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TMX BT Prime-Mover

Operator’s Manuals 303045-000 1994_June 303045-000 1994_December 303045-001 1995_April 303045-002 1995_October 303045-003 1996_January 303045-003 1997_October 303045-003 1998_June 303045-003 1998_October

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

022802

OPERATOR'S MANUAL

Manual Part Number 303045-000 TMX ELECTRIC TOW TRACTOR

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

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

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

ISSUED DECEMBER 1994 Return

ISSUED DECEMBER 1994

IMPORTANT NOTICE

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

BEFORE OPERATING THE UNIT:

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

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

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

LEARN AND PRACTICE USE OF CONTROLS BEFORE OPERATING.

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

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

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FOREWORD

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

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

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

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

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

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

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TABLE OF CONTENTS

NAME

PAGE #

NAME

PAGE #

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

1 2 3 4 5 5 6 6 7 8-13 14-16 17-23 24-26 27 28 29-30 31 32 33

This unit is designed under ANSI B56.9.

For additional operating instructions see ANSI B56.9 "OPERATING SAFETY RULES AND PRACTICES" .

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DRIVE SAFELY

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

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

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STAY ALERT!

INTRODUCTION

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

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

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

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

TO NEW BT PRIME-MOVER OWNERS:

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

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

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

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

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PRELIMINARY SERVICE

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

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

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

The new unit should be checked out by a QUALIFIED TECHNICAN. An arrival and pre-delivery checklist is at the THE PRIME-MOVER DEALERSHIP this sheet is to be returned to validate warranty and to assure that the user has received a quality BT Prime-Mover product ready to do its job.

This OPERATORS MANUAL must be kept with this unit. If a replacement manual is needed, please contact your BT PRIMEMOVER dealer or THE PRIME-MOVER Co. factory and a no charge replacement will be sent.

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

Check the transmission oil level before operation. Check to determine that the battery is adequately charged, properly installed and connected.

RIGHT, LEFT, FRONT, AND REAR SIDES

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

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

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OPERATOR

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

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

Proper operation of this unit is as shown when possible. Steering the truck is easier in this direction. Always look in the direction of travel.

When reversing into a confined area or elevator or on an incline, keep both hands on control handle. Keep both hands within the handle guard and always look in the direction of travel.

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OPERATING PRACTICES

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

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

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

IMPORTANT:

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

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

OPERATING RULES AND INSTRUCTIONS

OPERATOR QUALIFICATIONS

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

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OPERATING PRACTICES

OPERATOR TRAINING

An effective operator training program should center around user company's policies, operating conditions and trucks. The program should be presented completely to all new operators and not condensed for those claiming previous experience.

OPERATOR RESPONSIBILITY

Powered industrial truck operators shall abide by the following rules and practices.

• Avoid loose clothing, particularly cuffs and scarves.

• Know what safety equipment is required on this truck and use it. A hard hat, safety glasses, reflector-type vest, respirators, and ear plugs are some of the types of equipment you may need.

• DO NOT rush.

• Know the hand signals used on this job and who has responsibility for signaling.

• Safeguard the pedestrians at all times. DO NOT drive a truck up to anyone standing in front of a bench or other fixed object.

• PASSENGERS MUST NOT be permitted to ride.

• When operator is away from truck the parking brake lever must be in the ENGAGED POSITION (see page number 19 for further information) and all other controls neutralized to prevent movement.

• DO NOT place any part of body between moving and stationary or outside running lines of truck.

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OPERATING PRACTICES

WHEN A POWERED INDUSTRIAL TRUCK IS TO BE LEFT UNATTENDED

• Completely stop truck in a clear, authorized area.

• Place directional controls in neutral.

• Apply the parking brake lever (see page # 19).

• Turn key switch to OFF and disconnect battery connectors.

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

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

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

WHEN A POWERED INDUSTRIAL TRUCK IS TRAVELING:

• Local safety regulations must always be followed. Know and understand the traffic flow patterns of your job.

• Yield right of way to pedestrians.

• DO NOT pass another truck traveling in the same direction at intersections, blind spots or other dangerous locations.

• Slow down and sound the audible warning device(s) at cross aisles and other locations where vision is blocked. If the load being carried blocks any view, ask for assistance so the load can be moved without any danger to personal or property.

• Keep a clear view of the path of travel, and observe for traffic personnel and safe clearances.

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OPERATING PRACTICES

• GRADES, RAMPS, OR INCLINES; This unit is designed for level floor operation. If it is necessary to operate on a grade, ramp, or incline refer to ANSI B56.9 for requirements.

• Under all travel conditions this unit shall be operated at a speed that will permit it to be brought to a stop in a safe manner.

• Make start, stops, turns or direction reversals in a smooth manner so as not to shift load and/or overturn truck.

• DO NOT indulge in stunt driving or horseplay.

• Slow down for wet and slippery floors.

• Before driving over a dockboard or bridgeplate, be sure that it is properly secured. Drive carefully and slowly across the dockboard or bridgeplate and never exceed its rated capacity.

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

• Trucks shall enter confined areas with load end forward.

• Avoid running over loose objects, uneven surfaces or other obstructions on roadway surface.

• While negotiating turns, reduce speed, steer in a smooth motion. Except when maneuvering at a very low speed, turn the steering at a moderate even rate.

• Report any defect in unit noted during operation.

• Observe instruments and gauges frequently to determine if they are operating properly.

• DO NOT permit riders on unit.

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OPERATING PRACTICES

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

• NEVER get ON or OFF a moving truck.

• Remember to enter load slowly and squarely. Load should be centered.

• Handle only stable and properly arranged loads. Off-center loads must be handled with extra caution.

• Handle only loads within the capacity of the unit as rated on nameplate.

• Handle long and wide loads exceeding the dimensions used to establish truck capacity with extra caution. Stability and maneuverability may be adversely affected.

• The load shall only be lifted vertically and never dragged horizontally.

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

OPERATOR PRECHECKS AND INSPECTION

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

• Tires • Warning and safety Devices • Battery • Brake • Steering Mechanism • Couplers

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

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OPERATING PRACTICES

• DO NOT make repairs or adjustments unless specifically authorized to do so.

• DO NOT use open flames when checking electrolyte level in battery

• DO NOT adjust unit with any parts moving.

• DO NOT smoke while working around truck.

• Block securely with drive tire off of floor when working under truck, and on drive unit or electrical controls.

• DO NOT attempt repairs you do not understand. There is no disgrace in asking for help.

These warnings are NOT meant to be a complete list, and only the operator's intelligence, good sense, and care of unit will assure that most hazards will be avoided. Refer to ANSI B56.9 for further operator's information.

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DATA PLATE AND DECALS

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

1. Truck model number 2. Truck type 3. Truck serial number 4. Truck weight 5. Truck voltage 6. Battery type 7. Battery maximum AMP hours 8. Minimum battery weight 9. Maximum battery weight 10. Maximum drawbar pull 11. Normal drawbar pull 12. Maximum coupler height 13. Normal coupler height

1. Truck model number 2. Truck type 3. Truck serial number 4. Truck weight 5. Truck voltage 6. Battery type 7. Battery maximum AMP hours 8. Minimum battery weight 9. Maximum battery weight 10. Truck capacity 11. Normal drawbar pull 12. Maximum coupler height 13. Normal coupler height

This data plate is located on center, left side of backrest shield. Knowing the model and serial numbers for this unit is very helpful when ordering repair parts. For further information and specifications on this unit or any other, contact your BT PrimeMover dealer.

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DATA PLATE AND DECALS

OPERATING WARNINGS

The OPERATING WARNINGS decal is located on center, right side of load backrest shield. This decal describes basic warnings for safe operation of this unit. Carefully read the decal and make sure you understand the warning instructions.

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DATA PLATE AND DECALS

PARKING BRAKE WARNING

This truck has a PARKING BRAKE WARNING decal. Which is located on the base of the steering control handle. This decal describes action needed to apply the hand parking brake. Carefully read this decal and make sure you understand the warning.

WARNING DECALS

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

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

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

If a decal is on a part that is replaced, make sure you install a new decal on the new part. See your BT Prime-Mover dealer for new decals. New warning decals can be obtained from your BT PRIME-MOVER DEALER at NO charge.

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CONTROLS AND EQUIPMENT

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

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

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

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

THE CONTROL HANDLE

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

The Control Handle

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CONTROLS AND EQUIPMENT

THE CONTROL HANDLE

HORN SWITCH

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

DIRECTION AND SPEED

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

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CONTROLS AND EQUIPMENT

BRAKE LEVER CONTROLS

This truck has two brake engaging controls, 1) is a parking brake lever that locks in place when used, 2) is a hand controlled lever that is squeezed to apply brake. The hand brake lever can be used from either side of control handle or squeezed with both hands to apply maximum pressure for braking. This lever can be applied slowly to control braking pressure and stop slowly and smoothly.

The proper position for parking brake lever engaged and disengaged position is shown and described below.

PARKING BRAKE LEVER

The parking brake lever must be placed in the engaged position when unit is not in use (parked) or hand brake lever is not squeezed.

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

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CONTROLS AND EQUIPMENT

BRAKING USING PLUGGING FUNCTION

As stated under "BRAKE LEVER CONTROLS" the truck can be brought to a stop by using the hand brake lever. An equally acceptable method of stopping the truck's travel is by using the "plugging" function. This method involves reversing the travel control to the opposite direction without using the hand brake lever. This will cause the truck to come to a stop smoothly.

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

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

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CONTROLS AND EQUIPMENT

DASH PANEL ASSEMBLY

CONTROLS AND EQUIPMENT

EMERGENCY DISCONNECT BUTTON

The RED EMERGENCY DISCONNECT BUTTON is used to cut all electrical power to the unit when button is pushed. To reset emergency disconnect button turn key switch to the "OFF" position, repair emergency, pull emergency disconnect button out and turn key switch to the "ON" position.

The Hourmeter can be read any time the emergency disconnect button is pulled out.

KEY SWITCH

A KEY SWITCH is provided to prevent unauthorized use of this unit. The emergency disconnect button must be pulled out before electrical power can flow to the control circuit.

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

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

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

When unit is left unattended for extended period of time push the emergency disconnect button in, disconnect battery, and remove and secure key in a safe place.

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CONTROLS AND EQUIPMENT

BATTERY DISCHARGE INDICTOR/HOURMETER DASH DISPLAY

BATTERY DISCHARGE INDICATOR/HOURMETER

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

BDI/HOURMETER WITH LIFT INTERRUPT (optional)

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

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BEFORE OPERATION INSPECTION

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

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

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

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

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

• Inspect steering for looseness or binding and lack of lubrication.

• Inspect drive unit. Look for leakage.

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

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

• Make sure the operator's manual is in compartment and tethered to machine.

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

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

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BEFORE OPERATION INSPECTION

• Check the operation of the BDI/hourmeter.

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

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

• Turn steering control handle until steering is in the desired direction of travel.

• Squeezes the hand park lever with one hand to apply the brake and disengage parking brake. This will release the brake and make power available to drive motor.

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

• REARWARD TRAVEL: Put a firm grip on the directional control handle and rotate backward slowly. The unit must move slowly in a rearward direction. Rotate the handle more to increase speed. Unit should accelerate smoothly to maximum speed as handle is rotated. Direction controls MUST automatically return to the NEUTRAL position when released. Squeezes the hand brake lever with your hand(s) to apply the brakes.

• FORWARD TRAVEL: Put a firm grip on the directional control handle and rotate forward slowly. The unit must move slowly in a forward direction. Rotate the handle more to increase speed. Unit should accelerate smoothly to maximum speed as handle is rotated. Direction controls MUST automatically return to the NEUTRAL position when released. Squeezes the hand brake lever with your hand(s) to apply the brakes.

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

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BEFORE OPERATION INSPECTION

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

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

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

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

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

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OPERATION

STOPPING UNIT

1. Rotate direction control to the "NEUTRAL" position.

2. Squeeze handle brake lever and stop movement completely.

3. Place the parking brake lever in the engaged position (see page # 19).

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

5. Push the emergency disconnect button in to stop hourmeter from running.

BRAKE LEVERS AND KEY SWITCH LOCATION

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

2. Set parking brake lever to the "ENGAGED" position (see page # 19).

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

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

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BATTERY RETAINMENT/CARE

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

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

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

This unit uses a 24 volt wet cell Battery.

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

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

IMPORTANT

Use only batteries that meet the following specifications:

VOLTAGE Minimum Battery Weight Maximum Battery Weight

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

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

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BATTERY RETAINMENT/CARE

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

BATTERY SERVICE

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

ADDING WATER

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

CLEANING TERMINALS & CABLE CONNECTIONS

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

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SPECIFICATIONS AND LUBRICATIONS

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

Fluid Type

SAE 80W90 GL5 (cold storage) Dexron II

Grease Type

NOTE:

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Tex. Ref. C and C #880

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

SAE 80W90 GL5 (cold storage) Dexron II

Grease Type

NOTE:

Tex. Ref. C and C #880

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

SERVICE INTERVALS

200 HOURS OR MONTHLY

• Check condition of battery charge. • Visually inspect for leaks, loose, missing, or damaged parts. • Check all operating functions and adjustments. • Check transmission oil level. • Lubricate all grease fittings. • Inspect power cables and control wiring. • Clean with compressed air. • Inspect motor brushes.

2000 HOURS OR ANNUAL

• Clean battery and machine. • Drain, flush, and refill transmission gear case.

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FIELD MODIFICATIONS

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

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

PROUDLY Made in AMERICA

OPERATOR'S MANUAL

Manual Part Number 303045-000 TMX ELECTRIC TOW TRACTOR

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

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

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

ISSUED JUNE 1994

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ISSUED JUNE 1994

IMPORTANT NOTICE

BEFORE OPERATING THE UNIT:

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

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

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

LEARN AND PRACTICE USE OF CONTROLS BEFORE OPERATING.

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

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FOREWORD

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

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

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

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

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TABLE OF CONTENTS

NAME

PAGE #

NAME

PAGE #

1 2 3 4 5 5 6 6 7 8-13 14-16 17-22 23-25 26 27 28-29 30 31 32

This unit is designed under ANSI B56.9.

For additional operating instructions see ANSI B56.9 "OPERATING SAFETY RULES AND PRACTICES" .

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DRIVE SAFELY

B E F O R E Y O U O P E R A T E THIS INDUSTRIAL TRUCK, READ AND UNDERSTAND THE INSTRUCTIONS, SIGNS AND MESSAGES IN THIS MANUAL AND ON THE UNIT.

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

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STAY ALERT!

INTRODUCTION

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

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

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

TO NEW BT PRIME-MOVER OWNERS:

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

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PRELIMINARY SERVICE

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

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

This OPERATORS MANUAL must be kept with this unit. If a replacement manual is needed, please contact your BT PRIMEMOVER dealer or THE PRIME-MOVER Co. factory and a no charge replacement will be sent.

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

Check the transmission oil level before operation. Check to determine that the battery is adequately charged, properly installed and connected.

RIGHT, LEFT, FRONT, AND REAR SIDES

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

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

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OPERATOR

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

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

Proper operation of this unit is as shown when possible. Steering the truck is easier in this direction. Always look in the direction of travel.

When reversing into a confined area or elevator or on an incline, keep both hands on control handle. Keep both hands within the handle guard and always look in the direction of travel.

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OPERATING PRACTICES

IMPORTANT:

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

OPERATING RULES AND INSTRUCTIONS

OPERATOR QUALIFICATIONS

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OPERATING PRACTICES

OPERATOR TRAINING

OPERATOR RESPONSIBILITY

Powered industrial truck operators shall abide by the following rules and practices.

• Avoid loose clothing, particularly cuffs and scarves.

• Know what safety equipment is required on this truck and use it. A hard hat, safety glasses, reflector-type vest, respirators, and ear plugs are some of the types of equipment you may need.

• DO NOT rush.

• Know the hand signals used on this job and who has responsibility for signaling.

• Safeguard the pedestrians at all times. DO NOT drive a truck up to anyone standing in front of a bench or other fixed object.

• PASSENGERS MUST NOT be permitted to ride.

• When operator is away from truck the parking brake lever must be in the ENGAGED POSTION (see page number 19 for further information) and all other controls neutralized to prevent movement.

• DO NOT place any part of body between moving and stationary or outside running lines of truck.

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OPERATING PRACTICES

WHEN A POWERED INDUSTRIAL TRUCK IS TO BE LEFT UNATTENDED

• Completely stop truck in a clear, authorized area.

• Place directional controls in neutral.

• Apply the parking brake lever (see page # 19).

• Turn key switch to OFF and disconnect battery connectors.

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

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

WHEN A POWERED INDUSTRIAL TRUCK IS TRAVELING:

• Local safety regulations must always be followed. Know and understand the traffic flow patterns of your job.

• Yield right of way to pedestrians.

• DO NOT pass another truck traveling in the same direction at intersections, blind spots or other dangerous locations.

• Keep a clear view of the path of travel, and observe for traffic personnel and safe clearances.

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OPERATING PRACTICES

• GRADES, RAMPS, OR INCLINES; This unit is designed for level floor operation. If it is necessary to operate on a grade, ramp, or incline refer to ANSI B56.9 for requirements.

• Under all travel conditions this unit shall be operated at a speed that will permit it to be brought to a stop in a safe manner.

• Make start, stops, turns or direction reversals in a smooth manner so as not to shift load and/or overturn truck.

• DO NOT indulge in stunt driving or horseplay.

• Slow down for wet and slippery floors.

• Before driving over a dockboard or bridgeplate, be sure that it is properly secured. Drive carefully and slowly across the dockboard or bridgeplate and never exceed its rated capacity.

• Before the truck is driven into a elevator, the operator must make sure that the elevator is certificated for that particular load. When entering a elevator, the load goes first, not the driver. There must be no personnel in the elevator when the load is entering or being removed.

• Trucks shall enter confined areas with load end forward.

• Avoid running over loose objects, uneven surfaces or other obstructions on roadway surface.

• While negotiating turns, reduce speed, steer in a smooth motion. Except when maneuvering at a very low speed, turn the steering at a moderate even rate.

• Report any defect in unit noted during operation.

• Observe instruments and gauges frequently to determine if they are operating properly.

• DO NOT permit riders on unit.

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OPERATING PRACTICES

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

• Remember to enter load slowly and squarely. Load should be centered.

• Handle only stable and properly arranged loads. Off-center loads must be handled with extra caution.

• Handle only loads within the capacity of the unit as rated on nameplate.

• Handle long and wide loads exceeding the dimensions used to establish truck capacity with extra caution. Stability and maneuverability may be adversely affected.

• The load shall only be lifted vertically and never dragged horizontally.

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

OPERATOR PRECHECKS AND INSPECTION

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

• Tires • Warning and safety Devices • Battery • Brake • Steering Mechanism • Couplers

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OPERATING PRACTICES

• DO NOT make repairs or adjustments unless specifically authorized to do so.

• DO NOT use open flames when checking electrolyte level in battery

• DO NOT adjust unit with any parts moving.

• DO NOT smoke while working around truck.

• Block securely with drive tire off of floor when working under truck, and on drive unit or electrical controls.

• DO NOT attempt repairs you do not understand. There is no disgrace in asking for help.

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DATA PLATE AND DECALS

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

1. Truck model number 2. Truck type 3. Truck serial number 4. Truck weight 5. Truck voltage 6. Battery type 7. Battery maximum AMP hours 8. Minimum battery weight 9. Maximum battery weight 10. Truck capacity 11. Normal drawbar pull 12. Maximum coupler height 13. Normal coupler height

This data plate is located on center, left side of backrest shield. Knowing the model and serial numbers for this unit are very helpful when ordering repair parts. For further information and specifications on this unit or any other, contact your BT PrimeMover dealer.

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DATA PLATE AND DECALS

OPERATING WARNINGS

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DATA PLATE AND DECALS

WARNING DECALS

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

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

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

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CONTROLS AND EQUIPMENT

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

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

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

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

THE CONTROL HANDLE

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

The Control Handle

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CONTROLS AND EQUIPMENT

BRAKE LEVER CONTROLS

The proper position for parking brake lever engaged and disengaged position is shown and described below.

PARKING BRAKE LEVER

The parking brake lever must be placed in the engaged position when unit is not in use (parked) or hand brake lever is not squeezed.

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

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CONTROLS AND EQUIPMENT

BRAKING USING PLUGGING FUNCTION

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CONTROLS AND EQUIPMENT

KEY SWITCH

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

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

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

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

EMERGENCY DISCONNECT BUTTON

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

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CONTROLS AND EQUIPMENT

BATTERY DISCHARGE INDICTOR/HOURMETER DASH DISPLAY

BATTERY DISCHARGE INDICATOR/HOURMETER

This dash display is a two segment display that indicates the percentage of battery discharge and hourmeter. The hourmeter and battery condition can be read anytime the key is in the on position. This gauge has a ten-LED multicolored display. One LED is illuminated at a time, beginning with a green LED at the far right position. As the battery is drained of charge, the display moves one position to the left at a time. The first five LEDs are green, the next three are amber, and the last two are red. When the display moves to the ninth position from the right, the LED will go "ON" and "OFF". This position corresponds to a battery that is approximately 70% discharged. The next position is the tenth, or last, LED (red). This LED will flash alternately with the ninth LED. This corresponds to approximately 80% discharged. The dash display is physically located on the dash next to key switch.

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BEFORE OPERATION INSPECTION

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

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

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

• Inspect steering for looseness or binding and lack of lubrication.

• Inspect drive unit. Look for leakage.

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

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

• Make sure the operator's manual is in compartment and tethered to machine.

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

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

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BEFORE OPERATION INSPECTION

• Check the operation of the BDI/hourmeter.

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

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

• Turn steering control handle until steering is in the desired direction of travel.

• Squeezes the hand park lever with one hand to apply the brake and disengage parking brake This will release the brake and make power available to drive motor.

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

• REARWARD TRAVEL: Put a firm grip on the directional control handle and rotate backward (down) slowly. The unit must move slowly in a rearward direction. Rotate the handle more to increase speed. Unit should accelerate smoothly to maximum speed as handle is rotated. Direction controls MUST automatically return to the NEUTRAL position. When released. Squeezes the hand brake lever with your hand(s) to apply the brakes.

• FORWARD TRAVEL: Put a firm grip on the directional control handle and rotate forward (up) slowly. The unit must move slowly in a forward direction. Rotate the handle more to increase speed. Unit should accelerate smoothly to maximum speed as handle is rotated. Direction controls MUST automatically return to the NEUTRAL position. When released. Squeezes the hand brake lever with your hand(s) to apply the brakes.

• This unit is equipped with a plugging feature (direction reversal) which means that you need not brake to a complete stop to change directions. Use the direction/speed control handle to change direction.

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BEFORE OPERATION INSPECTION

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

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

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OPERATION

STOPPING UNIT

1. Rotate direction control grip to the "NEUTRAL" position.

2. Squeeze handle brake lever and stop movement completely.

3. Place the parking brake lever in the engaged position (see page # 19).

4. Turn key switch to "OFF" position and remove key,

BRAKE LEVERS AND KEY SWITCH LOCATION

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

2. Set parking brake lever to the "ENGAGED" position (see page # 19).

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

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

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BATTERY RETAINMENT/CARE

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

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

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

This unit uses a 24 volt wet cell Battery.

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

IMPORTANT

Use only batteries that meet the following specifications:

VOLTAGE Minimum Battery Weight Maximum Battery Weight

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

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

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BATTERY RETAINMENT/CARE

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

BATTERY SERVICE

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

ADDING WATER

CLEANING TERMINALS & CABLE CONNECTIONS

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SPECIFICATIONS AND LUBRICATIONS

Oil Capacity in Transmission .8 Quart [.75 l] or to bottom of the fluid fill hole in the transmission. Fluid Type SAE 80W90 GL5 (cold storage) Dexron II

Grease Type

Tex. Ref. C and C #880

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

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Tex. Ref. C and C #880

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

SERVICE INTERVALS

200 HOURS OR MONTHLY

2000 HOURS OR ANNUAL

• Clean battery and machine. • Drain, flush, and refill transmission gear case.

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FIELD MODIFICATIONS

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

PROUDLY Made in AMERICA

OPERATOR'S MANUAL

Manual Part Number 303045-001 TMX ELECTRIC TOW TRACTOR

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

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

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

ISSUED APRIL 1995

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ISSUED APRIL 1995

IMPORTANT NOTICE

BEFORE OPERATING THE UNIT:

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

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

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

LEARN AND PRACTICE USE OF CONTROLS BEFORE OPERATING.

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

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FOREWORD

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

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

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

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

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TABLE OF CONTENTS

NAME

PAGE #

NAME

PAGE #

1 2 3 4 5 5 6 6 7 8-13 14-16 17-23 24-26 27 28 29-30 31 32 33

This unit is designed under ANSI B56.9.

For additional operating instructions see ANSI B56.9 "OPERATING SAFETY RULES AND PRACTICES" .

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DRIVE SAFELY

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

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

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STAY ALERT!

INTRODUCTION

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

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

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

TO NEW BT PRIME-MOVER OWNERS:

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

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PRELIMINARY SERVICE

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

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

This OPERATORS MANUAL must be kept with this unit. If a replacement manual is needed, please contact your BT PRIMEMOVER dealer or THE PRIME-MOVER Co. factory and a no charge replacement will be sent.

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

Check the transmission oil level before operation. Check to determine that the battery is adequately charged, properly installed and connected.

RIGHT, LEFT, FRONT, AND REAR SIDES

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

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

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OPERATOR

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

Proper operation of this unit is as shown when possible. Steering the truck is easier in this direction. Always look in the direction of travel.

When reversing into a confined area or elevator or on an incline, keep both hands on control handle. Keep both hands within the handle guard and always look in the direction of travel.

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OPERATING PRACTICES

IMPORTANT:

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

OPERATING RULES AND INSTRUCTIONS

OPERATOR QUALIFICATIONS

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OPERATING PRACTICES

OPERATOR TRAINING

OPERATOR RESPONSIBILITY

Powered industrial truck operators shall abide by the following rules and practices.

• Avoid loose clothing, particularly cuffs and scarves.

• Know what safety equipment is required on this truck and use it. A hard hat, safety glasses, reflector-type vest, respirators, and ear plugs are some of the types of equipment you may need.

• DO NOT rush.

• Know the hand signals used on this job and who has responsibility for signaling.

• Safeguard the pedestrians at all times. DO NOT drive a truck up to anyone standing in front of a bench or other fixed object.

• PASSENGERS MUST NOT be permitted to ride.

• When operator is away from truck the parking brake lever must be in the ENGAGED POSITION (see page number 19 for further information) and all other controls neutralized to prevent movement.

• DO NOT place any part of body between moving and stationary or outside running lines of truck.

• Use caution when making a right or left turn into an aisle. Remember rear wheels do not follow turn path of front wheel. When making a turn allow for "corner-cutting" of trailers.

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OPERATING PRACTICES

WHEN A POWERED INDUSTRIAL TRUCK IS TO BE LEFT UNATTENDED

• Completely stop truck in a clear, authorized area.

• Place directional controls in neutral.

• Apply the parking brake lever (see page # 19).

• Turn key switch to OFF and disconnect battery connectors.

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

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

WHEN A POWERED INDUSTRIAL TRUCK IS TRAVELING:

• Local safety regulations must always be followed. Know and understand the traffic flow patterns of your job.

• Yield right of way to pedestrians.

• DO NOT pass another truck traveling in the same direction at intersections, blind spots or other dangerous locations.

• Keep a clear view of the path of travel, and observe for traffic personnel and safe clearances.

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OPERATING PRACTICES

• GRADES, RAMPS, OR INCLINES; This unit is designed for level floor operation. If it is necessary to operate on a grade, ramp, or incline refer to ANSI B56.9 for requirements.

• Under all travel conditions this unit shall be operated at a speed that will permit it to be brought to a stop in a safe manner.

• Make start, stops, turns or direction reversals in a smooth manner so as not to shift load and/or overturn truck.

• DO NOT indulge in stunt driving or horseplay.

• Slow down for wet and slippery floors.

• Before driving over a dockboard or bridgeplate, be sure that it is properly secured. Drive carefully and slowly across the dockboard or bridgeplate and never exceed its rated capacity.

• Trucks shall enter confined areas with load end forward.

• Avoid running over loose objects, uneven surfaces or other obstructions on roadway surface.

• While negotiating turns, reduce speed, steer in a smooth motion. Except when maneuvering at a very low speed, turn the steering at a moderate even rate.

• Report any defect in unit noted during operation.

• Observe instruments and gauges frequently to determine if they are operating properly.

• DO NOT permit riders on unit.

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OPERATING PRACTICES

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

• NEVER get ON or OFF a moving truck.

• Remember to enter load slowly and squarely. Load should be centered.

• Handle only stable and properly arranged loads. Off-center loads must be handled with extra caution.

• Handle only loads within the capacity of the unit as rated on nameplate.

• Handle long and wide loads exceeding the dimensions used to establish truck capacity with extra caution. Stability and maneuverability may be adversely affected.

• The load shall only be lifted vertically and never dragged horizontally.

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

OPERATOR PRECHECKS AND INSPECTION

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

• Tires • Warning and safety Devices • Battery • Brake • Steering Mechanism • Couplers

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OPERATING PRACTICES

• DO NOT make repairs or adjustments unless specifically authorized to do so.

• DO NOT use open flames when checking electrolyte level in battery

• DO NOT adjust unit with any parts moving.

• DO NOT smoke while working around truck.

• Block securely with drive tire off of floor when working under truck, and on drive unit or electrical controls.

• DO NOT attempt repairs you do not understand. There is no disgrace in asking for help.

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DATA PLATE AND DECALS

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

1. Truck model number 2. Truck type 3. Truck serial number 4. Truck weight 5. Truck voltage 6. Battery type 7. Battery maximum AMP hours 8. Minimum battery weight 9. Maximum battery weight 10. Tire Part Number 11. Maximum drawbar pull 12. Normal drawbar pull 13. Maximum coupler height 14. Normal coupler height

This data plate is located in the operator's compartment on left side below the knee pad. Knowing the model and serial numbers for this unit is very helpful when ordering service parts. For further information and specifications on this unit or any other, contact your BT Prime-Mover dealer.

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DATA PLATE AND DECALS

OPERATING WARNINGS

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

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DATA PLATE AND DECALS

PARKING BRAKE WARNING

WARNING DECALS

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

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

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

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CONTROLS AND EQUIPMENT

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

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

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

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

THE CONTROL HANDLE

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

The Control Handle

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CONTROLS AND EQUIPMENT

THE CONTROL HANDLE

HORN SWITCH

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

DIRECTION AND SPEED

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CONTROLS AND EQUIPMENT

BRAKE LEVER CONTROLS

The proper position for parking brake lever engaged and disengaged position is shown and described below.

PARKING BRAKE LEVER

The parking brake lever must be placed in the engaged position when unit is not in use (parked) or hand brake lever is not squeezed.

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

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CONTROLS AND EQUIPMENT

BRAKING USING PLUGGING FUNCTION

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CONTROLS AND EQUIPMENT

DASH PANEL ASSEMBLY

CONTROLS AND EQUIPMENT

EMERGENCY DISCONNECT BUTTON

The Hourmeter can be read any time the emergency disconnect button is pulled out.

KEY SWITCH

A KEY SWITCH is provided to prevent unauthorized use of this unit. The emergency disconnect button must be pulled out before electrical power can flow to the control circuit.

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

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

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

When unit is left unattended for extended period of time push the emergency disconnect button in, disconnect battery, and remove and secure key in a safe place.

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CONTROLS AND EQUIPMENT

BATTERY DISCHARGE INDICTOR/HOURMETER DASH DISPLAY

BATTERY DISCHARGE INDICATOR/HOURMETER

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

BDI/HOURMETER WITH LIFT INTERRUPT (optional)

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BEFORE OPERATION INSPECTION

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

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

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

• Inspect steering for looseness or binding and lack of lubrication.

• Inspect drive unit. Look for leakage.

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

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

• Make sure the operator's manual is in compartment and tethered to machine.

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

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

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BEFORE OPERATION INSPECTION

• Check the operation of the BDI/hourmeter.

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

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

• Turn steering control handle until steering is in the desired direction of travel.

• Squeezes the hand park lever with one hand to apply the brake and disengage parking brake. This will release the brake and make power available to drive motor.

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

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BEFORE OPERATION INSPECTION

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

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

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

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OPERATION

STOPPING UNIT

1. Rotate direction control to the "NEUTRAL" position.

2. Squeeze handle brake lever and stop movement completely.

3. Place the parking brake lever in the engaged position (see page # 19).

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

5. Push the emergency disconnect button in to stop hourmeter from running.

BRAKE LEVERS AND KEY SWITCH LOCATION

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

2. Set parking brake lever to the "ENGAGED" position (see page # 19).

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

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

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BATTERY RETAINMENT/CARE

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

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

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

This unit uses a 24 volt wet cell Battery.

IMPORTANT

Use only batteries that meet the following specifications:

VOLTAGE Minimum Battery Weight Maximum Battery Weight

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

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

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BATTERY RETAINMENT/CARE

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

BATTERY SERVICE

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

ADDING WATER

CLEANING TERMINALS & CABLE CONNECTIONS

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SPECIFICATIONS AND LUBRICATIONS

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

Fluid Type

SAE 80W90 GL5 (cold storage) Dexron II

Grease Type

NOTE:

Tex. Ref. C and C #880

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

31 Return

SAE 80W90 GL5 (cold storage) Dexron II

Grease Type

NOTE:

Tex. Ref. C and C #880

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

SERVICE INTERVALS

200 HOURS OR MONTHLY

2000 HOURS OR ANNUAL

• Clean battery and machine. • Drain, flush, and refill transmission gear case.

32 32 Return

FIELD MODIFICATIONS

33 Return

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

PROUDLY Made in AMERICA

OPERATOR'S MANUAL

Manual Part Number 303045-002 TMX ELECTRIC TOW TRACTOR

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

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

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

ISSUED OCTOBER 1995 Return

ISSUED OCTOBER 1995

IMPORTANT NOTICE

BEFORE OPERATING THE UNIT:

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

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

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

LEARN AND PRACTICE USE OF CONTROLS BEFORE OPERATING.

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

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FOREWORD

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

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

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

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

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TABLE OF CONTENTS

NAME

PAGE #

NAME

PAGE #

1 2 3 4 5 5 6 6 7 8-13 14-16 17-23 24-26 27 28 29-30 31 32 33

This unit is designed under ANSI B56.9.

For additional operating instructions see ANSI B56.9 "OPERATING SAFETY RULES AND PRACTICES" .

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DRIVE SAFELY

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

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

Return

STAY ALERT!

INTRODUCTION

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

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

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

TO NEW BT PRIME-MOVER OWNERS:

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

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PRELIMINARY SERVICE

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

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

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

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

This OPERATOR'S MANUAL must be kept with this unit. If a replacement manual is needed, please contact your BT PRIMEMOVER dealer or THE PRIME-MOVER Co. factory and a no charge replacement will be sent.

A parts manual has been provided with the machine. Additional copies are available.

Check the transmission oil level before operation. Check to determine that the battery is adequately charged, properly installed and connected.

RIGHT, LEFT, FRONT, AND REAR SIDES

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

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

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OPERATOR

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

Proper operation of this unit is as shown when possible. Steering the truck is easier in this direction. Always look in the direction of travel.

When reversing into a confined area or elevator or on an incline, keep both hands on control handle. Keep both hands within the handle guard and always look in the direction of travel.

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OPERATING PRACTICES

IMPORTANT:

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

OPERATING RULES AND INSTRUCTIONS

OPERATOR QUALIFICATIONS

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OPERATING PRACTICES

OPERATOR TRAINING

OPERATOR RESPONSIBILITY

Powered industrial truck operators shall abide by the following rules and practices.

• Avoid loose clothing, particularly cuffs and scarves.

• Know what safety equipment is required on this truck and use it. A hard hat, safety glasses, reflector-type vest, respirators, and ear plugs are some of the types of equipment you may need.

• DO NOT rush.

• Know the hand signals used on this job and who has responsibility for signaling.

• Safeguard the pedestrians at all times. DO NOT drive a truck up to anyone standing in front of a bench or other fixed object.

• PASSENGERS MUST NOT be permitted to ride.

• When the operator is away from truck, the parking brake lever must be in the ENGAGED POSITION (see page number 19 for further information) and all other controls neutralized to prevent movement.

• DO NOT place any part of body between moving and stationary or outside running lines of truck.

• Use caution when making a right or left turn into an aisle. Remember rear wheels do not follow turn path of front wheel. When making a turn allow for "corner-cutting" of trailers.

• Safeguard co-workers from truck operational hazards when their assistance is required to perform a task.

• ALWAYS LOOK IN DIRECTION OF TRAVEL , especially when reversing.

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OPERATING PRACTICES

WHEN A POWERED INDUSTRIAL TRUCK IS TO BE LEFT UNATTENDED

• Completely stop truck in a clear, authorized area.

• Place directional controls in neutral.

• Apply the parking brake lever (see page # 19).

• Turn key switch to OFF and disconnect battery connector.

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

WHEN A POWERED INDUSTRIAL TRUCK IS TRAVELING:

• Local safety regulations must always be followed. Know and understand the traffic flow patterns of your job.

• Yield right of way to pedestrians.

• DO NOT pass another truck traveling in the same direction at intersections, blind spots or other dangerous locations.

• Keep a clear view of the path of travel, and observe for traffic, personnel and safe clearances.

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OPERATING PRACTICES

• GRADES, RAMPS, OR INCLINES; This unit is designed for level floor operation. If it is necessary to operate on a grade, ramp, or incline refer to ANSI B56.9 for requirements.

• Under all travel conditions this unit shall be operated at a speed that will permit it to be brought to a stop in a safe manner.

• Make start, stops, turns or direction reversals in a smooth manner so as not to shift load and/or overturn truck.

• DO NOT indulge in stunt driving or horseplay.

• Slow down for wet and slippery floors.

• Before driving over a dockboard or bridgeplate, be sure that it is properly secured. Drive carefully and slowly across the dockboard or bridgeplate and never exceed its rated capacity.

• Before the truck is driven into an elevator, the operator must make sure that the elevator is certified for that particular load. When entering an elevator the load goes first not the driver. There must be no personnel in the elevator when the load is entering or being removed.

• Trucks shall enter confined areas with load end forward.

• Avoid running over loose objects, uneven surfaces or other obstructions on roadway surface.

• While negotiating turns, reduce speed, steer in a smooth motion. Except when maneuvering at a very low speed, turn the steering at a moderate even rate.

• Report any defect in unit noted during operation.

• Observe instruments and gauges frequently to determine if they are operating properly.

• DO NOT permit riders on unit.

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OPERATING PRACTICES

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

• NEVER get ON or OFF a moving truck.

• Handle only stable and properly arranged loads. Off-center loads must be handled with extra caution.

• Handle only loads within the capacity of the unit as rated on nameplate.

• Handle long and wide loads exceeding the dimensions used to establish truck capacity with extra caution. Stability and maneuverability may be adversely affected.

OPERATOR PRECHECKS AND INSPECTION

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

• Tires • Warning and safety Devices • Battery • Brake • Steering Mechanism • Couplers

• DO NOT make repairs or adjustments unless specifically authorized to do so.

• DO NOT use open flames when checking electrolyte level in battery

• DO NOT adjust unit with any parts moving.

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OPERATING PRACTICES

• DO NOT smoke while working around truck.

• Block securely with drive tire off of floor when working under truck, and on drive unit or electrical controls.

• DO NOT attempt repairs you do not understand. There is no disgrace in asking for help.

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DATA PLATE AND DECALS

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

1. Truck model number 2. Truck type 3. Truck serial number 4. Truck weight 5. Truck voltage 6. Battery type 7. Battery maximum AMP hours 8. Minimum battery weight 9. Maximum battery weight 10. Tire Part Number 11. Maximum drawbar pull 12. Normal drawbar pull 13. Maximum coupler height 14. Normal coupler height

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DATA PLATE AND DECALS

OPERATING WARNINGS

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DATA PLATE AND DECALS

PARKING BRAKE WARNING

This truck has a PARKING BRAKE WARNING decal. Decal is located on the base of the steering control handle. This decal describes action needed to apply the hand parking brake. Carefully read this decal and make sure you understand the warning.

WARNING DECALS

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

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

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

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CONTROLS AND EQUIPMENT

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

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

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

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

THE CONTROL HANDLE

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

The Control Handle

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CONTROLS AND EQUIPMENT

THE CONTROL HANDLE

HORN SWITCH

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

DIRECTION AND SPEED

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CONTROLS AND EQUIPMENT

BRAKE LEVER CONTROLS

The proper position for parking brake lever engaged and disengaged position is shown and described below.

PARKING BRAKE LEVER

The parking brake lever must be placed in the engaged position when unit is not in use (parked) or hand brake lever is not squeezed.

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

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CONTROLS AND EQUIPMENT

BRAKING USING PLUGGING FUNCTION

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CONTROLS AND EQUIPMENT

DASH PANEL ASSEMBLY

CONTROLS AND EQUIPMENT

EMERGENCY DISCONNECT BUTTON

The Hourmeter can be read any time the emergency disconnect button is pulled out.

KEY SWITCH

A KEY SWITCH is provided to prevent unauthorized use of this unit. The emergency disconnect button must be pulled out before electrical power can flow to the control circuit.

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

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

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

When unit is left unattended for extended period of time push the emergency disconnect button in, disconnect battery, and remove and secure key in a safe place.

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CONTROLS AND EQUIPMENT

BATTERY DISCHARGE INDICTOR/HOURMETER DASH DISPLAY

BATTERY DISCHARGE INDICATOR/HOURMETER

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

BDI/HOURMETER WITH SPEED DROPOUT (optional)

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

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BEFORE OPERATION INSPECTION

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

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

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

• Inspect steering for looseness or binding and lack of lubrication.

• Inspect drive unit. Look for leakage.

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

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

• Make sure the operator's manual is in compartment and tethered to machine.

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

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

• Connect the battery to unit (if disconnected), and turn the key switch to the "ON" position. 24

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BEFORE OPERATION INSPECTION

• Check the operation of the BDI/hourmeter.

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

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

• Turn steering control handle until steering is in the desired direction of travel.

• Squeeze the hand park lever with one hand to apply the brake and disengage parking brake This will release the brake and make power available to drive motor.

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

• REARWARD TRAVEL: Put a firm grip on the directional control handle and rotate backward slowly. The unit must move slowly in a rearward direction. Rotate the handle more to increase speed. Unit should accelerate smoothly to maximum speed as handle is rotated. Directional controls MUST automatically return to the NEUTRAL position when released. Squeeze the hand brake lever with your hand(s) to apply the brakes.

• FORWARD TRAVEL: Put a firm grip on the directional control handle and rotate forward slowly. The unit must move slowly in a forward direction. Rotate the handle more to increase speed. Unit should accelerate smoothly to maximum speed as handle is rotated. Directional controls MUST automatically return to the NEUTRAL position when released. Squeeze the hand brake lever with your hand(s) to apply the brakes.

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BEFORE OPERATION INSPECTION

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

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

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

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

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OPERATION

STOPPING UNIT

1. Rotate directional control to the "NEUTRAL" position.

2. Squeeze handle brake lever and stop movement completely.

3. Place the parking brake lever in the engaged position (see page # 19).

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

5. Push the emergency disconnect button in to stop hourmeter from running.

BRAKE LEVERS AND KEY SWITCH LOCATION

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

2. Set parking brake lever to the "ENGAGED" position (see page # 19).

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

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

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BATTERY RETAINMENT/CARE

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

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

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

This unit uses a 24 volt wet cell Battery.

IMPORTANT

Use only batteries that meet the following specifications:

VOLTAGE Minimum Battery Weight Maximum Battery Weight

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

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

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BATTERY RETAINMENT/CARE

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

BATTERY SERVICE

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

ADDING WATER

CLEANING TERMINALS & CABLE CONNECTIONS

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SPECIFICATIONS AND LUBRICATIONS

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

Fluid Type

SAE 80W90 GL5 (cold storage) Dexron II

Grease Type

NOTE:

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Tex. Ref. C and C #880

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

SAE 80W90 GL5 (cold storage) Dexron II

Grease Type

NOTE:

Tex. Ref. C and C #880

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

SERVICE INTERVALS

200 HOURS OR MONTHLY

2000 HOURS OR ANNUAL

• Clean battery and machine. • Drain, flush, and refill transmission gear case.

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FIELD MODIFICATIONS

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

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

PROUDLY Made in AMERICA

OPERATOR’S MANUAL

Manual Part Number 303045-003 TMX ELECTRIC TOW TRACTOR

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

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

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

ISSUED JANUARY 1996

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ISSUED JANUARY 1996

IMPORTANT NOTICE

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

BEFORE OPERATING THE UNIT:

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

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

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

LEARN AND PRACTICE USE OF CONTROLS BEFORE OPERATING.

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

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FOREWORD

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

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

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

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

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

California Proposition 65

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

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TABLE OF CONTENTS

NAME

PAGE #

NAME

PAGE #

1 2 3 4 5 5 6 6 7 8-13 14-16 17-24 25-27 28 29 30-31 32 33 34

This unit is designed under ANSI B56.9.

For additional operating instructions see ANSI B56.9 “OPERATING SAFETY RULES AND PRACTICES”.

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DRIVE SAFELY

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

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

STAY ALERT!

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INTRODUCTION

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

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

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

TO NEW BT PRIME-MOVER OWNERS:

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

Return

PRELIMINARY SERVICE

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

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

This OPERATORS MANUAL must be kept with this unit. If a replacement manual is needed, please contact your BT PRIME-MOVER dealer or THE PRIME-MOVER Co. factory and a no charge replacement will be sent.

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

Check the transmission oil level before operation. Check to determine that the battery is adequately charged, properly installed and connected.

RIGHT, LEFT, FRONT, AND REAR SIDES

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

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

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OPERATOR

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

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

Proper operation of this unit is as shown when possible. Steering the truck is easier in this direction. Always look in the direction of travel.

When reversing into a confined area or elevator or on an incline, keep both hands on control handle. Keep both hands within the handle guard and always look in the direction of travel.

Return

OPERATING PRACTICES

IMPORTANT:

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

OPERATING RULES AND INSTRUCTIONS

OPERATOR QUALIFICATIONS

Return

OPERATING PRACTICES

OPERATOR TRAINING

OPERATOR RESPONSIBILITY

Powered industrial truck operators shall abide by the following rules and practices.

l Avoid loose clothing, particularly cuffs and scarves.

l Know what safety equipment is required on this truck and

l DO NOT rush.

l Know

l Safeguard the pedestrians at all times. DO NOT drive a

l PASSENGERS MUST NOT be permitted to ride.

l When operator is away from truck the parking brake lever

l DO

l Use caution when making a right or left turn into an aisle.

l Safeguard co-workers from truck operational hazards when

l ALWAYS LOOK IN DIRECTION OF TRAVEL, especially

use it. A hard hat, safety glasses, reflector-type vest, respirators, and ear plugs are some of the types of equipment you may need.

the hand signals used on this job and who has responsibility for signaling. truck up to anyone standing in front of a bench or other fixed object.

must be in the “ENGAGED POSITION” (See page number 19 for further information) and all other controls neutralized to prevent movement. NOT place any part of body between moving and stationary or outside running lines of truck. Remember rear wheels do not follow turn path of front wheel. When making a turn allow for “corner-cutting” of trailers. their assistance is required to perform a task. when reversing.

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use it. A hard hat, safety glasses, reflector-type vest, respirators, and ear plugs are some of the types of equipment you may need.

the hand signals used on this job and who has responsibility for signaling. truck up to anyone standing in front of a bench or other fixed object.

Remember rear wheels do not follow turn path of front wheel. When making a turn allow for “corner-cutting” of trailers. their assistance is required to perform a task. when reversing.

OPERATING PRACTICES WHEN A POWERED UNATTENDED

INDUSTRIAL

TRUCK

OPERATING PRACTICES BE

LEFT

WHEN A POWERED UNATTENDED

INDUSTRIAL

TRUCK

LEFT

lCompletely stop truck in a clear, authorized area.

lPlace directional controls in neutral.

lApply the parking brake lever (see page # 19).

lTurn

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

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

WHEN A POWERED INDUSTRIAL TRUCK IS TRAVELING:

lLocal safety regulations must always be followed. Know and

key switch to OFF and disconnect battery connectors.

understand the traffic flow patterns of your job.

key switch to OFF and disconnect battery connectors.

understand the traffic flow patterns of your job.

lYield right of way to pedestrians.

lDO NOT pass another truck traveling in the same direction

at intersections, blind spots or other dangerous locations.

lSlow

lKeep a clear view of the path of travel, and observe for

down and sound the audible warning device(s) at cross aisles and other locations where vision is blocked. If the load being carried blocks any view, ask for assistance so the load can be moved without any danger to personal or property.

traffic personnel and safe clearances.

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traffic personnel and safe clearances. 10

OPERATING PRACTICES

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

level floor operation. If it is necessary to operate on a grade, ramp, or incline refer to ANSI B56.9 for requirements.

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

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

l Make start, stops, turns or direction reversals in a smooth

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

l DO NOT indulge in stunt driving or horseplay.

l Slow down for wet and slippery floors.

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

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

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

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

l Trucks shall enter confined areas with load end forward.

l Avoid running over loose objects, uneven surfaces or other

obstructions on roadway surface.

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

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

l Report any defect in unit noted during operation.

l Observe instruments and gauges frequently to determine if

they are operating properly.

l DO NOT permit riders on unit.

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OPERATING PRACTICES

l Understand unit limitations and keep unit under control.

l NEVER get ON or OFF a moving truck.

l Remember to enter load slowly and squarely. Load should

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

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

l Handle long and wide loads exceeding the dimensions used

l The load shall only be lifted vertically and never dragged

OPERATOR PRECHECKS AND INSPECTION

l Before

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

be centered.

loads must be handled with extra caution. nameplate.

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

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

l l l l l l

Tires Warning and safety Devices Battery Brake Steering Mechanism Couplers

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

be centered.

loads must be handled with extra caution. nameplate.

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

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

l l l l l l

Tires Warning and safety Devices Battery Brake Steering Mechanism Couplers

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OPERATING PRACTICES

l DO NOT make repairs or adjustments unless specifically

authorized to do so.

l DO NOT use open flames when checking electrolyte level in

battery

l DO NOT use open flames when checking electrolyte level in

battery

l DO NOT adjust unit with any parts moving.

l DO NOT smoke while working around truck.

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

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

disgrace in asking for help.

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

disgrace in asking for help.

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DATA PLATE AND DECALS

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

1. Truck model number 2. Truck type 3. Truck serial number 4. Truck weight 5. Truck voltage 6. Battery type 7. Battery maximum AMP hours 8. Minimum battery weight 9. Maximum battery weight 10. Tire Part Number 11. Maximum drawbar pull 12. Normal drawbar pull 13. Maximum coupler height 14. Normal coupler height

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DATA PLATE AND DECALS

OPERATING WARNINGS

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DATA PLATE AND DECALS

PARKING BRAKE WARNING

WARNING DECALS

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

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

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

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CONTROLS AND EQUIPMENT

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

DO NOT operate this equipment unless all factory installed guards and shields are properly secured in place. Decals are provided to warn of potential danger also to display special operating procedures. Read and observe all warnings on this unit before operating it.

THE CONTROL HANDLE

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

The Control Handle

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CONTROLS AND EQUIPMENT HORN SWITCH The horn is activated by pushing down on the horn bar located on top the steering control handle.

DIRECTION AND SPEED

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CONTROLS AND EQUIPMENT

BRAKE LEVER CONTROLS

The proper position for parking brake lever engaged and disengaged position is shown and described below.

PARKING BRAKE LEVER

The parking brake lever must be placed in the engaged position when unit is not in use (parked) or hand brake lever is not squeezed.

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

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CONTROLS AND EQUIPMENT

BRAKING USING PLUGGING FUNCTION

As stated under “BRAKE LEVER CONTROLS” the truck can be brought to a stop by using the hand brake lever. An equally acceptable method of stopping the truck's travel is by using the “plugging” function. This method involves reversing the travel control to the opposite direction without using the hand brake lever. This will cause the truck to come to a stop smoothly.

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

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CONTROLS AND EQUIPMENT

DASH PANEL ASSEMBLY

CONTROLS AND EQUIPMENT

EMERGENCY DISCONNECT BUTTON

The RED EMERGENCY DISCONNECT BUTTON is used to cut all electrical power to the unit when button is pushed. To reset emergency disconnect button turn key switch to the “OFF” position, repair emergency, pull emergency disconnect button out and turn key switch to the “ON” position.

The Hourmeter can be read any time the emergency disconnect button is pulled out.

KEY SWITCH

A KEY SWITCH is provided to prevent unauthorized use of this unit. The emergency disconnect button must be pulled out before electrical power can flow to the control circuit.

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

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

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

When unit is left unattended for extended period of time push the emergency disconnect button in, disconnect battery, and remove and secure key in a safe place.

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CONTROLS AND EQUIPMENT

BATTERY DISCHARGE INDICTOR/HOURMETER DASH DISPLAY

BATTERY DISCHARGE INDICATOR/HOURMETER

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

BDI/HOURMETER WITH LIFT INTERRUPT (optional)

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

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CONTROLS AND EQUIPMENT

Down

Tilt Control Lever

ADJUSTABLE TILTING CONTROL HANDLE

TILTING CONTROL HANDLE

The adjustable tilting control handle is used to adjust the height of the control handle. This function will alone more comfort and control for the operator.

To adjust the handle pull on the tilt control lever (backwards towards the operator) and lift/lower control handle to the position that is comfortable for you.

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BEFORE OPERATION INSPECTION

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

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

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

NOT operate unit until it is repaired.

l Inspect

l Inspect drive unit. Look for leakage.

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

steering for looseness or binding and lack of lubrication.

from tires.

steering for looseness or binding and lack of lubrication.

from tires.

l Inspect

l Make sure the operator's manual is in compartment and

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

tethered to machine.

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

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

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

BEFORE OPERATION INSPECTION

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

l Check the operation of the BDI/hourmeter.

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

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

lTurn steering control handle until steering is in the desired

l Squeezes the hand park lever with one hand to apply the

key switch to the “ON” position.

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

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

key switch to the “ON” position.

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

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

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

l REARWARD TRAVEL: Put a firm grip on the directional

l FORWARD

l This unit is equipped with a PLUG BRAKING FEATURE.

control handle and rotate backward slowly. The unit must move slowly in a rearward direction. Rotate the handle more to increase speed. Unit should accelerate smoothly to maximum speed as handle is rotated. Direction controls MUST automatically return to the NEUTRAL position when released. Squeezes the hand brake lever with your hand(s) to apply the brakes.

TRAVEL: Put a firm grip on the directional control handle and rotate forward slowly. The unit must move slowly in a forward direction. Rotate the handle more to increase speed. Unit should accelerate smoothly to maximum speed as handle is rotated. Direction controls MUST automatically return to the NEUTRAL position when released. Squeezes the hand brake lever with your hand(s) to apply the brakes.

This method involves simply reversing the travel control to opposite direction without applying the brake. This will cause the truck to come to a stop smoothly.

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This method involves simply reversing the travel control to opposite direction without applying the brake. This will cause the truck to come to a stop smoothly.

BEFORE OPERATION INSPECTION

As the truck comes to a full stop the operator may choose to: (1) Continue holding the controls in the opposite direction and thus start the truck moving in that direction. (2) The operator may squeeze the hand brake lever on the control handle to apply the brake and allow the truck to come to a complete halt.

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

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

distance. Report any unusual brake operation.

l Check steering control handle while truck is moving. Turn

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

l Make sure OPERATOR'S instruction manual is returned to

the case and storage box.

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the case and storage box.

OPERATION

STOPPING UNIT

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

2. Squeeze handle brake lever and stop movement completely.

3. Place the parking brake lever in the engaged position (see page # 19).

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

5. Push the emergency disconnect button in to stop hourmeter from running.

BRAKE LEVERS AND KEY SWITCH LOCATION

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PARKING 1. Park units in designated parking areas only.

Make sure unit does not block fire aisles, fire equipment, stairways or walkways.

2. Set parking brake lever to the “ENGAGED” position (See Page # 19).

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

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

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BATTERY RETAINMENT/CARE

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

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

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

This unit uses a 24 volt wet cell Battery.

IMPORTANT

Use only batteries that meet the following specifications:

VOLTAGE Minimum Battery Weight Maximum Battery Weight

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

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

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BATTERY RETAINMENT/CARE

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

BATTERY SERVICE

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

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

ADDING WATER

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

TERMINALS & CABLE CONNECTIONS

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

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SPECIFICATIONS AND LUBRICATIONS

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

Fluid Type

SAE 80W90 GL5 (cold storage) Dexron II

Fluid Type

SAE 80W90 GL5 (cold storage) Dexron II

Grease Type

Tex. Ref. C and C #880

Grease Type

Tex. Ref. C and C #880

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

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

SERVICE INTERVALS 200 HOURS OR MONTHLY

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

missing, or damaged

parts.

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

missing, or damaged

parts.

l Check all operating functions and adjustments. l Check transmission oil level. l Lubricate all grease fittings. l Inspect power cables and control wiring. l Clean with compressed air. l Inspect motor brushes.

2000 HOURS OR ANNUAL

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

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FIELD MODIFICATIONS

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

PROUDLY Made in AMERICA

Operator’s Manual

TMX

Electric Tow Tractor Effective Serial Number TMX0027297000

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: 303045-003 Return

Date: October 24, 1997

Part no: 303045-003

Date: October 24, 1997

Operator’s warning

IMPORTANT NOTICE

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

Before operating the truck:

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

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

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

LEARN AND PRACTICE USE OF CONTROLS BEFORE OPERATING.

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

WARNING INJURY OR DEATH TO YOU OR OTHER

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

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

Foreword

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

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

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

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

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

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

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

California Proposition 65

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

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Table of Contents

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

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

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

Presentation of truck ....................................................... 19 Application areas for BT’s trucks..................................... 20 Prohibited applications for BT’s trucks ............................ 20 Truck data ....................................................................... 21 TMX truck dimensions..................................................... 22 Data plate ........................................................................ 23

Presentation of truck ....................................................... 19 Application areas for BT’s trucks..................................... 20 Prohibited applications for BT’s trucks ............................ 20 Truck data ....................................................................... 21 TMX truck dimensions..................................................... 22 Data plate........................................................................ 23

Presentation of main components ................................. 24

Controls and instruments ............................................... 26 Control handle ................................................................. 26 Horn................................................................................. 27 Travel direction selector and speed control..................... 27 Brake lever controls......................................................... 28 Braking using plugging function ...................................... 29 Emergency disconnect switch ......................................... 30 Key switch (toggle switch) ............................................... 31 BDI/Hourmeter with lift interrupt ...................................... 32 Battery discharge indicator (BDI) .................................... 32 Hourmeter ....................................................................... 33 Adjustable tilting control handle....................................... 33

Controls and instruments ............................................... 26 Control handle................................................................. 26 Horn ................................................................................ 27 Travel direction selector and speed control..................... 27 Brake lever controls......................................................... 28 Braking using plugging function ...................................... 29 Emergency disconnect switch ......................................... 30 Key switch (toggle switch)............................................... 31 BDI/Hourmeter with lift interrupt ...................................... 32 Battery discharge indicator (BDI) .................................... 32 Hourmeter ....................................................................... 33 Adjustable tilting control handle....................................... 33

Driving............................................................................... 34 Starting the truck ............................................................. 34 Braking ............................................................................ 37 Steering ........................................................................... 39 Parking the truck ............................................................. 39

Driving............................................................................... 34 Starting the truck ............................................................. 34 Braking ............................................................................ 37 Steering........................................................................... 39 Parking the truck ............................................................. 39

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Table of Contents

Transporting loads .......................................................... 41 General............................................................................ 41 Collecting a load.............................................................. 44 Leaving a load................................................................. 45

Transporting loads ...........................................................41 General ............................................................................41 Collecting a load ..............................................................44 Leaving a load..................................................................45

Battery............................................................................... 46 Type of battery ................................................................ 46 Changing the battery ....................................................... 46 Charging the battery........................................................ 48 Battery maintenance ....................................................... 51

Battery ...............................................................................46 Type of battery .................................................................46 Changing the battery........................................................46 Charging the battery ........................................................48 Battery maintenance ........................................................51

Daily service/safety checks ............................................ 53

Daily service/safety checks .............................................53

Maintenance ..................................................................... 56 General............................................................................ 56 Safety regulations with maintenance work ...................... 56 Cleaning and washing ..................................................... 60 Maintenance chart........................................................... 62 Lubrication chart.............................................................. 65 Oil and grease specification ............................................ 66

Maintenance ......................................................................56 General ............................................................................56 Safety regulations with maintenance work.......................56 Cleaning and washing......................................................60 Maintenance chart ...........................................................62 Lubrication chart ..............................................................65 Oil and grease specification.............................................66

Transport and storing the truck ..................................... 67 The truck’s dimensions and weight as standard ............. 67 Lifting the truck................................................................ 67 Towing and transporting a disabled truck........................ 68 Storing the truck .............................................................. 69 Starting after a period of disuse ...................................... 69

Transport and storing the truck ......................................67 The truck’s dimensions and weight as standard ..............67 Lifting the truck.................................................................67 Towing and transporting a disabled truck ........................68 Storing the truck...............................................................69 Starting after a period of disuse .......................................69

Recycling/discarding....................................................... 70 Discarding the battery ..................................................... 70 Scrapping the truck ......................................................... 70

Recycling/discarding........................................................70 Discarding the battery ......................................................70 Scrapping the truck ..........................................................70

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Safety regulations Warning symbols

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

Warning levels

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

DANGER

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

WARNING

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

CAUTION

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

NOTE!

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

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

Safety regulations Prohibitory symbols

Prohibitory symbols

NO SMOKING

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

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

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

Ordinance symbols

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

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

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

Ordinance symbols

SAFETY SHOES

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

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

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Safety regulations

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

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

Safety regulations

These warnings are NOT meant to be a complete list, and only the operator's intelligence, good sense, and care of unit will assure that most hazards will be avoided. Refer to ASMEI B56.9 for further operator's information.

These warnings are NOT meant to be a complete list, and only the operator's intelligence, good sense, and care of unit will assure that most hazards will be avoided. Refer to ASME B56.9 for further operator's information.

General safety regulations

Control

•

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

•

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

•

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

•

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

•

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

•

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

•

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Safety regulations

General safety regulations

Operating the truck

•

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

•

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

•

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

•

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

•

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

•

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

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

To tow other trucks.

To transport/lift passengers.

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Safety regulations

General safety regulations

Operator’s responsibility

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

Local regulations regarding personal safety equipment shall be followed.

•

Local regulations regarding personal safety equipment shall be followed.

•

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

•

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

•

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

•

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

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Safety regulations

General safety regulations

Working area

•

If there are marked truck routes these shall be used.

•

If there are marked truck routes these shall be used.

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

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Safety regulations

General safety regulations

Driving and conduct while driving

•

Always drive the truck from the normal operator position.

•

Always drive the truck from the normal operator position.

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

Keep a safe distance from all vehicles ahead.

•

Keep a safe distance from all vehicles ahead.

•

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

•

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

•

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

•

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

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Safety regulations

•

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

•

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

•

Never allow passengers to ride on the truck.

•

Never allow passengers to ride on the truck.

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

DO NOT smoke while working around truck.

•

DO NOT smoke while working around truck.

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Safety regulations

General safety regulations

Handling loads

•

Drive with care when collecting or leaving a load.

•

Drive with care when collecting or leaving a load.

•

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

•

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

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Safety regulations

General safety regulations

Parking the truck

•

Always park in designated areas if available.

•

Always park in designated areas if available.

•

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

•

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

•

Never park the truck on an incline.

•

Never park the truck on an incline.

•

Never park the truck so that it obstructs emergency exits.

•

Never park the truck so that it obstructs emergency exits.

•

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

•

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

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Safety regulations

General safety regulations

Handling the battery

•

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

•

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

•

Always wear protective glasses when working with the battery.

•

Always wear protective glasses when working with the battery.

•

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

•

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

•

Make sure the battery is secured in its compartment.

•

Make sure the battery is secured in its compartment.

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Safety regulations

General safety regulations

Maintenance and repair

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

All replacement parts shall be BT approved spare parts.

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

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Warning and information signs

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

1. Signal/Horn

2. Truck data plate

3. Warning decal: Truck parking brake does not automatically engage

4. Warning decal: No Step, or No Standing, or No Riding

5. List of warnings

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Warning and information signs

Warning decals

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

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

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

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

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Presentation of truck

BT’s truck program is intended for towing trailers handling goods indoors or alternatively other types of loads using other load carriers. This truck is operated in a standing position.

Refer to the truck’s data plate for this information on towing.

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

The truck can be fitted with different accessories including an hourmeter/battery discharge indicator, and hourmeter/battery discharge indicator with travel cutout. The truck can also be fitted with stainless steel axles and low temperature oil for use in cool and humid conditions.

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Presentation of truck

Application area for BT’s trucks

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

Prohibited applications for BT’s trucks

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

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

Do not use to tow other trucks

Do not use to transport/lift passengers

Do not use to drive on gravel or grass

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Presentation of truck

Truck data

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

Truck type

TMX

Truck type

TMX

Operating speed without load

8.0 mph [12.87 km/h]

Operating speed without load

8.0 mph [12.87 km/h]

Operating speed with classified load

6.0 mph [9.65 km/h]

Operating speed with classified load

6.0 mph [9.65 km/h]

Maximum operating gradient with load, %

Continuous noise level. dB (A)

<80

Continuous noise level. dB (A)

<80

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

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Presentation of truck

TMX truck dimensions

The following diagrams show external dimensions for TMX trucks in its standard design.

C Area of ride platform (541 in.2 [13741.4 mm2])

30°

Area of ride platform (541 in.2 [13741.4 mm2])

30°

Battery compartment 13.3 in. [337.8 mm]

F Q

J 15°

Battery 26° roller height L M N

J 15°

Battery 26° roller height L M N

43.7 in. R [1110 mm] R

6.9 in. [175.26 mm]

34 in. 863.6 mm]

43.7 in. R [1110 mm] R

6.9 in. [175.26 mm]

34 in. 863.6 mm]

34.1 in. [866.14 mm]

6.2 - 11.7 in. [157.48 - 297.18 mm]

53.2 in. [1351.28 mm]

34.1 in. [866.14 mm]

6.2 - 11.7 in. [157.48 - 297.18 mm]

53.2 in. [1351.28 mm]

51.3 in. [1303.02 mm]

5.9 - 11.7 in. [149.86 - 297.18 mm]

9.7 in. 246.38 mm]

51.3 in. [1303.02 mm]

5.9 - 11.7 in. [149.86 - 297.18 mm]

9.7 in. 246.38 mm]

17.3 in. [439.42 mm]

6.6 - 12.1 in. [167.64 - 307.34 mm]

2.1 in. [53.34 mm]

17.3 in. [439.42 mm]

6.6 - 12.1 in. [167.64 - 307.34 mm]

2.1 in. [53.34 mm]

54.3 in. [1379.22 mm]

3.6 in. [91.44 mm]

31.8 in. [807.72 mm]

54.3 in. [1379.22 mm]

3.6 in. [91.44 mm]

31.8 in. [807.72 mm]

2.9 in. [73.66 mm]

8.9 in. [226.06 mm]

51.5 in. [1308.1 mm]

2.9 in. [73.66 mm]

8.9 in. [226.06 mm]

51.5 in. [1308.1 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 type 3 Truck serial number 4 Truck weight (less battery weight) 5 Truck voltage 6 Minimum battery weight 7 Battery type 8 Maximum battery weight 9 Battery maximum amp hours 10 Drive tire part number 11 Drawbar maximum pull 12 Drawbar normal pull 13 Coupler height at maximum drawbar pull 14 Coupler height at normal drawbar pull

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

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Presentation of main components

1. Steering control handle The truck is to be controlled by the operator with 180° steering angle. 2. Battery 24V with different capacities and weights. 3. Drive unit with brake Drive motor, gears, drive wheel, and brake are combined in the drive unit. 4. Data plate With data designation, manufacturing number, year of manufacture, service weight, battery weight, classified lifting capacity, battery voltage, and manufacturer. 5. Cover Removable to provide good access for servicing. 6. Gauge This provides information on the truck’s running hours and battery status. 7. Electronics All the electronics are collected in a protected compartment. 8. Circuit breaker 12A, BT Control circuit breaker part number 301889-000. 150A, BT Drive circuit breaker part number 307601-000. 9. Key switch (toggle switch) Shuts off electrical power to control system. 10. Emergency stop switch The emergency stop switch will stop all control functions. 11. Horn switch The horn sounds to warn others of your position. 12. Travel speed / direction selection To select direction rotate in the direction you wish to move. The further in that direction you rotate the faster you move.

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Presentation of main components

1/2

Presentation of main components

1 8

I O

11 9 12

7, 8

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1/2

7, 8

Controls and instruments

Controls and Instruments

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

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

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

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

Control Handle

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

Handle Brake Lever

Steering Control Handle

Horn Switch

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Handle Brake Lever

Steering Control Handle

Horn Switch

Directional Controls

Controls and instruments Horn

Horn

The horn sounds as long as the button is pressed.

Travel Direction Selector and Speed Control

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

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

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Controls and instruments

Brake Lever Controls

This truck has two brake engaging controls, 1) a hand controlled lever that is squeezed to apply brake, 2) a parking brake lever that locks in place when used.

Hand Control Lever

The hand brake lever can be used from either side of control handle or squeezed with both hands to apply maximum pressure for braking. This lever can be applied slowly to control braking pressure and stop slowly and smoothly.

The proper position for parking brake lever engaged and disengaged position is shown and described below.

Engaged Position (Brake ON)

Disengaged Position (Brake OFF)

Engaged Position (Brake ON)

Disengaged Position (Brake OFF)

The parking brake lever must be placed in the engaged position when unit is not in use (parked) or hand brake lever is not squeezed.

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

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Controls and instruments

Braking using Plugging Function

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Controls and instruments

Emergency Disconnect Switch

1/2

Battery Disconnect Indicator/Hourmeter Dash Display

1 8

Key Switch

Dash Controls and Locations

Controls and instruments

Emergency Disconnect Switch

1/2

Battery Disconnect Indicator/Hourmeter Dash Display

1 8

Key Switch

Dash Controls and Locations

Emergency Disconnect Switch

The red emergency disconnect switch is used to cut all electrical power to the unit when the switch is pushed. To reset emergency disconnect switch turn key switch to the OFF position, repair emergency, pull emergency disconnect switch out, and turn key switch to the ON position.

The hourmeter can be read any time the emergency disconnect switch is pulled out.

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Controls and instruments

Emergency Disconnect Switch

1/2

Battery Disconnect Indicator/Hourmeter Dash Display

1 8

Key Switch

Dash Controls and Locations

Controls and instruments

Emergency Disconnect Switch

1/2

Battery Disconnect Indicator/Hourmeter Dash Display

1 8

Key Switch

Dash Controls and Locations

Key Switch (toggle switch)

A Key Switch is provided to prevent unauthorized use of this unit. The emergency disconnect switch must be pulled out before electrical power can flow to the control circuit.

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

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

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

When the unit is left unattended for an extended period of time push the emergency disconnect switch in, disconnect the battery, and remove and secure key in a safe place.

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Controls and instruments

BDI/Hourmeter with travel interrupt

Fully-charged battery

1/2

Half-charged battery

1/2

Half-charged battery

Discharged battery

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

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

The hourmeter displays the time the drive motor is operating.

Battery Discharge Indicator (BDI)

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

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Controls and instruments

Hourmeter

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

Down

Tilt Control Lever

Adjustable Tilting Control Handle

The adjustable tilting control handle is used to adjust the height of the control handle. This function will allow more comfort and control for the operator.

To adjust the handle pull on the tilt control lever (backwards towards the operator) and lift/lower control handle to the position that is comfortable for you.

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Driving

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

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

Travel

Proper operation of this unit is as shown when possible. Steering the truck is easier in this direction. Always look in the direction of travel.

When reversing into a confined area, elevator, or on an incline keep both hands on control handle. Keep both hands within the handle guard and always look in the direction of travel.

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Driving

Starting the truck

Ensure the battery connector is connected to the truck.

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

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

NOTE! Low charge level. Prolonged operation with a low battery charge level can result in damage to the battery. Do not drive without first recharging the battery. Engaged Position (Brake ON)

Disengaged Position (Brake OFF)

Squeeze the handle brake levers located on control handle. Place the parking brake lever in the disengaged position. This releases the parking brake.

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

Engaged Position (Brake ON)

Disengaged Position (Brake OFF)

Squeeze the handle brake levers located on control handle. Place the parking brake lever in the disengaged position. This releases the parking brake.

Driving

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

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

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

- That the horn functions correctly.

- That the steering functions correctly.

- That the brakes function correctly.

- That the hydraulic functions are operational.

Start gently by accelerating slowly until you reach the desired speed. WARNING Dangerous driving. Accidents can occur. Always drive with care, good judgment, and responsibility.

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Start gently by accelerating slowly until you reach the desired speed. WARNING Dangerous driving. Accidents can occur. Always drive with care, good judgment, and responsibility.

Driving

Braking

Braking Hand Brake Lever

Hand Brake Lever

Parking Brake Lever

Key Switch

Location of Hand Brake Lever, Parking Brake Lever, and Key Switch

By squeezing the hand brake lever you will apply the travel brake. When you release the hand brake lever it automatically returns to the brake OFF position.

When truck is left unattended, or hand brake lever is NOT squeezed, the parking brake lever must be locked in the engaged position (brake ON).

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

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Driving handle will allow the automatically applied.

parking

Driving brake

become

handle will allow the automatically applied.

parking

brake

become

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

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

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Driving

Steering

Steer by means of the tiller arm.

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

WARNING Risk of slipping. You can lose control of the truck if your hands or shoes are oily. Always dry your hands and shoes before driving.

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WARNING Risk of slipping. You can lose control of the truck if your hands or shoes are oily. Always dry your hands and shoes before driving.

Driving

Parking the truck

Hand Brake Lever

Parking Brake Lever

Key Switch

Location of Hand Brake Lever, Parking Brake Lever, and Key Switch

Rotate directional control to the NEUTRAL position.

Squeeze the handle brake lever and stop movement completely.

Place the parking brake lever in the engaged position.

Lower the forks fully to the floor.

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

Push the emergency disconnect button in to stop the hourmeter from running.

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

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

Transporting loads

General

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

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

•

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

•

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

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

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

WARNING Lost stability. High loads can fall when cornering at high speed or cause tipover. Drive slowly and carefully when cornering and travel with loads in lowered position.

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

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Transporting loads

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

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

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

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

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

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

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

Transporting loads

WARNING Risk of overloading the elevator. An overloaded elevator can fall out of control down the elevator shaft. Always check the capacity of the elevator before driving in with the truck. •

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

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WARNING Risk of overloading the elevator. An overloaded elevator can fall out of control down the elevator shaft. Always check the capacity of the elevator before driving in with the truck. •

Transporting loads

Collecting a load

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

Drive the truck rearward so that the hitch is positioned and can be connected to drawbar.

Make sure connection is correct.

Drive carefully away. Start slowly and then increase the speed.

Travel

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Travel

Transporting loads

Leaving a load

•

Slow down and position truck carefully where load is to be left.

•

Slow down and position truck carefully where load is to be left.

•

Reverse truck to release hitch and disconnect hitch.

•

Reverse truck to release hitch and disconnect hitch.

•

Drive carefully away from the load. Start slowly and then increase the speed.

•

Drive carefully away from the load. Start slowly and then increase the speed.

Travel

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Travel

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Transporting loads

Battery

Type of battery

•

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

Changing the battery

•

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

When changing the battery proceed as follows:

•

Park truck at battery removal station.

•

Park truck at battery removal station.

•

Turn OFF key and remove.

•

Turn OFF key and remove.

•

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

•

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

•

Disconnect the battery connector from the battery.

•

Disconnect the battery connector from the battery.

•

Remove battery stops.

•

Remove battery stops.

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Battery

•

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

•

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

•

Connect battery and truck connectors.

•

Connect battery and truck connectors.

•

Connect the battery connector and truck connector.

•

Connect the battery connector and truck connector.

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

•

Push the emergency disconnect button to the ON position.

•

Push the emergency disconnect button to the ON position.

•

Install battery stops.

•

Install battery stops.

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

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

Battery

Charging the battery

General prohibition

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

Use an automatic charger intended for recharging traction batteries.

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

The charger shall have a minimum charging current of:

Battery (Ah)

Charger (A)

Battery (Ah)

Charger (A)

300-480

50-70

300-480

50-70

480-730

80-110

480-730

80-110

730-900

130-150

730-900

130-150

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

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

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Battery

Pre-charging

•

Park the truck in the assigned charging area.

•

Park the truck in the assigned charging area.

•

Ensure nothing prevents ventilation above the battery.

•

Ensure nothing prevents ventilation above the battery.

•

Turn key switch to the OFF position.

•

Turn key switch to the OFF position.

•

Remove the battery connector from the truck’s connector.

•

Remove the battery connector from the truck’s connector.

•

Make sure the battery charger is switched OFF.

•

Make sure the battery charger is switched OFF.

•

Connect the battery connector to charger connector.

•

Connect the battery connector to charger connector.

•

Never connect charger connector to truck connector.

•

Never connect charger connector to truck connector.

•

Switch ON the battery charger.

•

Switch ON the battery charger.

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

During charging

•

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

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After approximately ten minutes make sure that the ammeter indicates a normal reading and that the control lamp is ON. 54

Battery

After charging

•

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

•

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

•

Switch OFF the charger.

•

Switch OFF the charger.

•

Disconnect the battery connector from charger connector.

•

Disconnect the battery connector from charger connector.

CAUTION

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

CAUTION

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

Battery

Battery maintenance

Carry out battery maintenance after recharging.

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

Each week:

•

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

•

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

•

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

•

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

•

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

•

Refit all of the cell caps.

•

Refit all of the cell caps.

•

Rinse off and dry the battery.

•

Rinse off and dry the battery.

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Battery

Each month:

•

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

•

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

•

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

•

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

•

Adjust specific gravity with temperatures based on the chart below.

•

Adjust specific gravity with temperatures based on the chart below.

Temperature

Gravity

Temperature

Gravity

77°F [25.2°C]

1.280

77°F [25.2°C]

1.280

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

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

Daily service/safety checks

•

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

•

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

•

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

•

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

•

You need no tools to carry out the service checks.

•

You need no tools to carry out the service checks.

•

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

•

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

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

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Daily service/safety checks

Daily service/safety checks 0

1/2

Daily service/safety checks 13

7 I

I O

1 2

14 10

9 11

5 3

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

Check points

Action

Battery

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

Battery cables and connections

3 4

Return

1 2

Item #

1 8

1/2

12 8

1 8

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

Check points

Action

Battery

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

Check for breakage, cutting, or damage

Battery cables and connections

Check for breakage, cutting, or damage

Chassis

Check for damage, remove dirt and debris

Chassis

Check for damage, remove dirt and debris

Covers / guards

Check for damage, ensure placement

Covers / guards

Check for damage, ensure placement

Daily service/safety checks Item #

Check points

Action

Drive unit

Inspect abnormal noises and leakage

Wheels

Daily service/safety checks Item #

Check points

Action

Drive unit

Inspect abnormal noises and leakage

Check for damage, remove oil, metal chips, and debris

Wheels

Check for damage, remove oil, metal chips, and debris

Hand brake levers

Check its function

Hand brake levers

Check its function

Direction / speed control

Check its function

Direction / speed control

Check its function

Control console

Check its locking mechanism

Control console

Check its locking mechanism

Control functions

Check its function

Control functions

Check its function

Parking brake lever

Check its function

Parking brake lever

Check its function

Horn

Check its function

Horn

Check its function

Running time

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

Running time

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

Emergency stop switch

Check its function

Emergency stop switch

Check its function

Key switch (toggle switch)

Check its function

Key switch (toggle switch)

Check its function

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

Special equipment

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

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Maintenance

General information

•

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

•

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

•

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

•

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

•

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

Safety regulations with maintenance work

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

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Maintenance

WARNING Short-circuiting/burns. When working with the truck’s electrical system short circuiting/burns can occur if a metal object comes into contact with live electrical connections. Remove watches, rings, or other types of metal jewelry.

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

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

•

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

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

•

Only fill the hydraulic system with new clean oil. Oil should meet BT cleanliness specification 12-00-002. Contact your BT representative for assistance or more information. 63

Maintenance

WARNING The hydraulic system can be damaged. If oil is contaminated hydraulic components can be damaged. Always use new and clean oil in the hydraulic system.

•

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

•

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

•

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

•

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

•

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

•

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

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

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

Maintenance

Maintenance work that can be carried out by you

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

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

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

Maintenance work that may be carried out by trained maintenance personnel

All maintenance points as set out in the Maintenance chart.

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

Other service and repair work

•

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

Return

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

Maintenance

Cleaning and washing

General

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

•

Carry out general cleaning and washing weekly.

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

External cleaning

•

Remove debris, etc. from the wheels daily.

•

Remove debris, etc. from the wheels daily.

•

Use a degreasing agent diluted to a suitable concentration.

•

Use a degreasing agent diluted to a suitable concentration.

•

Rinse off loose grime using warm water.

•

Rinse off loose grime using warm water.

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

Cleaning the motor compartment

•

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

Return

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

Maintenance •

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

Maintenance •

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

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

•

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

•

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

•

Rinse off loose grime using warm water.

•

Rinse off loose grime using warm water.

Electrical components

•

Blow electric motors dry using compressed air. WARNING Compressed air used for cleaning MUST be reduced to less than 30 psi, and then only with effective chip-guarding and personal protective equipment.

•

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

•

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

•

Do not spray or pressure wash in the compartment.

•

Do not spray or pressure wash in the compartment.

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

Return

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

Maintenance

Maintenance chart

PM Interval:

A=5 Hours or 1 Day

E=500 Hours or 6 Months

A=5 Hours or 1 Day

E=500 Hours or 6 Months

B=20 Hours or 1 Week

F=1000 Hours or 12 Months

B=20 Hours or 1 Week

F=1000 Hours or 12 Months

C=80 Hours or 1 Month

G=3000 Hours or 36 Months

C=80 Hours or 1 Month

G=3000 Hours or 36 Months

D=250 Hours or 3 Months

No.

Action

1.0

Chassis

No.

Action

1.0

Chassis

1.1

Check that the truck’s data plate is legible

1.1

Check that the truck’s data plate is legible

1.2

Check the cover screws

1.2

Check the cover screws

1.3

Check door lock

1.3

Check door lock

1.4

Check wear on battery stop

1.4

Check wear on battery stop

1.5

Check for damage and crack formation

1.5

Check for damage and crack formation

2.0

Motors

2.0

Motors

2.1

Check for loose connections

2.1

Check for loose connections

2.2

Clean motor

2.2

Clean motor

2.3

Check mounting bolts

2.3

Check mounting bolts

2.4

Check for abnormal bearing noise

2.4

Check for abnormal bearing noise

2.5

Check brush wear

2.5

Check brush wear

3.0

Drive unit

3.0

Drive unit

3.1

Check for leakage

3.1

Check for leakage

3.2

Check oil level

3.2

Check oil level

3.3

Check for noises

3.3

Check for noises

3.4

Check the mounting on support

3.4

Check the mounting on support

4.0

Wheels

4.0

Wheels

4.1

Remove string & debris

4.1

Remove string & debris

4.2

Check all wheels for wear

4.2

Check all wheels for wear

4.3

Check that all wheels rotate and axles are fitted correctly

4.3

Check that all wheels rotate and axles are fitted correctly

4.4

Check all wheels for loose screws

4.4

Check all wheels for loose screws

4.5

Grease load wheel bearings

4.5

Grease load wheel bearings

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Maintenance No.

Action

No.

Action

4.6

Dismantle and lubricate all wheel bearings.

4.6

Dismantle and lubricate all wheel bearings.

5.0

Brake

5.0

Brake

5.1

Clean

5.1

Clean

5.2

Check shoes and discs for wear

5.2

Check shoes and discs for wear

5.3

Check correct clearance brake

5.3

Check correct clearance brake

5.4

Check brake operation

5.4

Check brake operation

6.0

Electrical panel

6.0

Electrical panel

6.1

Clean and check the mounting

6.1

Clean and check the mounting

6.2

Tighten cable connections

6.2

Tighten cable connections

6.3

Check contactor tips

6.3

Check contactor tips

6.4

Check the contactor tips for free movements

6.4

Check the contactor tips for free movements

6.5

Check all cable insulation for damage

6.5

Check all cable insulation for damage

7.0

Electronic card

7.0

Electronic card

7.1

Check for connections in harness connectors

7.1

Check for connections in harness connectors

8.0

Electronic control system

8.0

Electronic control system

8.1

Check key switch

8.1

Check key switch

8.2

Check brake switch

8.2

Check brake switch

8.3

Check control wiring harness for proper routing

8.3

Check control wiring harness for proper routing

9.0

Battery

9.0

Battery

9.1

Check electrolyte level, 0.5-0.65 in. (10-15mm above cell plate)

9.1

Check electrolyte level, 0.5-0.65 in. (10-15mm above cell plate)

9.2

Check the connections on battery, truck, and charger

9.2

Check the connections on battery, truck, and charger

9.3

Check all cells and pole guards

9.3

Check all cells and pole guards

9.4

Check the fluid density and temperature

9.4

Check the fluid density and temperature

9.5

Check power cables are not cut or frayed

9.5

Check power cables are not cut or frayed

10.0

Controls

10.1

Check handle mounting

Return

Maintenance B

10.0

Controls

10.1

Check handle mounting

G X

Maintenance No.

Action

10.2

Check the handle brake lever switches

10.3

Maintenance No.

Action

10.2

Check the handle brake lever switches

Check travel direction/speed control

10.3

Check travel direction/speed control

10.4

Check horn button function

10.4

Check horn button function

10.5

Check the handle control switches

10.5

Check the handle control switches

11.0

Gauge

11.1

Check dash display

12.0

Brake Levers

11.0

Gauge

11.1

Check dash display

12.0

Brake Levers

12.1

Check parking brake lever

12.1

Check parking brake lever

Check handle brake levers

12.2

Check handle brake levers

13.0

Emergency stop switch

13.0

Emergency stop switch

13.1

Check the emergency stop switch

13.1

Check the emergency stop switch

1/2

10 13 10

9 11

3 1

13 10

1 8

I O

Return

1/2

1 8

12.2

6, 7, 8

Maintenance chart

Maintenance

Lubrication chart

Lubrication chart Interval/Running hours

Pos No.

Service point

Wheel bearings

Travel brake

Drive gear

Hinges

Steering bearings

Gear ring

500h

L=Lubrication

Return

Service point

Wheel bearings

Travel brake

Drive gear

Hinges

Steering bearings

Gear ring

1000h

3000h L

C=Check

Interval/Running hours

Pos No.

Lubricant

O=Oil change

Lubricant 500h

L=Lubrication

C=Check

1000h

3000h L

O=Oil change

Maintenance

Approved Oils and Grease Pos. Lubricant

Approved Oils and Grease

Specification > 5°F-15°C

< 5°F-15°C

Application <-10°F-23°C

Grease

Transmission SAE 80W/90 oil

SAE 75W

Motor oil

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

SAE5W-20

SAE 40

Pos. Lubricant

area

Specification > 5°F-15°C

< 5°F-15°C

area

Grease

Gears

Transmission SAE 80W/90 oil

SAE 75W

Gears

Hinges

Motor oil

SAE5W-20

Hinges

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

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

SAE 40

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

B A

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Application <-10°F-23°C

Lubrication chart location points

Transporting and storing the truck

The truck’s dimensions and weight as standard

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

The TMX truck’s dimensions and weight

Height

60 in. [1524 mm]

Height

60 in. [1524 mm]

Width

34.1 in. [866 mm]

Width

34.1 in. [866 mm]

Length

53.2 in. [1352 mm]

Length

53.2 in. [1352 mm]

Minimum battery weight

900 lb [408.6 kg]

Minimum battery weight

900 lb [408.6 kg]

Service weight without battery

1350 lb [612.9 kg]

Service weight without battery

1350 lb [612.9 kg]

Lifting the truck

•

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

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

WARNING Risk of overturning. The truck can overturn if lifted incorrectly. Always lift the truck secured to, and with the center of gravity between, the lifting truck’s forks.

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 then 1 year. See the oil specification in the section Maintenance and lubrication chart.

Drive unit

•

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

Starting after a period of disuse

•

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

•

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

•

When stored for a period greater 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

Recyling/Discarding

Recycling/Discarding

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

Discarding the battery

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

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

Scrapping the truck

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

Chassis

Return

Chassis

Steel

Chassis

Steel

Drive unit

Steel and cast material

Drive unit

Steel and cast material

Bushings

Polyamide

Bushings

Polyamide

Finish

Epoxy-polyester

Finish

Epoxy-polyester

Wheels

Polyurethane

Wheels

Polyurethane

Recyling/Discarding

Electrical system

Recyling/Discarding

Electrical system

Cables

Copper cores with PVC sheaths

Cables

Copper cores with PVC sheaths

Electronic board

Reinforced fiberglass circuit board laminate

Electronic board

Reinforced fiberglass circuit board laminate

Motors

Steel and copper

Motors

Steel and copper

Return

Recyling/Discarding

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

Return

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

Operator’s Manual

TMX

Electric Tow Tractor Effective Serial Number TMX0027297000

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: 303045-003 Return

Date: June 02, 1998

Part no: 303045-003

Date: June 02, 1998

Operator’s warning

IMPORTANT NOTICE

Before operating the truck:

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

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

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

LEARN AND PRACTICE USE OF CONTROLS BEFORE OPERATING.

WARNING INJURY OR DEATH TO YOU OR OTHER

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

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

Foreword

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

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

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

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

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

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

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

California Proposition 65

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

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Table of Contents

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

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

Presentation of truck ....................................................... 19 Application areas for BT’s trucks..................................... 20 Prohibited applications for BT’s trucks ............................ 20 Truck data ....................................................................... 21 Truck battery dimensions ................................................ 21 TMX truck dimensions..................................................... 22 Data plate ........................................................................ 23

Presentation of truck ....................................................... 19 Application areas for BT’s trucks..................................... 20 Prohibited applications for BT’s trucks ............................ 20 Truck data ....................................................................... 21 Truck battery dimensions ................................................ 21 TMX truck dimensions..................................................... 22 Data plate........................................................................ 23

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

Controls and instruments ............................................... 27 Control handle ................................................................. 27 Horn................................................................................. 28 Travel direction selector and speed control..................... 28 Brake lever controls......................................................... 29 Braking using plugging function ...................................... 30 Emergency disconnect switch ......................................... 31 Key switch (toggle switch) ............................................... 32 BDI/Hourmeter with lift interrupt ...................................... 33 Battery discharge indicator (BDI) .................................... 33 Hourmeter ....................................................................... 34 Adjustable tilting control handle....................................... 34

Controls and instruments ............................................... 27 Control handle................................................................. 27 Horn ................................................................................ 28 Travel direction selector and speed control..................... 28 Brake lever controls......................................................... 29 Braking using plugging function ...................................... 30 Emergency disconnect switch ......................................... 31 Key switch (toggle switch)............................................... 32 BDI/Hourmeter with lift interrupt ...................................... 33 Battery discharge indicator (BDI) .................................... 33 Hourmeter ....................................................................... 34 Adjustable tilting control handle....................................... 34

Driving............................................................................... 35 Starting the truck ............................................................. 35 Braking ............................................................................ 38 Steering ........................................................................... 40 Parking the truck ............................................................. 40

Driving............................................................................... 35 Starting the truck ............................................................. 35 Braking ............................................................................ 38 Steering........................................................................... 40 Parking the truck ............................................................. 40

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Table of Contents

Transporting loads .......................................................... 42 General............................................................................ 42 Collecting a load.............................................................. 45 Leaving a load................................................................. 46

Transporting loads ...........................................................42 General ............................................................................42 Collecting a load ..............................................................45 Leaving a load..................................................................46

Battery............................................................................... 47 Type of battery ................................................................ 47 Changing the battery ....................................................... 47 Charging the battery........................................................ 49 Battery maintenance ....................................................... 52

Battery ...............................................................................47 Type of battery .................................................................47 Changing the battery........................................................47 Charging the battery ........................................................49 Battery maintenance ........................................................52

Daily service/safety checks ............................................ 54

Daily service/safety checks .............................................54

Maintenance ..................................................................... 57 General............................................................................ 57 Safety regulations with maintenance work ...................... 57 Cleaning and washing ..................................................... 61 Maintenance chart........................................................... 63 Lubrication chart.............................................................. 66 Oil and grease specification ............................................ 67

Maintenance ......................................................................57 General ............................................................................57 Safety regulations with maintenance work.......................57 Cleaning and washing......................................................61 Maintenance chart ...........................................................63 Lubrication chart ..............................................................66 Oil and grease specification.............................................67

Transport and storing the truck ..................................... 68 The truck’s dimensions and weight as standard ............. 68 Lifting the truck................................................................ 68 Towing and transporting a disabled truck........................ 69 Storing the truck .............................................................. 70 Starting after a period of disuse ...................................... 70

Transport and storing the truck ......................................68 The truck’s dimensions and weight as standard ..............68 Lifting the truck.................................................................68 Towing and transporting a disabled truck ........................69 Storing the truck...............................................................70 Starting after a period of disuse .......................................70

Recycling/discarding....................................................... 71 Discarding the battery ..................................................... 71 Scrapping the truck ......................................................... 71

Recycling/discarding........................................................71 Discarding the battery ......................................................71 Scrapping the truck ..........................................................71

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Safety regulations Warning symbols

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

Warning levels

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

DANGER

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

WARNING

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

CAUTION

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

NOTE!

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

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

Safety regulations Prohibitory symbols

Prohibitory symbols

NO SMOKING

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

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

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

Ordinance symbols

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

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

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

Ordinance symbols

SAFETY SHOES

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

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

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Safety regulations

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

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

Safety regulations

General safety regulations

Control

•

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

•

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

•

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

•

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

•

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Safety regulations

General safety regulations

Operating the truck

•

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

•

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

•

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

•

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

•

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

•

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

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

To tow other trucks.

To transport/lift passengers.

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Safety regulations

General safety regulations

Operator’s responsibility

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

Local regulations regarding personal safety equipment shall be followed.

•

Local regulations regarding personal safety equipment shall be followed.

•

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

•

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

•

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

•

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

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Safety regulations

General safety regulations

Working area

•

If there are marked truck routes these shall be used.

•

If there are marked truck routes these shall be used.

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

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Safety regulations

General safety regulations

Driving and conduct while driving

•

Always drive the truck from the normal operator position.

•

Always drive the truck from the normal operator position.

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

Keep a safe distance from all vehicles ahead.

•

Keep a safe distance from all vehicles ahead.

•

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

•

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

•

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

•

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

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Safety regulations

•

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

•

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

•

Never allow passengers to ride on the truck.

•

Never allow passengers to ride on the truck.

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

DO NOT run over loose objects, uneven surfaces, or other obstructions on roadway surfaces.

•

DO NOT smoke while working around truck.

•

DO NOT smoke while working around truck.

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Safety regulations

General safety regulations

Handling loads

•

Drive with care when collecting or leaving a load.

•

Drive with care when collecting or leaving a load.

•

Only handle loads that are within the truck’s permitted capacity.

•

Only handle loads that are within the truck’s permitted 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.

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Safety regulations

General safety regulations

Parking the truck

•

Always park in designated areas if available.

•

Always park in designated areas if available.

•

Never leave the truck parked with the key still in the key switch.

•

Never leave the truck parked with the key still in the key switch.

•

Never park the truck on an incline.

•

Never park the truck on an incline.

•

Never park the truck so that it obstructs emergency exits.

•

Never park the truck so that it obstructs emergency exits.

•

Never park the truck so that it obstructs traffic or work.

•

Never park the truck so that it obstructs traffic or work.

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Safety regulations

General safety regulations

Handling the battery

•

Always handle the battery and its connections with care. Read and follow the instructions for changing or recharging the battery carefully. See chapter Battery.

•

Always handle the battery and its connections with care. Read and follow the instructions for changing or recharging the battery carefully. See chapter Battery.

•

Always wear protective glasses when working with the battery.

•

Always wear protective glasses when working with the battery.

•

Make sure the battery in the truck is of a weight that corresponds with the information on the truck’s data plate.

•

Make sure the battery in the truck is of a weight that corresponds with the information on the truck’s data plate.

•

Make sure the battery is secured in its compartment.

•

Make sure the battery is secured in its compartment.

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Safety regulations

General safety regulations

Maintenance and repair

All replacement parts shall be BT approved spare parts.

Modifications and additions which affect capacity and safe operation shall not be performed by the customer or user without manufacturers prior written approval. Capacity, operation, maintenance instruction plate, tags, or decals shall be changed accordingly.

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Warning and information signs

The figure shows the position and significance of the signs’ location on the truck.

1. Signal/Horn

2. Truck data plate

3. Warning decal: Truck parking brake does not automatically engage

4. Warning decal: No Step, or No Standing, or No Riding

5. List of warnings

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Warning and information signs

Warning decals

Clean or replace all safety and instruction decals that cannot be read.

When you clean decals use only a cloth, soap, and water. DO NOT use solvent, gasoline, etc.

You must replace a decal if the decal is damaged, missing, or cannot be read.

If a decal is on a part that is replaced, make sure you install a new decal on the new part. New warning decals can be obtained from your BT dealer at NO charge.

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Presentation of truck

BT’s truck program is intended for towing trailers handling goods indoors or alternatively other types of loads using other load carriers. This truck is operated in a standing position.

Refer to the truck’s data plate for this information on towing.

The trucks are equipped with a 24 volt electrical system. The travel speeds are regulated by means of a transistor controller to provide gentle control of acceleration and speed while operating.

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Presentation of truck

Application area for BT’s trucks

BT’s trucks are solely designed and manufactured to handle goods. The truck should be fitted with the appropriate accessories relevant to the application.

Prohibited applications for BT’s trucks

The trucks are designed for handling goods indoors. It is not permitted to use the trucks for other purposes including the following:

Do not use in areas that contain gases which can cause fires or explosions

Do not use to tow other trucks

Do not use to transport/lift passengers

Do not use to drive on gravel or grass

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Presentation of truck

Truck data

The table provides information regarding some technical data which is of value with daily use of the truck.

Truck type

Operating speed without load

8.0 mph [12.87 km/h]

Operating speed without load

8.0 mph [12.87 km/h]

Operating speed with classified load

6.0 mph [9.65 km/h]

Operating speed with classified load

6.0 mph [9.65 km/h]

Maximum operating gradient with load, %

Continuous noise level. dB (A)

<80

Continuous noise level. dB (A)

<80

The truck’s lifting capacity 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: Minimum Maximum Deep 12.8 in. [325 mm] 13.3 in. [338 mm] Wide 32.9 in. [836 mm] 33.4 in. [848 mm] Battery Weight (Consult Data plate on truck) For smaller industrial battery sizes, provide blocking to restrain the battery from moving not more than 0.5 in. [12.7 mm] in any horizontal direction.

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Presentation of truck

Truck dimensions

The following diagrams show external dimensions for TMX trucks in its standard design.

C Area of ride platform (541 in.2 [13741.4 mm2])

30°

Area of ride platform (541 in.2 [13741.4 mm2])

30°

Battery compartment 13.3 in. [337.8 mm]

F Q

J 15°

Battery 26° roller height L M N

J 15°

Battery 26° roller height L M N

43.7 in. R [1110 mm] R

6.9 in. [175.26 mm]

34 in. 863.6 mm]

43.7 in. R [1110 mm] R

6.9 in. [175.26 mm]

34 in. 863.6 mm]

34.1 in. [866.14 mm]

6.2 - 11.7 in. [157.48 - 297.18 mm]

53.2 in. [1351.28 mm]

34.1 in. [866.14 mm]

6.2 - 11.7 in. [157.48 - 297.18 mm]

53.2 in. [1351.28 mm]

51.3 in. [1303.02 mm]

5.9 - 11.7 in. [149.86 - 297.18 mm]

9.7 in. 246.38 mm]

51.3 in. [1303.02 mm]

5.9 - 11.7 in. [149.86 - 297.18 mm]

9.7 in. 246.38 mm]

17.3 in. [439.42 mm]

6.6 - 12.1 in. [167.64 - 307.34 mm]

2.1 in. [53.34 mm]

17.3 in. [439.42 mm]

6.6 - 12.1 in. [167.64 - 307.34 mm]

2.1 in. [53.34 mm]

54.3 in. [1379.22 mm]

3.6 in. [91.44 mm]

31.8 in. [807.72 mm]

54.3 in. [1379.22 mm]

3.6 in. [91.44 mm]

31.8 in. [807.72 mm]

2.9 in. [73.66 mm]

8.9 in. [226.06 mm]

51.5 in. [1308.1 mm]

2.9 in. [73.66 mm]

8.9 in. [226.06 mm]

51.5 in. [1308.1 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.

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Presentation of truck

Presentation of main components

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Presentation of main components

1/2

Presentation of main components

1 8

I O

11 9 12

7, 8

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1/2

7, 8

Controls and instruments

Controls and Instruments

Guards and shields have been provided on unit for your protection.

WARNING DO NOT operate this equipment unless all factory installed guards and shields are properly secured in place.

Decals are also provided to warn of potential danger as well as to display special operating procedures.

WARNING Read and observe all warnings on this unit before operating it.

Control Handle

The control handle is used to provide hand brake, direction, speed, and horn on this machine.

Handle Brake Lever

Steering Control Handle

Horn Switch

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Handle Brake Lever

Steering Control Handle

Horn Switch

Directional Controls

Controls and instruments Horn

Horn

The horn sounds as long as the button is pressed.

Travel Direction Selector and Speed Control

Select the travel direction by rotating ‘R’ in the required direction. The speed is controlled variably based on the position of the lever.

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Controls and instruments

Brake Lever Controls

This truck has two brake engaging controls, 1) a hand controlled lever that is squeezed to apply brake, 2) a parking brake lever that locks in place when used.

Hand Control Lever

The proper position for parking brake lever engaged and disengaged position is shown and described below.

Engaged Position (Brake ON)

Disengaged Position (Brake OFF)

Engaged Position (Brake ON)

Disengaged Position (Brake OFF)

The parking brake lever must be placed in the engaged position when unit is not in use (parked) or hand brake lever is not squeezed.

The brake function should always be checked before using this unit.

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Controls and instruments

Braking using Plugging Function

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Controls and instruments

Emergency Disconnect Switch

1/2

Battery Disconnect Indicator/Hourmeter Dash Display

1 8

Key Switch

Dash Controls and Locations

Controls and instruments

Emergency Disconnect Switch

1/2

Battery Disconnect Indicator/Hourmeter Dash Display

1 8

Key Switch

Dash Controls and Locations

Emergency Disconnect Switch

The hourmeter can be read any time the emergency disconnect switch is pulled out.

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Controls and instruments

Emergency Disconnect Switch

1/2

Battery Disconnect Indicator/Hourmeter Dash Display

1 8

Key Switch

Dash Controls and Locations

Controls and instruments

Emergency Disconnect Switch

1/2

Battery Disconnect Indicator/Hourmeter Dash Display

1 8

Key Switch

Dash Controls and Locations

Key Switch (toggle switch)

A Key Switch is provided to prevent unauthorized use of this unit. The emergency disconnect switch must be pulled out before electrical power can flow to the control circuit.

The key switch has two (2) positions: OFF and ON.

1.OFF Position: Turning the key to OFF will stop all electrical power from going to the control circuit from battery.

2.ON Position: Turn the key to ON to check function of battery discharge indicator. The key switch must be in this position to provide power to the control circuit when unit is operated.

When the unit is left unattended for an extended period of time push the emergency disconnect switch in, disconnect the battery, and remove and secure key in a safe place.

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Controls and instruments

BDI/Hourmeter with travel interrupt

Fully-charged battery

1/2

Half-charged battery

1/2

Half-charged battery

Discharged battery

The battery indicator shows the actual charge level of the truck’s battery.

The hourmeter displays the time the drive motor is operating.

Battery Discharge Indicator (BDI)

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Controls and instruments

Hourmeter

The hourmeter displays the time the drive motor and/or the pump motor are operating.

Down

Tilt Control Lever

Adjustable Tilting Control Handle

The adjustable tilting control handle is used to adjust the height of the control handle. This function will allow more comfort and control for the operator.

To adjust the handle pull on the tilt control lever (backwards towards the operator) and lift/lower control handle to the position that is comfortable for you.

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Driving

The proper operator position for this truck is shown and described below.

Travel

Proper operation of this unit is as shown when possible. Steering the truck is easier in this direction. Always look in the direction of travel.

When reversing into a confined area, elevator, or on an incline keep both hands on control handle. Keep both hands within the handle guard and always look in the direction of travel.

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Driving

Starting the truck

Ensure the battery connector is connected to the truck.

Turn the key switch to position I. The instrument lighting comes on.

Make sure the battery indicator indicates a sufficient charge level (1/2 - 1) to operate the truck.

NOTE! Low charge level. Prolonged operation with a low battery charge level can result in damage to the battery. Do not drive without first recharging the battery. Engaged Position (Brake ON)

Disengaged Position (Brake OFF)

Squeeze the handle brake levers located on control handle. Place the parking brake lever in the disengaged position. This releases the parking brake.

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NOTE! Low charge level. Prolonged operation with a low battery charge level can result in damage to the battery. Do not drive without first recharging the battery.

Engaged Position (Brake ON)

Disengaged Position (Brake OFF)

Squeeze the handle brake levers located on control handle. Place the parking brake lever in the disengaged position. This releases the parking brake.

Driving

WARNING Risk of crushing exists if any part of the body is outside of the operator’s compartment. Always have your whole body inside the operator’s compartment. Ÿ

Move the travel direction selector/speed control in the desired direction.

WARNING Risk of crushing exists if any part of the body is outside of the operator’s compartment. Always have your whole body inside the operator’s compartment. Ÿ

Move the travel direction selector/speed control in the desired direction.

WARNING Function failure. Safety can be jeopardized. Always complete the daily operator’s checks before starting the day’s work.

- That the horn functions correctly.

- That the steering functions correctly.

- That the brakes function correctly.

- That the hydraulic functions are operational.

Start gently by accelerating slowly until you reach the desired speed. WARNING Dangerous driving. Accidents can occur. Always drive with care, good judgment, and responsibility.

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Start gently by accelerating slowly until you reach the desired speed. WARNING Dangerous driving. Accidents can occur. Always drive with care, good judgment, and responsibility.

Driving

Braking

Braking Hand Brake Lever

Hand Brake Lever

Parking Brake Lever

Key Switch

Location of Hand Brake Lever, Parking Brake Lever, and Key Switch

By squeezing the hand brake lever you will apply the travel brake. When you release the hand brake lever it automatically returns to the brake OFF position.

When truck is left unattended, or hand brake lever is NOT squeezed, the parking brake lever must be locked in the engaged position (brake ON).

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Driving handle will allow the automatically applied.

parking

Driving brake

become

handle will allow the automatically applied.

parking

brake

become

THE CONTROL HANDLE MUST NOT BE PLACED IN THE BRAKE POSITION DURING THE PLUG BRAKING OPERATION.

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Driving

Steering

Steer by means of the tiller arm.

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WARNING Risk of slipping. You can lose control of the truck if your hands or shoes are oily. Always dry your hands and shoes before driving.

Driving

Parking the truck

Hand Brake Lever

Parking Brake Lever

Key Switch

Location of Hand Brake Lever, Parking Brake Lever, and Key Switch

Rotate directional control to the NEUTRAL position.

Squeeze the handle brake lever and stop movement completely.

Place the parking brake lever in the engaged position.

Lower the forks fully to the floor.

Turn the key switch to the O position and remove the key.

Push the emergency disconnect button in to stop the hourmeter from running.

WARNING Unauthorized use. Accidents can happen. Always remove the key switch when the truck is left unattended.

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WARNING Unauthorized use. Accidents can happen. Always remove the key switch when the truck is left unattended.

Transporting loads

General

The weight of the load should be within the truck’s permitted lifting capacity. See the truck’s data plate.

WARNING Risk of overturning. The lifting capacity is reduced if additional equipment is attached to the truck. Always check the truck’s overall lifting capacity.

•

Only handle loads that are stable and arranged safely. Take particular care when handling high and long loads.

•

Only handle loads that are stable and arranged safely. Take particular care when handling high and long loads.

Make sure that the truck is equipped with a suitable load support when handling high loads.

Always drive with the forks fully lowered except when collecting or leaving a load.

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WARNING Lost stability. High loads can fall when cornering at high speed or cause tipover. Drive slowly and carefully when cornering and travel with loads in lowered position.

WARNING Protruding loads. The load can collide with personnel, fixed or moving objects. A truck with a protruding load requires more room when cornering.

Transporting loads

NOTE! Increased machine width. The load can collide with fixed objects. A truck with wide loads requires a greater operating area.

Drive the truck with the load trailing when the load impairs the line of vision.

If necessary, when the operator’s vision is impaired, ask someone to direct operations so that transportation can take place without the risk of causing personal injury or material damage.

DO NOT use the truck on grades, ramps, or inclines.

WARNING Risk of overturning. A loaded truck can overturn when attempting to turn on an incline. Never turn a loaded truck on an incline.

WARNING Increased braking distance. The braking distance is increased when traveling downhill. Drive at a reduced speed using the truck’s motor brake.

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Transporting loads

WARNING Risk of overloading the elevator. An overloaded elevator can fall out of control down the elevator shaft. Always check the capacity of the elevator before driving in with the truck. •

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WARNING Risk of overloading the elevator. An overloaded elevator can fall out of control down the elevator shaft. Always check the capacity of the elevator before driving in with the truck. •

Transporting loads

Collecting a load

Slow down and position the truck carefully in front of the load.

Drive the truck rearward so that the hitch is positioned and can be connected to drawbar.

Make sure connection is correct.

Drive carefully away. Start slowly and then increase the speed.

Travel

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Travel

Transporting loads

Leaving a load

•

Slow down and position truck carefully where load is to be left.

•

Slow down and position truck carefully where load is to be left.

•

Reverse truck to release hitch and disconnect hitch.

•

Reverse truck to release hitch and disconnect hitch.

•

Drive carefully away from the load. Start slowly and then increase the speed.

•

Drive carefully away from the load. Start slowly and then increase the speed.

Travel

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Travel

Battery

Type of battery

•

Changing the battery

•

When changing the battery proceed as follows:

•

Park truck at battery removal station.

•

Park truck at battery removal station.

•

Turn OFF key and remove.

•

Turn OFF key and remove.

•

Push the emergency disconnect button to the OFF position to stop hourmeter from running.

•

Push the emergency disconnect button to the OFF position to stop hourmeter from running.

•

Disconnect the battery connector from the battery.

•

Disconnect the battery connector from the battery.

•

Remove battery stops.

•

Remove battery stops.

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Battery

•

Slide out the discharged/old battery, then slide in the new battery.

•

Slide out the discharged/old battery, then slide in the new battery.

•

Connect battery and truck connectors.

•

Connect battery and truck connectors.

•

Connect the battery connector and truck connector.

•

Connect the battery connector and truck connector.

WARNING Risk of short-circuiting. The cables can be damaged and cause a short-circuit. Ensure the battery cables are not crushed.

•

Push the emergency disconnect button to the ON position.

•

Push the emergency disconnect button to the ON position.

•

Install battery stops.

•

Install battery stops.

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WARNING Falling battery. If the truck should tip over the battery can fall out if the battery stops have not been installed. Make sure the battery stops have been installed.

WARNING Falling battery. When charging the battery, it can be dropped. Always lift battery using an approved lifting device, and use a battery yoke intended for the battery.

Battery

Charging the battery

General prohibition

When recharging the battery it is absolutely forbidden to smoke or use an open flame.

Use an automatic charger intended for recharging traction batteries.

The charger shall have a minimum charging current of:

Battery (Ah)

Charger (A)

Battery (Ah)

Charger (A)

300-480

50-70

300-480

50-70

480-730

80-110

480-730

80-110

730-900

130-150

730-900

130-150

ALWAYS WEAR PROTECTIVE GLASSES AND PROTECTIVE GLOVES WHEN CHECKING THE BATTERY.

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Battery

Pre-charging

•

Park the truck in the assigned charging area.

•

Park the truck in the assigned charging area.

•

Ensure nothing prevents ventilation above the battery.

•

Ensure nothing prevents ventilation above the battery.

•

Turn key switch to the OFF position.

•

Turn key switch to the OFF position.

•

Remove the battery connector from the truck’s connector.

•

Remove the battery connector from the truck’s connector.

•

Make sure the battery charger is switched OFF.

•

Make sure the battery charger is switched OFF.

•

Connect the battery connector to charger connector.

•

Connect the battery connector to charger connector.

•

Never connect charger connector to truck connector.

•

Never connect charger connector to truck connector.

•

Switch ON the battery charger.

•

Switch ON the battery charger.

During charging

•

After approximately ten minutes make sure that the ammeter indicates a normal reading and that the control lamp is ON.

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After approximately ten minutes make sure that the ammeter indicates a normal reading and that the control lamp is ON. 50

Battery

After charging

•

Make sure that the ammeter indicates an insignificant or no reading and that maintenance charge lamp is ON, if equipped.

•

Make sure that the ammeter indicates an insignificant or no reading and that maintenance charge lamp is ON, if equipped.

•

Switch OFF the charger.

•

Switch OFF the charger.

•

Disconnect the battery connector from charger connector.

•

Disconnect the battery connector from charger connector.

CAUTION

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Risk of short circuiting. The terminals can otherwise be damaged inside and result in a subsequent short circuit. Do not pull the cables to disconnect from the charger.

CAUTION

Risk of short circuiting. The terminals can otherwise be damaged inside and result in a subsequent short circuit. Do not pull the cables to disconnect from the charger.

Battery

Battery maintenance

Carry out battery maintenance after recharging.

ALWAYS WEAR PROTECTIVE GLASSES AND PROTECTIVE GLOVES WHEN CHECKING THE BATTERY.

Each week:

•

Remove all cell caps. NOTE! This does not apply to batteries with level caps or central filling.

•

Check the fluid level in the cells and note any cells that consume more than a normal amount of fluid.

•

Check the fluid level in the cells and note any cells that consume more than a normal amount of fluid.

•

Fill using distilled water. The fluid level should be 1/4 in. (10-15 mm) above the cell plates.

•

Fill using distilled water. The fluid level should be 1/4 in. (10-15 mm) above the cell plates.

•

Refit all of the cell caps.

•

Refit all of the cell caps.

•

Rinse off and dry the battery.

•

Rinse off and dry the battery.

Return

Battery

Each month:

•

Measure the temperature in one of the center cells immediately after charging. The temperature should not exceed 122°F [50°C.]

•

Measure the temperature in one of the center cells immediately after charging. The temperature should not exceed 122°F [50°C.]

•

Measure the density of the battery fluid using an acid tester. Hold the acid tester absolutely vertical and extract sufficient fluid so that the hydrometer float moves freely.

•

Measure the density of the battery fluid using an acid tester. Hold the acid tester absolutely vertical and extract sufficient fluid so that the hydrometer float moves freely.

•

Adjust specific gravity with temperatures based on the chart below.

•

Adjust specific gravity with temperatures based on the chart below.

Temperature

Gravity

Temperature

Gravity

77°F [25.2°C]

1.280

77°F [25.2°C]

1.280

WARNING Battery manufactories maintenance and charging procedures must be followed. Battery acid is very corrosive and must be immediately cleaned up after spillage.

Return

WARNING Battery manufactories maintenance and charging procedures must be followed. Battery acid is very corrosive and must be immediately cleaned up after spillage.

Daily service/safety checks

•

The operator is responsible for the daily service and care of the truck.

•

The operator is responsible for the daily service and care of the truck.

•

Carry out the daily service at the start of the day or shift, before the truck is used. The daily service is a simple safety and function control as set in the check list below.

•

Carry out the daily service at the start of the day or shift, before the truck is used. The daily service is a simple safety and function control as set in the check list below.

•

You need no tools to carry out the service checks.

•

You need no tools to carry out the service checks.

•

If you fail to carry out the daily service the safety and reliability of the truck can be affected.

•

If you fail to carry out the daily service the safety and reliability of the truck can be affected.

Return

Daily service/safety checks

Daily service/safety checks 0

1/2

Daily service/safety checks 13

1 8

7 I

1 2

14 10

9 11

5 3

WARNING DO NOT continue to operate the truck when it is not functioning properly. Item #

1 2

1 8

12 8

1/2

Check points

Action

Battery

Check acid level, charge, and condition (see battery maintenance)

Battery cables and connections

3 4

WARNING DO NOT continue to operate the truck when it is not functioning properly. Item #

Check points

Action

Battery

Check acid level, charge, and condition (see battery maintenance)

Check for breakage, cutting, or damage

Battery cables and connections

Check for breakage, cutting, or damage

Chassis

Check for damage, remove dirt and debris

Chassis

Check for damage, remove dirt and debris

Covers / guards

Check for damage, ensure placement

Covers / guards

Check for damage, ensure placement

Return

Daily service/safety checks Item #

Check points

Action

Drive unit

Inspect abnormal noises and leakage

Wheels

Daily service/safety checks Item #

Check points

Action

Drive unit

Inspect abnormal noises and leakage

Check for damage, remove oil, metal chips, and debris

Wheels

Check for damage, remove oil, metal chips, and debris

Hand brake levers

Check its function

Hand brake levers

Check its function

Direction / speed control

Check its function

Direction / speed control

Check its function

Control console

Check its locking mechanism

Control console

Check its locking mechanism

Control functions

Check its function

Control functions

Check its function

Parking brake lever

Check its function

Parking brake lever

Check its function

Horn

Check its function

Horn

Check its function

Running time

Inform your supervisor if your truck is ready for a schedule maintenance check. See “Maintenance” chapter.

Running time

Inform your supervisor if your truck is ready for a schedule maintenance check. See “Maintenance” chapter.

Emergency stop switch

Check its function

Emergency stop switch

Check its function

Key switch (toggle switch)

Check its function

Key switch (toggle switch)

Check its function

If any of the functions fail to operate properly, inform your supervisor or maintenance personnel to have the truck repaired.

Special equipment

Return

Maintenance

General information

•

Only use BT approved spare parts when service and repair work are carried out.

•

Only use BT approved spare parts when service and repair work are carried out.

•

BT recommends that you contact your BT representative to set up a service and maintenance agreement to ensure your truck’s operating economy and safety.

•

BT recommends that you contact your BT representative to set up a service and maintenance agreement to ensure your truck’s operating economy and safety.

Safety regulations with maintenance work

•

Only personnel that have been trained in the service and repair of this type of truck are authorized to carry out service and repair work.

•

Only personnel that have been trained in the service and repair of this type of truck are authorized to carry out service and repair work.

•

Do not carry out any maintenance work on the truck unless you have the correct training and knowledge to do so.

•

Do not carry out any maintenance work on the truck unless you have the correct training and knowledge to do so.

•

Keep the area where you carry out service clean. Oil or water makes the floor slippery.

•

Keep the area where you carry out service clean. Oil or water makes the floor slippery.

•

Never wear loose objects or jewelry when working on the truck.

•

Never wear loose objects or jewelry when working on the truck.

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.

WARNING Risk of burns. Hot transmission and hydraulic oil. Let the truck cool before changing the oil.

•

Only fill the hydraulic system with new clean oil. Oil should meet BT cleanliness specification 12-00-002. Contact your BT representative for assistance or more information.

Return

WARNING Risk of burns. Hot transmission and hydraulic oil. Let the truck cool before changing the oil.

•

Only fill the hydraulic system with new clean oil. Oil should meet BT cleanliness specification 12-00-002. Contact your BT representative for assistance or more information. 58

Maintenance

WARNING The hydraulic system can be damaged. If oil is contaminated hydraulic components can be damaged. Always use new and clean oil in the hydraulic system.

•

Store and dispose of changed oil in accordance with local regulations.

•

Store and dispose of changed oil in accordance with local regulations.

•

Do not dump solvents, which are used for cleaning/ washing, into drains that are not intended for this purpose. Follow the local regulations that apply for disposal.

•

Do not dump solvents, which are used for cleaning/ washing, into drains that are not intended for this purpose. Follow the local regulations that apply for disposal.

•

When working underneath the truck support the truck on trestle-blocks.

•

When working underneath the truck support the truck on trestle-blocks.

WARNING Risk of crushing. A badly supported truck can fall. Never work under a truck that is not supported on trestle-blocks and secured by a lifting device.

Return

WARNING Risk of crushing. A badly supported truck can fall. Never work under a truck that is not supported on trestle-blocks and secured by a lifting device.

Maintenance

Maintenance work that can be carried out by you

The Daily service/Safety checks as set out in the check list.

Maintenance points with intervals 1 day, 1 week, and 1 month as set out in the Maintenance chart may be carried out by the driver without more knowledge than that provided by the Operator’s Manual.

Other maintenance points as set out in the Maintenance chart may only be carried out by personnel who have completed maintenance training for this type of truck.

Maintenance work that may be carried out by trained maintenance personnel

All maintenance points as set out in the Maintenance chart.

If you are uncertain regarding working procedures consult the Service Manual for the truck.

Other service and repair work

•

In addition to the maintenance points in the Maintenance chart all service and repair work should be carried out by personnel with special training for this type of truck.

Return

In addition to the maintenance points in the Maintenance chart all service and repair work should be carried out by personnel with special training for this type of truck.

Maintenance

Cleaning and washing

General

Cleaning and washing the truck is important to ensure the truck will operate safely and reliably.

•

Carry out general cleaning and washing weekly.

External cleaning

•

Remove debris, etc. from the wheels daily.

•

Remove debris, etc. from the wheels daily.

•

Use a degreasing agent diluted to a suitable concentration.

•

Use a degreasing agent diluted to a suitable concentration.

•

Rinse off loose grime using warm water.

•

Rinse off loose grime using warm water.

NOTE! Mechanical components can be damaged. After washing, the truck should be lubricated as set out in the chapter Maintenance and Lubrication chart.

Cleaning the motor compartment

•

Cover the electric motors, electrical compartments, connectors, and valves before washing.

Return

Cover the electric motors, electrical compartments, connectors, and valves before washing. 61

Maintenance •

Clean carefully using the minimum of water and detergent. Never pressure wash or steam clean in the compartments.

Maintenance •

Clean carefully using the minimum of water and detergent. Never pressure wash or steam clean in the compartments.

NOTE! Risk of short-circuiting. The electrical system can be damaged. Electrical components must not be cleaned with a high pressure washing unit.

•

Clean the motor compartment using a degreasing agent diluted to a suitable concentration.

•

Clean the motor compartment using a degreasing agent diluted to a suitable concentration.

•

Rinse off loose grime using warm water.

•

Rinse off loose grime using warm water.

Electrical components

•

Clean the electrical panels, electronic boards, contacts, connector, solenoid valves, etc. using a damp cloth and a cleaning agent.

•

Clean the electrical panels, electronic boards, contacts, connector, solenoid valves, etc. using a damp cloth and a cleaning agent.

•

Do not spray or pressure wash in the compartment.

•

Do not spray or pressure wash in the compartment.

NOTE! Risk of short-circuiting. Electrical components can be damaged. Do not break the warranty seal on the electronic board.

Return

NOTE! Risk of short-circuiting. Electrical components can be damaged. Do not break the warranty seal on the electronic board.

Maintenance

Maintenance chart

PM Interval:

A=5 Hours or 1 Day

E=500 Hours or 6 Months

A=5 Hours or 1 Day

E=500 Hours or 6 Months

B=20 Hours or 1 Week

F=1000 Hours or 12 Months

B=20 Hours or 1 Week

F=1000 Hours or 12 Months

C=80 Hours or 1 Month

G=3000 Hours or 36 Months

C=80 Hours or 1 Month

G=3000 Hours or 36 Months

D=250 Hours or 3 Months

No.

Action

1.0

Chassis

No.

Action

1.0

Chassis

1.1

Check that the truck’s data plate is legible

1.1

Check that the truck’s data plate is legible

1.2

Check the cover screws

1.2

Check the cover screws

1.3

Check door lock

1.3

Check door lock

1.4

Check wear on battery stop

1.4

Check wear on battery stop

1.5

Check for damage and crack formation

1.5

Check for damage and crack formation

2.0

Motors

2.0

Motors

2.1

Check for loose connections

2.1

Check for loose connections

2.2

Clean motor

2.2

Clean motor

2.3

Check mounting bolts

2.3

Check mounting bolts

2.4

Check for abnormal bearing noise

2.4

Check for abnormal bearing noise

2.5

Check brush wear

2.5

Check brush wear

3.0

Drive unit

3.0

Drive unit

3.1

Check for leakage

3.1

Check for leakage

3.2

Check oil level

3.2

Check oil level

3.3

Check for noises

3.3

Check for noises

3.4

Check the mounting on support

3.4

Check the mounting on support

4.0

Wheels

4.0

Wheels

4.1

Remove string & debris

4.1

Remove string & debris

4.2

Check all wheels for wear

4.2

Check all wheels for wear

4.3

Check that all wheels rotate and axles are fitted correctly

4.3

Check that all wheels rotate and axles are fitted correctly

4.4

Check all wheels for loose screws

4.4

Check all wheels for loose screws

4.5

Grease load wheel bearings

4.5

Grease load wheel bearings

Return

Maintenance No.

Action

No.

Action

4.6

Dismantle and lubricate all wheel bearings.

4.6

Dismantle and lubricate all wheel bearings.

5.0

Brake

5.0

Brake

5.1

Clean

5.1

Clean

5.2

Check shoes and discs for wear

5.2

Check shoes and discs for wear

5.3

Check correct clearance brake

5.3

Check correct clearance brake

5.4

Check brake operation

5.4

Check brake operation

6.0

Electrical panel

6.0

Electrical panel

6.1

Clean and check the mounting

6.1

Clean and check the mounting

6.2

Tighten cable connections

6.2

Tighten cable connections

6.3

Check contactor tips

6.3

Check contactor tips

6.4

Check the contactor tips for free movements

6.4

Check the contactor tips for free movements

6.5

Check all cable insulation for damage

6.5

Check all cable insulation for damage

7.0

Electronic card

7.0

Electronic card

7.1

Check for connections in harness connectors

7.1

Check for connections in harness connectors

8.0

Electronic control system

8.0

Electronic control system

8.1

Check key switch

8.1

Check key switch

8.2

Check brake switch

8.2

Check brake switch

8.3

Check control wiring harness for proper routing

8.3

Check control wiring harness for proper routing

9.0

Battery

9.0

Battery

9.1

Check electrolyte level, 0.5-0.65 in. (10-15mm above cell plate)

9.1

Check electrolyte level, 0.5-0.65 in. (10-15mm above cell plate)

9.2

Check the connections on battery, truck, and charger

9.2

Check the connections on battery, truck, and charger

9.3

Check all cells and pole guards

9.3

Check all cells and pole guards

9.4

Check the fluid density and temperature

9.4

Check the fluid density and temperature

9.5

Check power cables are not cut or frayed

9.5

Check power cables are not cut or frayed

10.0

Controls

10.1

Check handle mounting

Return

Maintenance B

10.0

Controls

10.1

Check handle mounting

G X

Maintenance No.

Action

10.2

Check the handle brake lever switches

10.3

Maintenance B

No.

Action

10.2

Check the handle brake lever switches

Check travel direction/speed control

10.3

Check travel direction/speed control

10.4

Check horn button function

10.4

Check horn button function

10.5

Check the handle control switches

10.5

Check the handle control switches

11.0

Gauge

11.1

Check dash display

12.0

Brake Levers

12.1

Check parking brake lever

12.1

Check parking brake lever

12.2

Check handle brake levers

12.2

Check handle brake levers

13.0

Emergency stop switch

13.0

Emergency stop switch

13.1

Check the emergency stop switch

13.1

Check the emergency stop switch

1/2

11.0

Gauge

11.1

Check dash display

12.0

Brake Levers

10 13 10

9 11

3 1

13 10

1 8

I O

Return

1/2

1 8

6, 7, 8

Maintenance chart

Maintenance

Lubrication chart

Lubrication chart Interval/Running hours

Pos No.

Service point

Wheel bearings

Travel brake

Drive gear

Hinges

Steering bearings

Gear ring

500h

L=Lubrication

Return

Service point

Wheel bearings

Travel brake

Drive gear

Hinges

Steering bearings

Gear ring

1000h

3000h L

C=Check

Interval/Running hours

Pos No.

Lubricant

O=Oil change

Lubricant 500h

L=Lubrication

C=Check

1000h

3000h L

O=Oil change

Maintenance

Approved Oils and Grease

Specification Pos.

Lubricant

Grease

B C

Above 5°F [-15°C]

Application

SAE 40

Specification Pos.

Lubricant

Bearings and bushings

Grease

Below -10°F[-23°C]

Tex. Ref. C & Tex. Ref. C & Tex. Ref. C & C #880 C #880 C #880

Transmission SAE 80W/90 oil Motor oil

Below 5°F [-15°C]

area

SAE 75W

Gears

SAE5W-20

Hinges

Oil should meet BT cleanliness specification 12-00-002. Contact your BT representative for assistance or for more information.

Above 5°F [-15°C]

SAE 40

area Bearings and bushings

SAE 75W

Gears

SAE5W-20

Hinges

Oil should meet BT cleanliness specification 12-00-002. Contact your BT representative for assistance or for more information.

B A

Return

Application Below -10°F[-23°C]

Tex. Ref. C & Tex. Ref. C & Tex. Ref. C & C #880 C #880 C #880

Transmission SAE 80W/90 oil Motor oil

Below 5°F [-15°C]

Lubrication chart location points

Transporting and storing the truck

The truck’s dimensions and weight as standard

NOTE! The truck’s dimensions and weight can vary with different accessories.

The TMX truck’s dimensions and weight

Height

60 in. [1524 mm]

Height

60 in. [1524 mm]

Width

34.1 in. [866 mm]

Width

34.1 in. [866 mm]

Length

53.2 in. [1352 mm]

Length

53.2 in. [1352 mm]

Minimum battery weight

900 lb [408.6 kg]

Minimum battery weight

900 lb [408.6 kg]

Service weight without battery

1350 lb [612.9 kg]

Service weight without battery

1350 lb [612.9 kg]

Lifting the truck

•

Lift the truck from the marked lifting points when lifting using a lifting device.

Return

Lift the truck from the marked lifting points when lifting using a lifting device.

WARNING Risk of overturning. The truck can overturn if lifted from the wrong lifting points. Always lift the truck from the marked lifting points.

WARNING Risk of overturning. The truck can overturn if lifted incorrectly. Always lift the truck secured to, and with the center of gravity between, the lifting truck’s forks.

Transporting and storing the truck

Towing and transporting a disabled truck

WARNING DO NOT tow a disabled truck.

It is not recommended to tow a disabled lift truck.

Return

Transporting and storing the truck

Storing the truck

Take the following action if the truck is not used for one week or more:

Battery

•

Recharge the battery fully and carry out usual battery maintenance.

•

Recharge the battery fully and carry out usual battery maintenance.

•

Maintenance charge the battery every 3rd month and check the fluid level.

•

Maintenance charge the battery every 3rd month and check the fluid level.

Hydraulic system

•

Change the oil in the hydraulic system when stored for periods longer then 1 year. See the oil specification in the section Maintenance and lubrication chart.

Drive unit

•

Block up the truck’s drive section to take the load off the drive wheel and load wheels when storing for periods longer than one week.

Starting after a period of disuse

•

Before the truck is put into operation after a period of disuse it should undergo a function and safety check as stated in the section Daily service/safety checks.

•

Before the truck is put into operation after a period of disuse it should undergo a function and safety check as stated in the section Daily service/safety checks.

•

When stored for a period greater 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

Recyling/Discarding

Recycling/Discarding

Batteries are hazardous to the environment and should be returned to the manufacturer for recycling.

Discarding the battery

Scrapping the truck

The truck consists of parts that contain recyclable metals and plastics. Below is a list of those materials used in the truck’s sub-systems.

Chassis

Steel

Chassis

Steel

Drive unit

Steel and cast material

Drive unit

Steel and cast material

Bushings

Polyamide

Bushings

Polyamide

Finish

Epoxy-polyester

Finish

Epoxy-polyester

Wheels

Polyurethane

Wheels

Polyurethane

Return

Recyling/Discarding

Electrical system

Return

Recyling/Discarding

Electrical system

Cables

Copper cores with PVC sheaths

Cables

Copper cores with PVC sheaths

Electronic board

Reinforced fiberglass circuit board laminate

Electronic board

Reinforced fiberglass circuit board laminate

Motors

Steel and copper

Motors

Steel and copper

BT Prime-Mover, Inc., 3305 N. Highway 38 Muscatine, Iowa 52761-8800 U.S.A Tel (319) 262-7700 • Fax (319) 262-7600

Return

BT Prime-Mover, Inc., 3305 N. Highway 38 Muscatine, Iowa 52761-8800 U.S.A Tel (319) 262-7700 • Fax (319) 262-7600

Operator’s Manual

TMX

Electric Tow Tractor Effective Serial Number TMX0027297000

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: 303045-003 Return

Date: October 21, 1998

Part no: 303045-003

Date: October 21, 1998

Operator’s warning

IMPORTANT NOTICE

Before operating the truck:

1. The operator must be instructed on safe and correct use of this truck.

2. The operator must read and understand the Operator's Manual for this truck.

BEFORE OPERATING TRUCK STUDY OPERATOR’S MANUAL SAFETY MESSAGES. READ ALL SAFETY DECALS ON TRUCK. CLEAR THE AREA OF OTHER PERSONS.

LEARN AND PRACTICE USE OF CONTROLS BEFORE OPERATING.

WARNING INJURY OR DEATH TO YOU OR OTHER

PERSONNEL COULD OCCUR IF YOU DO NOT FOLLOW THESE INSTRUCTIONS AND MESSAGES.

Return

PERSONNEL COULD OCCUR IF YOU DO NOT FOLLOW THESE INSTRUCTIONS AND MESSAGES.

Foreword

It is important that you read and understand this Operator’s Manual for your own safety and the safety of those who work with you!

Before you start to use this truck it is of extreme importance that you have read the contents of the entire Operator’s Manual to be able to use the truck in a safe and efficient manner.

This Operator’s Manual contains information on how you should use the truck and how to keep the truck in a safe condition by following daily service routines.

Only personnel that have been trained as a truck operator, for this type of truck, are permitted to use this truck.

It is your employer’s responsibility to ensure that you have been trained to use your truck safely. Contact your supervisor if you feel uncertain about how to use this truck.

Always follow the warnings given in this Operator’s Manual and on the truck to avoid accidents.

Return

Table of Contents

Safety regulations............................................................. 5 Warning symbols.............................................................. 5 Prohibitory symbols .......................................................... 6 General safety regulations ............................................... 7

Warning and information signs ...................................... 17

Presentation of truck ....................................................... 19 Application areas for BT’s trucks..................................... 20 Prohibited applications for BT’s trucks ............................ 20 Truck data ....................................................................... 21 Truck battery dimensions ................................................ 21 TMX truck dimensions..................................................... 22 Data plate ........................................................................ 23

Presentation of truck ....................................................... 19 Application areas for BT’s trucks..................................... 20 Prohibited applications for BT’s trucks ............................ 20 Truck data ....................................................................... 21 Truck battery dimensions ................................................ 21 TMX truck dimensions..................................................... 22 Data plate........................................................................ 23

Presentation of main components ................................. 25

Controls and instruments ............................................... 27 Control handle................................................................. 27 Horn ................................................................................ 28 Travel direction selector and speed control..................... 28 Brake lever controls......................................................... 29 Braking using plugging function ...................................... 30 Emergency disconnect switch ......................................... 31 Key switch (toggle switch)............................................... 32 BDI/Hourmeter with lift interrupt ...................................... 33 Battery discharge indicator (BDI) .................................... 33 Hourmeter ....................................................................... 34 Adjustable tilting control handle....................................... 34

Driving............................................................................... 35 Starting the truck ............................................................. 35 Braking ............................................................................ 38 Steering........................................................................... 40 Parking the truck ............................................................. 40

Return

Table of Contents

Battery ...............................................................................47 Type of battery .................................................................47 Changing the battery........................................................47 Charging the battery ........................................................49 Battery maintenance ........................................................52

Daily service/safety checks ............................................ 54

Daily service/safety checks .............................................54

Return

Safety regulations Warning symbols

Always follow the warnings given in this Instruction Manual and on the truck to avoid accidents from occurring.

Warning levels

Warning texts are given in four levels and provide information on the risks, describe the consequences, and instruct how to avoid accidents.

DANGER

Warns that an accident will occur if you do not follow the instructions. The consequences are serious personal injury or possibly death, and/or extremely large material damage.

WARNING

Warns that an accident can occur if the instructions are not followed. The consequences are serious personal injury or possibly death, and/or large material damage.

CAUTION

Warns that an accident can occur if the instructions are not followed. The consequences are personal injury and/or material damage.

NOTE!

Marks the risk of a crash/breakdown if the instructions are not followed.

Return

Marks the risk of a crash/breakdown if the instructions are not followed.

Safety regulations Prohibitory symbols

Prohibitory symbols

NO SMOKING

If smoking occurs in situations where a restriction against smoking is stated, a serious accident can occur.

OPEN FLAMES PROHIBITED If open flames are used in situations where open flames are prohibited, a serious accident can occur.

GENERAL PROHIBITION If the prohibition is ignored, a serious accident can occur.

Ordinance symbols

If smoking occurs in situations where a restriction against smoking is stated, a serious accident can occur.

OPEN FLAMES PROHIBITED If open flames are used in situations where open flames are prohibited, a serious accident can occur.

GENERAL PROHIBITION If the prohibition is ignored, a serious accident can occur.

Ordinance symbols

SAFETY SHOES

When the directive for safety shoes is given, safety shoes shall always be worn to avoid personal injury.

PROTECTIVE GLASSES When the directive for protective glasses is given, protective glasses shall always be worn to avoid personal injury.

Return

Safety regulations

When the directive for safety shoes is given, safety shoes shall always be worn to avoid personal injury.

PROTECTIVE GLASSES When the directive for protective glasses is given, protective glasses shall always be worn to avoid personal injury.

Safety regulations

General safety regulations

Control

•

The battery must be secured in its intended compartment. The battery shall have a weight that corresponds with the value stated on the truck’s data plate.

•

The battery must be secured in its intended compartment. The battery shall have a weight that corresponds with the value stated on the truck’s data plate.

•

Read the nameplates. Do not operate the truck if there are any differences between the data stated on the nameplate and the truck.

•

Read the nameplates. Do not operate the truck if there are any differences between the data stated on the nameplate and the truck.

•

Return

Safety regulations

General safety regulations

Operating the truck

•

The truck is designed and produced to be your tool when transporting goods to locations.

•

The truck is designed and produced to be your tool when transporting goods to locations.

•

If the truck is to be used in cold storage environments the truck must be especially built for this type of use.

•

If the truck is to be used in cold storage environments the truck must be especially built for this type of use.

•

It is not permitted to use the truck for other purposes than it has been designed and produced for, e.g. the following applications:

•

It is not permitted to use the truck for other purposes than it has been designed and produced for, e.g. the following applications:

Return

In areas where the atmosphere contains gases that can cause fires or explosions.

To tow other trucks.

To transport/lift passengers.

Safety regulations

General safety regulations

Operator’s responsibility

•

The truck shall only be driven by personnel that have been specially trained and that have permission to drive the truck.

•

The truck shall only be driven by personnel that have been specially trained and that have permission to drive the truck.

•

The truck shall only be driven with care, good judgment and in a responsible manner.

•

The truck shall only be driven with care, good judgment and in a responsible manner.

•

The truck should be insured in accordance with local directives and laws where the truck is used.

•

The truck should be insured in accordance with local directives and laws where the truck is used.

•

Any accidents or near accidents (incidents) must be reported to your supervisor.

•

Any accidents or near accidents (incidents) must be reported to your supervisor.

•

The truck shall only be driven with care, good judgment and in a responsible manner.

•

The truck shall only be driven with care, good judgment and in a responsible manner.

•

Local regulations regarding personal safety equipment shall be followed.

•

Local regulations regarding personal safety equipment shall be followed.

•

The truck should not be driven with oily hands or oily shoes due to the risk of slipping.

•

The truck should not be driven with oily hands or oily shoes due to the risk of slipping.

•

DO NOT place any part of body between moving and stationary objects.

•

DO NOT place any part of body between moving and stationary objects.

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Safety regulations

General safety regulations

Working area

•

If there are marked truck routes these shall be used.

•

If there are marked truck routes these shall be used.

•

The truck should only be driven on dry clean 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 and even surfaces, e.g. concrete or asphalt.

•

The truck should only be driven on hard and even surfaces, e.g. concrete or asphalt.

•

Ensure that the floor where the truck is to be used has sufficient load bearing capacity for total weight of the truck including the maximum load.

•

Ensure that the floor where the truck is to be used has sufficient load bearing capacity for total weight of the truck including the maximum load.

•

Take special care if there are protruding parts from racks, shelves, or walls that can cause injury or damage the truck.

•

Take special care if there are protruding parts from racks, shelves, or walls that can cause injury or damage the truck.

•

Grades, ramps or inclines: This truck is designed for use on level floor operation. If it is necessary to operate on grade, ramp, or incline refer to ASME B56.1 for requirements.

•

Grades, ramps or inclines: This truck is designed for use on level floor operation. If it is necessary to operate on grade, ramp, or incline refer to ASME B56.1 for requirements.

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Safety regulations

General safety regulations

Driving and conduct while driving

•

Always drive the truck from the normal operator position.

•

Always drive the truck from the normal operator position.

•

Always drive the truck in a responsible manner and with full control. Sudden starts and braking as well as cornering at high speed should be avoided.

•

Always drive the truck in a responsible manner and with full control. Sudden starts and braking as well as cornering at high speed should be avoided.

•

Drive at a reduced speed on inclines. Drive the truck straight up and down on inclines. It is not permitted to turn the truck on an incline.

•

Drive at a reduced speed on inclines. Drive the truck straight up and down on inclines. It is not permitted to turn the truck on an incline.

•

Reduce the speed if the surface is slippery to prevent the truck from sliding or overturning.

•

Reduce the speed if the surface is slippery to prevent the truck from sliding or overturning.

•

Pay particular attention to other personnel as well as fixed and moving objects within the working area and thereby avoid accidents.

•

Pay particular attention to other personnel as well as fixed and moving objects within the working area and thereby avoid accidents.

•

Always be prepared to stop if other personnel are in the working area.

•

Always be prepared to stop if other personnel are in the working area.

•

Keep a safe distance from all vehicles ahead.

•

Keep a safe distance from all vehicles ahead.

•

Always keep a safe distance from the edges of loading bays and loading ramps. Be attentive to marked risk areas.

•

Always keep a safe distance from the edges of loading bays and loading ramps. Be attentive to marked risk areas.

•

Sound the horn when overtaking other vehicles and when the attention of other personnel is required.

•

Sound the horn when overtaking other vehicles and when the attention of other personnel is required.

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Safety regulations

•

Always give way to a loaded truck at junctions and in confined aisles.

•

Always give way to a loaded truck at junctions and in confined aisles.

•

Never allow passengers to ride on the truck.

•

Never allow passengers to ride on the truck.

•

Before the truck is driven over a loading ramp ensure that the ramp is correctly secured and has the necessary load bearing capacity. Drive slowly and carefully across the ramp.

•

Before the truck is driven over a loading ramp ensure that the ramp is correctly secured and has the necessary load bearing capacity. Drive slowly and carefully across the ramp.

•

When the truck is driven on to another vehicle make sure the vehicle is stable and that the brakes have been applied correctly and the wheels chocked.

•

When the truck is driven on to another vehicle make sure the vehicle is stable and that the brakes have been applied correctly and the wheels chocked.

•

When the load impairs the line of vision, always drive with the load to the rear.

•

When the load impairs the line of vision, always drive with the load to the rear.

•

DO NOT run over loose objects, uneven surfaces, or other obstructions on roadway surfaces.

•

DO NOT run over loose objects, uneven surfaces, or other obstructions on roadway surfaces.

•

DO NOT smoke while working around truck.

•

DO NOT smoke while working around truck.

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Safety regulations

General safety regulations

Handling loads

•

Drive with care when collecting or leaving a load.

•

Drive with care when collecting or leaving a load.

•

Only handle loads that are within the truck’s permitted capacity.

•

Only handle loads that are within the truck’s permitted 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.

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Safety regulations

General safety regulations

Parking the truck

•

Always park in designated areas if available.

•

Always park in designated areas if available.

•

Never leave the truck parked with the key still in the key switch.

•

Never leave the truck parked with the key still in the key switch.

•

Never park the truck on an incline.

•

Never park the truck on an incline.

•

Never park the truck so that it obstructs emergency exits.

•

Never park the truck so that it obstructs emergency exits.

•

Never park the truck so that it obstructs traffic or work.

•

Never park the truck so that it obstructs traffic or work.

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Safety regulations

General safety regulations

Handling the battery

•

Always handle the battery and its connections with care. Read and follow the instructions for changing or recharging the battery carefully. See chapter Battery.

•

Always handle the battery and its connections with care. Read and follow the instructions for changing or recharging the battery carefully. See chapter Battery.

•

Always wear protective glasses when working with the battery.

•

Always wear protective glasses when working with the battery.

•

Make sure the battery in the truck is of a weight that corresponds with the information on the truck’s data plate.

•

Make sure the battery in the truck is of a weight that corresponds with the information on the truck’s data plate.

•

Make sure the battery is secured in its compartment.

•

Make sure the battery is secured in its compartment.

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Safety regulations

General safety regulations

Maintenance and repair

All replacement parts shall be BT approved spare parts.

Modifications and additions which affect capacity and safe operation shall not be performed by the customer or user without manufacturers prior written approval. Capacity, operation, maintenance instruction plate, tags, or decals shall be changed accordingly.

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Warning and information signs

The figure shows the position and significance of the signs’ location on the truck.

1. Signal/Horn

2. Truck data plate

3. Warning decal: Truck parking brake does not automatically engage

4. Warning decal: No Step, or No Standing, or No Riding

5. List of warnings

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Warning and information signs

Warning decals

Clean or replace all safety and instruction decals that cannot be read.

When you clean decals use only a cloth, soap, and water. DO NOT use solvent, gasoline, etc.

You must replace a decal if the decal is damaged, missing, or cannot be read.

If a decal is on a part that is replaced, make sure you install a new decal on the new part. New warning decals can be obtained from your BT dealer at NO charge.

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Presentation of truck

BT’s truck program is intended for towing trailers handling goods indoors or alternatively other types of loads using other load carriers. This truck is operated in a standing position.

Refer to the truck’s data plate for this information on towing.

The trucks are equipped with a 24 volt electrical system. The travel speeds are regulated by means of a transistor controller to provide gentle control of acceleration and speed while operating.

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Presentation of truck

Application area for BT’s trucks

BT’s trucks are solely designed and manufactured to handle goods. The truck should be fitted with the appropriate accessories relevant to the application.

Prohibited applications for BT’s trucks

The trucks are designed for handling goods indoors. It is not permitted to use the trucks for other purposes including the following:

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Do not use in areas that contain gases which can cause fires or explosions

Do not use to tow other trucks

Do not use to transport/lift passengers

Do not use to drive on gravel or grass

Presentation of truck

Truck data

The table provides information regarding some technical data which is of value with daily use of the truck.

Truck type

Operating speed without load

8.0 mph [12.87 km/h]

Operating speed without load

8.0 mph [12.87 km/h]

Operating speed with classified load

6.0 mph [9.65 km/h]

Operating speed with classified load

6.0 mph [9.65 km/h]

Maximum operating gradient with load, %

Continuous noise level. dB (A)

<80

Continuous noise level. dB (A)

<80

The truck’s lifting capacity and weight can be found on the truck’s data plate.

Truck battery dimensions

Important

Use only batteries that meet the following specifications:

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Presentation of truck

Truck dimensions

The following diagrams show external dimensions for TMX trucks in its standard design.

C Area of ride platform (541 in.2 [13741.4 mm2])

30°

Area of ride platform (541 in.2 [13741.4 mm2])

30°

Battery compartment 13.3 in. [337.8 mm]

F Q

J 15°

Battery 26° roller height L M N

J 15°

Battery 26° roller height L M N

43.7 in. R [1110 mm] R

6.9 in. [175.26 mm]

34 in. 863.6 mm]

43.7 in. R [1110 mm] R

6.9 in. [175.26 mm]

34 in. 863.6 mm]

34.1 in. [866.14 mm]

6.2 - 11.7 in. [157.48 - 297.18 mm]

53.2 in. [1351.28 mm]

34.1 in. [866.14 mm]

6.2 - 11.7 in. [157.48 - 297.18 mm]

53.2 in. [1351.28 mm]

51.3 in. [1303.02 mm]

5.9 - 11.7 in. [149.86 - 297.18 mm]

9.7 in. 246.38 mm]

51.3 in. [1303.02 mm]

5.9 - 11.7 in. [149.86 - 297.18 mm]

9.7 in. 246.38 mm]

17.3 in. [439.42 mm]

6.6 - 12.1 in. [167.64 - 307.34 mm]

2.1 in. [53.34 mm]

17.3 in. [439.42 mm]

6.6 - 12.1 in. [167.64 - 307.34 mm]

2.1 in. [53.34 mm]

54.3 in. [1379.22 mm]

3.6 in. [91.44 mm]

31.8 in. [807.72 mm]

54.3 in. [1379.22 mm]

3.6 in. [91.44 mm]

31.8 in. [807.72 mm]

2.9 in. [73.66 mm]

8.9 in. [226.06 mm]

51.5 in. [1308.1 mm]

2.9 in. [73.66 mm]

8.9 in. [226.06 mm]

51.5 in. [1308.1 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.

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Presentation of truck

Presentation of main components

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Presentation of main components

1/2

Presentation of main components

1 8

I O

11 9 12

7, 8

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1/2

7, 8

Controls and instruments

Controls and Instruments

Guards and shields have been provided on unit for your protection.

WARNING DO NOT operate this equipment unless all factory installed guards and shields are properly secured in place.

Decals are also provided to warn of potential danger as well as to display special operating procedures.

WARNING Read and observe all warnings on this unit before operating it.

Control Handle

The control handle is used to provide hand brake, direction, speed, and horn on this machine.

Handle Brake Lever

Steering Control Handle

Horn Switch

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Handle Brake Lever

Steering Control Handle

Horn Switch

Directional Controls

Controls and instruments Horn

Horn

The horn sounds as long as the button is pressed.

Travel Direction Selector and Speed Control

Select the travel direction by rotating ‘R’ in the required direction. The speed is controlled variably based on the position of the lever.

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Controls and instruments

Brake Lever Controls

This truck has two brake engaging controls, 1) a hand controlled lever that is squeezed to apply brake, 2) a parking brake lever that locks in place when used.

Hand Control Lever

The proper position for parking brake lever engaged and disengaged position is shown and described below.

Engaged Position (Brake ON)

Disengaged Position (Brake OFF)

Engaged Position (Brake ON)

Disengaged Position (Brake OFF)

The parking brake lever must be placed in the engaged position when unit is not in use (parked) or hand brake lever is not squeezed.

The brake function should always be checked before using this unit.

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Controls and instruments

Braking using Plugging Function

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Controls and instruments

Emergency Disconnect Switch

1/2

Battery Disconnect Indicator/Hourmeter Dash Display

1 8

Key Switch

Dash Controls and Locations

Controls and instruments

Emergency Disconnect Switch

1/2

Battery Disconnect Indicator/Hourmeter Dash Display

1 8

Key Switch

Dash Controls and Locations

Emergency Disconnect Switch

The hourmeter can be read any time the emergency disconnect switch is pulled out.

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Controls and instruments

Emergency Disconnect Switch

1/2

Battery Disconnect Indicator/Hourmeter Dash Display

1 8

Key Switch

Dash Controls and Locations

Controls and instruments

Emergency Disconnect Switch

1/2

Battery Disconnect Indicator/Hourmeter Dash Display

1 8

Key Switch

Dash Controls and Locations

Key Switch (toggle switch)

A Key Switch is provided to prevent unauthorized use of this unit. The emergency disconnect switch must be pulled out before electrical power can flow to the control circuit.

The key switch has two (2) positions: OFF and ON.

1.OFF Position: Turning the key to OFF will stop all electrical power from going to the control circuit from battery.

2.ON Position: Turn the key to ON to check function of battery discharge indicator. The key switch must be in this position to provide power to the control circuit when unit is operated.

When the unit is left unattended for an extended period of time push the emergency disconnect switch in, disconnect the battery, and remove and secure key in a safe place.

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Controls and instruments

BDI/Hourmeter with travel interrupt

Fully-charged battery

1/2

Half-charged battery

1/2

Half-charged battery

Discharged battery

The battery indicator shows the actual charge level of the truck’s battery.

The hourmeter displays the time the drive motor is operating.

Battery Discharge Indicator (BDI)

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Controls and instruments

Hourmeter

The hourmeter displays the time the drive motor and/or the pump motor are operating.

Down

Tilt Control Lever

Adjustable Tilting Control Handle

The adjustable tilting control handle is used to adjust the height of the control handle. This function will allow more comfort and control for the operator.

To adjust the handle pull on the tilt control lever (backwards towards the operator) and lift/lower control handle to the position that is comfortable for you.

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Driving

The proper operator position for this truck is shown and described below.

Travel

Proper operation of this unit is as shown when possible. Steering the truck is easier in this direction. Always look in the direction of travel.

When reversing into a confined area, elevator, or on an incline keep both hands on control handle. Keep both hands within the handle guard and always look in the direction of travel.

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Driving

Starting the truck

Ensure the battery connector is connected to the truck.

Turn the key switch to position I. The instrument lighting comes on.

Make sure the battery indicator indicates a sufficient charge level (1/2 - 1) to operate the truck.

NOTE! Low charge level. Prolonged operation with a low battery charge level can result in damage to the battery. Do not drive without first recharging the battery. Engaged Position (Brake ON)

Disengaged Position (Brake OFF)

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NOTE! Low charge level. Prolonged operation with a low battery charge level can result in damage to the battery. Do not drive without first recharging the battery.

Squeeze the handle brake levers located on control handle. Place the parking brake lever in the disengaged position. This releases the parking brake.

Engaged Position (Brake ON)

Disengaged Position (Brake OFF)

Squeeze the handle brake levers located on control handle. Place the parking brake lever in the disengaged position. This releases the parking brake.

Driving

WARNING Risk of crushing exists if any part of the body is outside of the operator’s compartment. Always have your whole body inside the operator’s compartment. Ÿ

Move the travel direction selector/speed control in the desired direction.

WARNING Risk of crushing exists if any part of the body is outside of the operator’s compartment. Always have your whole body inside the operator’s compartment. Ÿ

Move the travel direction selector/speed control in the desired direction.

WARNING Function failure. Safety can be jeopardized. Always complete the daily operator’s checks before starting the day’s work.

- That the horn functions correctly.

- That the steering functions correctly.

- That the brakes function correctly.

- That the hydraulic functions are operational.

Start gently by accelerating slowly until you reach the desired speed. WARNING Dangerous driving. Accidents can occur. Always drive with care, good judgment, and responsibility.

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Start gently by accelerating slowly until you reach the desired speed. WARNING Dangerous driving. Accidents can occur. Always drive with care, good judgment, and responsibility.

Driving

Braking

Braking Hand Brake Lever

Hand Brake Lever

Parking Brake Lever

Key Switch

Location of Hand Brake Lever, Parking Brake Lever, and Key Switch

By squeezing the hand brake lever you will apply the travel brake. When you release the hand brake lever it automatically returns to the brake OFF position.

When truck is left unattended, or hand brake lever is NOT squeezed, the parking brake lever must be locked in the engaged position (brake ON).

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Driving handle will allow the automatically applied.

parking

Driving brake

become

handle will allow the automatically applied.

parking

brake

become

THE CONTROL HANDLE MUST NOT BE PLACED IN THE BRAKE POSITION DURING THE PLUG BRAKING OPERATION.

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Driving

Steering

Steer by means of the tiller arm.

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WARNING Risk of slipping. You can lose control of the truck if your hands or shoes are oily. Always dry your hands and shoes before driving.

Driving

Parking the truck

Hand Brake Lever

Parking Brake Lever

Key Switch

Location of Hand Brake Lever, Parking Brake Lever, and Key Switch

Rotate directional control to the NEUTRAL position.

Squeeze the handle brake lever and stop movement completely.

Place the parking brake lever in the engaged position.

Lower the forks fully to the floor.

Turn the key switch to the O position and remove the key.

Push the emergency disconnect button in to stop the hourmeter from running.

WARNING Unauthorized use. Accidents can happen. Always remove the key switch when the truck is left unattended.

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WARNING Unauthorized use. Accidents can happen. Always remove the key switch when the truck is left unattended.

Transporting loads

General

The weight of the load should be within the truck’s permitted lifting capacity. See the truck’s data plate.

WARNING Risk of overturning. The lifting capacity is reduced if additional equipment is attached to the truck. Always check the truck’s overall lifting capacity.

•

Only handle loads that are stable and arranged safely. Take particular care when handling high and long loads.

•

Only handle loads that are stable and arranged safely. Take particular care when handling high and long loads.

Make sure that the truck is equipped with a suitable load support when handling high loads.

Always drive with the forks fully lowered except when collecting or leaving a load.

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WARNING Lost stability. High loads can fall when cornering at high speed or cause tipover. Drive slowly and carefully when cornering and travel with loads in lowered position.

WARNING Protruding loads. The load can collide with personnel, fixed or moving objects. A truck with a protruding load requires more room when cornering.

Transporting loads

NOTE! Increased machine width. The load can collide with fixed objects. A truck with wide loads requires a greater operating area.

Drive the truck with the load trailing when the load impairs the line of vision.

If necessary, when the operator’s vision is impaired, ask someone to direct operations so that transportation can take place without the risk of causing personal injury or material damage.

DO NOT use the truck on grades, ramps, or inclines.

WARNING Risk of overturning. A loaded truck can overturn when attempting to turn on an incline. Never turn a loaded truck on an incline.

WARNING Increased braking distance. The braking distance is increased when traveling downhill. Drive at a reduced speed using the truck’s motor brake.

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Transporting loads

WARNING Risk of overloading the elevator. An overloaded elevator can fall out of control down the elevator shaft. Always check the capacity of the elevator before driving in with the truck. •

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WARNING Risk of overloading the elevator. An overloaded elevator can fall out of control down the elevator shaft. Always check the capacity of the elevator before driving in with the truck. •

Transporting loads

Collecting a load

Slow down and position the truck carefully in front of the load.

Drive the truck rearward so that the hitch is positioned and can be connected to drawbar.

Make sure connection is correct.

Drive carefully away. Start slowly and then increase the speed.

Travel

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Travel

Transporting loads

Leaving a load

•

Slow down and position truck carefully where load is to be left.

•

Slow down and position truck carefully where load is to be left.

•

Reverse truck to release hitch and disconnect hitch.

•

Reverse truck to release hitch and disconnect hitch.

•

Drive carefully away from the load. Start slowly and then increase the speed.

•

Drive carefully away from the load. Start slowly and then increase the speed.

Travel

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Travel

Battery

Type of battery

•

Changing the battery

•

When changing the battery proceed as follows:

•

Park truck at battery removal station.

•

Park truck at battery removal station.

•

Turn OFF key and remove.

•

Turn OFF key and remove.

•

Push the emergency disconnect button to the OFF position to stop hourmeter from running.

•

Push the emergency disconnect button to the OFF position to stop hourmeter from running.

•

Disconnect the battery connector from the battery.

•

Disconnect the battery connector from the battery.

•

Remove battery stops.

•

Remove battery stops.

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Battery

•

Slide out the discharged/old battery, then slide in the new battery.

•

Slide out the discharged/old battery, then slide in the new battery.

•

Connect battery and truck connectors.

•

Connect battery and truck connectors.

•

Connect the battery connector and truck connector.

•

Connect the battery connector and truck connector.

WARNING Risk of short-circuiting. The cables can be damaged and cause a short-circuit. Ensure the battery cables are not crushed.

•

Push the emergency disconnect button to the ON position.

•

Push the emergency disconnect button to the ON position.

•

Install battery stops.

•

Install battery stops.

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WARNING Falling battery. If the truck should tip over the battery can fall out if the battery stops have not been installed. Make sure the battery stops have been installed.

WARNING Falling battery. When charging the battery, it can be dropped. Always lift battery using an approved lifting device, and use a battery yoke intended for the battery.

Battery

Charging the battery

General prohibition

When recharging the battery it is absolutely forbidden to smoke or use an open flame.

Use an automatic charger intended for recharging traction batteries.

The charger shall have a minimum charging current of:

Battery (Ah)

Charger (A)

Battery (Ah)

Charger (A)

300-480

50-70

300-480

50-70

480-730

80-110

480-730

80-110

730-900

130-150

730-900

130-150

ALWAYS WEAR PROTECTIVE GLASSES AND PROTECTIVE GLOVES WHEN CHECKING THE BATTERY.

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Battery

Pre-charging

•

Park the truck in the assigned charging area.

•

Park the truck in the assigned charging area.

•

Ensure nothing prevents ventilation above the battery.

•

Ensure nothing prevents ventilation above the battery.

•

Turn key switch to the OFF position.

•

Turn key switch to the OFF position.

•

Remove the battery connector from the truck’s connector.

•

Remove the battery connector from the truck’s connector.

•

Make sure the battery charger is switched OFF.

•

Make sure the battery charger is switched OFF.

•

Connect the battery connector to charger connector.

•

Connect the battery connector to charger connector.

•

Never connect charger connector to truck connector.

•

Never connect charger connector to truck connector.

•

Switch ON the battery charger.

•

Switch ON the battery charger.

During charging

•

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After approximately ten minutes make sure that the ammeter indicates a normal reading and that the control lamp is ON. 50

Battery

After charging

•

Make sure that the ammeter indicates an insignificant or no reading and that maintenance charge lamp is ON, if equipped.

•

Make sure that the ammeter indicates an insignificant or no reading and that maintenance charge lamp is ON, if equipped.

•

Switch OFF the charger.

•

Switch OFF the charger.

•

Disconnect the battery connector from charger connector.

•

Disconnect the battery connector from charger connector.

CAUTION

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Risk of short circuiting. The terminals can otherwise be damaged inside and result in a subsequent short circuit. Do not pull the cables to disconnect from the charger.

CAUTION

Risk of short circuiting. The terminals can otherwise be damaged inside and result in a subsequent short circuit. Do not pull the cables to disconnect from the charger.

Battery

Battery maintenance

Carry out battery maintenance after recharging.

ALWAYS WEAR PROTECTIVE GLASSES AND PROTECTIVE GLOVES WHEN CHECKING THE BATTERY.

Each week:

•

Remove all cell caps. NOTE! This does not apply to batteries with level caps or central filling.

•

Check the fluid level in the cells and note any cells that consume more than a normal amount of fluid.

•

Check the fluid level in the cells and note any cells that consume more than a normal amount of fluid.

•

Fill using distilled water. The fluid level should be 1/4 in. (10-15 mm) above the cell plates.

•

Fill using distilled water. The fluid level should be 1/4 in. (10-15 mm) above the cell plates.

•

Refit all of the cell caps.

•

Refit all of the cell caps.

•

Rinse off and dry the battery.

•

Rinse off and dry the battery.

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Battery

Each month:

•

Measure the temperature in one of the center cells immediately after charging. The temperature should not exceed 122°F [50°C.]

•

Measure the temperature in one of the center cells immediately after charging. The temperature should not exceed 122°F [50°C.]

•

Measure the density of the battery fluid using an acid tester. Hold the acid tester absolutely vertical and extract sufficient fluid so that the hydrometer float moves freely.

•

Measure the density of the battery fluid using an acid tester. Hold the acid tester absolutely vertical and extract sufficient fluid so that the hydrometer float moves freely.

•

Adjust specific gravity with temperatures based on the chart below.

•

Adjust specific gravity with temperatures based on the chart below.

Temperature

Gravity

Temperature

Gravity

77°F [25.2°C]

1.280

77°F [25.2°C]

1.280

WARNING Battery manufactories maintenance and charging procedures must be followed. Battery acid is very corrosive and must be immediately cleaned up after spillage.

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WARNING Battery manufactories maintenance and charging procedures must be followed. Battery acid is very corrosive and must be immediately cleaned up after spillage.

Daily service/safety checks

•

The operator is responsible for the daily service and care of the truck.

•

The operator is responsible for the daily service and care of the truck.

•

Carry out the daily service at the start of the day or shift, before the truck is used. The daily service is a simple safety and function control as set in the check list below.

•

Carry out the daily service at the start of the day or shift, before the truck is used. The daily service is a simple safety and function control as set in the check list below.

•

You need no tools to carry out the service checks.

•

You need no tools to carry out the service checks.

•

If you fail to carry out the daily service the safety and reliability of the truck can be affected.

•

If you fail to carry out the daily service the safety and reliability of the truck can be affected.

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Daily service/safety checks

Daily service/safety checks 0

1/2

Daily service/safety checks 13

1 8

7 I

1 2

14 10

9 11

5 3

WARNING DO NOT continue to operate the truck when it is not functioning properly. Item #

1 2

1 8

12 8

1/2

Check points

Action

Battery

Check acid level, charge, and condition (see battery maintenance)

Battery cables and connections

3 4

WARNING DO NOT continue to operate the truck when it is not functioning properly. Item #

Check points

Action

Battery

Check acid level, charge, and condition (see battery maintenance)

Check for breakage, cutting, or damage

Battery cables and connections

Check for breakage, cutting, or damage

Chassis

Check for damage, remove dirt and debris

Chassis

Check for damage, remove dirt and debris

Covers / guards

Check for damage, ensure placement

Covers / guards

Check for damage, ensure placement

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Daily service/safety checks Item #

Check points

Action

Drive unit

Inspect abnormal noises and leakage

Wheels

Daily service/safety checks Item #

Check points

Action

Drive unit

Inspect abnormal noises and leakage

Check for damage, remove oil, metal chips, and debris

Wheels

Check for damage, remove oil, metal chips, and debris

Hand brake levers

Check its function

Hand brake levers

Check its function

Direction / speed control

Check its function

Direction / speed control

Check its function

Control console

Check its locking mechanism

Control console

Check its locking mechanism

Control functions

Check its function

Control functions

Check its function

Parking brake lever

Check its function

Parking brake lever

Check its function

Horn

Check its function

Horn

Check its function

Running time

Inform your supervisor if your truck is ready for a schedule maintenance check. See “Maintenance” chapter.

Running time

Inform your supervisor if your truck is ready for a schedule maintenance check. See “Maintenance” chapter.

Emergency stop switch

Check its function

Emergency stop switch

Check its function

Key switch (toggle switch)

Check its function

Key switch (toggle switch)

Check its function

If any of the functions fail to operate properly, inform your supervisor or maintenance personnel to have the truck repaired.

Special equipment

Return

Maintenance

General information

•

Only use BT approved spare parts when service and repair work are carried out.

•

Only use BT approved spare parts when service and repair work are carried out.

•

BT recommends that you contact your BT representative to set up a service and maintenance agreement to ensure your truck’s operating economy and safety.

•

BT recommends that you contact your BT representative to set up a service and maintenance agreement to ensure your truck’s operating economy and safety.

Safety regulations with maintenance work

•

Only personnel that have been trained in the service and repair of this type of truck are authorized to carry out service and repair work.

•

Only personnel that have been trained in the service and repair of this type of truck are authorized to carry out service and repair work.

•

Do not carry out any maintenance work on the truck unless you have the correct training and knowledge to do so.

•

Do not carry out any maintenance work on the truck unless you have the correct training and knowledge to do so.

•

Keep the area where you carry out service clean. Oil or water makes the floor slippery.

•

Keep the area where you carry out service clean. Oil or water makes the floor slippery.

•

Never wear loose objects or jewelry when working on the truck.

•

Never wear loose objects or jewelry when working on the truck.

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Maintenance

•

Always switch OFF the truck’s power supply before opening the covers on the drive unit or electrical systems.

•

Always switch OFF the truck’s power supply before opening the covers on the drive unit or electrical systems.

•

Always disconnect the battery by pulling out the battery connector when carrying out maintenance work on the truck unless otherwise stated in this publication or the Service Manual.

•

Always disconnect the battery by pulling out the battery connector when carrying out maintenance work on the truck unless otherwise stated in this publication or the Service Manual.

•

Relieve the system pressure slowly before starting work on the truck’s hydraulic systems.

•

Relieve the system pressure slowly before starting work on the truck’s hydraulic systems.

•

Use paper or a rigid sheet of cardboard when checking for oil leakage. Never use your hand.

•

Use paper or a rigid sheet of cardboard when checking for oil leakage. Never use your hand.

•

Bear in mind that the oil in the transmission or the hydraulic system can be hot.

•

Bear in mind that the oil in the transmission or the hydraulic system can be hot.

WARNING Risk of burns. Hot transmission and hydraulic oil. Let the truck cool before changing the oil.

•

Return

Only fill the hydraulic system with new clean oil. Oil should meet BT cleanliness specification 12-00-002. Contact your BT representative for assistance or more information. 58

WARNING Risk of burns. Hot transmission and hydraulic oil. Let the truck cool before changing the oil.

•

Only fill the hydraulic system with new clean oil. Oil should meet BT cleanliness specification 12-00-002. Contact your BT representative for assistance or more information. 58

Maintenance

WARNING The hydraulic system can be damaged. If oil is contaminated hydraulic components can be damaged. Always use new and clean oil in the hydraulic system.

•

Store and dispose of changed oil in accordance with local regulations.

•

Store and dispose of changed oil in accordance with local regulations.

•

Do not dump solvents, which are used for cleaning/ washing, into drains that are not intended for this purpose. Follow the local regulations that apply for disposal.

•

Do not dump solvents, which are used for cleaning/ washing, into drains that are not intended for this purpose. Follow the local regulations that apply for disposal.

•

When working underneath the truck support the truck on trestle-blocks.

•

When working underneath the truck support the truck on trestle-blocks.

WARNING Risk of crushing. A badly supported truck can fall. Never work under a truck that is not supported on trestle-blocks and secured by a lifting device.

Return

WARNING Risk of crushing. A badly supported truck can fall. Never work under a truck that is not supported on trestle-blocks and secured by a lifting device.

Maintenance

Maintenance work that can be carried out by you

The Daily service/Safety checks as set out in the check list.

Maintenance points with intervals 1 day, 1 week, and 1 month as set out in the Maintenance chart may be carried out by the driver without more knowledge than that provided by the Operator’s Manual.

Other maintenance points as set out in the Maintenance chart may only be carried out by personnel who have completed maintenance training for this type of truck.

Maintenance work that may be carried out by trained maintenance personnel

All maintenance points as set out in the Maintenance chart.

If you are uncertain regarding working procedures consult the Service Manual for the truck.

Other service and repair work

•

Return

In addition to the maintenance points in the Maintenance chart all service and repair work should be carried out by personnel with special training for this type of truck.

Maintenance

Cleaning and washing

General

Cleaning and washing the truck is important to ensure the truck will operate safely and reliably.

•

Carry out general cleaning and washing weekly.

External cleaning

•

Remove debris, etc. from the wheels daily.

•

Remove debris, etc. from the wheels daily.

•

Use a degreasing agent diluted to a suitable concentration.

•

Use a degreasing agent diluted to a suitable concentration.

•

Rinse off loose grime using warm water.

•

Rinse off loose grime using warm water.

NOTE! Mechanical components can be damaged. After washing, the truck should be lubricated as set out in the chapter Maintenance and Lubrication chart.

Cleaning the motor compartment

•

Cover the electric motors, electrical compartments, connectors, and valves before washing.

Return

Cover the electric motors, electrical compartments, connectors, and valves before washing. 61

Maintenance •

Clean carefully using the minimum of water and detergent. Never pressure wash or steam clean in the compartments.

Maintenance •

Clean carefully using the minimum of water and detergent. Never pressure wash or steam clean in the compartments.

NOTE! Risk of short-circuiting. The electrical system can be damaged. Electrical components must not be cleaned with a high pressure washing unit.

•

Clean the motor compartment using a degreasing agent diluted to a suitable concentration.

•

Clean the motor compartment using a degreasing agent diluted to a suitable concentration.

•

Rinse off loose grime using warm water.

•

Rinse off loose grime using warm water.

Electrical components

•

Clean the electrical panels, electronic boards, contacts, connector, solenoid valves, etc. using a damp cloth and a cleaning agent.

•

Clean the electrical panels, electronic boards, contacts, connector, solenoid valves, etc. using a damp cloth and a cleaning agent.

•

Do not spray or pressure wash in the compartment.

•

Do not spray or pressure wash in the compartment.

NOTE! Risk of short-circuiting. Electrical components can be damaged. Do not break the warranty seal on the electronic board.

Return

NOTE! Risk of short-circuiting. Electrical components can be damaged. Do not break the warranty seal on the electronic board.

Maintenance

Maintenance chart

PM Interval:

A=5 Hours or 1 Day

E=500 Hours or 6 Months

A=5 Hours or 1 Day

E=500 Hours or 6 Months

B=20 Hours or 1 Week

F=1000 Hours or 12 Months

B=20 Hours or 1 Week

F=1000 Hours or 12 Months

C=80 Hours or 1 Month

G=3000 Hours or 36 Months

C=80 Hours or 1 Month

G=3000 Hours or 36 Months

D=250 Hours or 3 Months

No.

Action

1.0

Chassis

No.

Action

1.0

Chassis

1.1

Check that the truck’s data plate is legible

1.1

Check that the truck’s data plate is legible

1.2

Check the cover screws

1.2

Check the cover screws

1.3

Check door lock

1.3

Check door lock

1.4

Check wear on battery stop

1.4

Check wear on battery stop

1.5

Check for damage and crack formation

1.5

Check for damage and crack formation

2.0

Motors

2.0

Motors

2.1

Check for loose connections

2.1

Check for loose connections

2.2

Clean motor

2.2

Clean motor

2.3

Check mounting bolts

2.3

Check mounting bolts

2.4

Check for abnormal bearing noise

2.4

Check for abnormal bearing noise

2.5

Check brush wear

2.5

Check brush wear

3.0

Drive unit

3.0

Drive unit

3.1

Check for leakage

3.1

Check for leakage

3.2

Check oil level

3.2

Check oil level

3.3

Check for noises

3.3

Check for noises

3.4

Check the mounting on support

3.4

Check the mounting on support

4.0

Wheels

4.0

Wheels

4.1

Remove string & debris

4.1

Remove string & debris

4.2

Check all wheels for wear

4.2

Check all wheels for wear

4.3

Check that all wheels rotate and axles are fitted correctly

4.3

Check that all wheels rotate and axles are fitted correctly

4.4

Check all wheels for loose screws

4.4

Check all wheels for loose screws

4.5

Grease load wheel bearings

4.5

Grease load wheel bearings

Return

Maintenance No.

Action

No.

Action

4.6

Dismantle and lubricate all wheel bearings.

4.6

Dismantle and lubricate all wheel bearings.

5.0

Brake

5.0

Brake

5.1

Clean

5.1

Clean

5.2

Check shoes and discs for wear

5.2

Check shoes and discs for wear

5.3

Check correct clearance brake

5.3

Check correct clearance brake

5.4

Check brake operation

5.4

Check brake operation

6.0

Electrical panel

6.0

Electrical panel

6.1

Clean and check the mounting

6.1

Clean and check the mounting

6.2

Tighten cable connections

6.2

Tighten cable connections

6.3

Check contactor tips

6.3

Check contactor tips

6.4

Check the contactor tips for free movements

6.4

Check the contactor tips for free movements

6.5

Check all cable insulation for damage

6.5

Check all cable insulation for damage

7.0

Electronic card

7.0

Electronic card

7.1

Check for connections in harness connectors

7.1

Check for connections in harness connectors

8.0

Electronic control system

8.0

Electronic control system

8.1

Check key switch

8.1

Check key switch

8.2

Check brake switch

8.2

Check brake switch

8.3

Check control wiring harness for proper routing

8.3

Check control wiring harness for proper routing

9.0

Battery

9.0

Battery

9.1

Check electrolyte level, 0.5-0.65 in. (10-15mm above cell plate)

9.1

Check electrolyte level, 0.5-0.65 in. (10-15mm above cell plate)

9.2

Check the connections on battery, truck, and charger

9.2

Check the connections on battery, truck, and charger

9.3

Check all cells and pole guards

9.3

Check all cells and pole guards

9.4

Check the fluid density and temperature

9.4

Check the fluid density and temperature

9.5

Check power cables are not cut or frayed

9.5

Check power cables are not cut or frayed

10.0

Controls

10.1

Check handle mounting

Return

Maintenance B

10.0

Controls

10.1

Check handle mounting

G X

Maintenance No.

Action

10.2

Check the handle brake lever switches

10.3

Maintenance B

No.

Action

10.2

Check the handle brake lever switches

Check travel direction/speed control

10.3

Check travel direction/speed control

10.4

Check horn button function

10.4

Check horn button function

10.5

Check the handle control switches

10.5

Check the handle control switches

11.0

Gauge

11.1

Check dash display

12.0

Brake Levers

12.1

Check parking brake lever

12.1

Check parking brake lever

12.2

Check handle brake levers

12.2

Check handle brake levers

13.0

Emergency stop switch

13.0

Emergency stop switch

13.1

Check the emergency stop switch

13.1

Check the emergency stop switch

1/2

11.0

Gauge

11.1

Check dash display

12.0

Brake Levers

10 13 10

9 11

3 1

13 10

1 8

I O

Return

1/2

1 8

6, 7, 8

Maintenance chart

Maintenance

Lubrication chart

Lubrication chart Interval/Running hours

Pos No.

Service point

Wheel bearings

Travel brake

Drive gear

Hinges

Steering bearings

Gear ring

500h

L=Lubrication

Return

Service point

Wheel bearings

Travel brake

Drive gear

Hinges

Steering bearings

Gear ring

1000h

3000h L

C=Check

Interval/Running hours

Pos No.

Lubricant

O=Oil change

Lubricant 500h

L=Lubrication

C=Check

1000h

3000h L

O=Oil change

Maintenance

Approved Oils and Grease

Specification Pos.

Lubricant

Grease

B C

Above 5°F [-15°C]

Application

SAE 40

Specification Pos.

Lubricant

Bearings and bushings

Grease

Below -10°F[-23°C]

Tex. Ref. C & Tex. Ref. C & Tex. Ref. C & C #880 C #880 C #880

Transmission SAE 80W/90 oil Motor oil

Below 5°F [-15°C]

area

SAE 75W

Gears

SAE5W-20

Hinges

Oil should meet BT cleanliness specification 12-00-002. Contact your BT representative for assistance or for more information.

Above 5°F [-15°C]

SAE 40

area Bearings and bushings

SAE 75W

Gears

SAE5W-20

Hinges

Oil should meet BT cleanliness specification 12-00-002. Contact your BT representative for assistance or for more information.

B A

Return

Application Below -10°F[-23°C]

Tex. Ref. C & Tex. Ref. C & Tex. Ref. C & C #880 C #880 C #880

Transmission SAE 80W/90 oil Motor oil

Below 5°F [-15°C]

Lubrication chart location points

Transporting and storing the truck

The truck’s dimensions and weight as standard

NOTE! The truck’s dimensions and weight can vary with different accessories.

The TMX truck’s dimensions and weight

Height

60 in. [1524 mm]

Height

60 in. [1524 mm]

Width

34.1 in. [866 mm]

Width

34.1 in. [866 mm]

Length

53.2 in. [1352 mm]

Length

53.2 in. [1352 mm]

Minimum battery weight

900 lb [408.6 kg]

Minimum battery weight

900 lb [408.6 kg]

Service weight without battery

1350 lb [612.9 kg]

Service weight without battery

1350 lb [612.9 kg]

Lifting the truck

•

Return

Lift the truck from the marked lifting points when lifting using a lifting device.

WARNING Risk of overturning. The truck can overturn if lifted from the wrong lifting points. Always lift the truck from the marked lifting points.

WARNING Risk of overturning. The truck can overturn if lifted incorrectly. Always lift the truck secured to, and with the center of gravity between, the lifting truck’s forks.

Transporting and storing the truck

Towing and transporting a disabled truck

WARNING DO NOT tow a disabled truck.

It is not recommended to tow a disabled lift truck.

Return

Transporting and storing the truck

Storing the truck

Take the following action if the truck is not used for one week or more:

Battery

•

Recharge the battery fully and carry out usual battery maintenance.

•

Recharge the battery fully and carry out usual battery maintenance.

•

Maintenance charge the battery every 3rd month and check the fluid level.

•

Maintenance charge the battery every 3rd month and check the fluid level.

Hydraulic system

•

Change the oil in the hydraulic system when stored for periods longer then 1 year. See the oil specification in the section Maintenance and lubrication chart.

Drive unit

•

Block up the truck’s drive section to take the load off the drive wheel and load wheels when storing for periods longer than one week.

Starting after a period of disuse

•

Before the truck is put into operation after a period of disuse it should undergo a function and safety check as stated in the section Daily service/safety checks.

•

Before the truck is put into operation after a period of disuse it should undergo a function and safety check as stated in the section Daily service/safety checks.

•

When stored for a period greater 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

Recyling/Discarding

Recycling/Discarding

Batteries are hazardous to the environment and should be returned to the manufacturer for recycling.

Discarding the battery

Scrapping the truck

The truck consists of parts that contain recyclable metals and plastics. Below is a list of those materials used in the truck’s sub-systems.

Chassis

Steel

Chassis

Steel

Drive unit

Steel and cast material

Drive unit

Steel and cast material

Bushings

Polyamide

Bushings

Polyamide

Finish

Epoxy-polyester

Finish

Epoxy-polyester

Wheels

Polyurethane

Wheels

Polyurethane

Return

Recyling/Discarding

Electrical system

Return

Recyling/Discarding

Electrical system

Cables

Copper cores with PVC sheaths

Cables

Copper cores with PVC sheaths

Electronic board

Reinforced fiberglass circuit board laminate

Electronic board

Reinforced fiberglass circuit board laminate

Motors

Steel and copper

Motors

Steel and copper

BT Prime-Mover, Inc., 3305 N. Highway 38 Muscatine, Iowa 52761-8800 U.S.A Tel (319) 262-7700 • Fax (319) 262-7600 Return

BT Prime-Mover, Inc., 3305 N. Highway 38 Muscatine, Iowa 52761-8800 U.S.A Tel (319) 262-7700 • Fax (319) 262-7600