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HMX/RMX BT Prime-Mover

Operator’s Manuals 302063-000 1994_February 302063-001 1994_July 302063-002 1995_May 302063-002 1997_April 302063-002 1997_October 302063-002 1998_June 302063-002 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

051001

OPERATOR'S MANUAL

Manual Number 9402 Manual Part Number 302063-000 RMX/HMX ELECTRIC LOW LIFT PALLET 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 FEBRUARY 1994

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ISSUED FEBRUARY 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

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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 24-27 27 28 29-30 31 32 33

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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

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 periodic maintenance and lubrication must be followed.

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

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PRELIMINARY SERVICE

Examine your BT Prime-Mover 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.

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 and hydraulic 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.

Travel with forks trailling when possible. Steering the truck is easier with the forks trailling. Walk ahead of the truck and lead it from either side of the control handle, operating the speed/direction control with one hand. Always look in the direction of travel.

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

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OPERATING PRACTICES

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

Read this manual completely and make sure you understand the controls. Make sure you understand, for example, the characteristics of speed, stability, brakes, and steering of this unit. If you have any questions, contact your local BT 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 load-engaging means shall be fully lowered, controls neutralized and brake set to prevent movement.

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OPERATING PRACTICES

WHEN A POWERED INDUSTRIAL TRUCK IS TO BE LEFT UNATTENDED

• Stop truck in a clear, authorized area.

• Lower load-engaging means to the floor.

• Place directional controls in neutral.

• Apply the brake.

• Turn key switch to OFF and disconnect battery connectors.

• Block wheels if truck is on a slight incline.

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

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 obstructed. If the load being carried obstructs view, the operator shall travel with the load trailing.

• 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 B56.1 for requirements.

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

• Carry your load low so you have maximum stability while still maintaining ground clearance.

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

• 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.

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OPERATING PRACTICES

• DO NOT permit riders on unit.

• 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.

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

• 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 Devices • Battery • Lift Systems including forks, and limit switches. • Brake • Steering Mechanism

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.

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DATA PLATE AND DECALS

Know the rated capacity on the data plate and understand areas 1 through 10 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

This data plate is located on the left side of dash panel. 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

The OPERATING WARNINGS decal is located directly in front of the operator.This decal describes basic warnings for safe operation of this unit. Carefully read the decal and make sure you understand the warning instructions.

The OPERATING WARNINGS decal is located directly in front of the operator. 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

COAST FEATURE WARNING

The HMX truck has a COAST FEATURE WARNING decal. Which is located on the base of the steering control handle. This decal describes actions needed to use the steering control handle for braking. 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 also provided to warn of potential danger as well as to display special operating procedures.

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

THE CONTROL HANDLE

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

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CONTROLS AND EQUIPMENT

RAISE SWITCH

CONTROLS AND EQUIPMENT

RAISE SWITCH

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

LOWER SWITCH

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

HORN SWITCH

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

REVERSER SWITCH

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

DIRECTION AND SPEED

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

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CONTROLS AND EQUIPMENT

BRAKE CONTROL

The brakes are applied when steering control handle is in the fully raised or fully lowered position. Moving the steering control handle to the middle of its travel releases brake and closes a switch in control circuit that allows operation of unit. The brake and brake interlock switch should always be checked prior to any operation on unit.

When the steering control handle is moved to "BRAKE" position, all powered movement is stopped. To stop all movement, gradually and deliberately move the steering control handle to the "BRAKE" (fully raised or fully lowered) position.

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

CONTROLS AND EQUIPMENT

BATTERY DISCHARGE INDICTOR/HOURMETER DASH DISPLAY

HOURMETER (optional)

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

BATTERY DISCHARGE INDICATOR/HOURMETER (optional)

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

BDI/HOURMETER WITH LIFT INTERRUPT (optional)

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

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CONTROLS AND EQUIPMENT

RIDER HANDRAIL

HANDRAIL HIGH SPEED CONTROL SWITCH

The high speed control switch bar is used with the rider control. The switch is located on handrail over the battery compartment. The switch is physically located third from the top of handrail.

HORN SWITCH

HANDRAIL HIGH SPEED CONTROL SWITCH

The high speed control switch bar is used with the rider control. The switch is located on handrail over the battery compartment. The switch is physically located third from the top of handrail.

HORN SWITCH

The horn bar is activated by pushing down on the horn located on handrail over the battery compartment. The switch is physically located at the last position on handrail.

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CONTROLS AND EQUIPMENT

RIDER HANDRAIL

LOWER SWITCH

Lowering of forks is controlled by pushing down on either the switch on steering control handle or the switch on handrail. The forks will continue to lower as long as switch is depressed or until the lowering stops are reached. Releasing switch will automatically stop the lowering.

WITH THE RIDER CONTROLS, the switch is located on handrail over the battery compartment. The switch is physically located first from the top of handrail.

RAISE SWITCH

Raising of the forks is controlled by pushing down on either the switch on steering control handle or the switch on handrail. The forks will continue to raise as long as the switch is depressed or until the lifting stops are reached. Releasing switch will automatically stop the raising.

WITH THE RIDER CONTROLS, the switch is located on handrail over the battery compartment. The switch is physically located second from the top of handrail.

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CONTROLS AND EQUIPMENT

COAST CONTROL (HMX only)

The coast position is used to operate truck when operator is walking along side, in this position the automatic braking can be neutralized. Operator must flip coast control to the engaged position, in this position the brakes are released. When coast control is used the brakes are applied when steering control handle is pushed down or up all the way. The coast control is physically located at the base of steering control handle.

Coast control MUST be re-flipped to allow the steering control handle to raise fully for automatic braking.

DASH DISPLAY

The dash display is a five segment light emitting diode (LED) display that displays the status codes, hourmeter readings, battery discharge indication, and maintenance increments from the controller. Upon turning on the key switch, dash display will light and check functions. When hourmeter LED is lit the display is hourmeter reading. When battery LED is lit the display is percent of battery discharge. The battery condition is displayed anytime unit is in the operating mode. At each 200 hour increment, the controller's internal clock will trip. Nothing will happen until the next time the handle returns to the "UP" position. At that time, the maintenance light (grease gun) will flash (2 times on & off per second) for 15 seconds also the character display will flash "200". These displays will flash until service maintenance is done. When status code (wrench) LED is lit display is a status code for failure with unit. The dash display is physically located on the dash next to key switch and emergency disconnect button.

The dash display is a five segment light emitting diode (LED) displays that display the status codes, hourmeter readings, battery discharge indication, and maintenance increments from the controller. Upon turning on the key switch, dash display will light and check functions. When hourmeter LED is lit the display is hourmeter reading. When battery LED is lit the display is percent of battery discharge. The battery condition is displayed anytime unit is in the operating mode. At each 200 hour increment, the controller's internal clock will trip. Nothing will happen until the next time the handle returns to the "UP" position. At that time, the maintenance light (grease gun) will flash (2 times on & off per second) for 15 seconds also the character display will flash "200". These displays will flash until service maintenance is done. When status code (wrench) LED is lit display is a status code for failure with unit. The dash display is physically located on the dash next to key switch and emergency disconnect button.

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CONTROLS AND EQUIPMENT

COAST CONTROL (HMX only)

Coast control MUST be disengaged to allow the steering control handle to raise fully for automatic braking.

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CONTROLS AND EQUIPMENT

DASH DISPLAY

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

Status Code -01 Indicates that brake switch is not closed. Make sure handle is not in the brake applied position.

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

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

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

Status Code -05 Indicates brake switch is not closed. Make sure brake switch is closed.

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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 hydraulic system. Look for leakage around hoses, fittings, and pump.

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

• Check condition of load backrest extension (if equipped). Be sure it is correctly positioned and secured.

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BEFORE OPERATION INSPECTION

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

• Check the operation of the BDI/hourmeter (if equipped).

• 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.

• Put your hands on the steering control handle and pull down (not all the way.) 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 (away from you) 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 control handle MUST automatically return to the NEUTRAL position. When released. Position and raise control handle fully up or fully down to stop unit using the brakes.

• FORWARD TRAVEL: Put a firm grip on the directional control handle and rotate forward (towards you) 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 control handle MUST automatically return to the NEUTRAL position. When released. Position and raise control handle fully up or fully down to stop unit using 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.

• 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.

• To RAISE forks, push down on the raise control bar with your thumb or fingers. The forks will continue to raise as long as the bar is depressed or until the lifting stops are reached. Releasing the bar will automatically stop the raising.

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

• To LOWER forks, push down on the lower control bar with your thumb or fingers. The forks will continue to lower as long as the bar is depressed or until the lowering stops are reached. Releasing the bar will automatically stop the lowering.

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

• Both lifting and lowering of forks should be a smooth movement.

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

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

4. Make sure that all motion has stopped .

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

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PARKING

1. Park units in designated parking areas only.

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

2. Lower forks fully.

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

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

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BATTERY RETAINMENT/CARE

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

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

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

This unit uses a 12/24 volt wet cell Battery.

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

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

IMPORTANT

Use only batteries that meet the following specifications:

VOLTAGE Minimum Battery Weight Maximum Battery Weight

12/24 (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

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

Oil capacity in Hydraulic Reservoir Fluid

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

1 Quart SAE 10W40 SG (cold storage) Dexron II

Grease Type

NOTE:

1 Quart SAE 10W40 SG (cold storage) Dexron II 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 hydraulic fluid level. • 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. • Drain, flush, and refill hydraulic reservoir.

32 Return

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.

Return

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

PROUDLY Made in AMERICA Return

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

PROUDLY Made in AMERICA

OPERATOR'S MANUAL

Manual Part Number 302063-001 RMX/HMX ELECTRIC LOW LIFT PALLET TRUCK

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 JULY 1994

Return

ISSUED JULY 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 you read the instructions and safety regulations before you attempt to assemble or use this unit.

BEFORE OPERATING THE UNIT:

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

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

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

LEARN AND PRACTICE USE OF CONTROLS BEFORE OPERATING.

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

1 Return

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.

Return

TABLE OF CONTENTS

NAME

PAGE #

NAME

PAGE #

1 2 3 4 5 5 6 6 7 8-13 14-16 17-23 24-27 28 29 30-31 32 33 34

3 Return

DRIVE SAFELY

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

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

STAY ALERT!

Return

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.

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 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 and hydraulic 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

6 Return

OPERATOR

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

Travel with forks trailing when possible. Steering the truck is easier with the forks trailing. Walk ahead of the truck and lead it from either side of the control handle, operating the speed/direction control with one hand. Always look in the direction of travel.

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

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.

• 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 load-engaging means shall be fully lowered, controls neutralized and brake set to prevent movement.

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OPERATING PRACTICES

WHEN A POWERED INDUSTRIAL TRUCK IS TO BE LEFT UNATTENDED

• Stop truck in a clear, authorized area.

• Lower load-engaging means to the floor.

• Place directional controls in neutral.

• Apply the brake.

• Turn key switch to OFF and disconnect battery connectors.

• Block wheels if truck is on a slight incline.

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

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.

Return

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 B56.1 for requirements.

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

• Carry your load low so you have maximum stability while still maintaining ground clearance.

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

• 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.

Return

OPERATING PRACTICES

• DO NOT permit riders on unit.

• 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 Devices Battery Lift Systems including forks, and limit switches. Brake Steering Mechanism

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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.

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DATA PLATE AND DECALS

Know the rated capacity on the data plate and understand areas 1 through 10 as shown in the illustration.

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DATA PLATE AND DECALS

OPERATING WARNINGS

The OPERATING WARNINGS decal is located directly in front of the operator. 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

COAST FEATURE 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 also provided to warn of potential danger as well as to display special operating procedures.

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

THE CONTROL HANDLE

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

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CONTROLS AND EQUIPMENT

RAISE SWITCH

LOWER SWITCH

HORN SWITCH

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

REVERSER SWITCH

DIRECTION AND SPEED

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CONTROLS AND EQUIPMENT

BRAKE CONTROL

KEY SWITCH

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

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

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

EMERGENCY DISCONNECT BUTTON

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CONTROLS AND EQUIPMENT

BATTERY DISCHARGE INDICTOR/HOURMETER DASH DISPLAY

HOURMETER (optional)

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

BATTERY DISCHARGE INDICATOR/HOURMETER (optional)

BDI/HOURMETER WITH LIFT INTERRUPT (optional)

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CONTROLS AND EQUIPMENT RIDER HANDRAIL

HANDRAIL HIGH SPEED CONTROL SWITCH

The high speed control switch bar is used with the rider control. The switch is located on handrail over the battery compartment. The switch is physically located third from the top of handrail.

HORN SWITCH

HANDRAIL HIGH SPEED CONTROL SWITCH

The high speed control switch bar is used with the rider control. The switch is located on handrail over the battery compartment. The switch is physically located third from the top of handrail.

HORN SWITCH

The horn bar is activated by pushing down on the horn located on handrail over the battery compartment. The switch is physically located at the last position on handrail.

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CONTROLS AND EQUIPMENT RIDER HANDRAIL

LOWER SWITCH

WITH THE RIDER CONTROLS, the switch is located on handrail over the battery compartment. The switch is physically located first from the top of handrail.

RAISE SWITCH

WITH THE RIDER CONTROLS, the switch is located on handrail over the battery compartment. The switch is physically located second from the top of handrail.

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CONTROLS AND EQUIPMENT

COAST CONTROL (HMX only)

Coast control MUST be disengaged to allow the steering control handle to raise fully for automatic braking.

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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 hydraulic system. Look for leakage around hoses, fittings, and pump.

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

• Check condition of load backrest extension (if equipped). Be sure it is correctly positioned and secured.

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BEFORE OPERATION INSPECTION

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

• Check the operation of the BDI/hourmeter (if equipped).

• 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.

• Put your hands on the steering control handle and pull down (not all the way). 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.

• 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 to automatically applied.

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.

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

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

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BEFORE OPERATION INSPECTION

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

• Both lifting and lowering of forks should be a smooth movement.

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

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

4. Make sure that all motion has stopped .

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

28 Return

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

2. Lower forks fully.

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

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

29 Return

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 12/24 volt wet cell Battery.

IMPORTANT

Use only batteries that meet the following specifications:

VOLTAGE Minimum Battery Weight

12/24 (consult nameplate on unit)

VOLTAGE Minimum Battery Weight

12/24 (consult nameplate on unit)

Maximum Battery Weight

(consult nameplate on unit)

Maximum Battery Weight

(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

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

Oil capacity in Hydraulic Reservoir Fluid

1 Quart SAE 10W40 SG (cold storage) Dexron II

Oil capacity in Hydraulic Reservoir Fluid

1 Quart SAE 10W40 SG (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.

32 Return

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. • Drain, flush, and refill hydraulic reservoir.

33 Return

FIELD MODIFICATIONS

Return

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

PROUDLY Made in AMERICA

OPERATOR'S MANUAL

Manual Part Number 302063-002 RMX/HMX ELECTRIC LOW LIFT PALLET TRUCK

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 MAY 1995

Return

ISSUED MAY 1995

IMPORTANT NOTICE

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

BEFORE OPERATING THE UNIT:

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

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

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

LEARN AND PRACTICE USE OF CONTROLS BEFORE OPERATING.

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

1 Return

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.

Return

TABLE OF CONTENTS

NAME

PAGE #

NAME

PAGE #

1 2 3 4 5 5 6 6 7 8-13 14-16 17-23 24-27 28 29 30-31 32 33 34

3 Return

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.

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 periodic 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 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 and hydraulic 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

6 Return

OPERATOR

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

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

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.

• 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 load-engaging means shall be fully lowered, controls neutralized and brake set to prevent movement.

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

Return

OPERATING PRACTICES

WHEN A POWERED INDUSTRIAL TRUCK IS TO BE LEFT UNATTENDED

• Stop truck in a clear, authorized area.

• Lower load-engaging means to the floor.

• Place directional controls in neutral.

• Apply the brake.

• Turn key switch to OFF and disconnect battery connectors.

• Block wheels if truck is on a slight incline.

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

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.

Return

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 B56.1 for requirements.

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

• Carry your load low so you have maximum stability while still maintaining ground clearance.

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

• 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.

Return

OPERATING PRACTICES

• DO NOT permit riders on unit.

• 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 Devices Battery Lift Systems including forks, and limit switches. Brake Steering Mechanism

Return

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.

Return

DATA PLATE AND DECALS

Know the rated capacity on the data plate and understand areas 1 through 10 as shown in the illustration.

Return

DATA PLATE AND DECALS

OPERATING WARNINGS

The OPERATING WARNINGS decal is located directly in front of the operator. This decal describes basic warnings for safe operation of this unit. Carefully read the decal and make sure you understand the warning instructions.

NO STEP DECAL (RMX trucks only)

This NO STEP decal is located below the access door on both sides of unit.

This decal is used to help you remember that this truck is not designed to be ridden or stepped on.

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DATA PLATE AND DECALS

COAST FEATURE 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.

Return

CONTROLS AND EQUIPMENT

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

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

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

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

THE CONTROL HANDLE

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

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CONTROLS AND EQUIPMENT

RAISE SWITCH

LOWER SWITCH

HORN SWITCH

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

REVERSER SWITCH

DIRECTION AND SPEED

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CONTROLS AND EQUIPMENT

BRAKE CONTROL

KEY SWITCH

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

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

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

EMERGENCY DISCONNECT BUTTON

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CONTROLS AND EQUIPMENT

BATTERY DISCHARGE INDICTOR/HOURMETER DASH DISPLAY

HOURMETER (optional)

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

BATTERY DISCHARGE INDICATOR/HOURMETER (optional)

BDI/HOURMETER WITH LIFT INTERRUPT (optional)

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CONTROLS AND EQUIPMENT RIDER HANDRAIL

HANDRAIL HIGH SPEED CONTROL SWITCH

The high speed control switch bar is used with the rider control. The switch is located on handrail over the battery compartment. The switch is physically located third from the top of handrail.

HORN SWITCH

HANDRAIL HIGH SPEED CONTROL SWITCH

The high speed control switch bar is used with the rider control. The switch is located on handrail over the battery compartment. The switch is physically located third from the top of handrail.

HORN SWITCH

The horn bar is activated by pushing down on the horn located on handrail over the battery compartment. The switch is physically located at the last position on handrail.

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CONTROLS AND EQUIPMENT RIDER HANDRAIL

LOWER SWITCH

WITH THE RIDER CONTROLS, the switch is located on handrail over the battery compartment. The switch is physically located first from the top of handrail.

RAISE SWITCH

WITH THE RIDER CONTROLS, the switch is located on handrail over the battery compartment. The switch is physically located second from the top of handrail.

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CONTROLS AND EQUIPMENT

COAST CONTROL (HMX only)

Coast control MUST be disengaged to allow the steering control handle to raise fully for automatic braking.

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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 hydraulic system. Look for leakage around hoses, fittings, and pump.

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

• Check condition of load backrest extension (if equipped). Be sure it is correctly positioned and secured.

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BEFORE OPERATION INSPECTION

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

• Check the operation of the BDI/hourmeter (if equipped).

• 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.

• Put your hands on the steering control handle and pull down (not all the way). 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.

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

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BEFORE OPERATION INSPECTION

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

• Both lifting and lowering of forks should be a smooth movement.

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

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

4. Make sure that all motion has stopped .

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

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

2. Lower forks fully.

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

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

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BATTERY RETAINMENT/CARE

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

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

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

This unit uses a 12/24 volt wet cell Battery.

IMPORTANT

Use only batteries that meet the following specifications:

VOLTAGE Minimum Battery Weight

12/24 (consult nameplate on unit)

VOLTAGE Minimum Battery Weight

12/24 (consult nameplate on unit)

Maximum Battery Weight

(consult nameplate on unit)

Maximum Battery Weight

(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

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

Oil capacity in Hydraulic Reservoir Fluid

1 Quart SAE 10W40 SG (cold storage) Dexron II

Oil capacity in Hydraulic Reservoir Fluid

1 Quart SAE 10W40 SG (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

2000 HOURS OR ANNUAL

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

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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

RMX/HMX

Electric Low Lift Pallet Truck

Effective Serial Number _MX__27091001

HMX

RMX

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

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

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

Part no: 302063-002

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

Date: April 1997

Part no: 302063-002

Date: April 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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WARNING INJURY

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

Foreword

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

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

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

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

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

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

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

Table of Contents PAGE #

NAME

PAGE #

Operator's Warning ........................................................ 1

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

Table of contents............................................................ 3

Drive safely..................................................................... 4

Introduction..................................................................... 5

Introduction .................................................................... 5

To New BT Owners .................................................... 5

Preliminary Service ........................................................ 6

Right, Left, Front, Back............................................... 6

Operator ......................................................................... 7

Operating practices ..................................................... 8-13

Data plate and Decals ................................................ 14-16

Controls and Equipment ............................................. 17-25

Controls and Equipment............................................. 17-25

Before Operation Inspection....................................... 26-28

Operation....................................................................... 29

Operation ...................................................................... 29

Stopping Unit.............................................................. 29

Parking .......................................................................... 30

Battery Retainment/Care............................................ 31-32

Specifications and lubrications ......................................33

Specifications and lubrications ...................................... 33

Service intervals ............................................................ 34

Field Modifications......................................................... 35

Recycling/discarding .................................................. 36-37

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Drive Safely

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

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

STAY ALERT!

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Introduction

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

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

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

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

To new BT 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 equipment.

The BT 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 unit in good condition the planned maintenance and lubrication must be followed.

BT 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 unit in peak operating condition.

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Preliminary Service

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

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

The new unit should be checked out by a QUALIFIED TECHNICIAN. An arrival and pre-delivery checklist is at the BT dealership. This form is to be returned to validate warranty and to assure that the user has received a quality BT 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 dealership or BT factory and a no charge replacement will be sent.

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

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

RIGHT, LEFT, FRONT, AND REAR SIDES

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

A. Right Side

B. Rear

C. Left Side

D. Front

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Operator

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

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

When forks are first to enter a confined area or elevator or on an incline, keep both hands on control handle. Keep both hands within the handle guard and always look in the direction of travel. 7 Return

When forks are first to enter a confined area or elevator or on an incline, keep both hands on control handle. Keep both hands within the handle guard and always look in the direction of travel. 7

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 load-engaging means shall be lowered, controls neutralized, and brake set to prevent movement. DO NOT place any part of body between moving and stationary or outside running lines of truck. Use caution when making a right or left turn into an aisle. Remember rear wheels do not follow turn path of front wheel. When making a turn allow for “corner-cutting” of trailers. Safeguard co-workers from truck operational hazards when their assistance is required to perform a task.

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Operating Practices

ALWAYS LOOK IN DIRECTION OF TRAVEL, especially

When a powered industrial truck is to be left unattended

when reversing.

Completely stop truck in a clear, authorized area. Lower load-engaging means to the floor. Place directional controls in neutral. Apply the brake. Turn key switch to OFF and disconnect battery connectors. If truck must be left on an incline, block wheels.

when reversing.

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. A load backrest extension shall be used when necessary to guard against the load, or part of it, falling toward the operator. NEVER get ON or OFF a moving truck.

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Operating Practices

WHEN A POWERED INDUSTRIAL TRUCK IS TRAVELING:

Local safety regulations must always be followed. Know

and understand the traffic flow patterns of your job. Yield right of way to pedestrians. DO NOT pass another truck traveling in the same direction at intersections, blind spots or other dangerous locations. Slow down and sound the audible warning device(s) at cross aisles and other locations where vision is blocked. If the load being carried blocks any view, ask for assistance so the load can be moved without any danger to personal or property. Keep a clear view of the path of travel, and observe for traffic personnel and safe clearances. GRADES, RAMPS, OR INCLINES; This unit is designed for level floor operation. If it is necessary to operate on a ANSI B56.1 for grade, ramp, or incline refer to requirements. Under all travel conditions this unit shall be operated at a speed that will permit it to be brought to a stop in a safe manner. Carry your load low so you have maximum stability while still maintaining ground clearance. Make start, stops, turns or direction reversals in a smooth manner so as not to shift load and/or overturn truck. 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

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and understand the traffic flow patterns of your job. Yield right of way to pedestrians. DO NOT pass another truck traveling in the same direction at intersections, blind spots or other dangerous locations. Slow down and sound the audible warning device(s) at cross aisles and other locations where vision is blocked. If the load being carried blocks any view, ask for assistance so the load can be moved without any danger to personal or property. Keep a clear view of the path of travel, and observe for traffic personnel and safe clearances. GRADES, RAMPS, OR INCLINES; This unit is designed for level floor operation. If it is necessary to operate on a grade, ramp, or incline refer to ANSI B56.1 for requirements. Under all travel conditions this unit shall be operated at a speed that will permit it to be brought to a stop in a safe manner. Carry your load low so you have maximum stability while still maintaining ground clearance. Make start, stops, turns or direction reversals in a smooth manner so as not to shift load and/or overturn truck. 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 11

Operating Practices

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.

Operating Practices

Understand unit limitations and keep unit under control.

Remember to enter load slowly and squarely. Load should

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

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.

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

Operating Practices

OPERATOR PRECHECKS AND INSPECTION

Before each shift (every 8 hours) it is the operator's

Tires Warning and safety Devices Battery Brake Steering Mechanism Couplers

responsibility to carry out the following checks and inspections before beginning truck operation.

Horn Reverser Proper operation of truck

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 B56.1 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 10 as shown in the illustration.

1.Truck model number 2.Truck type 3.Truck serial number 4.Truck weight 5.Truck voltage

6. 7. 8. 9. 10.

Battery type Battery maximum AMP hours Minimum battery weight Maximum battery weight Truck capacity

1.Truck model number 2.Truck type 3.Truck serial number 4.Truck weight 5.Truck voltage

6. 7. 8. 9. 10.

Battery type Battery maximum AMP hours Minimum battery weight Maximum battery weight Truck capacity

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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.

NO STEP DECAL (RMX trucks only)

This NO STEP decal is located below the access door on both sides of unit.

decal is used to help you remember that this truck is not designed to be ridden or stepped on.

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Data Plate and Decals

COAST FEATURE 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 dealer for new decals. New warning decals can be obtained from your BT Dealer at NO charge.

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

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

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

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

THE CONTROL HANDLE

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

The Control Handle

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Controls and Equipment

RAISE SWITCH

LOWER SWITCH

HORN SWITCH

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

REVERSER SWITCH

DIRECTION AND SPEED

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Controls and Equipment

8 9

HMX

3 4

RMX 3

HMX

RMX 3

1 COMPONENT IDENTIFICATION

1.Drive Unit

2.Steering Control Handle 3.Load Backrest 4.Battery Compartment 5.Forks 6.Load Wheels 7.Directional Control Lever 8.Reverser Switch 9.Lift/Lower Mast Control Lever

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COMPONENT IDENTIFICATION

Controls and Equipment

KEY SWITCH

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

The key switch has two (2) positions: OFF and ON. 1. OFF POSITION: Turning the key to “OFF” will stop all electrical power from going to the control circuit from battery. 2. ON POSITION: Turn the key to “ON” to check function of hourmeter and battery discharge indicator. The key switch must be in this position to provide power to the control circuit when unit is operated.

EMERGENCY DISCONNECT BUTTON

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

Key Switch

Battery Discharge Indicator/Hourmeter Dash Display

Emergency Disconnect Switch

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Battery Discharge Indicator/Hourmeter Dash Display

Emergency Disconnect Switch

Dash Panel Layout

Controls and Equipment

BRAKE CONTROL

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

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

BRAKING USING PLUGGING FUNCTION

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

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

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

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Controls and Equipment

BATTERY DISCHARGE INDICATOR/HOURMETER DASH DISPLAY

HOURMETER (optional)

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

BATTERY DISCHARGE INDICATOR/HOURMETER (optional)

BDI/HOURMETER WITH LIFT INTERRUPT (optional)

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

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Controls and Equipment RIDER HANDRAIL

HANDRAIL High Speed Control Switch The high speed control switch bar is used with the rider control. The switch is located on handrail over the battery compartment. The switch is physically located third from the top of handrail.

Horn Switch

The horn bar is activated by pushing down on the horn located on handrail over the battery compartment. The switch is physically located at the last position on handrail.

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Controls and Equipment RIDER HANDRAIL

Lower Switch

WITH THE RIDER CONTROLS, the switch is located on handrail over the battery compartment. The switch is physically located first from the top of handrail.

Raise Switch

WITH THE RIDER CONTROLS, the switch is located on handrail over the battery compartment. The switch is physically located second from the top of handrail.

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Controls and Equipment

COAST CONTROL (HMX only)

Coast control MUST be disengaged to allow the steering control handle to raise fully for automatic braking.

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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.

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

Inspect hydraulic system. Look for leakage around hoses,

NOT operate unit until it is repaired.

fittings, and pump. 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 lift forks for cracks, breaks, bending and wear. The fork, surfaces should be level and even with each other. Check condition of load backrest (optional). Be sure it is correctly positioned and secured.

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NOT operate unit until it is repaired.

Before Operation Inspection

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

key switch to the "ON" position. Check the operation of the BDI/hourmeter (if equipped). 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. Put your hands on the steering control handle and pull down partially. This will release the brake and make power available to drive motor.

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

REARWARD TRAVEL: Put a firm grip on the directional control handle and rotate backward slowly. The unit must move slowly in a rearward direction. Rotate the handle more to increase speed. Unit should accelerate smoothly to maximum speed as handle is rotated. Direction controls MUST automatically return to the NEUTRAL position when released. Position and raise control handle fully up or fully down to stop unit using the parking brake. FORWARD TRAVEL: Put a firm grip on the directional control handle and rotate forward slowly. The unit must move slowly in a forward direction. Rotate the handle more to increase speed. Unit should accelerate smoothly to maximum speed as handle is rotated. Direction controls MUST automatically return to the NEUTRAL position when released. Position and raise control handle fully up or fully This unit is equipped with a PLUGGING FEATURE. This method involves simply reversing the travel control to opposite direction without applying the brake. This will cause the truck to come to a stop smoothly. Brake action should be smooth and stop unit in a normal

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Before Operation Inspection

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. To RAISE forks, push down on the raise control bar with your thumb or fingers. The forks will continue to raise as long as the bar is depressed or until the lifting stops are reached. Releasing the bar will automatically stop the raising. The raise bar is physically located on top of the steering control handle for ease or operation when needed. To LOWER forks, push down on the lower control bar with your thumb or fingers. The forks will continue to lower as long as the bar is depressed or until the lowering stops are reached. Releasing the bar will automatically stop the lowering The lower bar is physically located on top of the steering control handle for ease of operation when needed. Both lifting and lowering of forks should be a smooth movement. Use minimum forward and reverse tilt when stacking and unstacking loads. Make sure Operator's Manual is returned to the case and storage box.

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Before Operation Inspection 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. To RAISE forks, push down on the raise control bar with your thumb or fingers. The forks will continue to raise as long as the bar is depressed or until the lifting stops are reached. Releasing the bar will automatically stop the raising. The raise bar is physically located on top of the steering control handle for ease or operation when needed. To LOWER forks, push down on the lower control bar with your thumb or fingers. The forks will continue to lower as long as the bar is depressed or until the lowering stops are reached. Releasing the bar will automatically stop the lowering The lower bar is physically located on top of the steering control handle for ease of operation when needed. Both lifting and lowering of forks should be a smooth movement. Use minimum forward and reverse tilt when stacking and unstacking loads. Make sure Operator's Manual is returned to the case and storage box.

Operation

STOPPING UNIT

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

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

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

4. Make sure that all motion has stopped.

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

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

2. Lower forks fully.

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

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

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Battery Retainment/Care

DO NOT allow alkaline solution to fall in the Battery Cell. This will result in a dead or weak cell. IF ACID contacts your skin, eyes, or clothing, flush the area immediately with large amounts of water and contact a physician. DO NOT attempt to recharge a frozen Battery; this may cause it to rupture or explode DO NOT attempt to recharge the Battery in an area of sparks or near an open flame.

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 12/24 volt wet cell Battery.

Proper care and servicing of the battery is vital to assure satisfactory operation and lift of your BT 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

12/24 (consult nameplate on unit) (consult nameplate on unit)

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

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Battery Retainment/Care

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

BATTERY SERVICE

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

ADDING WATER

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

TERMINALS & CABLE CONNECTIONS

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

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Specifications and Lubrications

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

Transmission Fluid Type

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

Oil capacity in Hydraulic Reservoir 1 Quart [.75 l] Fluid Greater then 5°F Sunoco TH Less then 5°F ATF Dexron III

Grease Type

Tex. Ref. C and C #880

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

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Tex. Ref. C and C #880

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

Service Intervals 200 HOURS OR MONTHLY

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 hydraulic fluid level. 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

Check condition of battery charge. Visually inspect for leaks, loose, missing, or damaged

2000 HOURS OR ANNUAL

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

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Service Intervals

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

Field Modifications

Field Modification

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Recycling/discarding

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

Discarding the battery

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

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

Scrapping the truck

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

Chassis

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Chassis

Steel

Chassis

Stee

Mast

Steel

Mast

Stee

Battery cover

Steel

Battery cover

Stee

Drive unit

Steel and cast material

Drive unit

Steel and cast material

Bushings

Iron/coppe

Bushings

Iron/copper

Finish

Epoxy-polyester

Finish

Epoxy-polyeste

Recycling/discarding Chassis

Wheels

Polyurethane

Hydraulic system

Wheels

Polyurethane

Hydraulic system

Oil tank

Polyethylene

Oil tank

Polyethylene

Pump unit

Steel and aluminium

Pump unit

Steel and aluminium

Hoses

Rubber and steel

Hoses

Rubber and steel

Cylinders

Steel

Cylinders

Steel

Electrical system

Cables

Copper cores with PVC sheaths

Cables

Copper cores with PVC sheaths

Electronic board

Reinforced fiberglass circuit board laminate

Electronic board

Reinforced fiberglass circuit board laminate

Motors

Steel and coppe

Motors

Steel and copper

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

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

Operator’s Manual

RMX/HMX

Electric Low Lift Pallet Truck Effective Serial Number _MX__27297001

HMX

RMX

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

RMX

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: 302063-002 Return

Date: October 24, 1997

Part no: 302063-002

Date: October 24, 1997

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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WARNING INJURY

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

Foreword

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

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

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

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

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

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

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 RMX truck dimensions .................................................... 22 HMX truck dimensions .................................................... 23 RMX Data plate ............................................................... 24 HMX Data plate ............................................................... 25 U.L. construction type...................................................... 26

Presentation of truck ....................................................... 19 Application areas for BT’s trucks..................................... 20 Prohibited applications for BT’s trucks ............................ 20 Truck data ....................................................................... 21 RMX truck dimensions .................................................... 22 HMX truck dimensions .................................................... 23 RMX Data plate............................................................... 24 HMX Data plate............................................................... 25 U.L. construction type...................................................... 26

Presentation of main components ................................. 27

Controls and instruments ............................................... 30 Control handle ................................................................. 30 Control for raising the forks ............................................. 31 Control for lowering the forks .......................................... 31 Travel direction selector and speed control ..................... 32 Horn................................................................................. 32 Reverser switch............................................................... 33 Steering control handle/brake control.............................. 34 Braking using plugging function ...................................... 35 Key switch (toggle switch) ............................................... 36 Emergency disconnect switch ......................................... 36 BDI/Hourmeter with lift interrupt ...................................... 37 Battery discharge indicator (BDI) .................................... 37 Hourmeter ....................................................................... 38 Rider handrail (HMX only) ............................................... 39 Control for High Speed Control ....................................... 39 Horn................................................................................. 39 Control for Lowering the Forks ........................................ 40 Control for raising the forks ............................................. 40 Coast control (HMX only) ................................................ 41

Controls and instruments ............................................... 30 Control handle ................................................................. 30 Control for raising the forks ............................................. 31 Control for lowering the forks .......................................... 31 Travel direction selector and speed control..................... 32 Horn ................................................................................ 32 Reverser switch............................................................... 33 Steering control handle/brake control.............................. 34 Braking using plugging function ...................................... 35 Key switch (toggle switch) ............................................... 36 Emergency disconnect switch ......................................... 36 BDI/Hourmeter with lift interrupt ...................................... 37 Battery discharge indicator (BDI) .................................... 37 Hourmeter ....................................................................... 38 Rider handrail (HMX only) ............................................... 39 Control for High Speed Control ....................................... 39 Horn ................................................................................ 39 Control for Lowering the Forks ........................................ 40 Control for raising the forks ............................................. 40 Coast control (HMX only) ................................................ 41

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Table of Contents

Driving............................................................................... 42 Starting the truck ............................................................. 43 Braking ............................................................................ 45 Steering ........................................................................... 47 Parking the truck ............................................................. 47

Driving ............................................................................... 42 Starting the truck.............................................................. 43 Braking............................................................................. 45 Steering............................................................................ 47 Parking the truck .............................................................. 47

Transporting loads .......................................................... 48 General............................................................................ 48 Collecting a load.............................................................. 51 Leaving a load ................................................................. 52

Transporting loads ........................................................... 48 General ............................................................................ 48 Collecting a load .............................................................. 51 Leaving a load.................................................................. 52

Battery............................................................................... 53 Type of battery ................................................................ 53 Changing the battery ....................................................... 53 Charging the battery........................................................ 55 Battery maintenance ....................................................... 58

Battery ............................................................................... 53 Type of battery ................................................................. 53 Changing the battery........................................................ 53 Charging the battery ........................................................ 55 Battery maintenance ........................................................ 58

Daily service/safety checks ............................................ 60

Daily service/safety checks ............................................. 60

Maintenance ..................................................................... 64 General............................................................................ 64 Safety regulations with maintenance work...................... 64 Cleaning and washing ..................................................... 68 Maintenance chart........................................................... 70 Lubrication chart.............................................................. 74 Oil and grease specification ............................................ 75

Maintenance ...................................................................... 64 General ............................................................................ 64 Safety regulations with maintenance work....................... 64 Cleaning and washing...................................................... 68 Maintenance chart ........................................................... 70 Lubrication chart .............................................................. 74 Oil and grease specification............................................. 75

Transport and storing the truck ..................................... 76 The truck’s dimensions and weight as standard ............. 76 Lifting the truck ................................................................ 76 Towing and transporting a disabled truck........................ 78 Storing the truck .............................................................. 79 Starting after a period of disuse ...................................... 79

Transport and storing the truck ...................................... 76 The truck’s dimensions and weight as standard .............. 76 Lifting the truck................................................................. 76 Towing and transporting a disabled truck ........................ 78 Storing the truck ............................................................... 79 Starting after a period of disuse ....................................... 79

Recycling/discarding ....................................................... 80 Discarding the battery ..................................................... 80 Scrapping the truck ......................................................... 80

Recycling/discarding........................................................ 80 Discarding the battery ...................................................... 80 Scrapping the truck .......................................................... 80

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Safety regulations Warning symbols

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

Warning levels

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

DANGER

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

WARNING

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

CAUTION

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

NOTE!

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

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

Safety regulations Prohibitory symbols

Prohibitory symbols

NO SMOKING

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

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

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

Ordinance symbols

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

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

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

Ordinance symbols

SAFETY SHOES

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

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

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Safety regulations

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

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

Safety regulations

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

General safety regulations

Control

•

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

•

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

•

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

•

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

•

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

•

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

•

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Safety regulations

General safety regulations

Operating the truck

•

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

•

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

•

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

•

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

•

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

•

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

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

As a towing truck for trailers.

To tow other trucks.

To transport/lift passengers.

Safety regulations

General safety regulations

Operator’s responsibility

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

Local regulations regarding personal safety equipment shall be followed.

•

Local regulations regarding personal safety equipment shall be followed.

•

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

•

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

•

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

•

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

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Safety regulations

General safety regulations

Working area

•

If there are marked truck routes these shall be used.

•

If there are marked truck routes these shall be used.

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

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Safety regulations

General safety regulations

Driving and conduct while driving

•

Always drive the truck from the normal operator position.

•

Always drive the truck from the normal operator position.

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

Keep a safe distance from all vehicles ahead.

•

Keep a safe distance from all vehicles ahead.

•

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

•

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

•

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

•

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

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Safety regulations

•

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

•

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

•

Never allow passengers to ride on the truck.

•

Never allow passengers to ride on the truck.

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

DO NOT smoke while working around truck.

•

DO NOT smoke while working around truck.

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Safety regulations

General safety regulations

Handling loads

•

Drive with care when collecting or leaving a load.

•

Drive with care when collecting or leaving a load.

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

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Safety regulations

General safety regulations

Parking the truck

•

Always park in designated areas if available.

•

Always park in designated areas if available.

•

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

•

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

•

Never park the truck on an incline.

•

Never park the truck on an incline.

•

Never park the truck so that it obstructs emergency exits.

•

Never park the truck so that it obstructs emergency exits.

•

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

•

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

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Safety regulations

General safety regulations

Handling the battery

•

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

•

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

•

Always wear protective glasses when working with the battery.

•

Always wear protective glasses when working with the battery.

•

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

•

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

•

Make sure the battery is secured in its compartment.

•

Make sure the battery is secured in its compartment.

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Safety regulations

General safety regulations

Maintenance and repair

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

All replacement parts shall be BT approved spare parts.

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

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Warning and information signs

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

1. List of warnings 2. Horn: Control handle Horn sign 3. Hydraulic controls: Control handle Raising sign 4. Hydraulic controls: Control handle Lowering sign 5. Warning decal: No Riding (RMX only) 6. Hydraulic controls: Rider bar Lowering sign (HMX only) 7. Hydraulic controls: Rider bar Raising sign (HMX only) 8. High Speed: Rider bar High Speed sign (HMX only) 9. Horn: Rider bar Horn sign (HMX only) 10. Truck data plate (HMX only) 11. Warning decal: Truck parking brake does not automatically engage (HMX only) 12. Warning decal: No Step, or No Standing, or No Riding (RMX only) 13. Truck data plate (RMX only) 14. U.L. listed

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Warning and information signs

Breaking these rules may cause serious or fatal injury to yourself or others Read and understand all warnings and operating instructions in the operator's manual before operating this truck.

2 3 4

Only authorized and trained operators are to operate this machine. Keep feet clear of drive wheel and lowering frame. Make a safty check before operating the truck and do not operate if in need of repairs or maintenance. Maintenance is to be performed by authorized personnel only. This machine is designed of level floors and normal industrial operations. Additional operator's manuals can be obtained from your dealer or BT Prime-Mover, Inc., Muscatine, IA 52761. 305955-000

Warning and information signs

Breaking these rules may cause serious or fatal injury to yourself or others Read and understand all warnings and operating instructions in the operator's manual before operating this truck.

2 3 4

RMX

6 7 8 9

11 MACHINE EQUIPPED WITH COAST FEATURE.

6 7 8 9

11 MACHINE EQUIPPED WITH COAST FEATURE.

MOVE HANDLE FULLY UP OR DOWN TO APPLY BRAKE. 302523-000

HMX

MOVE HANDLE FULLY UP OR DOWN TO APPLY BRAKE. 302523-000

HMX

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. 18 Return

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. 18

Presentation of truck

BT’s truck program is intended for handling pallets indoors or alternatively other types of loads using other load carriers. The RMX trucks are operated by a walking operator. The HMX trucks are operated by either a walking or riding (standing) operator. This BT truck has available different fork lengths and lifting capacities. Refer to the truck’s data plate for this information.

The truck has a maximum lifting capacity of 8000 lb. Refer to the truck’s data plate for this information on lifting capacities.

The RMX trucks are equipped with either a 12 or 24 volt electrical system, and the HMX has a 24 volt electrical system. The travel speeds are regulated by means of a transistor controller to provide gentle control of acceleration and speed while operating.

The forks are raised by means of a hydraulic pump unit. Both raising and lowering are done electrically with separate push buttons on the control handle. HMX trucks have additional controls for raising, lowering, horn, and high speed located on the rider control bar and can be operated with either hand.

The truck can be fitted with different accessories including an hourmeter/battery discharge indicator, an hourmeter/battery discharge indicator with lift cutout, and a package guard on the backrest. 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:

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

Do not use as a towing truck for trailers

Do not use to tow other trucks

Do not use to transport/lift passengers

Do not use to drive on gravel or grass

Presentation of truck

Truck data

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

RMX

Truck type

5000 lb [2270 kg]

6500 lb [2951 kg]

8000 lb [3632 kg]

Voltage Operating speed without load

3.7 mph [5.95 km/h]

Operating speed with classified load

2.3 mph 2.6 mph 2.4 mph [3.7 km/h] [4.18 km/h] [3.86 km/h]

Truck type

5000 lb [2270 kg]

6500 lb [2951 kg]

8000 lb [3632 kg]

Voltag Operating speed without load

3.7 mph [5.95 km/h]

Operating speed with classified load

2.3 mph 2.6 mph 2.4 mph [3.7 km/h] [4.18 km/h] [3.86 km/h]

Maximum operating gradient with load, %

Maximum operating gradient with load,

Continuous noise level. dB (A)

<80

Continuous noise level. dB (A)

<80

HMX

HMX 6500 lb [2951 kg]

Truck type Voltage

8000 lb [3632 kg] 24

Operating speed without load

8 mph [12.87 km/h]

Operating speed with classified load

6 mph 5 mph [9.65 km/h] [8.04 km/h]

6500 lb [2951 kg]

Truck type Voltag

8000 lb [3632 kg] 24

Operating speed without load

8 mph [12.87 km/h]

Operating speed with classified load

6 mph 5 mph [9.65 km/h] [8.04 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 Truck battery dimensions RMX truck battery dimensions

Important

Use only batteries that meet the following specifications:

12 Volt 24 Volt Compartment Size: Deep Minimum 7.6 in. [193 mm] 12.8 in. [325 mm] Deep Maximum 8.1 in. [206 mm] 13.3 in. [338 mm] Wide Minimum 32.9 in. [836 mm] 32.9 in. [836 mm] Wide Maximum 33.4 in. [848 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.

HMX 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

RMX truck dimensions

The following diagrams show external dimensions for the RMX truck in its standard design.

Extended tip forks

B D

D E

77.7 in. [1973.58 mm] 12 Volt 83.0 in. [2108.2 mm] 24 Volt

Battery Compartment 8.1 in. [205.74 mm] 12 Volt Battery Compartment 13.3 in. [337.82 mm] 24 Volt

67° 12.5°

Battery roller height

56.4 in. [1432.56 mm] 12 Volt 61.6 in. [1564.64 mm] 24 Volt

Battery Compartment 8.1 in. [205.74 mm] 12 Volt Battery Compartment 13.3 in. [337.82 mm] 24 Volt

67° 12.5°

Battery roller height

F N

56.4 in. [1432.56 mm] 12 Volt 61.6 in. [1564.64 mm] 24 Volt

F N

L H

J 30.2 in. [767.08 mm] 12 Volt 35.4 in. [899.16 mm] 24 Volt

All Dimensions shown for 48 in. [1219.2 mm] long pallet

34.1 in. [866.14 mm]

47.6 in. [1209.0 mm]

9.8 in. [248.92 mm]

34.1 in. [866.14 mm]

47.6 in. [1209.0 mm]

9.8 in. [248.92 mm]

9.1 in. [231.14 mm]

3.25 in. [82.55 mm]

2.3 in. [58.42 mm]

9.1 in. [231.14 mm]

3.25 in. [82.55 mm]

2.3 in. [58.42 mm]

27.0 in. [685.8 mm]

6.0 in. [152.4 mm]

24.9 in. [632.46 mm]

27.0 in. [685.8 mm]

6.0 in. [152.4 mm]

24.9 in. [632.46 mm]

10.1 in. [256.54 mm]

4.2 in. [106.7 mm]

32.3 in. [820.42 mm]

10.1 in. [256.54 mm]

4.2 in. [106.7 mm]

32.3 in. [820.42 mm]

28.0 in. [711.2 mm]

6.1 in. [154.94 mm]

55.4 in. [1407.1 mm]

28.0 in. [711.2 mm]

6.1 in. [154.94 mm]

55.4 in. [1407.1 mm]

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Presentation of truck

HMX truck dimensions

The following diagrams show external dimensions for the HMX truck in its standard design.

Extended tip forks

B D

D E

Area of ride platform

Battery Compartment 13.3 [337.82 mm

67° 12.5°

S R

S I

P O

All Dimensions shown for 48” long pallet

37.4 in. [949.96 mm]

61.6 in. [1564.64 mm]

3.6 in. [91.44 mm]

37.4 in. [949.96 mm]

61.6 in. [1564.64 mm]

3.6 in. [91.44 mm]

9.1 in. [231.14 mm]

3.25 in. [82.55 mm]

9.1 in. [231.14 mm]

3.25 in. [82.55 mm]

9.1 in. [231.14 mm]

27.0 in. [685.8 mm]

6.0 in. [152.4 mm]

27.2 in. [690.88 mm]

27.0 in. [685.8 mm]

6.0 in. [152.4 mm]

27.2 in. [690.88 mm]

10.1 in. [256.54 mm]

4.2 in. [106.68 mm]

32.3 in. [820.42 mm]

10.1 in. [256.54 mm]

4.2 in. [106.68 mm]

32.3 in. [820.42 mm]

28.0 in. [711.2 mm]

6.1 in. [154.94 mm]

47.9 in. [1216.7 mm]

28.0 in. [711.2 mm]

6.1 in. [154.94 mm]

47.9 in. [1216.7 mm]

88.1 in. [2237.7 mm]

40.5 in. [1028.7 mm]

55.4 in. [1407.2 mm]

88.1 in. [2237.7 mm]

40.5 in. [1028.7 mm]

55.4 in. [1407.2 mm]

47.6 in. [1209 mm]

14.9 in. [378.46 mm]

47.6 in. [1209 mm]

14.9 in. [378.46 mm]

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Presentation of truck

RMX data plate

The diagram shows the data plate used on the truck.

Legend

1. Truck model number 2. Truck type 3. Truck serial number 4. Truck weight (less battery) 5. Truck voltage DC 6. Battery type UL class 7. Battery maximum AMP hours 8. Truck lifting capacity 9. Maximum battery weight 10. Minimum battery weight

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Presentation of truck

HMX data plate

The diagram shows the data plate used on the truck.

Legend

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Presentation of truck

U.L. construction type

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

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Presentation of main components

1. Steering control handle The truck is to be controlled by the operator with 180 degree steering angle. The brake is applied in the upper and lower position of the steering control handle. 2. Data plate Contains type designation, serial number, service weight, battery weight, rated lifting capacity, battery voltage, and manufacturer. 3. Door Swing open which provides good accessibility when servicing. The door can be completely removed from the truck by lifting the door from the hinges. 4. Gauge Combined hourmeter/battery indicator, hourmeter/battery indicator with lift cutout, or hourmeter only. 5. Hydraulic unit Pump motor, pump, electric valves and oil tank integrated in a compact unit. 6. Hydraulic electric solenoid valve For controlling lifting and lowering function with electric solenoid valve. 7. Drive unit with brake Fixed drive unit with a spring applied brake, drive motor, gear box, and drive wheel combined into a compact unit. The steering bearings are at the top of the drive unit. 8. Steering pivot point Lubricate pivot point to prevent stiff steering.

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Presentation of main components

9. Electric panel 12/24 volt electrical system. Vehicle speed is regulated by means of a transistor controller. 10. Circuit breaker 12A, BT Control circuit breaker part number 301889-000. 105A, BT Pump circuit breaker part number 307601-001. 150A, BT Drive circuit breaker part number 307601-000. 11. Load wheel Lubricate load wheels to prevent wheels from locking up. 12. Battery 12/24 volt with different capacities and weights. 13. Reverser switch The function is to prevent the operator from being pinched between the handle and an obstruction when traveling in the forward direction. 14. Horn switch The horn sounds to warn others of your position. 15. Fork raise switch The forks will raise when switch is pressed or until lift stops are reached. 16. Fork lower switch The forks will lower when switch is pressed or until lower stops are reached. 17. 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. 18. Key switch (toggle switch) Shuts off electrical power to control system. 19. Emergency stop switch The emergency stop switch will stop all control functions. 20. High speed switch (HMX only) High speed is engaged when steering handle speed switch is at full and high speed switch on hand rail is pressed.

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Presentation of main components

4 1

9 10

11 2

19 3

RMX

RMX 16 15 20 14

5 6

16 15 20 14

5 11

HMX

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HMX

Controls and instruments

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

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

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

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

Control handle

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

Switch

Switch Steering Control Handle

Horn Switch

Steering Control Handle Horn Switch

Rearward

Directional Controls

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Forward

Rearward

Directional Controls 31

Forward

Controls and instruments

Control for raising the forks

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

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

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

Control for lowering the forks

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

Control for lowering the forks E

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

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

Controls and instruments Travel direction selector and speed control

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

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

Horn

The horn sounds as long as the button is pressed.

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The horn sounds as long as the button is pressed.

Controls and instruments Reverser switch

Reverser Switch

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

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Controls and instruments Steering control handle/brake control

B1 F

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

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

Parking brake (B1):

The arm automatically returns to position B1 when released.

Travel brake (B2):

Apply the brake by pushing the steering control handle downwards.

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

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Controls and instruments Braking using plugging function

•

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

•

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

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

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.

Controls and instruments Key Switch

Battery Discharge Indicator/Hourmeter Dash Display

Emergency Disconnect Switch

Dash Panel Layout

Controls and instruments Key Switch

Battery Discharge Indicator/Hourmeter Dash Display

Emergency Disconnect Switch

Dash Panel Layout

Key switch (toggle switch)

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

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

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

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

Emergency disconnect switch

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

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Controls and instruments

BDI/hourmeter with travel interrupt

Fully-charged battery

1/2

Half-charged battery

1/2

Half-charged battery

Discharged battery

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

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

The hourmeter displays the time the drive motor is operating.

Battery discharge indicator (BDI)

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

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Controls and instruments

Hourmeter

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

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Controls and instruments Rider Handrail (HMX only)

Fork Lower

High Speed

Fork Lower

High Speed

Fork Raise

Horn

Fork Raise

Horn

Control for High Speed Control

The high speed control switch is used with the rider control. The switch is located on handrail over the battery compartment. The switch is physically located third from the top of handrail. The high speed control is engaged when the steering control handle speed switch is at full and high speed control switch on handrail is pressed.

Horn

The horn switch on handrail works the same way that it does on the steering control handle. The horn sounds as long as the button is pressed.

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Controls and instruments

Control for Lowering the Forks

Control for Raising the Forks

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Controls and instruments

Coast Control (HMX only)

The coast position is used to operate truck when operator is walking along side. In this position the automatic braking can be neutralized. Operator must flip coast control to the engaged position. In this position the brakes are released. When coast control is used the brakes are applied when steering control handle is pushed down or up all the way. The coast control is physically located at the base of steering control handle.

Coast control MUST be disengaged to allow the steering control handle to raise fully for automatic braking.

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Driving

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

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

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

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

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Driving

Starting the truck

•

Ensure the battery connector is connected to the truck.

•

Ensure the battery connector is connected to the truck.

•

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

•

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

•

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

•

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

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

•

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

•

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

•

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

•

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

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

Driving

•

Driving

- That the horn functions correctly.

- That the steering functions correctly.

- That the brakes function correctly.

Start gently by accelerating slowly until you reach the desired speed. WARNING Dangerous driving. Accidents can occur. Always drive with care, good judgement, and responsibility as set out in the general safety guidelines.

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•

Driving

Braking

Braking B1

2 B2

•

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

•

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

•

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

•

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

•

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When using the “plug braking” the operator may regulate, within the programmed capabilities, the severity of the “plugging” force and the stopping distance. For the lightest 46

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

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Driving

Steering

•

Steer by means of the control handle.

•

Steer by means of the control handle.

•

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

•

WARNING Risk of slipping. You can lose control of the truck if your hands or shoes are oily. Always dry your hands and shoes before driving.

Parking the truck

•

Stop the truck and disengage the travel direction selector.

•

Stop the truck and disengage the travel direction selector.

•

Release the steering control handle. The handle will return automatically to the parking brake position and the brakes are applied. Disengage coast control ( HMX only) for automatic braking.

•

Release the steering control handle. The handle will return automatically to the parking brake position and the brakes are applied. Disengage coast control ( HMX only) for automatic braking.

•

Turn the key switch to the O position.

•

Turn the key switch to the O position.

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WARNING Unauthorized use. Accidents can happen. Always remove the key when the truck is left unattended. 48

Transporting loads

General

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

WARNING Risk of overturning.

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

•

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

•

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

•

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

•

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

•

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

•

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

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.

•

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

•

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

•

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

•

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

•

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

•

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 on a grade. 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.

•

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

•

Lower the forks to the fully down position.

•

Lower the forks to the fully down position.

•

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

•

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

•

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

•

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

•

Drive carefully away. Start slowly and then increase the speed.

•

Drive carefully away. Start slowly and then increase the speed.

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

Return

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

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.

•

Lower the forks to the fully down position so that they clear the load.

•

Lower the forks to the fully down position so that they clear the load.

•

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.

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

Return

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

Battery

Type of battery

•

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.

Return

Battery

•

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

•

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

•

Connect battery and truck connectors.

•

Connect battery and truck connectors.

•

Connect the battery connector and truck connector.

•

Connect the battery connector and truck connector.

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

•

Push the emergency disconnect button to the ON position.

•

Push the emergency disconnect button to the ON position.

•

Install battery stops.

•

Install battery stops.

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.

Return

Battery

Charging the battery

General prohibition

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

Use an automatic charger intended for recharging traction batteries.

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

The charger shall have a minimum charging current of:

Return

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.

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.

Return

After approximately ten minutes make sure that the ammeter indicates a normal reading and that the control lamp is ON. 57

Battery

After charging

•

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

•

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

•

Switch OFF the charger.

•

Switch OFF the charger.

•

Disconnect the battery connector from charger connector.

•

Disconnect the battery connector from charger connector.

CAUTION

Return

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

CAUTION

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

Battery

Battery maintenance

Carry out battery maintenance after recharging.

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

Each week:

•

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

•

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

•

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

•

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

•

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

•

Refit all of the cell caps.

•

Refit all of the cell caps.

•

Rinse off and dry the battery.

•

Rinse off and dry the battery.

Return

Battery

Each month:

•

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

•

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

•

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

•

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

•

Adjust specific gravity with temperatures based on the chart below.

•

Adjust specific gravity with temperatures based on the chart below.

Temperature

Gravity

Temperature

Gravity

77°F [25.2°C]

1.280

77°F [25.2°C]

1.280

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

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 shown in the chart.

•

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

•

You need no tools to carry out the service checks.

•

You need no tools to carry out the service checks.

•

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

•

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

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.

Return

Daily service/safety checks

12 3 4

3 4

9 2

RMX

5 8

11 17 13 2

9 1

HMX

5 8

11 17 13 2

9 8

HMX

Return

7 5

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

Daily service/safety checks Item #

Check points

Action

Hydraulic system

Daily service/safety checks Item #

Check points

Action

Check for oil leakage, hoses, and floor

Hydraulic system

Check for oil leakage, hoses, and floor

Lifting device

Check for damage, noise function

Lifting device

Check for damage, noise function

Battery

Check acid level, charge, and condition. See “Battery Maintenance” section

Battery

Check acid level, charge, and condition. See “Battery Maintenance” section

Battery cables and connections

Check for breakage, cutting, or damage

Battery cables and connections

Check for breakage, cutting, or damage

Chassis

Check for damage, remove dirt an debris

Chassis

Check for damage, remove dirt and debris

Covers / guards

Check for damage, ensure placement

Covers / guards

Check for damage, ensure placement

Drive unit

Inspect abnormal noises and leakage

Drive unit

Inspect abnormal noises and leakage

Wheels

Check for damage, remove oil, metal chips, and debris

Wheels

Check for damage, remove oil, metal chips, and debris

Hand brake

Check its functio

Hand brake

Check its function

Direction / speed control

Check its functio

Direction / speed control

Check its function

Hydraulic function

Check its functio

Hydraulic function

Check its function

Reverser switch

Check its functio

Reverser switch

Check its function

Horn

Check its functio

Horn

Check its function

Running time

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

Running time

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

Emergency stop switch

Check its functio

Emergency stop switch

Check its function

Key switch (toggle switch)

Check its functio

Key switch (toggle switch)

Check its function

High speed switch

Check its functio

High speed switch

Check its function

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

Return

Daily service/safety checks

Special equipment

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

Return

Maintenance

General information

•

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.

Return

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.

•

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. 66

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. 66

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.

•

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. 69

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

No.

Action

1.0

Chassis

1.1

Check that the truck’s data plate is legible

1.0

Chassis

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

1.6

Check fork frame mounting

1.6

Check fork frame mounting

2.0

Motors

2.0

Motors

2.1

Check for loose connections

2.1

Check for loose connections

2.2

Clean motor

2.2

Clean motor

2.3

Check mounting bolts

2.3

Check mounting bolts

2.4

Check for abnormal bearing noise

2.4

Check for abnormal bearing noise

2.5

Check brush wear

2.5

Check brush wear

3.0

Drive unit

3.0

Drive unit

3.1

Check for leakage

3.1

Check for leakage

3.2

Check oil level

3.2

Check oil level

3.3

Check for noises

3.3

Check for noises

3.4

Check the mounting on support

3.4

Check the mounting on support

4.0

Wheels

4.0

Wheels

4.1

Remove string & 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

Return

Maintenance No.

Action

4.5

Grease load wheel bearings

4.6

Grease caster and caster wheels

4.7

Dismantle and lubricate all wheel bearings.

5.0

Brake

5.1

Clean

5.2

Maintenance B

No.

Action

4.5

Grease load wheel bearings

4.6

Grease caster and caster wheels

4.7

Dismantle and lubricate all wheel bearings.

5.0

Brake

5.1

Clean

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 syste

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. (10-15 mm above cell plate)

9.2

Check the connections on battery, truck, and charger

9.1

Check electrolyte level, 0.5-0.65 in. (10-15 mm above cell plate)

9.2

Check the connections on battery, truck, and charger

9.3

Check all cells and pole guards

9.3

Check all cells and pole guards

9.4

Check the fluid density and temperature

9.4

Check the fluid density and temperature

9.5

Check power cables are not cut or frayed

9.5

Check power cables are not cut or frayed

Return

Maintenance No.

Action

No.

Action

10.0

Hydraulic system

10.0

Hydraulic system

10.1

Check hoses and connections for leakage

10.1

Check hoses and connections for leakage

10.2

Check hoses for wear and damage

10.2

Check hoses for wear and damage

10.3

Check oil tank for cracks, leaks, and mounting

10.3

Check oil tank for cracks, leaks, and mounting

10.4

Check oil level

10.4

Check oil level

10.5

Change oil

10.5

Change oil

11.0

Cylinder

11.0

Cylinder

11.1

Check for leakage

11.1

Check for leakage

11.2

Check the mountings

11.2

Check the mountings

12.0

Lift devices

12.0

Lift devices

12.1

Check for damage and cracks

12.1

Check for damage and cracks

12.2

Check for play on the pull rods

12.2

Check for play on the pull rods

12.3

Check the electrical limit switch function

12.3

Check the electrical limit switch function

12.4

Check for wear to the forks and other lifting devices

12.4

Check for wear to the forks and other lifting devices

12.5

Lube all grease fittings

12.5

Lube all grease fittings

13.0

Controls

13.0

Controls

13.1

Check handle mounting

13.1

Check handle mounting

13.2

Check the handle brake lever switches

13.2

Check the handle brake lever switches

13.3

Check travel direction/speed control

13.3

Check travel direction/speed control

13.4

Check horn button function

13.4

Check horn button function

13.5

Check hydraulic button functions

13.5

Check hydraulic button functions

13.6

Check the handle control switches

13.6

Check the handle control switches

14.0

Gauge

14.0

Gauge

14.1

Check dash display

14.1

Check dash display

15.0

Brake Levers

15.2

Check handle brake levers

16.0

Key switch (toggle switch)

16.1

Maintenance C

X X X

Check switch function

Return

15.0

Brake Levers

15.2

Check handle brake levers

16.0

Key switch (toggle switch)

16.1

Check switch function

X X X

Maintenance No.

Action

17.0

Emergency stop switch

17.1

Check the emergency stop switch

Maintenance B

No.

Action

17.0

Emergency stop switch

17.1

Check the emergency stop switch

16 11

8 6 7

2 RMX

3 4 15

13 11

6 7

1 4

4 8

RMX

13 11

4 8

10 5

6 7

2 HMX 3

Return

8 6 7

HMX 3

Maintenance chart

Maintenance

Lubrication chart

Lubrication chart Interval/Running hours

Pos No.

Service point

Wheel bearings

Hydraulic system

Travel brake

Drive gear

Hinges

Steering bearings

Gear ring

500h

L=Lubrication

Return

Service point

Wheel bearings

Hydraulic system

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

1000h

3000h L

C=Check

A B

O=Oil change

Maintenance

Approved Oils and Grease

Specification Pos.

Lubricant

Grease

Hydraulic oil

Sunoco TH

Transmission SAE 80W/90 oil

Above 5°F [-15°C]

Application

Lubricant

Bearings and bushings

Grease

Texaco 15

Hydraulic system

Hydraulic oil

SAE 75W

Gears

Transmission SAE 80W/90 oil

SAE5W-20

Hinges

Below -10°F [-23°C]

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

Motor oil

SAE 40

Specification Pos.

Below 5°F [-15°C]

area

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

Below 5°F [-15°C]

Application Below -10°F [-23°C]

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

Motor oil

Sunoco TH

SAE 40

area Bearings and bushings

Sunoco TH

Texaco 15

Hydraulic system

SAE 75

Gears

SAE5W-20

Hinges

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

RMX

HMX C

Return

Above 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.

RMX truck’s dimensions and weight

Height

60 in. [1524 mm]

Height

60 in. [1524 mm]

Width

34.1 in. [867 mm]

Width

34.1 in. [867 mm]

Length (this length is with 48 in. [1219.2 mm] forks)

88.1 in. [2238 mm]

Length (this length is with 48 in. [1219.2 mm] forks)

88.1 in. [2238 mm]

Minimum battery weight

400 lb [181.6 kg]

Minimum battery weight

400 lb [181.6 kg]

Service weight without battery (this weight is with 48 in. [1219.2 mm] forks)

1350 lb [612.9 kg]

Service weight without battery (this weight is with 48 in. [1219.2 mm] forks)

1350 lb [612.9 kg]

HMX truck’s dimensions and weight

Height

60 in. [1524 mm]

Height

60 in. [1524 mm]

Width

37.4 in [950 mm]

Width

37.4 in [950 mm]

Length (this weight is with 48 in. [1219.2 mm] forks)

88.1 in. [2238 mm]

Length (this weight is with 48 in. [1219.2 mm] forks)

88.1 in. [2238 mm]

Minimum battery weight

400 lb [181.6 kg]

Minimum battery weight

400 lb [181.6 kg]

Service weight without battery (this weight is with 48 in. [1219.2 mm] forks)

1450 lb [658.3 kg]

Service weight without battery (this weight is with 48 in. [1219.2 mm] forks)

1450 lb [658.3 kg]

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Transporting and storing the truck

Lifting the truck

•

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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.

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Transporting and storing the truck

Storing the truck

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

Battery

•

Recharge the battery fully and carry out usual battery maintenance.

•

Recharge the battery fully and carry out usual battery maintenance.

•

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

•

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

Hydraulic system

•

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

Drive unit

•

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

Starting after a period of disuse

•

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

•

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

•

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

•

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

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Recyling/Discarding

Recycling/Discarding

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

Discarding the battery

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

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

Scrapping the truck

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

Chassis

Steel

Chassis

Steel

Drive unit

Steel and cast material

Drive unit

Steel and cast material

Bushings

Iron/copper

Bushings

Iron/copper

Finish

Epoxy-polyester

Finish

Epoxy-polyester

Wheels

Polyurethane

Wheels

Polyurethane

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Recyling/Discarding

Hydraulic system

Oil tank

Steel

Oil tank

Stee

Pump unit

Steel and aluminium

Pump unit

Steel and aluminium

Hoses

Rubber and stee

Hoses

Rubber and steel

Cylinders

Steel

Cylinders

Stee

Electrical system

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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

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

Operator’s Manual

RMX/HMX

Electric Low Lift Pallet Truck Effective Serial Number _MX__27297001

HMX

RMX

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: 302063-002 Return

Date: June 02, 1998

Part no: 302063-002

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 ................................................ 22 RMX truck battery dimensions .................................... 22 HMX truck battery dimensions .................................... 22 RMX truck dimensions .................................................... 23 HMX truck dimensions .................................................... 24 RMX data plate................................................................ 25 HMX data plate................................................................ 26 U.L. construction type...................................................... 27

Presentation of main components ................................. 28

Controls and instruments ............................................... 31 Control handle ................................................................. 31 Control for raising the forks ............................................. 32 Control for lowering the forks .......................................... 32 Travel direction selector and speed control..................... 33 Horn................................................................................. 33 Reverser switch............................................................... 34 Steering control handle/brake control.............................. 35 Braking using plugging function ...................................... 36 Key switch (toggle switch) ............................................... 37 Emergency disconnect switch ......................................... 37 BDI/Hourmeter with lift interrupt ...................................... 38 Battery discharge indicator (BDI) .................................... 38 Hourmeter ....................................................................... 39 Rider handrail (HMX only) ............................................... 40 Control for High Speed Control ....................................... 40 Horn................................................................................. 40

Controls and instruments ............................................... 31 Control handle ................................................................. 31 Control for raising the forks ............................................. 32 Control for lowering the forks .......................................... 32 Travel direction selector and speed control..................... 33 Horn ................................................................................ 33 Reverser switch............................................................... 34 Steering control handle/brake control.............................. 35 Braking using plugging function ...................................... 36 Key switch (toggle switch) ............................................... 37 Emergency disconnect switch ......................................... 37 BDI/Hourmeter with lift interrupt ...................................... 38 Battery discharge indicator (BDI) .................................... 38 Hourmeter ....................................................................... 39 Rider handrail (HMX only) ............................................... 40 Control for High Speed Control ....................................... 40 Horn ................................................................................ 40

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Table of Contents

Control for Lowering the Forks ........................................ 41 Control for raising the forks ............................................. 41 Coast control (HMX only) ................................................ 42

Control for Lowering the Forks.........................................41 Control for raising the forks..............................................41 Coast control (HMX only).................................................42

Driving............................................................................... 43 Starting the truck ............................................................. 44 Braking ............................................................................ 46 Steering ........................................................................... 48 Parking the truck ............................................................. 48

Driving ...............................................................................43 Starting the truck..............................................................44 Braking.............................................................................46 Steering............................................................................48 Parking the truck ..............................................................48

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

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

Battery............................................................................... 54 Type of battery ................................................................ 54 Changing the battery ....................................................... 54 Charging the battery........................................................ 56 Battery maintenance ....................................................... 59

Battery ...............................................................................54 Type of battery .................................................................54 Changing the battery........................................................54 Charging the battery ........................................................56 Battery maintenance ........................................................59

Daily service/safety checks ............................................ 61

Daily service/safety checks .............................................61

Maintenance ..................................................................... 65 General............................................................................ 65 Safety regulations with maintenance work ...................... 65 Cleaning and washing ..................................................... 69 Maintenance chart........................................................... 71 Lubrication chart.............................................................. 75 Oil and grease specification ............................................ 76

Maintenance ......................................................................65 General ............................................................................65 Safety regulations with maintenance work.......................65 Cleaning and washing......................................................69 Maintenance chart ...........................................................71 Lubrication chart ..............................................................75 Oil and grease specification.............................................76

Transport and storing the truck ..................................... 77 The truck’s dimensions and weight as standard ............. 77 Lifting the truck ................................................................ 78 Towing and transporting a disabled truck........................ 79 Storing the truck .............................................................. 80 Starting after a period of disuse ...................................... 80

Transport and storing the truck ......................................77 The truck’s dimensions and weight as standard ..............77 Lifting the truck.................................................................78 Towing and transporting a disabled truck ........................79 Storing the truck...............................................................80 Starting after a period of disuse .......................................80

Recycling/discarding ....................................................... 81 Discarding the battery ..................................................... 81 Scrapping the truck ......................................................... 81

Recycling/discarding........................................................81 Discarding the battery ......................................................81 Scrapping the truck ..........................................................81

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Safety regulations Warning symbols

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

Warning levels

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

DANGER

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

WARNING

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

CAUTION

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

NOTE!

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

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

Safety regulations Prohibitory symbols

Prohibitory symbols

NO SMOKING

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

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

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

Ordinance symbols

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

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

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

Ordinance symbols

SAFETY SHOES

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

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

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Safety regulations

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

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

Safety regulations

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:

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

As a towing truck for trailers.

To tow other trucks.

To transport/lift passengers.

Safety regulations

General safety regulations

Operator’s responsibility

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

Local regulations regarding personal safety equipment shall be followed.

•

Local regulations regarding personal safety equipment shall be followed.

•

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

•

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

•

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

•

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

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Safety regulations

General safety regulations

Working area

•

If there are marked truck routes these shall be used.

•

If there are marked truck routes these shall be used.

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

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Safety regulations

General safety regulations

Driving and conduct while driving

•

Always drive the truck from the normal operator position.

•

Always drive the truck from the normal operator position.

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

Keep a safe distance from all vehicles ahead.

•

Keep a safe distance from all vehicles ahead.

•

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

•

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

•

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

•

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

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Safety regulations

•

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

•

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

•

Never allow passengers to ride on the truck.

•

Never allow passengers to ride on the truck.

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

DO NOT smoke while working around truck.

•

DO NOT smoke while working around truck.

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Safety regulations

General safety regulations

Handling loads

•

Drive with care when collecting or leaving a load.

•

Drive with care when collecting or leaving a load.

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

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Safety regulations

General safety regulations

Parking the truck

•

Always park in designated areas if available.

•

Always park in designated areas if available.

•

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

•

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

•

Never park the truck on an incline.

•

Never park the truck on an incline.

•

Never park the truck so that it obstructs emergency exits.

•

Never park the truck so that it obstructs emergency exits.

•

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

•

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

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Safety regulations

General safety regulations

Handling the battery

•

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

•

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

•

Always wear protective glasses when working with the battery.

•

Always wear protective glasses when working with the battery.

•

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

•

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

•

Make sure the battery is secured in its compartment.

•

Make sure the battery is secured in its compartment.

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Safety regulations

General safety regulations

Maintenance and repair

All replacement parts shall be BT approved spare parts.

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Warning and information signs

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

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Warning and information signs

Breaking these rules may cause serious or fatal injury to yourself or others Read and understand all warnings and operating instructions in the operator's manual before operating this truck.

2 3 4

Warning and information signs

Breaking these rules may cause serious or fatal injury to yourself or others Read and understand all warnings and operating instructions in the operator's manual before operating this truck.

2 3 4

RMX

6 7 8 9

11 MACHINE EQUIPPED WITH COAST FEATURE.

6 7 8 9

11 MACHINE EQUIPPED WITH COAST FEATURE.

MOVE HANDLE FULLY UP OR DOWN TO APPLY BRAKE. 302523-000

HMX

MOVE HANDLE FULLY UP OR DOWN TO APPLY BRAKE. 302523-000

HMX

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. 18 Return

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. 18

Presentation of truck

The truck has a maximum lifting capacity of 8000 lb [3632 kg]. Refer to the truck’s data plate for this information on lifting capacities.

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Presentation of truck

Application area for BT’s trucks

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

Prohibited applications for BT’s trucks

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

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

Do not use as a towing truck for trailers

Do not use to tow other trucks

Do not use to transport/lift passengers

Do not use to drive on gravel or grass

Presentation of truck

Truck data

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

RMX truck data

Truck type

5000 lb [2270 kg]

6500 lb [2951 kg]

8000 lb [3632 kg]

Voltage

5000 lb 6500 lb [2270 kg] [2951 kg]

Truck type Voltage

8000 lb [3632 kg]

Operating speed without load

3.7 mph [5.95 km/h]

Operating speed without load

3.7 mph [5.95 km/h]

Operating speed with classified load

2.3 mph 2.6 mph 2.4 mph [3.7 km/h] [4.18 km/h] [3.86 km/h]

Operating speed with classified load

2.3 mph 2.6 mph 2.4 mph [3.7 km/h] [4.18 km/h] [3.86 km/h]

Maximum operating gradient with load, %

Continuous noise level. dB (A)

<80

Continuous noise level. dB (A)

<80

HMX truck data

HMX truck data 6500 lb [2951 kg]

Truck type Voltage

8000 lb [3632 kg] 24

Operating speed without load

8 mph [12.87 km/h]

Operating speed with classified load

6 mph 5 mph [9.65 km/h] [8.04 km/h]

6500 lb [2951 kg]

Truck type Voltage

8000 lb [3632 kg] 24

Operating speed without load

8 mph [12.87 km/h]

Operating speed with classified load

6 mph 5 mph [9.65 km/h] [8.04 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 Truck battery dimensions RMX truck battery dimensions

Important

Use only batteries that meet the following specifications:

Compartment Size: 12 Volt 24 Volt Deep Minimum 7.6 in. [193 mm] 12.8 in. [325 mm] Deep Maximum 8.1 in. [206 mm] 13.3 in. [338 mm] Wide Minimum 32.9 in. [836 mm] 32.9 in. [836 mm] Wide Maximum 33.4 in. [848 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.

HMX truck battery dimensions

Important

Use only batteries that meet the following specifications:

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Presentation of truck

RMX truck dimensions

The following diagrams show external dimensions for the RMX truck in its standard design.

Extended tip forks

B D

D E

77.7 in. [1973.58 mm] 12 Volt 83.0 in. [2108.2 mm] 24 Volt

Battery Compartment 8.1 in. [205.74 mm] 12 Volt Battery Compartment 13.3 in. [337.82 mm] 24 Volt

67° 12.5°

Battery roller height

56.4 in. [1432.56 mm] 12 Volt 61.6 in. [1564.64 mm] 24 Volt

Battery Compartment 8.1 in. [205.74 mm] 12 Volt Battery Compartment 13.3 in. [337.82 mm] 24 Volt

67° 12.5°

Battery roller height

F N

56.4 in. [1432.56 mm] 12 Volt 61.6 in. [1564.64 mm] 24 Volt

F N

L H

J 30.2 in. [767.08 mm] 12 Volt 35.4 in. [899.16 mm] 24 Volt

All Dimensions shown for 48 in. [1219.2 mm] long pallet

34.1 in. [866.14 mm]

47.6 in. [1209.0 mm]

9.8 in. [248.92 mm]

34.1 in. [866.14 mm]

47.6 in. [1209.0 mm]

9.8 in. [248.92 mm]

9.1 in. [231.14 mm]

3.25 in. [82.55 mm]

2.3 in. [58.42 mm]

9.1 in. [231.14 mm]

3.25 in. [82.55 mm]

2.3 in. [58.42 mm]

27.0 in. [685.8 mm]

6.0 in. [152.4 mm]

24.9 in. [632.46 mm]

27.0 in. [685.8 mm]

6.0 in. [152.4 mm]

24.9 in. [632.46 mm]

10.1 in. [256.54 mm]

4.2 in. [106.7 mm]

32.3 in. [820.42 mm]

10.1 in. [256.54 mm]

4.2 in. [106.7 mm]

32.3 in. [820.42 mm]

28.0 in. [711.2 mm]

6.1 in. [154.94 mm]

55.4 in. [1407.1 mm]

28.0 in. [711.2 mm]

6.1 in. [154.94 mm]

55.4 in. [1407.1 mm]

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Presentation of truck

HMX truck dimensions

The following diagrams show external dimensions for the HMX truck in its standard design.

Extended tip forks

B D

D E

Area of ride platform

Battery Compartment 13.3 [337.82 mm]

67° 12.5°

S R

S I

P O

All Dimensions shown for 48 in. [1219.2 mm] long pallet

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All Dimensions shown for 48 in. [1219.2 mm] long pallet

37.4 in. [949.96 mm]

61.6 in. [1564.64 mm]

3.6 in. [91.44 mm]

37.4 in. [949.96 mm]

61.6 in. [1564.64 mm]

3.6 in. [91.44 mm]

9.1 in. [231.14 mm]

3.25 in. [82.55 mm]

9.1 in. [231.14 mm]

3.25 in. [82.55 mm]

9.1 in. [231.14 mm]

27.0 in. [685.8 mm]

6.0 in. [152.4 mm]

27.2 in. [690.88 mm]

27.0 in. [685.8 mm]

6.0 in. [152.4 mm]

27.2 in. [690.88 mm]

10.1 in. [256.54 mm]

4.2 in. [106.68 mm]

32.3 in. [820.42 mm]

10.1 in. [256.54 mm]

4.2 in. [106.68 mm]

32.3 in. [820.42 mm]

28.0 in. [711.2 mm]

6.1 in. [154.94 mm]

47.9 in. [1216.7 mm]

28.0 in. [711.2 mm]

6.1 in. [154.94 mm]

47.9 in. [1216.7 mm]

88.1 in. [2237.7 mm]

40.5 in. [1028.7 mm]

55.4 in. [1407.2 mm]

88.1 in. [2237.7 mm]

40.5 in. [1028.7 mm]

55.4 in. [1407.2 mm]

47.6 in. [1209 mm]

14.9 in. [378.46 mm]

47.6 in. [1209 mm]

14.9 in. [378.46 mm]

Presentation of truck

RMX data plate

The diagram shows the data plate used on the truck.

Legend

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Presentation of truck

HMX data plate

The diagram shows the data plate used on the truck.

Legend

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Presentation of truck

U.L. construction type

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Presentation of main components

3. Door Swing open which provides good accessibility when servicing. The door can be completely removed from the truck by lifting the door from the hinges. 4. Gauge Combined hourmeter/battery indicator, hourmeter/battery indicator with lift cutout, or hourmeter only. 5. Hydraulic unit Pump motor, pump, electric valves and oil tank integrated in a compact unit. 6. Hydraulic electric solenoid valve For controlling lifting and lowering function with electric solenoid valve. 7. Drive unit with brake Fixed drive unit with a spring applied brake, drive motor, gear box, and drive wheel combined into a compact unit. The steering bearings are at the top of the drive unit. 8. Steering pivot point Lubricate pivot point to prevent stiff steering.

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Presentation of main components

9. Electric panel 12/24 volt electrical system. Vehicle speed is regulated by means of a transistor controller. 10. Circuit breaker 12A, Control circuit breaker part number 301889-000. 105A, Pump circuit breaker part number 307601-001. 150A, Drive circuit breaker part number 307601-000. 11. Load wheel Lubricate load wheels to prevent wheels from locking up. 12. Battery 12/24 volt with different capacities and weights. 13. Reverser switch The function is to prevent the operator from being pinched between the handle and an obstruction when traveling in the forward direction. 14. Horn switch The horn sounds to warn others of your position. 15. Fork raise switch The forks will raise when switch is pressed or until lift stops are reached. 16. Fork lower switch The forks will lower when switch is pressed or until lower stops are reached. 17. 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.

18. Key switch (toggle switch) Shuts off electrical power to control system. 19. Emergency stop switch The emergency stop switch will stop all control functions. 20. High speed switch (HMX only) High speed is engaged when steering handle speed switch is at full and high speed switch on hand rail is pressed.

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Presentation of main components

4 1

9 10

11 2

19 3

RMX

RMX 16 15 20 14

5 6

16 15 20 14

5 11

HMX

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HMX

Controls and instruments

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

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

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

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

Control handle

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

Switch

Switch Steering Control Handle

Horn Switch

Steering Control Handle Horn Switch

Rearward

Directional Controls Return

Forward

Rearward

Directional Controls 31

Forward

Controls and instruments

Control for raising the forks

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

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

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

Control for lowering the forks

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

Control for lowering the forks E

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

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

Controls and instruments Travel direction selector and speed control

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

Horn

The horn sounds as long as the button is pressed.

Return

The horn sounds as long as the button is pressed.

Controls and instruments Reverser switch

Reverser Switch

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Controls and instruments Steering control handle/brake control

B1 F

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

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

Parking brake (B1):

The arm automatically returns to position B1 when released.

Travel brake (B2):

Apply the brake by pushing the steering control handle downwards.

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

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Controls and instruments

Braking using plugging function

•

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

•

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

Controls and instruments Key Switch

Battery Discharge Indicator/Hourmeter Dash Display

Emergency Disconnect Switch

Dash Panel Layout

Controls and instruments Key Switch

Battery Discharge Indicator/Hourmeter Dash Display

Emergency Disconnect Switch

Dash Panel Layout

Key switch (toggle switch)

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

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

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

Emergency disconnect switch

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Controls and instruments

BDI/hourmeter with travel interrupt

Fully-charged battery

1/2

Half-charged battery

1/2

Half-charged battery

Discharged battery

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

The hourmeter displays the time the drive motor is operating.

Battery discharge indicator (BDI)

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Controls and instruments

Hourmeter

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

Return

Controls and instruments Rider Handrail (HMX only)

Fork Lower

High Speed

Fork Lower

High Speed

Fork Raise

Horn

Fork Raise

Horn

Control for High Speed Control

Horn

The horn switch on handrail works the same way that it does on the steering control handle. The horn sounds as long as the button is pressed.

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Controls and instruments

Control for Lowering the Forks

Control for Raising the Forks

Return

Controls and instruments

Coast Control (HMX only)

Coast control MUST be disengaged to allow the steering control handle to raise fully for automatic braking.

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Driving

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

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

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

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Driving

Starting the truck

•

Ensure the battery connector is connected to the truck.

•

Ensure the battery connector is connected to the truck.

•

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

•

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

•

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

•

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

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

•

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

•

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

•

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

•

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

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

Driving

•

Driving

- That the horn functions correctly.

- That the steering functions correctly.

- That the brakes function correctly.

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•

Driving

Braking

Braking B1

2 B2

•

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

•

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

•

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

•

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When using the “plug braking” the operator may regulate, within the programmed capabilities, the severity of the “plugging” force and the stopping distance. For the lightest 46

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Driving

Steering

•

Steer by means of the control handle.

•

Steer by means of the control handle.

•

WARNING Risk of slipping. You can lose control of the truck if your hands or shoes are oily. Always dry your hands and shoes before driving.

Parking the truck

•

Stop the truck and disengage the travel direction selector.

•

Stop the truck and disengage the travel direction selector.

•

Release the steering control handle. The handle will return automatically to the parking brake position and the brakes are applied. Disengage coast control (HMX only) for automatic braking.

•

Release the steering control handle. The handle will return automatically to the parking brake position and the brakes are applied. Disengage coast control (HMX only) for automatic braking.

•

Turn the key switch to the O position.

•

Turn the key switch to the O position.

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WARNING Unauthorized use. Accidents can happen. Always remove the key when the truck is left unattended. 48

Transporting loads

General

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

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

•

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

•

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

•

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

•

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

•

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

•

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

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.

•

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

•

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

•

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

•

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

•

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

•

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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 on a grade. 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. •

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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.

•

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

•

Lower the forks to the fully down position.

•

Lower the forks to the fully down position.

•

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

•

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

•

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

•

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

•

Drive carefully away. Start slowly and then increase the speed.

•

Drive carefully away. Start slowly and then increase the speed.

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

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

Transporting loads

Leaving a load

•

Slow down and position truck carefully where load is to be left.

•

Slow down and position truck carefully where load is to be left.

•

Lower the forks to the fully down position so that they clear the load.

•

Lower the forks to the fully down position so that they clear the load.

•

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.

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

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

Battery

Type of battery

•

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.

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.

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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:

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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.

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. 57

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 shown in the chart.

•

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

•

You need no tools to carry out the service checks.

•

You need no tools to carry out the service checks.

•

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

•

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

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Daily service/safety checks

12 3 4

3 4

9 2

RMX

5 8

11 17 13 2

9 1

HMX

5 8

11 17 13 2

9 8

HMX

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7 5

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

Daily service/safety checks Item #

Check points

Action

Hydraulic system

Daily service/safety checks Item #

Check points

Action

Check for oil leakage, hoses, and floor

Hydraulic system

Check for oil leakage, hoses, and floor

Lifting device

Check for damage, noise function

Lifting device

Check for damage, noise function

Battery

Check acid level, charge, and condition. See “Battery Maintenance” section

Battery

Check acid level, charge, and condition. See “Battery Maintenance” section

Battery cables and connections

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

Drive unit

Inspect abnormal noises and leakage

Drive unit

Inspect abnormal noises and leakage

Wheels

Check for damage, remove oil, metal chips, and debris

Wheels

Check for damage, remove oil, metal chips, and debris

Hand brake

Check its function

Hand brake

Check its function

Direction / speed control

Check its function

Direction / speed control

Check its function

Hydraulic function

Check its function

Hydraulic function

Check its function

Reverser switch

Check its function

Reverser switch

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” section

Running time

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

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

High speed switch

Check its function

High speed switch

Check its function

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

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Daily service/safety checks

Special equipment

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

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Maintenance

General information

•

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.

•

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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. 66

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. 66

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

•

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. 69

Maintenance •

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

Maintenance •

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

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

•

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

•

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

•

Rinse off loose grime using warm water.

•

Rinse off loose grime using warm water.

Electrical components

•

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

•

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

•

Do not spray or pressure wash in the compartment.

•

Do not spray or pressure wash in the compartment.

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

Return

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

Maintenance

Maintenance chart

PM Interval:

A=5 Hours or 1 Day

E=500 Hours or 6 Months

A=5 Hours or 1 Day

E=500 Hours or 6 Months

B=20 Hours or 1 Week

F=1000 Hours or 12 Months

B=20 Hours or 1 Week

F=1000 Hours or 12 Months

C=80 Hours or 1 Month

G=3000 Hours or 36 Months

C=80 Hours or 1 Month

G=3000 Hours or 36 Months

D=250 Hours or 3 Months

No.

Action

No.

Action

1.0

Chassis

1.1

Check that the truck’s data plate is legible

1.0

Chassis

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

1.6

Check fork frame mounting

1.6

Check fork frame mounting

2.0

Motors

2.0

Motors

2.1

Check for loose connections

2.1

Check for loose connections

2.2

Clean motor

2.2

Clean motor

2.3

Check mounting bolts

2.3

Check mounting bolts

2.4

Check for abnormal bearing noise

2.4

Check for abnormal bearing noise

2.5

Check brush wear

2.5

Check brush wear

3.0

Drive unit

3.0

Drive unit

3.1

Check for leakage

3.1

Check for leakage

3.2

Check oil level

3.2

Check oil level

3.3

Check for noises

3.3

Check for noises

3.4

Check the mounting on support

3.4

Check the mounting on support

4.0

Wheels

4.0

Wheels

4.1

Remove string & 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

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Maintenance No.

Action

No.

Action

4.5

Grease load wheel bearings

4.5

Grease load wheel bearings

4.6

Grease caster and caster wheels

4.6

Grease caster and caster wheels

4.7

Dismantle and lubricate all wheel bearings.

4.7

Dismantle and lubricate all wheel bearings.

5.0

Brake

5.0

Brake

5.1

Clean

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. (10-15 mm above cell plate)

9.1

Check electrolyte level, 0.5-0.65 in. (10-15 mm above cell plate)

9.2

Check the connections on battery, truck, and charger

9.2

Check the connections on battery, truck, and charger

9.3

Check all cells and pole guards

9.3

Check all cells and pole guards

9.4

Check the fluid density and temperature

9.4

Check the fluid density and temperature

9.5

Check power cables are not cut or frayed

9.5

Check power cables are not cut or frayed

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Maintenance B

Maintenance No.

Action

10.0

Hydraulic system

10.1

Check hoses and connections for leakage

10.2

Maintenance B

No.

Action

10.0

Hydraulic system

10.1

Check hoses and connections for leakage

Check hoses for wear and damage

10.2

Check hoses for wear and damage

10.3

Check oil tank for cracks, leaks, and mounting

10.3

Check oil tank for cracks, leaks, and mounting

10.4

Check oil level

10.4

Check oil level

10.5

Change oil

10.5

Change oil

11.0

Cylinder

11.0

Cylinder

11.1

Check for leakage

11.1

Check for leakage

11.2

Check the mountings

11.2

Check the mountings

12.0

Lift devices

12.0

Lift devices

12.1

Check for damage and cracks

12.1

Check for damage and cracks

12.2

Check for play on the pull rods

12.2

Check for play on the pull rods

12.3

Check the electrical limit switch function

12.3

Check the electrical limit switch function

12.4

Check for wear to the forks and other lifting devices

12.4

Check for wear to the forks and other lifting devices

12.5

Lube all grease fittings

12.5

Lube all grease fittings

X X X

Controls

13.0

Controls

13.1

Check handle mounting

13.2

Check the handle brake lever switches

13.2

Check the handle brake lever switches

13.3

Check travel direction/speed control

13.3

Check travel direction/speed control

13.4

Check horn button function

13.4

Check horn button function

13.5

Check hydraulic button functions

13.5

Check hydraulic button functions

13.6

Check the handle control switches

13.6

Check the handle control switches

14.0

Gauge

14.0

Gauge

14.1

Check dash display

14.1

Check dash display

15.0

Brake Levers

15.0

Brake Levers

15.2

Check handle brake levers

15.2

Check handle brake levers

16.0

Key switch (toggle switch)

16.0

Key switch (toggle switch)

16.1

Check switch function

16.1

Check switch function

Return

Check handle mounting

13.1

13.0

Maintenance No.

Action

17.0

Emergency stop switch

17.1

Check the emergency stop switch

Maintenance B

No.

Action

17.0

Emergency stop switch

17.1

Check the emergency stop switch

13 16

8 6 7

2 RMX

3 4 15

13 11

6 7

1 4

4 8

RMX

13 11

4 8

10 5

6 7

2 HMX 3

Return

8 6 7

HMX 3

Maintenance chart

Maintenance

Lubrication chart

Lubrication chart Interval/Running hours

Pos No.

Service point

Wheel bearings

Hydraulic system

Travel brake

Drive gear

Hinges

Steering bearings

Gear ring

500h

L=Lubrication

Return

Service point

Wheel bearings

Hydraulic system

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

1000h

3000h L

C=Check

A B

O=Oil change

Maintenance

Approved Oils and Grease

Specification Pos.

Lubricant

Grease

Hydraulic oil

Sunoco TH

Transmission SAE 80W/90 oil

Above 5°F [-15°C]

Application

SAE 40

Bearings and bushings

Grease

Texaco 15

Hydraulic system

Hydraulic oil

Sunoco TH

Texaco 15

Hydraulic system

SAE 75W

Gears

Transmission SAE 80W/90 oil

SAE 75W

Gears

SAE5W-20

Hinges

SAE5W-20

Hinges

area

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

Above 5°F [-15°C]

Below 5°F [-15°C]

Below -10°F [-23°C]

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

Motor oil

SAE 40

area Bearings and bushings

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

RMX

HMX C

Return

Application

Lubricant

Below -10°F [-23°C]

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

Motor oil

Specification Pos.

Below 5°F [-15°C]

HMX 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.

RMX truck’s dimensions and weight

Height

60 in. [1524 mm]

Height

60 in. [1524 mm]

Width

34.1 in. [867 mm]

Width

34.1 in. [867 mm]

Length (this length is with 48 in. [1219.2 mm] forks)

88.1 in. [2238 mm]

Length (this length is with 48 in. [1219.2 mm] forks)

88.1 in. [2238 mm]

Minimum battery weight

400 lb [181.6 kg]

Minimum battery weight

400 lb [181.6 kg]

Service weight without battery (this weight is with 48 in. [1219.2 mm] forks)

1350 lb [612.9 kg]

Service weight without battery (this weight is with 48 in. [1219.2 mm] forks)

1350 lb [612.9 kg]

HMX truck’s dimensions and weight

Height

60 in. [1524 mm]

Height

60 in. [1524 mm]

Width

37.4 in [950 mm]

Width

37.4 in [950 mm]

Length (this weight is with 48 in. [1219.2 mm] forks)

88.1 in. [2238 mm]

Length (this weight is with 48 in. [1219.2 mm] forks)

88.1 in. [2238 mm]

Minimum battery weight

400 lb [181.6 kg]

Minimum battery weight

400 lb [181.6 kg]

1450 lb [658.3 kg]

Service weight without battery (this weight is with 48 in. [1219.2 mm] forks)

1450 lb [658.3 kg]

Service weight without battery (this weight is with 48 in. [1219.2 mm] forks)

Return

Transporting and storing the truck

Lifting the truck

•

Return

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

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

WARNING Risk of overturning. The truck can overturn if lifted incorrectly. Always lift the truck secured to, and with the center of gravity between, the lifting truck’s forks.

Transporting and storing the truck

Towing and transporting a disabled truck

WARNING DO NOT tow a disabled truck.

It is not recommended to tow a disabled lift truck.

Return

Transporting and storing the truck

Storing the truck

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

Battery

•

Recharge the battery fully and carry out usual battery maintenance.

•

Recharge the battery fully and carry out usual battery maintenance.

•

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

•

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

Hydraulic system

•

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

Drive unit

•

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

Starting after a period of disuse

•

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

•

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

•

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

•

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

Return

Recyling/Discarding

Recycling/Discarding

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

Discarding the battery

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

Scrapping the truck

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

Chassis

Steel

Chassis

Steel

Drive unit

Steel and cast material

Drive unit

Steel and cast material

Bushings

Iron/copper

Bushings

Iron/copper

Finish

Epoxy-polyester

Finish

Epoxy-polyester

Wheels

Polyurethane

Wheels

Polyurethane

Return

Recyling/Discarding

Hydraulic system

Oil tank

Steel

Oil tank

Steel

Pump unit

Steel and aluminium

Pump unit

Steel and aluminium

Hoses

Rubber and steel

Hoses

Rubber and steel

Cylinders

Steel

Cylinders

Steel

Electrical system

Return

Recyling/Discarding

Electrical system

Cables

Copper cores with PVC sheaths

Cables

Copper cores with PVC sheaths

Electronic board

Reinforced fiberglass circuit board laminate

Electronic board

Reinforced fiberglass circuit board laminate

Motors

Steel and copper

Motors

Steel and copper

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

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

Operator’s Manual

RMX/HMX

Electric Low Lift Pallet Truck Effective Serial Number _MX__27297001 - UP

HMX

RMX

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

RMX

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: 302063-002 Return

Date: October 20, 1998

Part no: 302063-002

Date: October 20, 1998

Operator’s warning

IMPORTANT NOTICE

Before operating the truck:

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

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

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

LEARN AND PRACTICE USE OF CONTROLS BEFORE OPERATING.

WARNING INJURY

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

Return

WARNING INJURY

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

Foreword

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

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

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

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

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

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

Return

Table of Contents

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 ................................................ 22 RMX truck battery dimensions .................................... 22 HMX truck battery dimensions .................................... 22 RMX truck dimensions .................................................... 23 HMX truck dimensions .................................................... 24 RMX data plate................................................................ 25 HMX data plate................................................................ 26 U.L. construction type...................................................... 27

Presentation of truck ....................................................... 19 Application areas for BT’s trucks..................................... 20 Prohibited applications for BT’s trucks ............................ 20 Truck data ....................................................................... 21 Truck battery dimensions ................................................ 22 RMX truck battery dimensions .................................... 22 HMX truck battery dimensions .................................... 22 RMX truck dimensions .................................................... 23 HMX truck dimensions .................................................... 24 RMX data plate................................................................ 25 HMX data plate................................................................ 26 U.L. construction type...................................................... 27

Presentation of main components ................................. 28

Controls and instruments ............................................... 31 Control handle ................................................................. 31 Control for raising the forks ............................................. 32 Control for lowering the forks .......................................... 32 Travel direction selector and speed control ..................... 33 Horn................................................................................. 33 Reverser switch............................................................... 34 Steering control handle/brake control.............................. 35 Braking using plugging function ...................................... 36 Key switch (toggle switch) ............................................... 37 Emergency disconnect switch ......................................... 37 BDI/Hourmeter with lift interrupt ...................................... 38 Battery discharge indicator (BDI) .................................... 38 Hourmeter ....................................................................... 39 Rider handrail (HMX only) ............................................... 40 Control for High Speed Control ....................................... 40 Horn................................................................................. 40

Controls and instruments ............................................... 31 Control handle ................................................................. 31 Control for raising the forks ............................................. 32 Control for lowering the forks .......................................... 32 Travel direction selector and speed control..................... 33 Horn ................................................................................ 33 Reverser switch............................................................... 34 Steering control handle/brake control.............................. 35 Braking using plugging function ...................................... 36 Key switch (toggle switch) ............................................... 37 Emergency disconnect switch ......................................... 37 BDI/Hourmeter with lift interrupt ...................................... 38 Battery discharge indicator (BDI) .................................... 38 Hourmeter ....................................................................... 39 Rider handrail (HMX only) ............................................... 40 Control for High Speed Control ....................................... 40 Horn ................................................................................ 40

Return

Table of Contents

Control for Lowering the Forks......................................... 41 Control for raising the forks.............................................. 41 Coast control (HMX only)................................................. 42

Driving ............................................................................... 43 Starting the truck.............................................................. 44 Braking............................................................................. 46 Steering............................................................................ 48 Parking the truck .............................................................. 48

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

Battery ............................................................................... 54 Type of battery ................................................................. 54 Changing the battery........................................................ 54 Charging the battery ........................................................ 56 Battery maintenance ........................................................ 59

Daily service/safety checks ............................................ 61

Daily service/safety checks ............................................. 61

Maintenance ..................................................................... 65 General............................................................................ 65 Safety regulations with maintenance work...................... 65 Cleaning and washing ..................................................... 69 Maintenance chart........................................................... 71 Lubrication chart.............................................................. 75 Oil and grease specification ............................................ 76

Maintenance ...................................................................... 65 General ............................................................................ 65 Safety regulations with maintenance work....................... 65 Cleaning and washing...................................................... 69 Maintenance chart ........................................................... 71 Lubrication chart .............................................................. 75 Oil and grease specification............................................. 76

Transport and storing the truck ...................................... 77 The truck’s dimensions and weight as standard .............. 77 Lifting the truck................................................................. 78 Towing and transporting a disabled truck ........................ 79 Storing the truck ............................................................... 80 Starting after a period of disuse ....................................... 80

Recycling/discarding........................................................ 81 Discarding the battery ...................................................... 81 Scrapping the truck .......................................................... 81

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 severe material damage.

WARNING

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

CAUTION

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

NOTE!

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

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.

•

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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:

Return

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

As a towing truck for trailers.

To tow other trucks.

To transport/lift passengers.

Safety regulations

General safety regulations

Operator’s responsibility

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

Local regulations regarding personal safety equipment shall be followed.

•

Local regulations regarding personal safety equipment shall be followed.

•

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

•

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

•

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

•

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

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Safety regulations

General safety regulations

Working area

•

If there are marked truck routes these shall be used.

•

If there are marked truck routes these shall be used.

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

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Safety regulations

General safety regulations

Driving and conduct while driving

•

Always drive the truck from the normal operator position.

•

Always drive the truck from the normal operator position.

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

Keep a safe distance from all vehicles ahead.

•

Keep a safe distance from all vehicles ahead.

•

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

•

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

•

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

•

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

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Safety regulations

•

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

•

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

•

Never allow passengers to ride on the truck.

•

Never allow passengers to ride on the truck.

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

DO NOT smoke while working around truck.

•

DO NOT smoke while working around truck.

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Safety regulations

General safety regulations

Handling loads

•

Drive with care when collecting or leaving a load.

•

Drive with care when collecting or leaving a load.

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

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Safety regulations

General safety regulations

Parking the truck

•

Always park in designated areas if available.

•

Always park in designated areas if available.

•

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

•

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

•

Never park the truck on an incline.

•

Never park the truck on an incline.

•

Never park the truck so that it obstructs emergency exits.

•

Never park the truck so that it obstructs emergency exits.

•

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

•

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

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Safety regulations

General safety regulations

Handling the battery

•

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

•

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

•

Always wear protective glasses when working with the battery.

•

Always wear protective glasses when working with the battery.

•

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

•

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

•

Make sure the battery is secured in its compartment.

•

Make sure the battery is secured in its compartment.

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Safety regulations

General safety regulations

Maintenance and repair

All replacement parts shall be BT approved spare parts.

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Warning and information signs

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

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Warning and information signs

Breaking these rules may cause serious or fatal injury to yourself or others Read and understand all warnings and operating instructions in the operator's manual before operating this truck.

2 3 4

Warning and information signs

Breaking these rules may cause serious or fatal injury to yourself or others Read and understand all warnings and operating instructions in the operator's manual before operating this truck.

2 3 4

RMX

6 7 8 9

11 MACHINE EQUIPPED WITH COAST FEATURE.

6 7 8 9

11 MACHINE EQUIPPED WITH COAST FEATURE.

MOVE HANDLE FULLY UP OR DOWN TO APPLY BRAKE. 302523-000

HMX

MOVE HANDLE FULLY UP OR DOWN TO APPLY BRAKE. 302523-000

HMX

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. 18 Return

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. 18

Presentation of truck

The truck has a maximum lifting capacity of 8000 lb [3632 kg]. Refer to the truck’s data plate for this information on lifting capacities.

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Presentation of truck

Application area for BT’s trucks

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

Prohibited applications for BT’s trucks

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

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

Do not use as a towing truck for trailers

Do not use to tow other trucks

Do not use to transport/lift passengers

Do not use to drive on gravel or grass

Presentation of truck

Truck data

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

RMX truck data

Truck type

5000 lb [2270 kg]

6500 lb [2951 kg]

8000 lb [3632 kg]

Voltage

5000 lb 6500 lb [2270 kg] [2951 kg]

Truck type Voltage

8000 lb [3632 kg]

Operating speed without load

3.7 mph [5.95 km/h]

Operating speed without loa

3.7 mph [5.95 km/h]

Operating speed with classified load

2.3 mph 2.6 mph 2.4 mph [3.7 km/h] [4.18 km/h] [3.86 km/h]

Operating speed with classified loa

2.3 mph 2.6 mph 2.4 mph [3.7 km/h] [4.18 km/h] [3.86 km/h]

Maximum operating gradient with load, %

Continuous noise level. dB (A)

<80

Continuous noise level. dB (A)

<80

HMX truck data

HMX truck data 6500 lb [2951 kg]

Truck type Voltage

8000 lb [3632 kg] 24

Operating speed without load

8 mph [12.87 km/h]

Operating speed with classified load

6 mph 5 mph [9.65 km/h] [8.04 km/h]

6500 lb [2951 kg]

Truck type Voltage

8000 lb [3632 kg] 24

Operating speed without loa

8 mph [12.87 km/h]

Operating speed with classified load

6 mph 5 mph [9.65 km/h] [8.04 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 Truck battery dimensions RMX truck battery dimensions

Important

Use only batteries that meet the following specifications:

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.

HMX truck battery dimensions

Important

Use only batteries that meet the following specifications:

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Presentation of truck

RMX truck dimensions

The following diagrams show external dimensions for the RMX truck in its standard design.

Extended tip forks

B D

D E

77.7 in. [1973.58 mm] 12 Volt 83.0 in. [2108.2 mm] 24 Volt

Battery Compartment 8.1 in. [205.74 mm] 12 Volt Battery Compartment 13.3 in. [337.82 mm] 24 Volt

67° 12.5°

Battery roller height

56.4 in. [1432.56 mm] 12 Volt 61.6 in. [1564.64 mm] 24 Volt

Battery Compartment 8.1 in. [205.74 mm] 12 Volt Battery Compartment 13.3 in. [337.82 mm] 24 Volt

67° 12.5°

Battery roller height

F N

56.4 in. [1432.56 mm] 12 Volt 61.6 in. [1564.64 mm] 24 Volt

F N

L H

J 30.2 in. [767.08 mm] 12 Volt 35.4 in. [899.16 mm] 24 Volt

All Dimensions shown for 48 in. [1219.2 mm] long pallet

34.1 in. [866.14 mm]

47.6 in. [1209.0 mm]

9.8 in. [248.92 mm]

34.1 in. [866.14 mm]

47.6 in. [1209.0 mm]

9.8 in. [248.92 mm]

9.1 in. [231.14 mm]

3.25 in. [82.55 mm]

2.3 in. [58.42 mm]

9.1 in. [231.14 mm]

3.25 in. [82.55 mm]

2.3 in. [58.42 mm]

27.0 in. [685.8 mm]

6.0 in. [152.4 mm]

24.9 in. [632.46 mm]

27.0 in. [685.8 mm]

6.0 in. [152.4 mm]

24.9 in. [632.46 mm]

10.1 in. [256.54 mm]

4.2 in. [106.7 mm]

32.3 in. [820.42 mm]

10.1 in. [256.54 mm]

4.2 in. [106.7 mm]

32.3 in. [820.42 mm]

28.0 in. [711.2 mm]

6.1 in. [154.94 mm]

55.4 in. [1407.1 mm]

28.0 in. [711.2 mm]

6.1 in. [154.94 mm]

55.4 in. [1407.1 mm]

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Presentation of truck

HMX truck dimensions

The following diagrams show external dimensions for the HMX truck in its standard design.

Extended tip forks

B D

D E

Area of ride platform

Battery Compartment 13.3 [337.82 mm

67° 12.5°

S R

S I

P O

All Dimensions shown for 48 in. [1219.2 mm] long pallet

37.4 in. [949.96 mm]

61.6 in. [1564.64 mm]

3.6 in. [91.44 mm]

37.4 in. [949.96 mm]

61.6 in. [1564.64 mm]

3.6 in. [91.44 mm]

9.1 in. [231.14 mm]

3.25 in. [82.55 mm]

9.1 in. [231.14 mm]

3.25 in. [82.55 mm]

9.1 in. [231.14 mm]

27.0 in. [685.8 mm]

6.0 in. [152.4 mm]

27.2 in. [690.88 mm]

27.0 in. [685.8 mm]

6.0 in. [152.4 mm]

27.2 in. [690.88 mm]

10.1 in. [256.54 mm]

4.2 in. [106.68 mm]

32.3 in. [820.42 mm]

10.1 in. [256.54 mm]

4.2 in. [106.68 mm]

32.3 in. [820.42 mm]

28.0 in. [711.2 mm]

6.1 in. [154.94 mm]

47.9 in. [1216.7 mm]

28.0 in. [711.2 mm]

6.1 in. [154.94 mm]

47.9 in. [1216.7 mm]

88.1 in. [2237.7 mm]

40.5 in. [1028.7 mm]

55.4 in. [1407.2 mm]

88.1 in. [2237.7 mm]

40.5 in. [1028.7 mm]

55.4 in. [1407.2 mm]

47.6 in. [1209 mm]

14.9 in. [378.46 mm]

47.6 in. [1209 mm]

14.9 in. [378.46 mm]

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Presentation of truck

RMX data plate

The diagram shows the data plate used on the truck.

Legend

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Presentation of truck

HMX data plate

The diagram shows the data plate used on the truck.

Legend

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Presentation of truck

U.L. construction type

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Presentation of main components

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Presentation of main components

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Presentation of main components

4 1

9 10

11 2

19 3

RMX

RMX 16 15 20 14

5 6

16 15 20 14

5 11

HMX

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HMX

Controls and instruments

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

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

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

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

Control handle

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

Switch

Switch Steering Control Handle

Horn Switch

Steering Control Handle Horn Switch

Rearward

Directional Controls

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Forward

Rearward

Directional Controls 31

Forward

Controls and instruments

Control for raising the forks

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

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

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

Control for lowering the forks

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

Control for lowering the forks E

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

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

Controls and instruments Travel direction selector and speed control

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

Horn

The horn sounds as long as the button is pressed.

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The horn sounds as long as the button is pressed.

Controls and instruments Reverser switch

Reverser Switch

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Controls and instruments Steering control handle/brake control

B1 F

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

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

Parking brake (B1):

The arm automatically returns to position B1 when released.

Travel brake (B2):

Apply the brake by pushing the steering control handle downwards.

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

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Controls and instruments Braking using plugging function

•

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

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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.

Controls and instruments Key Switch

Battery Discharge Indicator/Hourmeter Dash Display

Emergency Disconnect Switch

Dash Panel Layout

Controls and instruments Key Switch

Battery Discharge Indicator/Hourmeter Dash Display

Emergency Disconnect Switch

Dash Panel Layout

Key switch (toggle switch)

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

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

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

Emergency disconnect switch

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Controls and instruments

BDI/hourmeter with travel interrupt

Fully-charged battery

1/2

Half-charged battery

1/2

Half-charged battery

Discharged battery

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

The hourmeter displays the time the drive motor is operating.

Battery discharge indicator (BDI)

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Controls and instruments

Hourmeter

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

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Controls and instruments Rider Handrail (HMX only)

Fork Lower

High Speed

Fork Lower

High Speed

Fork Raise

Horn

Fork Raise

Horn

Control for High Speed Control

Horn

The horn switch on handrail works the same way that it does on the steering control handle. The horn sounds as long as the button is pressed.

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Controls and instruments

Control for Lowering the Forks

Control for Raising the Forks

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Controls and instruments

Coast Control (HMX only)

Coast control MUST be disengaged to allow the steering control handle to raise fully for automatic braking.

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Driving

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

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

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

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Driving

Starting the truck

•

Ensure the battery connector is connected to the truck.

•

Ensure the battery connector is connected to the truck.

•

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

•

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

•

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

•

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

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

•

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

•

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

•

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

•

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

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

Driving

•

Driving

- That the horn functions correctly.

- That the steering functions correctly.

- That the brakes function correctly.

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•

Driving

Braking

Braking B1

2 B2

•

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

•

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

•

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

•

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When using the “plug braking” the operator may regulate, within the programmed capabilities, the severity of the “plugging” force and the stopping distance. For the lightest 46

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Driving

Steering

•

Steer by means of the control handle.

•

Steer by means of the control handle.

•

WARNING Risk of slipping. You can lose control of the truck if your hands or shoes are oily. Always dry your hands and shoes before driving.

Parking the truck

•

Stop the truck and disengage the travel direction selector.

•

Stop the truck and disengage the travel direction selector.

•

Release the steering control handle. The handle will return automatically to the parking brake position and the brakes are applied. Disengage coast control ( HMX only) for automatic braking.

•

Release the steering control handle. The handle will return automatically to the parking brake position and the brakes are applied. Disengage coast control ( HMX only) for automatic braking.

•

Turn the key switch to the O position.

•

Turn the key switch to the O position.

WARNING Unauthorized use. Accidents can happen. Always remove the key when the truck is left unattended. 48 Return

WARNING Unauthorized use. Accidents can happen. Always remove the key when the truck is left unattended. 48

Transporting loads

General

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

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

•

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

•

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

•

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

•

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

•

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

•

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

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.

•

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

•

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

•

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

•

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

•

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

•

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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 on a grade. 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. •

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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.

•

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

•

Lower the forks to the fully down position.

•

Lower the forks to the fully down position.

•

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

•

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

•

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

•

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

•

Drive carefully away. Start slowly and then increase the speed.

•

Drive carefully away. Start slowly and then increase the speed.

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

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

Transporting loads

Leaving a load

•

Slow down and position truck carefully where load is to be left.

•

Slow down and position truck carefully where load is to be left.

•

Lower the forks to the fully down position so that they clear the load.

•

Lower the forks to the fully down position so that they clear the load.

•

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.

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

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

Battery

Type of battery

•

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.

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.

Return

Battery

Charging the battery

General prohibition

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

Use an automatic charger intended for recharging traction batteries.

The charger shall have a minimum charging current of:

Return

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.

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.

Return

After approximately ten minutes make sure that the ammeter indicates a normal reading and that the control lamp is ON. 57

Battery

After charging

•

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

•

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

•

Switch OFF the charger.

•

Switch OFF the charger.

•

Disconnect the battery connector from charger connector.

•

Disconnect the battery connector from charger connector.

CAUTION

Return

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

CAUTION

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

Battery

Battery maintenance

Carry out battery maintenance after recharging.

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

Each week:

•

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

•

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

•

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

•

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

•

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

•

Refit all of the cell caps.

•

Refit all of the cell caps.

•

Rinse off and dry the battery.

•

Rinse off and dry the battery.

Return

Battery

Each month:

•

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

•

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

•

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

•

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

•

Adjust specific gravity with temperatures based on the chart below.

•

Adjust specific gravity with temperatures based on the chart below.

Temperature

Gravity

Temperature

Gravity

77°F [25.2°C]

1.280

77°F [25.2°C]

1.280

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

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 shown in the chart.

•

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

•

You need no tools to carry out the service checks.

•

You need no tools to carry out the service checks.

•

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

•

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

Return

Daily service/safety checks

12 3 4

3 4

9 2

RMX

5 8

11 17 13 2

9 1

HMX

5 8

11 17 13 2

9 8

HMX

Return

7 5

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

Daily service/safety checks Item #

Check points

Action

Hydraulic system

Daily service/safety checks Item #

Check points

Action

Check for oil leakage, hoses, and floor

Hydraulic system

Check for oil leakage, hoses, and floor

Lifting device

Check for damage, noise function

Lifting device

Check for damage, noise function

Battery

Check acid level, charge, and condition. See “Battery Maintenance” section

Battery

Check acid level, charge, and condition. See “Battery Maintenance” section

Battery cables and connections

Check for breakage, cutting, or damage

Battery cables and connections

Check for breakage, cutting, or damage

Chassis

Check for damage, remove dirt an debris

Chassis

Check for damage, remove dirt and debris

Covers / guards

Check for damage, ensure placement

Covers / guards

Check for damage, ensure placement

Drive unit

Inspect abnormal noises and leakage

Drive unit

Inspect abnormal noises and leakage

Wheels

Check for damage, remove oil, metal chips, and debris

Wheels

Check for damage, remove oil, metal chips, and debris

Hand brake

Check its functio

Hand brake

Check its function

Direction / speed control

Check its functio

Direction / speed control

Check its function

Hydraulic function

Check its functio

Hydraulic function

Check its function

Reverser switch

Check its functio

Reverser switch

Check its function

Horn

Check its functio

Horn

Check its function

Running time

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

Running time

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

Emergency stop switch

Check its functio

Emergency stop switch

Check its function

Key switch (toggle switch)

Check its functio

Key switch (toggle switch)

Check its function

High speed switch

Check its functio

High speed switch

Check its function

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

Return

Daily service/safety checks

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. 66

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. 66

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.

•

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. 69

Maintenance •

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

Maintenance •

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

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

•

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

•

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

•

Rinse off loose grime using warm water.

•

Rinse off loose grime using warm water.

Electrical components

•

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

•

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

•

Do not spray or pressure wash in the compartment.

•

Do not spray or pressure wash in the compartment.

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

Return

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

Maintenance

Maintenance chart

PM Interval:

A=5 Hours or 1 Day

E=500 Hours or 6 Months

A=5 Hours or 1 Day

E=500 Hours or 6 Months

B=20 Hours or 1 Week

F=1000 Hours or 12 Months

B=20 Hours or 1 Week

F=1000 Hours or 12 Months

C=80 Hours or 1 Month

G=3000 Hours or 36 Months

C=80 Hours or 1 Month

G=3000 Hours or 36 Months

D=250 Hours or 3 Months

No.

Action

No.

Action

1.0

Chassis

1.1

Check that the truck’s data plate is legible

1.0

Chassis

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

1.6

Check fork frame mounting

1.6

Check fork frame mounting

2.0

Motors

2.0

Motors

2.1

Check for loose connections

2.1

Check for loose connections

2.2

Clean motor

2.2

Clean motor

2.3

Check mounting bolts

2.3

Check mounting bolts

2.4

Check for abnormal bearing noise

2.4

Check for abnormal bearing noise

2.5

Check brush wear

2.5

Check brush wear

3.0

Drive unit

3.0

Drive unit

3.1

Check for leakage

3.1

Check for leakage

3.2

Check oil level

3.2

Check oil level

3.3

Check for noises

3.3

Check for noises

3.4

Check the mounting on support

3.4

Check the mounting on support

4.0

Wheels

4.0

Wheels

4.1

Remove string & 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

Return

Maintenance No.

Action

4.5

Grease load wheel bearings

4.6

Grease caster and caster wheels

4.7

Dismantle and lubricate all wheel bearings.

5.0

Brake

5.1

Clean

5.2

Maintenance B

No.

Action

4.5

Grease load wheel bearings

4.6

Grease caster and caster wheels

4.7

Dismantle and lubricate all wheel bearings.

5.0

Brake

5.1

Clean

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 syste

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. (10-15 mm above cell plate)

9.2

Check the connections on battery, truck, and charger

9.1

Check electrolyte level, 0.5-0.65 in. (10-15 mm above cell plate)

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

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Maintenance No.

Action

No.

Action

10.0

Hydraulic system

10.0

Hydraulic system

10.1

Check hoses and connections for leakage

10.1

Check hoses and connections for leakage

10.2

Check hoses for wear and damage

10.2

Check hoses for wear and damage

10.3

Check oil tank for cracks, leaks, and mounting

10.3

Check oil tank for cracks, leaks, and mounting

10.4

Check oil level

10.4

Check oil level

10.5

Change oil

10.5

Change oil

11.0

Cylinder

11.0

Cylinder

11.1

Check for leakage

11.1

Check for leakage

11.2

Check the mountings

11.2

Check the mountings

12.0

Lift devices

12.0

Lift devices

12.1

Check for damage and cracks

12.1

Check for damage and cracks

12.2

Check for play on the pull rods

12.2

Check for play on the pull rods

12.3

Check the electrical limit switch function

12.3

Check the electrical limit switch function

12.4

Check for wear to the forks and other lifting devices

12.4

Check for wear to the forks and other lifting devices

12.5

Lube all grease fittings

12.5

Lube all grease fittings

13.0

Controls

13.0

Controls

13.1

Check handle mounting

13.1

Check handle mounting

13.2

Check the handle brake lever switches

13.2

Check the handle brake lever switches

13.3

Check travel direction/speed control

13.3

Check travel direction/speed control

13.4

Check horn button function

13.4

Check horn button function

13.5

Check hydraulic button functions

13.5

Check hydraulic button functions

13.6

Check the handle control switches

13.6

Check the handle control switches

14.0

Gauge

14.0

Gauge

14.1

Check dash display

14.1

Check dash display

15.0

Brake Levers

15.2

Check handle brake levers

16.0

Key switch (toggle switch)

16.1

Maintenance C

X X X

Check switch function

Return

15.0

Brake Levers

15.2

Check handle brake levers

16.0

Key switch (toggle switch)

16.1

Check switch function

X X X

Maintenance No.

Action

17.0

Emergency stop switch

17.1

Check the emergency stop switch

Maintenance B

No.

Action

17.0

Emergency stop switch

17.1

Check the emergency stop switch

16 11

8 6 7

2 RMX

3 4 15

13 11

6 7

1 4

4 8

RMX

13 11

4 8

10 5

6 7

2 HMX 3

Return

8 6 7

HMX 3

Maintenance chart

Maintenance

Lubrication chart

Lubrication chart Interval/Running hours

Pos No.

Service point

Wheel bearings

Hydraulic system

Travel brake

Drive gear

Hinges

Steering bearings

Gear ring

500h

L=Lubrication

Return

Service point

Wheel bearings

Hydraulic system

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

1000h

3000h L

C=Check

A B

O=Oil change

Maintenance

Approved Oils and Grease

Specification Pos.

Lubricant

Grease

Hydraulic oil

Sunoco TH

Transmission SAE 80W/90 oil

Above 5°F [-15°C]

Application

Lubricant

Bearings and bushings

Grease

Texaco 15

Hydraulic system

Hydraulic oil

SAE 75W

Gears

Transmission SAE 80W/90 oil

SAE5W-20

Hinges

Below -10°F [-23°C]

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

Motor oil

SAE 40

Specification Pos.

Below 5°F [-15°C]

area

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

Below 5°F [-15°C]

Application Below -10°F [-23°C]

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

Motor oil

Sunoco TH

SAE 40

area Bearings and bushings

Sunoco TH

Texaco 15

Hydraulic system

SAE 75

Gears

SAE5W-20

Hinges

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

RMX

HMX C

Return

Above 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.

RMX truck’s dimensions and weight

Height

60 in. [1524 mm]

Height

60 in. [1524 mm]

Width

34.1 in. [867 mm]

Width

34.1 in. [867 mm]

Length (this length is with 48 in. [1219.2 mm] forks)

88.1 in. [2238 mm]

Length (this length is with 48 in. [1219.2 mm] forks)

88.1 in. [2238 mm]

Minimum battery weight

400 lb [181.6 kg]

Minimum battery weight

400 lb [181.6 kg]

Service weight without battery (this weight is with 48 in. [1219.2 mm] forks)

1350 lb [612.9 kg]

Service weight without battery (this weight is with 48 in. [1219.2 mm] forks)

1350 lb [612.9 kg]

HMX truck’s dimensions and weight

Height

60 in. [1524 mm]

Height

60 in. [1524 mm]

Width

37.4 in [950 mm]

Width

37.4 in [950 mm]

Length (this weight is with 48 in. [1219.2 mm] forks)

88.1 in. [2238 mm]

Length (this weight is with 48 in. [1219.2 mm] forks)

88.1 in. [2238 mm]

Minimum battery weight

400 lb [181.6 kg]

Minimum battery weight

400 lb [181.6 kg]

1450 lb [658.3 kg]

Service weight without battery (this weight is with 48 in. [1219.2 mm] forks)

1450 lb [658.3 kg]

Service weight without battery (this weight is with 48 in. [1219.2 mm] forks)

Return

Transporting and storing the truck

Lifting the truck

•

Return

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

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

WARNING Risk of overturning. The truck can overturn if lifted incorrectly. Always lift the truck secured to, and with the center of gravity between, the lifting truck’s forks.

Transporting and storing the truck

Towing and transporting a disabled truck

WARNING DO NOT tow a disabled truck.

It is not recommended to tow a disabled lift truck.

Return

Transporting and storing the truck

Storing the truck

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

Battery

•

Recharge the battery fully and carry out usual battery maintenance.

•

Recharge the battery fully and carry out usual battery maintenance.

•

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

•

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

Hydraulic system

•

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

Drive unit

•

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

Starting after a period of disuse

•

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

•

Before the truck is put into operation after a period of disuse it should undergo a function and safety check as stated in the section Daily service/safety checks.

•

When stored for a period greater then 3 months carry out preventive maintenance as stated in the instructions 500 hours interval.

•

When stored for a period greater then 3 months carry out preventive maintenance as stated in the instructions 500 hours interval.

Return

Recyling/Discarding

Recycling/Discarding

Batteries are hazardous to the environment and should be returned to the manufacturer for recycling.

Discarding the battery

Spent batteries shall be returned/sent to the manufacturer of the battery or its representatives (see the label on the battery) for disposal/recycling. You can also return batteries to your local BT representative who will then return the battery to the manufacturer.

Scrapping the truck

The truck consists of parts that contain recyclable metals and plastics. Below is a list of those materials used in the truck’s sub-systems.

Chassis

Steel

Chassis

Steel

Drive unit

Steel and cast material

Drive unit

Steel and cast material

Bushings

Iron/copper

Bushings

Iron/copper

Finish

Epoxy-polyester

Finish

Epoxy-polyester

Wheels

Polyurethane

Wheels

Polyurethane

Return

Recyling/Discarding

Hydraulic system

Oil tank

Steel

Oil tank

Stee

Pump unit

Steel and aluminium

Pump unit

Steel and aluminium

Hoses

Rubber and stee

Hoses

Rubber and steel

Cylinders

Steel

Cylinders

Stee

Electrical system

Return

Recyling/Discarding

Electrical system

Cables

Copper cores with PVC sheaths

Cables

Copper cores with PVC sheaths

Electronic board

Reinforced fiberglass circuit board laminate

Electronic board

Reinforced fiberglass circuit board laminate

Motors

Steel and copper

Motors

Steel and copper

BT Prime-Mover, Inc., 3305 N. Highway 38 Muscatine, Iowa 52761-8800 U.S.A Tel (319) 262-7700 • Fax (319) 262-7600

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BT Prime-Mover, Inc., 3305 N. Highway 38 Muscatine, Iowa 52761-8800 U.S.A Tel (319) 262-7700 • Fax (319) 262-7600