lifting capacity, battery voltage and manufacturer. 8 Cover: Easily removed to provide good access for servicing. 9 Pedal: Brake pedal. 10 Operator Controls: The operator controls are located either on the console cover or on the control handle. The steering wheel, instrument panel, and switches (key switch, emergency stop, and light/fan cluster) are on the console cover. The hydraulic functions (lift, reach, and auxiliary), horn, and travel speed and direction are controlled through the control handle. 11 Instrument panel (Operator display): This provides information on the truck’s running hours, time display, error codes, parking brake, and battery status. 12 Mast: The mast is clear view model. 13 Electronics: All the electronics are collected in a protected compartment. 14 Control circuit fuse (F50): 10A, BT part number 25275-12

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Hydraulic valve: The valves are located to provide easy access. 2 Battery: 24/36V with different capacities and weights. 3 Recharge connector: The battery is recharged through the battery connection. 4 Hydraulic unit: Pump motor and pump are an integrated unit 5 Drive unit with brakes: Drive motor, gears, drive wheel, and electrical brake combined in the drive unit. 6 Electrical steering: A servo steer motor drives a gear ring enabling the drive unit to be rotated through 180 degrees (90 degrees in either direction). 7 Data plate: With data designation, manufacturing number, year of manufacture, service weight, battery weight, classified lifting capacity, battery voltage, and manufacturer. 8 Cover: Easily removed to provide good access for servicing. 9 Pedal: Brake pedal. 10 Operator Controls: The operator controls are located either on the console cover or on the control handle. The steering wheel, instrument panel, and switches (key switch, emergency stop, and light/fan cluster) are on the console cover. The hydraulic functions (lift, reach, and auxiliary), horn, and travel speed and direction are controlled through the control handle. 11 Instrument panel (Operator display): This provides information on the truck’s running hours, time display, error codes, parking brake, and battery status. 12 Mast: The mast is clear view model. 13 Electronics: All the electronics are collected in a protected compartment. 14 Control circuit fuse (F50): 10A, BT part number 25275-12

Presentation of Main Components

15 Steering circuit fuse (F51): 30A, BT part number 25275-13 16 Drive motor fuse (F1, F4): 250A, BT part number 305656-000 17 Pump motor fuse (F3): RTX35 425A, 24V BT part number 305656-002 RTX35 355A, 36V BT part number 305656-001 RTX45 500A, 36V BT part number 305656-004 18 Right foot pedal A red triangle (warning light) will be displayed on instrument panel if the right foot pedal is not depressed. This safety feature is installed so operator’s keep their right foot within the operator’s compartment. 19 Emergency stop The emergency stop switch will stop all control functions. 20 Lift height indicator fuse (F52): 1/4A, BT part number 25275-11 21 12 volt sensor feed fuse (F53): 1/4A, BT part number 25275-11 22 Display power fuse (F54): 1/4A, BT part number 25275-11 23 Relay1 fuse (F55): 10A, BT part number 25275-12 24 Fuse (AF1): 10A, BT part number 25275-12 25 Fuse (AF2): 10A, BT part number 25275-12 26 Auxiliary power circuit fuse (AF3): 2A, BT part number 25275-15

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Presentation of Main Components

12 19

11 16 17

10 8 +-1 01/2

11 16 17

10 8 + 1/021 -

9 18

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14 15 20 21 22 23 24 25

9 18

14 15 20 21 22 23 24 25

Controls and Instruments

Controls and instruments

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

DO NOT operate this equipment unless

! WARNING all factory installed guards and shields

! WARNING

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

! WARNING unit before operating it.

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

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

! WARNING

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

Emergency stop

The truck is fitted with an emergency stop button (red in color), which is located to the right of the key switch on the control console.

Pressing the emergency stop will cut the power supply.

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Controls and Instruments Light & Fan Switches

Lift & Lower

Key Switch

Emergency Stop

Clip Board

Controls and Instruments Tilt & Sideshift

Light & Fan Switches

Instrument Panel

Clip Board

Lift & Lower

Key Switch

+ 1 1/2 0

Horn Switch

Spinner

Control Handle (travel speed / direction)

Steering Wheel

Spinner

Reach & Retract Switches

Tilt & Sideshift Instrument Panel

+ 1 1/2 0

Steering Wheel

Emergency Stop

Horn Switch Reach & Retract Switches

Control Handle (travel speed / direction)

Key switch

The key switch is the main power switch for the control circuit.

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

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

Horn control

The horn sounds as long as the switch is pressed.

Directional/Speed control handle

With the key switch in the ON position and start-up complete, the truck is ready for travel. To move the truck, rotate the control handle in the direction you want to move (away from the operator for forks-first travel, toward the operator for tractor-first travel). The more you rotate the control handle, the faster the truck travels. 29 Return

Controls and Instruments

Stopping is accomplished by two methods. The preferred method, plugging, is achieved by moving the control handle through neutral to the opposite direction of travel. The further the control handle is moved in the opposite direction, the faster the truck will slow. The second method is using the deadman brake pedal. Refer to “Brake pedal” on page 35 for detailed information.

Steering wheel

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

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

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

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

Lost stability.

! WARNING The truck can overturn and the load fall if

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

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Controls and Instruments Hydraulic controls

Lower

Tilt Down Sideshift Right

Lift

Tilt Down Sideshift Right

Lift

Tilt Up

Reach

Sideshift Left

Reach

Sideshift Left

Retract

Horn

Retract

Horn

The lift and lower forks thumb knob is on the end of the control handle. Press up on the thumb knob to lift the forks. Press down on the thumb knob to lower the forks.

The reach and retract forks buttons are also on the control handle. Press one, either reach or retract, button for single speed function. With the reach or retract button depressed, pressing the opposite button will activate high-speed reach or retract.

A disc on the control handle activates tilt or sideshift. Press the right side of the disc to shift the forks right. Press the left side of the disc to shift the forks left. Press the top of the disc to tilt the forks down. Press the bottom of the disc to tilt the forks up.

Lowering the forks and one other function can be used together. When the lift button is activated, all other hydraulic functions will disengage.

Note: No hydraulic functions can be used if the key switch is in the OFF position or if the operator is not in the operator’s compartment (right foot switch depressed).

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Controls and Instruments Display

1/2

I H G F E

B. Time display

A digital clock indicates the actual time.

C. Display of hourmeter reading/error code

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

Character

Time

Character

Time

Key time

Total running time

Drive motor time

Pump motor time

When the warning/error codes are displayed, the indicating window (G) will be lit. A character, E or C, will be displayed in the lefthand side of the character window and the error code in

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Controls and Instruments

the righthand side. The meaning of the codes is explained in “Warning/Caution codes” on page 37 and “Error Codes” on page 41.

D. Battery guard

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

Full charge battery

1/2

Half charged battery

1/2

Half charged battery

Discharged battery

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

F. Parameter control

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

H. Parking brake indicator

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

I. Extra indicator window

This light indicates that either the brake pedal or compartment floor (right foot) switch has not been successfully engaged while selecting a hydraulic function. The indicator also lights if

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Controls and Instruments

the truck is driven without both the brake pedal and the compartment floor (right foot) switch engaged.

Switches: Lamps and fans

+ 1 1/2 0

+ 11/2 0

Switches for the lights and fan are located on the control console. They are positioned for easy operator access.

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Controls and Instruments

Brake pedal

•

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

•

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

•

To apply the proportional brake, lift the brake pedal until the desired level of braking is felt. A complete stop can be made by fully raising the brake pedal.

•

To apply the proportional brake, lift the brake pedal until the desired level of braking is felt. A complete stop can be made by fully raising the brake pedal.

Risk of crushing exists if any part of the the operator’s compartment. Always have your entire body inside the operator’s compartment.

! WARNING body is outside of

Risk of crushing exists if any part of the

! WARNING body is outside of the operator’s compartment. Always have your entire body inside the operator’s compartment.

The second plug braking method is achieved by slowly releasing the deadman pedal until the desired plugging force is achieved. Once the desired speed is reached, depress the deadman pedal to continue traveling. When the deadman pedal remains released and the truck’s travel speed approaches zero, the parking brake will set.

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Controls and Instruments Height indicator

1/02+1 -

Brake pedal

1/02+-1

Brake pedal

Height indicator (option)

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

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Warning/Caution codes

Character

Error

Character

Error

Warning

When an error occurs a buzzer will sound. A code displays for 10 seconds on the righthand side of the character window (C). If the error remains after 1 minute, the warning code and buzzer will be reactivated for an additional 2 seconds. This process continues until the fault is corrected. The truck can be driven with all functions unless otherwise specified in the warning table on pages 38 through 40.

The error is also indicated in the indicator window (G).

Do not ignore error indications.

! WARNING Always contact a service technician

before the truck is used again after an error code has been displayed.

I H G F E Return

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I H G F E 37

Warning/Caution codes Error No.

Error Code Name

Pump Type Parameter Error

Pump Chopper Limit

Steer Chopper Limit

Comment

Error No.

Error Code Name

Comment

Pump Type Parameter Error

Pump Chopper Limit

Steer chopper high temperature current limit.

Steer Chopper Limit

Steer chopper high temperature current limit.

Height Indicator Error

Height counter error.

Height Indicator Error

Height counter error.

Fork Reference Error

Forks are above free height at power-on with Special Height parameter set greater than zero (a height counter is installed).

Fork Reference Error

Forks are above free height at power-on with Special Height parameter set greater than zero (a height counter is installed).

Pump Brush Error

Worn pump motor brush.

Pump Brush Error

Worn pump motor brush.

Drive Brush Error

Worn drive motor brush.

Drive Brush Error

Worn drive motor brush.

Nov Ram Error

Control module internal error.

Nov Ram Error

Control module internal error.

Default Par

Pump Voltage Error

Lift Pot Z Error

Lift pot not centered at key on time.

Lift Pot Z Error

Lift pot not centered at key on time.

Tilt Request Z Error

Tilt request at key on time.

Tilt Request Z Error

Tilt request at key on time.

Reach Request Z Error

Reach request at key on time.

Reach Request Z Error

Reach request at key on time.

Sideshift Request Z Error

Sideshift request at key on time.

Sideshift Request Z Error

Sideshift request at key on time.

Accelerator Pot Z Error

Accelerator pot not centered at key on time.

Accelerator Pot Z Error

Accelerator pot not centered at key on time.

Bat Measure Error

Low battery voltage detected.

Bat Measure Error

Low battery voltage detected.

Motor Overtemperature

Drive motor overtemperature.

Motor Overtemperature

Drive motor overtemperature.

Control Handle Calibration Error 1

Control handle calibration required - No operation.

Control Handle Calibration Error 1

Control handle calibration required - No operation.

Lift Pot Memory Value Error

Lift potentiometer zero memory value or span memory value error. Control handle calibration required. No lift/lower operation.

Lift Pot Memory Value Error

Lift potentiometer zero memory value or span memory value error. Control handle calibration required. No lift/lower operation.

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Parameter 14 set incorrectly.

Warning/Caution codes

Parameter 14 set incorrectly.

Warning/Caution codes Error No.

Error Code Name

Comment

Lift Pot Zero Calibration Error

Lift potentiometer not centered within calibration limits. Center, recalibrate, or replace control handle. No lift/lower operation.

Lift Pot Span Calibration Error

Warning/Caution codes Error No.

Error Code Name

Comment

Lift Pot Zero Calibration Error

Lift potentiometer not centered within calibration limits. Center, recalibrate, or replace control handle. No lift/lower operation.

Complete lift potentiometer calibration by moving the lift lever to both ends of travel. Left (deadman) and right foot pedals must be released during calibration.

Lift Pot Span Calibration Error

Complete lift potentiometer calibration by moving the lift lever to both ends of travel. Left (deadman) and right foot pedals must be released during calibration.

Control Handle Calibration Error 2

Control handle calibration required. Allowed operation may be limited.

Control Handle Calibration Error 2

Control handle calibration required. Allowed operation may be limited.

Accelerator Pot Memory Value Error

Accelerator potentiometer pot zero memory value or span memory value error. Control handle calibration required. No travel operation.

Accelerator Pot Memory Value Error

Accelerator potentiometer pot zero memory value or span memory value error. Control handle calibration required. No travel operation.

Accelerator Pot Zero Calibration Error

Accelerator potentiometer not centered within calibration limits. Center, recalibrate, or replace control handle.

Accelerator Pot Zero Calibration Error

Accelerator potentiometer not centered within calibration limits. Center, recalibrate, or replace control handle.

Accelerator Pot Span Calibration Error

Complete accelerator potentiometer calibration by moving the control handle to both ends of travel. Left foot pedal (deadman) must be released during calibration.

Accelerator Pot Span Calibration Error

Complete accelerator potentiometer calibration by moving the control handle to both ends of travel. Left foot pedal (deadman) must be released during calibration.

Travel Error

Function of drive motor speed and direction sensors. Significant travel speed requested with minimum movement detected. Travel speed limited.

Travel Error

Function of drive motor speed and direction sensors. Significant travel speed requested with minimum movement detected. Travel speed limited.

Mast Switch Sequencing Error

A mast switch has opened or closed incorrectly relative to the state of the other switch.

Mast Switch Sequencing Error

A mast switch has opened or closed incorrectly relative to the state of the other switch.

O Lift Error

Shorted or opened lift valve output.

O Lift Error

Shorted or opened lift valve output.

O Tilt Error

Shorted or opened tilt valve output.

O Tilt Error

Shorted or opened tilt valve output.

O Direction A Error

Shorted or opened direction A valve output.

O Direction A Error

Shorted or opened direction A valve output.

O Direction B Error

Shorted or opened direction B valve output.

O Direction B Error

Shorted or opened direction B valve output.

O Sideshift Error

Shorted or opened sideshift valve output.

O Sideshift Error

Shorted or opened sideshift valve output.

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Warning/Caution codes Error No.

Error Code Name

Comment

Warning/Caution codes Error No.

Error Code Name

Comment

O Hydraulic Dump Error

Shorted or opened hydraulic dump valve output.

O Hydraulic Dump Error

Shorted or opened hydraulic dump valve output.

O Alarm Out Error

Shorted or opened alarm output.

O Alarm Out Error

Shorted or opened alarm output.

O Reach In Error

Shorted or opened reach in valve output.

O Reach In Error

Shorted or opened reach in valve output.

O Reach Out Error

Shorted or opened reach out valve output.

O Reach Out Error

Shorted or opened reach out valve output.

O Lower Prop Error

Shorted or opened lowering proportional valve output.

O Lower Prop Error

Shorted or opened lowering proportional valve output.

O Forward Contactor Error

Shorted or opened forward contactor output.

O Forward Contactor Error

Shorted or opened forward contactor output.

O Backward Contactor Error

Shorted or opened backward contactor output.

O Backward Contactor Error

Shorted or opened backward contactor output.

Steer Sense Error

Shorted or opened steer limit sensor(s). One or more of the drive wheel steering limit control sensors are not correctly signalling the control module. A minimum of one sensor and control module input LED should be on during the allowed steering rotational distance of the drive wheel. If all three sensors are on or if all three sensors are off, error code 80 will be displayed.

Steer Sense Error

Lift Pot Max Error

Lift potentiometer end value(s) exceeded the maximum limits.

Lift Pot Max Error

Lift potentiometer end value(s) exceeded the maximum limits.

Lift Pot Error

Shorted or opened lift potentiometer input.

Lift Pot Error

Shorted or opened lift potentiometer input.

Tilt Request Error

Shorted or opened tilt request input.

Tilt Request Error

Shorted or opened tilt request input.

Reach Request Error

Shorted or opened reach request input.

Reach Request Error

Shorted or opened reach request input.

Sideshift Request Error

Shorted or opened sideshift request input.

Sideshift Request Error

Shorted or opened sideshift request input.

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Error Codes

Error codes

Error codes Character

Error

Character

Error

When an error occurs, a buzzer will sound. An error code is displayed on the righthand side of the character window (C). The buzzer will sound until the key switch is turned OFF. If the error remains when the key is turned ON, the buzzer will sound and the error code is displayed again. The truck cannot be used when the Error Codes listed on pages 42 and 43 are displayed in the character window (C).

The error is also indicated in the window (G).

Do not ignore error indications.

! WARNING Truck safety in jeopardy.

Always contact a service technician before the truck is used again after an error code has been displayed. B

Return

Always contact a service technician before the truck is used again after an error code has been displayed. B

I H G F E

Do not ignore error indications.

! WARNING Truck safety in jeopardy.

1/2

I H G F E 41

Error Codes Error No.

Error Codes

Error Code Name

Comment

Error No.

100

Pump Temperature Error

Pump chopper over or under temperature.

101

Pump Current Error

102

Drive Chopper Error

104

Error Code Name

Comment

100

Pump Temperature Error

Pump chopper over or under temperature.

101

Pump Current Error

Drive chopper internal error.

102

Drive Chopper Error

Drive chopper internal error.

Accelerator Pot Memory Value Error 2

Accelerator potentiometer zero or maximum travel memory value error. Control handle calibration required. Lift/lower may also be in error and disabled.

104

Accelerator Pot Memory Value Error 2

Accelerator potentiometer zero or maximum travel memory value error. Control handle calibration required. Lift/lower may also be in error and disabled.

105

Accelerator Pot Error

Shorted or opened accelerator potentiometer input.

105

Accelerator Pot Error

Shorted or opened accelerator potentiometer input.

106

Accelerator Pot Max Error

Accelerator potentiometer end point value(s) exceeded the maximum limit.

106

Accelerator Pot Max Error

Accelerator potentiometer end point value(s) exceeded the maximum limit.

110

Pot Ref Error

Potentiometer/pushbutton supply voltage failure.

110

Pot Ref Error

Potentiometer/pushbutton supply voltage failure.

111

P Brake Pot Error

Pedal/parking brake potentiometer adjustment or failure.

111

P Brake Pot Error

Pedal/parking brake potentiometer adjustment or failure.

112

P Brake Switch Error

Pedal/parking brake switch adjustment or failure.

112

P Brake Switch Error

Pedal/parking brake switch adjustment or failure.

113

P Brake Out Error

Shorted or open parking brake output.

113

P Brake Out Error

Shorted or open parking brake output.

114

Speed and Direction Sensor Error

Speed and direction sensor failure.

114

Speed and Direction Sensor Error

Speed and direction sensor failure.

115

Speed Sensor Error

Drive motor speed sensor failure.

115

Speed Sensor Error

Drive motor speed sensor failure.

116

Direction Sensor Error

Drive motor direction sensor failure.

116

Direction Sensor Error

Drive motor direction sensor failure.

117

Reversing Signal Error

Drive chopper reversing signal failure.

117

Reversing Signal Error

Drive chopper reversing signal failure.

120

Steer Data Error

Control module internal error.

120

Steer Data Error

Control module internal error.

Return

Error Codes Error No.

Error Code Name

121

Steer Chopper Error

122

Steer Overtemperature Error

123

Error Codes Error No.

Error Code Name

Steer chopper error.

121

Steer Chopper Error

Steer chopper error.

Steer chopper high temperature limit.

122

Steer Overtemperature Error

Steer chopper high temperature limit.

Steer Volt Error

123

Steer Volt Error

124

Steer Current Error

124

Steer Current Error

125

Steer Tacho Error

Steer tacho error.

125

Steer Tacho Error

Steer tacho error.

126

Steer Connection Error

Opened steer motor output - motor or connection failure.

126

Steer Connection Error

Opened steer motor output - motor or connection failure.

127

Steer Comm Error

Control module internal error.

127

Steer Comm Error

Control module internal error.

130

Slave Comm Error

Control module internal error.

130

Slave Comm Error

Control module internal error.

131

Security Rel Error 1

Security relay error 1.

131

Security Rel Error 1

Security relay error 1.

132

Steer Power Error

Steer chopper supply voltage under-voltage.

132

Steer Power Error

Steer chopper supply voltage under-voltage.

133

Security Rel Error 2

Security relay error 2.

133

Security Rel Error 2

Security relay error 2.

140

Check Sum Error

Control module internal error.

140

Check Sum Error

Control module internal error.

Return

Comment

Driving

Starting the truck

•

Make sure the emergency stop is not pressed in.

•

Make sure the emergency stop is not pressed in.

•

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

•

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

•

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

•

If only the colon (B) is displayed when the key switch is turned to the ON position, the truck must be serviced.

•

If only the colon (B) is displayed when the key switch is turned to the ON position, the truck must be serviced. B

•

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

Return

•

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

Driving NOTE:

•

Driving

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

Place your foot on the brake pedal to release the brake.

NOTE:

•

Risk of crushing exists if any part of the the operator’s compartment. Always have your whole body inside the operator’s compartment.

Select the travel direction.

! WARNING body is outside of the operator’s

compartment. Always have your whole body inside the operator’s compartment. •

Always complete the daily operator’s

! WARNING checks before starting the day’s work.

Accidents can occur.

! WARNING Always drive with care, good judgment,

and responsibility. To stop the lift truck in an emergency, release the deadman pedal immediately. Releasing the pedal disables travel and applies the parking brake to stop the lift truck in the shortest possible distance.

Return

Select the travel direction. Always complete the daily operator’s

! WARNING checks before starting the day’s work.

•

Place your foot on the brake pedal to release the brake. Risk of crushing exists if any part of the

! WARNING body is outside of

•

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.

and responsibility. •

To stop the lift truck in an emergency, release the deadman pedal immediately. Releasing the pedal disables travel and applies the parking brake to stop the lift truck in the shortest possible distance.

Driving

Braking

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

This truck is equipped with two stopping methods. The preferred method, plugging, involves simply reversing the directional/speed control handle to the opposite direction without applying the brake. This will cause the truck to come to a stop smoothly. Refer to “Directional/Speed control handle” on page 29 for detailed information on this method. The second stopping method is achieved by slowly releasing the deadman pedal until the desired stopping force is achieved. Refer to “Brake pedal” on page 35 for detailed information.

+01/12

Brake pedal

Return

Driving

Steering

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

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

Steering direction depends on whether the truck is equipped with standard or reverse steering. Rotate the steering wheel in the direction you want to turn when traveling forks-first with standard steering or traveling tractor-first with reverse steering. Rotate the steering wheel in the opposite direction you want to turn when traveling tractor-first with standard steering or forks-first with reverse steering.

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

•

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

Return

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

Driving

Lost stability.

•

Lost stability.

! WARNING The truck can overturn and the load fall if

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

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

•

Risk of slipping.

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

! WARNING You can lose control of the truck if your

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

Parking the truck

•

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

•

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

•

Retract the reach.

•

Retract the reach.

•

Lower the forks to the floor.

•

Lower the forks to the floor.

•

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

•

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

•

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

•

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

Unauthorized use.

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

Return

Unauthorized use.

! WARNING Accidents can happen. Always remove the key from the key switch when truck is left unattended. 48

Transporting Loads

Transporting loads

General

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

Risk of overturning. lifting capacity is reduced if additional equipment is attached to the truck. Always check the truck data plate for the truck’s overall lifting capacity.

! WARNING The

•

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

•

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

•

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

•

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

•

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

•

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

•

Adjust the distance between forks to the width of the load.

•

Adjust the distance between forks to the width of the load.

Lost stability.

! WARNING High loads can fall when cornering at

high speed or cause the truck to tip over. Drive slowly and carefully when cornering and travel with loads in lowered position.

Protruding loads.

! WARNING The load can collide with personnel, fixed

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

Return

Transporting Loads

Driving with reach extended will cause

! WARNING excessive wear and maintenance.

Always drive with the reach in the fully retracted position. NOTE:

Always drive with the reach in the fully retracted position.

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

NOTE:

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

•

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

•

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

•

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

•

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

•

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

•

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.

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.

! WARNING The braking distance is increased when

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

Return

Transporting Loads •

Before the truck is driven into an elevator, ensure that the elevator is certified for the overall load (the weight of the truck, the load, and the operator). When entering an elevator, the load goes first, not the driver. There must be no personnel in the elevator when entering or exiting.

Transporting Loads •

Risk of overloading the elevator.

•

! WARNING An overloaded elevator can fall out of

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

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

! WARNING The truck can tip over. Always check the ramp’s load bearing capacity. Be sure the ramp is secured correctly. Drive at a safe distance from the edges of the ramp.

Return

•

! WARNING The truck can tip over. Always check the ramp’s load bearing capacity. Be sure the ramp is secured correctly. Drive at a safe distance from the edges of the ramp.

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

•

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

Forks not horizontal.

! WARNING The load can slide off the forks or catch

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

•

Lift the forks so that the load is lifted free.

•

Lift the forks so that the load is lifted free.

•

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

•

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

•

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

•

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

•

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

•

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

CAUTION

Return

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

CAUTION

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

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 forks to the required lifting position.

•

Lift the forks to the required lifting position.

•

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

•

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

Forks not horizontal.

! WARNING The load can slide off the forks or catch

•

Lower the forks so that they clear the load.

•

Lower the forks so that they clear the load.

•

Retract the reach and reverse the truck.

•

Retract the reach and reverse the truck.

•

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

•

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

CAUTION

Return

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

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

Battery

Batt ery

Bat ter y

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.

Risk of moving the center of gravity.

! WARNING 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 the truck at the battery removal station.

•

Park the truck at the battery removal station.

•

Turn the key switch OFF and remove the key.

•

Turn the key switch OFF and remove the key.

•

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 the battery retainer plates.

•

Remove the battery retainer plates.

•

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

•

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

Return

Battery •

Battery

Connect the battery connector and truck connector.

•

Risk of short-circuiting.

! WARNING The cables can be damaged and cause a short-circuit. Ensure the battery crushed.

cables

are

Connect the battery connector and truck connector.

! WARNING The cables can be damaged and cause a short-circuit. Ensure the battery crushed.

not

cables

are

not

•

Pull the emergency disconnect button to the ON position.

•

Pull the emergency disconnect button to the ON position.

•

Install the battery retainer plates.

•

Install the battery retainer plates.

Falling battery.

! WARNING If the truck should tip over, the battery

can fall out if the battery retainer plates have not been installed. Make sure the battery retainer plates 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 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

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.

Return

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 the key switch to the OFF position.

•

Turn the 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 the charger connector.

•

Connect the battery connector to the charger connector.

•

Never connect the charger connector to the truck connector.

•

Never connect the charger connector to the truck connector.

•

Switch ON the battery charger.

•

Switch ON the battery charger.

During the charging process oxygen and

! WARNING 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.

Return

Battery

After charging

•

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

•

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

•

Switch OFF the charger.

•

Switch OFF the charger.

•

Disconnect the battery connector from the charger connector.

•

Disconnect the battery connector from the 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.

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 comes in 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.

Each week:

•

Remove all cell caps. NOTE!

This does not apply to batteries with level caps or central filling.

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 inch [10-15 mm] above the cell plates.

•

Fill using distilled water. The fluid level should be 1/4 inch [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° C]

1.280

77° F [25° C]

1.280

Battery manufacturer’s maintenance and

! WARNING charging procedures must be followed.

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

Return

Daily Service/Safety Checks

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 each day or shift, before the truck is used. The daily service is a simple safety and function control check indicated in the list below.

•

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

Never neglect the daily service and safety

! WARNING checks. Serious accidents can occur.

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. Check points

Action

Always report any faults or damage to your supervisor without delay. Never use a truck that does not function properly. Check points

Action

Hydraulic system

Check for oil leakage, hoses and floor.

Hydraulic system

Check for oil leakage, hoses and floor.

Lifting device

Check for damage, noise function.

Lifting device

Check for damage, noise function.

Battery

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

Battery

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

Battery cables and connections

Check for breakage cutting or damage.

Battery cables and connections

Check for breakage cutting or damage.

Battery retainer plates

Check correct location.

Battery retainer plates

Check correct location.

Chassis

Check for damage, remove dirt and debris.

Chassis

Check for damage, remove dirt and debris.

Overhead guard & safety guards

Check for damage, ensure placement.

Overhead guard & safety guards

Check for damage, ensure placement.

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.

Return

Daily Service/Safety Checks Check points

Daily Service/Safety Checks

Action

Check points

Action

Brake pedal

Check its function.

Brake pedal

Check its function.

Direction / accelerator

Check its function.

Direction / accelerator

Check its function.

Control handle

Check functions. Check for freedom of movement.

Control handle

Check functions. Check for freedom of movement.

Hydraulic function

Check its function.

Hydraulic function

Check its function.

Control functions

Check its function.

Control functions

Check its function.

Parking brake

Check its function.

Parking brake

Check its function.

Horn

Check its function.

Horn

Check its function.

Running time

Inform your supervisor if your truck is ready for a schedule maintenance check. See “Maintenance” on page 63.

Running time

Inform your supervisor if your truck is ready for a schedule maintenance check. See “Maintenance” on page 63.

Emergency stop

Check its function.

Emergency stop

Check its function.

Steering

Check its function.

Steering

Check its function.

Special equipment

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

Special equipment

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

DO NOT operate the truck when it is not

! WARNING functioning properly.

Return

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

DO NOT operate the truck when it is not

! WARNING functioning properly.

Maintenance

General

•

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

•

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

•

Only use BT 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.

•

Contact your BT Prime-Mover representative to setup a service and maintenance agreement to ensure your truck’s operating economy and safety.

•

Contact your BT Prime-Mover representative to setup a service and maintenance agreement to ensure your truck’s operating economy and safety.

Safety regulations with maintenance work

•

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

•

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

•

Do not carry out any maintenance work on the truck unless you have the correct training and knowledge to do so.

•

Do not carry out any maintenance work on the truck unless you have the correct training and knowledge to do so.

•

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

•

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

•

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

•

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

Short-circuiting/burns.

! WARNING When working with the truck’s electrical

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

Return

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.

Risk of burns.

! WARNING Hot transmission and hydraulic oil.

Let the truck cool before changing the oil. •

Only fill the hydraulic system with new, clean oil which meets cleanliness specification 12-00-002. Contact your BT Prime-Mover representative for assistance or more information.

Let the truck cool before changing the oil. •

The hydraulic system can be damaged.

Only fill the hydraulic system with new, clean oil which meets cleanliness specification 12-00-002. Contact your BT Prime-Mover representative for assistance or more information. The hydraulic system can be damaged.

! WARNING If the oil is contaminated, hydraulic

components can be damaged. Always use new and clean oil in the hydraulic system.

•

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

•

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

•

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

•

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

Return

Maintenance •

When working underneath the truck, support the truck on trestle-blocks. Risk of crushing.

! WARNING A badly supported truck can fall.

Maintenance •

When working underneath the truck, support the truck on trestle-blocks. Risk of crushing.

! WARNING A badly supported truck can fall.

Never work under a truck that is not supported on trestle-blocks and secured by a lifting device.

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

Maintenance

Cleaning and washing

General

Cleaning and washing of the truck is important to ensure the truck will operate safely and reliability.

NOTE:

Risk of short circuiting. The electrical system can be damaged. Disconnect the battery before washing by pulling out the battery connector. Do not spray water directly into the electrical compartments of the truck.

External cleaning

•

Remove debris, etc. from the wheels daily.

•

Remove debris, etc. from the wheels daily.

•

Use a degreasing concentration.

•

Use a degreasing concentration.

•

Rinse off loose grime using warm water.

•

Rinse off loose grime using warm water.

NOTE:

agent,

diluted

suitable

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

NOTE:

agent,

diluted

suitable

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:

Maintenance

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

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. Compressed air used for cleaning MUST

Compressed air used for cleaning MUST

! WARNING be reduced to less than 30 psi (206 kPa), and then only guarding and equipment.

Blow electric motors dry using compressed air.

! WARNING be reduced to less than 30 psi (206 kPa)

with effective chippersonal protective

and then only guarding and equipment.

with effective chippersonal protective

•

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:

Return

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

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.

D=250 Hours or 3 Months

Action

1.0

Chassis

1.1

Check door lock

1.2

No.

Action

1.0

Chassis

1.1

Check door lock

Check wear on battery stop

1.2

Check wear on battery stop

1.3

Check for damage and crack formation

1.3

Check for damage and crack formation

1.4

Check outriggers mounting

1.4

Check outriggers mounting

2.0

Motors

2.0

Motors

2.1

Check for loose connections

2.1

Check for loose connections

2.2

Clean motor

2.2

Clean motor

2.3

Check mounting bolts

2.3

Check mounting bolts

2.4

Check for abnormal bearing noise

2.4

Check for abnormal bearing noise

2.5

Brush wear

2.5

Brush wear

3.0

Drive unit

3.0

Drive unit

3.1

Check for leakage

3.1

Check for leakage

3.2

Check oil level

3.2

Check oil level

3.3

Check for noises

3.3

Check for noises

3.4

Check the mounting on support

3.4

Check the mounting on support

Return

Maintenance No.

Action

Maintenance B

No.

Action

4.0

Wheels

4.1

Remove string & debris

4.2

Check drive wheel wear and nuts

4.3

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

4.4

Check support arm wheel for wear

4.5

Dismantle and lubricate the support wheel bearing

5.0

Brake

4.0

Wheels

4.1

Remove string & debris

4.2

Check drive wheel wear and nuts

4.3

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

4.4

Check support arm wheel for wear

4.5

Dismantle and lubricate the support wheel bearing

5.0

Brake

5.1

Clean

5.1

Clean

5.2

Check for wear to the brake discs

5.2

Check for wear to the brake discs

5.3

Check for play in released position

5.3

Check for play in released position

5.4

Check brake wires for wear

5.4

Check brake wires for wear

6.0

Electrical panel

6.0

Electrical panel

6.1

Clean and check the mounting

6.1

Clean and check the mounting

6.2

Tighten cable connections

6.2

Tighten cable connections

6.3

Check contactor points

6.3

Check contactor points

6.4

Check the contactor’s movement

6.4

Check the contactor’s movement

7.0

Battery

7.0

Battery

7.1

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

7.1

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

7.2

Check the connections on battery, truck and charger

7.2

Check the connections on battery, truck and charger

7.3

Check cell and pole guard

7.3

Check cell and pole guard

7.4

Check the fluid density and temperature

7.4

Check the fluid density and temperature

7.5

Check power cables are not cut or frayed

7.5

Check power cables are not cut or frayed

Return

Maintenance No.

Action

Maintenance B

8.0

Hydraulic system

8.1

Check hoses and couplings for leakage

8.2

Check pipes and hoses for wear

8.3

Check the hydraulic tank for leakage and its mountings

8.5

Check oil level

8.6

Change oil

9.0

Cylinders

9.1

Check for leakage

9.2

Check the mountings

10.0

Mast and reach carriage

10.1

Check for damage and cracks

10.2

No.

Action

8.0

Hydraulic system

8.1

Check hoses and couplings for leakage

8.2

Check pipes and hoses for wear

8.3

Check the hydraulic tank for leakage and its mountings

8.5

Check oil level

8.6

Change oil

9.0

Cylinders

9.1

Check for leakage

9.2

Check the mountings

10.0

Mast and reach carriage

10.1

Check for damage and cracks

Check mast mounting bolt torque

10.2

Check mast mounting bolt torque

10.3

Check for play on the rollers

10.3

Check for play on the rollers

10.4

Check the electrical limit switch function

10.4

Check the electrical limit switch function

10.5

Check for wear and stretch on the chains and sheaves

10.5

Check for wear and stretch on the chains and sheaves

10.6

Check hoses and couplings for leakage cuts and other damage

10.6

Check hoses and couplings for leakage cuts and other damage

10.7

Check for wear to the forks and other lifting devices

10.7

Check for wear to the forks and other lifting devices

10.8

Check the reach attachment for proper reach stoke and timing.

10.8

Check the reach attachment for proper reach stoke and timing.

10.9

Check the reach attachment for damaged retract bumpers

10.9

Check the reach attachment for damaged retract bumpers

10.10

Lube all grease fittings on reach attachment

10.10

Lube all grease fittings on reach attachment

Return

Maintenance No.

Action

11.0

Control console

11.1

Check for control handle freedom of movement and that it returns to neutral when released

11.2

Check the micro switches and hydraulic function

12.0

Pedal

12.1

Check the pedal function

13.0

Emergency stop switch

13.1

Check the emergency stop switch

Maintenance B

No.

Action

11.0

Control handle

11.1

Check for control handle freedom of movement and that it returns to neutral when released

X X

11.2

Check the micro switches and hydraulic functions

12.0

Pedal

12.1

Check the pedal function

13.0

Emergency stop switch

13.1

Check the emergency stop switch

13 9

+ 1/021 -

+-1 0/12

12 1

1 4

Return

Maintenance

Lubrication chart

Lubrication chart 2

4 3

1+01/2

7 1

Lubrication chart location points

Interval/Running hours Service point

Lubricant

Wheel bearings

Mast beam

1000 h

9 10

500 h

+1/102

9 10

Pos. No.

3000 h

Pos. No.

Interval/Running hours Service point

Lubricant 500 h

1000 h

3000 h

Wheel bearings

Mast beam

Reach rails

Lifting chains

Side movement

Hydraulic system

Travel brake

Drive gear

Hinges

Return

O L

C D

Maintenance

Interval/Running hours

Pos. No.

Service point

Steering bearings

Gear ring

12 13

Interval/Running hours

Pos. No.

Service point

Steering bearings

Gear ring

Mast chain sheaves

Mast cable sheaves

Lubricant 500 h

L=Lubrication

1000 h

3000 h

C=Check

O=Oil change

Approved oils and grease

Lubricant 500 h

L=Lubrication

Grease

3000 h

C=Check

O=Oil change

Approved oils and grease

Specification Type Lubricant

1000 h

Specification

Above Below Below 23° F [-5° C] 23° F [-5° C] 5° F [-15° C]

Application area

Type Lubricant

Above Below Below 23° F [-5° C] 23° F [-5° C] 5° F [-15° C]

Application area

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

ATF

Texaco 15

Hydraulic system

Hydraulic oil

Sunoco TH

ATF

Texaco 15

Hydraulic system

Transmission oil

SAE 80w/90

ATF

Gears

Transmission oil

SAE 80w/90

ATF

Gears

Motor oil

SAE 40

SAE5w-20

Chains

Motor oil

SAE 40

SAE5w-20

Chains

Grease

Molykote 200025

Mast rails Sideshift

Grease

Molykote 200025

Mast rails Sideshift

Grease

49670-00

Mast rails Sideshift

Grease

49670-00

Mast rails Sideshift

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

Return

Transporting and Storing the Truck

Transporting and storing the truck

The truck’s dimensions and weight as standard

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

The RTX35 truck’s dimensions and weight

14.4 inch [365.8 mm]

Battery Width Height, truck without mast/OHG

16.4 inch [416.6 mm]

53.5 inch [1358.9 mm]

Height, dependent on mast

Height, truck without mast/OHG

40.6 inch - 61.0 inch [1031.2 mm - 1549.4 mm]

16.4 inch [416.6 mm]

53.5 inch [1358.9 mm]

Height, dependent on mast

95 inch [2413 mm]

Width, dependent on outrigger

14.4 inch [365.8 mm]

Battery Width

95 inch [2413 mm]

Width, dependent on outrigger

40.6 inch - 61.0 inch [1031.2 mm - 1549.4 mm]

Length [excluding forks]

70.5 inch [1790.7 mm]

72.2 inch [1833.8 mm]

Length [excluding forks]

70.5 inch [1790.7 mm]

72.2 inch [1833.8 mm]

Minimum battery weight

1600 lb. [725.7 kg]

2000 lb. [907 kg]

Minimum battery weight

1600 lb. [725.7 kg]

2000 lb. [907 kg]

Service weight without battery

Return

5400 lb. and Up [2449.4 kg and Up]

Service weight without battery

5400 lb. and Up [2449.4 kg and Up]

Transporting and Storing the Truck

The RTX45 truck’s dimensions and weight

16.4 inch [416.6 mm]

Battery Width Height, truck without mast/OHG

20.9 inch [530.9 mm]

53.5 inch [1358.9 mm]

Height, dependent on mast

95 inch [2413 mm]

Width, dependent on outrigger

40.6 inch - 61.0 inch [1031.2 mm - 1549.4 mm]

16.4 inch [416.6 mm]

Battery Width Height, truck without mast/OHG

20.9 inch [530.9 mm]

53.5 inch [1358.9 mm]

Height, dependent on mast

95 inch [2413 mm]

Width, dependent on outrigger

40.6 inch - 61.0 inch [1031.2 mm - 1549.4 mm]

Length [excluding forks]

74.64 inch [1895.86 mm]

79.14 inch [2010.16 mm]

Length [excluding forks]

74.64 inch [1895.86 mm]

79.14 inch [2010.16 mm]

Minimum battery weight

2000 lb. [907 kg]

2400 lb. [1088.6 kg]

Minimum battery weight

2000 lb. [907 kg]

2400 lb. [1088.6 kg]

Service weight without battery

Return

5400 lb. and Up [2449.4 kg and Up]

Service weight without battery

5400 lb. and Up [2449.4 kg and Up]

Transporting and Storing the Truck

Lifting the truck

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

Risk of overturning.

! WARNING The truck can overturn if lifted from the

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

Risk of overturning.

! WARNING The truck can overturn if lifted incorrectly.

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

Return

Transporting and Storing the Truck

Towing and transporting a disabled truck

! WARNING DO NOT tow a disabled truck

It is not recommended to tow a disabled lift truck.

Return

Transporting and Storing the Truck

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 than 1 year, see the oil specification in the “Lubrication chart” on page 72.

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 “Daily Service/Safety Checks” on page 61.

•

Before the truck is put into operation after a period of disuse, it should undergo a function and safety check as stated in the “Daily Service/Safety Checks” on page 61.

•

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

•

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

Return

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 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

Mast

Steel

Mast

Steel

Instrument panels

Polypropylene

Instrument panels

Polypropylene

Drive unit

Steel and cast material

Drive unit

Steel and cast material

Bushings

Iron/copper

Bushings

Iron/copper

Finish

Epoxy-polyester

Finish

Epoxy-polyester

Wheels

Polyurethane

Wheels

Polyurethane

Return

Recycling/Discarding

Hydraulic system

Hydraulic tank

Polyethylene

Hydraulic tank

Polyethylene

Pump unit

Steel and aluminium

Pump unit

Steel and aluminium

Hoses

Rubber and steel

Hoses

Rubber and steel

Cylinders

Steel

Cylinders

Steel

Electrical system

Cables

Copper cores with PVC sheaths

Cables

Copper cores with PVC sheaths

Electronic board

Reinforced fiberglass circuit board laminate

Electronic board

Reinforced fiberglass circuit board laminate

Motors

Steel and copper

Motors

Steel and copper

Return

Index

Applications, Acceptable . . . . . . . . . . . . . . . . . . . . . . . . 19 Applications, Prohibited . . . . . . . . . . . . . . . . . . . . . . . . . 8, 19

B Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54–60 Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Pre-charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Battery Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Applications, Acceptable . . . . . . . . . . . . . . . . . . . . . . . . 19 Applications, Prohibited . . . . . . . . . . . . . . . . . . . . . . . . . 8, 19

Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52, 53, 58 Codes Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Warning/Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Component Location Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Data Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Electric Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Emergency Stop Switch . . . . . . . . . . . . . . . . . . . . . . 26 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Hydraulic Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Hydraulic Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Operator Controls . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Operator Display . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Right Foot Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Components, Location . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52, 53, 58 Codes Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Warning/Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Component Location Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Data Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Electric Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Emergency Stop Switch . . . . . . . . . . . . . . . . . . . . . 26 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Hydraulic Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Hydraulic Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Operator Controls . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Operator Display . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Right Foot Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Components, Location . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Return

Index

Controls Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Directional/Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Height Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Hydraulic Functions . . . . . . . . . . . . . . . . . . . . . . . . . 31 Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Plug Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30, 35, 46 Steering Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Controls and Instruments . . . . . . . . . . . . . . . . . . . . . . . . 28–36

Controls Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Directional/Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Height Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Hydraulic Functions . . . . . . . . . . . . . . . . . . . . . . . . . 31 Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Plug Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30, 35, 46 Steering Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Controls and Instruments . . . . . . . . . . . . . . . . . . . . . . . . 28–36

Daily Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61–62 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Battery Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Battery Connections . . . . . . . . . . . . . . . . . . . . . . . . . 61 Battery Retainer Plates . . . . . . . . . . . . . . . . . . . . . . . 61 Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Control Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Guards, Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Lifting Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Overhead Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Special Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Data Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Decals, Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Definition Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Return

Daily Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61–62 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Battery Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Battery Connections . . . . . . . . . . . . . . . . . . . . . . . . . 61 Battery Retainer Plates . . . . . . . . . . . . . . . . . . . . . . 61 Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Control Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Guards, Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Lifting Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Overhead Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Special Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Data Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Decals, Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Definition Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Index

Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Discarding Truck Components Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44–48 Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Elevators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Operator Position . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Plug Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30, 35, 46 Ramps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11, 12 Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Starting the Truck . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Discarding Truck Components Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44–48 Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Elevators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Operator Position . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Plug Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30, 35, 46 Ramps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11, 12 Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Starting the Truck . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41–43

I Indicators Battery Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Brake/Platform Switch . . . . . . . . . . . . . . . . . . . . . . . 33 Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Information Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Instruments Error Code Display . . . . . . . . . . . . . . . . . . . . . . . . . 32 Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Operator Display . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Time Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

L Lifting the Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Load Handling Collecting a Load . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Elevator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Fork Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

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Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41–43

I Indicators Battery Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Brake/Platform Switch . . . . . . . . . . . . . . . . . . . . . . . 33 Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Information Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Instruments Error Code Display . . . . . . . . . . . . . . . . . . . . . . . . . 32 Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Operator Display . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Time Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Index Fork Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Grades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Leaving a Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Ramp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Vision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Locator, Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Lubrication Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

M Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63–73 Approved Oils and Grease . . . . . . . . . . . . . . . . . . . . 73 Cleaning and Washing . . . . . . . . . . . . . . . . . . . . . . . 66 Electrical Components, Cleaning . . . . . . . . . . . . . . . 67 External Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Interval Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Motor Compartment, Cleaning . . . . . . . . . . . . . . . . . 66

Index Fork Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Grades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Leaving a Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Ramp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Vision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Locator, Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Lubrication Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44, 50, 59, 66, 67, 74 Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Oils and Grease, Approved . . . . . . . . . . . . . . . . . . . . . . 73

Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Plug Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30, 35, 46 Presentation Main Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Presentation of Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . 19–24

Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Plug Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30, 35, 46 Presentation Main Components . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Presentation of Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . 19–24

Ramps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Recycling/Discarding . . . . . . . . . . . . . . . . . . . . . . . . . . . 79–80

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Ramps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Recycling/Discarding . . . . . . . . . . . . . . . . . . . . . . . . . . . 79–80

Index

Safety Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–16 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Conduct while Driving . . . . . . . . . . . . . . . . . . . . . . . 11 Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Handling Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Maintenance and Repair . . . . . . . . . . . . . . . . . . . . . 16 Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Operator Responsibility . . . . . . . . . . . . . . . . . . . . . . 9 Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Work Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Safety Symbol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Signs Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Specification Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Specifications Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Storage Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Starting after Period of Disuse . . . . . . . . . . . . . . . . . 78 Storing the Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Symbols General Prohibition . . . . . . . . . . . . . . . . . . . . . . . . . 6 Glasses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 No Smoking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Open Flames . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Ordinance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Prohibitory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Safety Alert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Safety Equipment Required . . . . . . . . . . . . . . . . . . . 6 Shoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Return

Safety Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–16 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Conduct while Driving . . . . . . . . . . . . . . . . . . . . . . . 11 Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Handling Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Maintenance and Repair . . . . . . . . . . . . . . . . . . . . . 16 Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Operator Responsibility . . . . . . . . . . . . . . . . . . . . . . 9 Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Work Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Safety Symbol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Signs Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Specification Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Specifications Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Storage Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Starting after Period of Disuse . . . . . . . . . . . . . . . . . 78 Storing the Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Symbols General Prohibition . . . . . . . . . . . . . . . . . . . . . . . . . 6 Glasses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 No Smoking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Open Flames . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Ordinance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Prohibitory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Safety Alert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Safety Equipment Required . . . . . . . . . . . . . . . . . . . 6 Shoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Index

Transporting Disabled Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Transporting and Storage . . . . . . . . . . . . . . . . . . . . . . . . 74–78 Transporting Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49–53 Transporting the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Truck Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Applications, Prohibited . . . . . . . . . . . . . . . . . . . . . . 19 Dimensional Data (RTX35) . . . . . . . . . . . . . . . . . . . . 21 Dimensional Data (RTX45) . . . . . . . . . . . . . . . . . . . . 22 Presentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Truck Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

U U.L. Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Transporting Disabled Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Transporting and Storage . . . . . . . . . . . . . . . . . . . . . . . . 74–78 Transporting Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49–53 Transporting the truck . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Truck Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Applications, Prohibited . . . . . . . . . . . . . . . . . . . . . . 19 Dimensional Data (RTX35) . . . . . . . . . . . . . . . . . . . 21 Dimensional Data (RTX45) . . . . . . . . . . . . . . . . . . . 22 Presentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Truck Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

U U.L. Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1, 28, 30, 35, 37, 41, 44, 45, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 59, 60, 61, 62, 63, 64, 65, 67, 76, 77 Warning and Information Signs . . . . . . . . . . . . . . . . . . . 17–18 Warning/Caution Codes . . . . . . . . . . . . . . . . . . . . . . . . . 37–40 Warning Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

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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