Download PDF: BT Minimover LW13 Forklift Operator’s Manual SN555494AA

WARNING! Do not use the truck before first reading through the OPERATOR’S MANUAL. NOTE! Keep for future reference.

Operator’s Manual

GB

BT Minimover LW13 Valid from serial number: 555494AA-

Order number: 208591-040 Issued: 2002-06-19 ITS Valid only for serial number: BT Products AB S-595 81 MJÖLBY SWEDEN © BT Industries AB

It is important that you read this Operator’s Manual for your own safety!

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, safety regulations and how to keep the truck in a safe condition by following daily service routines.

Only personnel who have been trained on the operation of this type of truck, are permitted to use this truck.

It is your employer’s responsibility to ensure that you have sufficient knowledge of how to use your truck safely. Do not hesitate to contact your supervisor if you feel the slightest uncertainty of how to use this truck.

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

BT Products AB

© BT Industries AB 208591-040 2

Table of Contents

Safety regulations ............................................................................... 5 Warning symbols .............................................................................. 5 General safety regulations ................................................................ 7 Warning and information plates and symbols ............................... 12 Presentation of the truck ................................................................. 14 Intended application of the truck ..................................................... 14 Forbidden application of the truck .................................................. 14 Truck data ...................................................................................... 15 Truck dimensions ........................................................................... 16 Identification plate .......................................................................... 17 Main components ............................................................................. 18 Controls and instruments ................................................................ 20 Accessories ....................................................................................... 25 Driving ............................................................................................... 26 Starting the truck ............................................................................ 26 Braking ........................................................................................... 26 Deceleration ................................................................................... 27 Steering .......................................................................................... 27 Parking the truck ............................................................................. 27 Transporting loads ........................................................................... 28 Loading and unloading ................................................................... 29 Collecting a load ............................................................................. 29 Depositing a load ............................................................................ 30 Battery ............................................................................................... 31 Changing the battery ...................................................................... 31 Charging the battery ....................................................................... 32 Daily service and function checks .................................................. 34 Maintenance ...................................................................................... 36 Cleaning and washing .................................................................... 38 Maintenance chart .......................................................................... 40 Lubrication chart ............................................................................. 44 Oil and grease specification ........................................................... 44

© BT Industries AB 208591-040 3

Table of Contents

Transporting and storing the truck ................................................. 46 The truck’s dimensions and weight as standard ............................. 46 Lifting the truck ............................................................................... 47 Towing and transporting a defective truck ...................................... 48 Storing the truck ............................................................................. 48 Starting after a period of disuse ...................................................... 49 Recycling/discarding ........................................................................ 50 Discarding the battery ..................................................................... 50 Scrapping the truck ......................................................................... 50

© BT Industries AB 208591-040 4

Safety regulations

Safety regulations Warning symbols Always follow the warnings given in this Operator’s Manual and on the truck to avoid accidents and incidents from occurring.

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

DANGER! Warns that an accident will occur if you do not follow the instructions.

The consequences are serious personal injury or possibly death and/or extremely large material damage.

WARNING! Warns that accidents can occur if the instructions are not followed.

The consequences are serious personal injury or possibly death and/or large material damage.

CAUTION! Warns that accidents can occur if the instructions are not followed.

The consequences are personal injury and/or material damage.

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

© BT Industries AB 208591-040 5

Safety regulations

Prohibitory symbols NO SMOKING If smoking occurs in situations where a restriction against smoking is stated, a serious accident can occur.

NAKED FLAMES PROHIBITED If naked flames are used in situations where naked 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 must always be worn to avoid personal injury.

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

© BT Industries AB 208591-040 6

Safety regulations

General safety regulations • Always carry out daily service before the truck is used, see chapter Daily service and function checks. 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.

• Check to make sure that all warning and machine designation plates are clean and undamaged.

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

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 authorised by BT.

Operating the truck The truck is designed and produced to be your tool when transporting, collecting and leaving loads.

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

It is not permitted to use the truck for purposes that it has not been designed and produced for, e.g. the following applications: - In areas where the atmosphere contains dust or gases that can cause fires or explosions.

- As a towing truck for trailers.

- To tow other trucks.

- To transport/lift passengers.

Operator’s responsibility • The truck shall only be driven by personnel that have been specially trained and have the management’s permission to drive the truck.

• 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 national regulations, the local safety regulations should be followed.

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

• Any accidents that have caused personal injury or damage to buildings or equipment must be reported to the supervisor.

Incidents and faults on the truck shall also be reported. © BT Industries AB 208591-040 7

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

• 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.

Working area • If there are marked truck routes these shall be used.

• 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 the total weight of the truck including the maximum load and the weight of the operator.

• Take special care if there are protruding parts from racks, shelves or walls that can cause personal injury or damage to 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 load handling devices or in the truck’s manoeuvring area.

Driving and conduct while driving • Always drive the truck from a specified 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.

• Drive at a reduced speed on inclines. Always drive with the load downwards on the incline. 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.

• Adapt your speed to suit the driving conditions, and where there are pedestrians or other trucks in the working area.

Reduce speed when the line of vision is limited and when pedestrians or other vehicles can be encountered.

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

• 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.

• Pay particular attention to other personnel as well as fixed and moving objects within the working area and thereby avoid accidents. © BT Industries AB 208591-040 8

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

• 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.

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

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

• Never allow passengers to ride on the truck.

• Before the truck is driven on to 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.

• Before you drive the truck into a lift, ensure that the lift is approved for the total weight of the truck, the load and the operator. Enter with the load first. No other personnel should be in the lift.

Handling loads • Drive with care when collecting or depositing a load.

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

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

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

• Ensure the truck is equipped with an appropriate load support when handling high loads.

Parking the truck • Always park with the load carrier fully lowered and the brake applied.

• Always park in designated areas if available.

• Never leave the truck parked with the ignition key still in the ignition.

• 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 traffic or work.

© BT Industries AB 208591-040 9

Safety regulations

Handling the battery • Always handle the battery and its connections with care.

Read and follow the instructions carefully before changing or charging the battery. See chapter 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 identification plate.

• Make sure the battery is secured in its compartment.

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

All replacement parts shall be BT approved spare parts.

Modifications or conversions to the truck that affect the safe use or function are not permitted.

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Safety regulations

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Warning and information plates and symbols

Warning and information plates and symbols The figure shows the position and significance of the plates and symbols located on the truck.

1.

2.

3.

4.

5.

6.

7.

8.

9.

Hydraulic control: Lift Hydraulic control: Lower Travel direction Signal/Horn Passengers prohibited Hydraulic oil filling Serial number Lifting points Identification plate

© BT Industries AB 208591-040 12

Warning and information plates and symbols

A B C D E E F G

© BT Industries AB 208591-040 13

Presentation of the truck

Presentation of the truck Minimover LW13 is a battery powered support arm truck equipped with a tiller arm for walking operation and castor wheels for extra stability.

LW13 is a compact truck intended for horizontal transport and for loading and unloading goods in confined areas. The truck is also ideal for use onboard trucks due to its small outside dimensions and low weight.

The truck has a maximum lifting capacity of 1300 kg.

The truck has a 24V electrical system with variable transistor control that provides gentle control of the speed while driving.

The truck is equipped as standard with a built-in battery charger for 230 V mains supply. This is combined with a start block to prevent the truck from being accidentally driven during charging.

The status of the battery is indicated by a single LED on the truck’s electrical panel.

The forks are lifted by means of a powerful and compact hydraulic unit, which is shutoff automatically once the forks have reached the highest lifting height. The automatic shutoff is designed to reduce the sound level when the highest lifting height has been reached, increase the life of hydraulic components and reduce energy consumption from the batteries.

Intended application of the truck The truck is solely designed and manufactured for indoor transportation, collecting and leaving of loads. The truck should be fitted with the appropriate accessories relevant to the application.

Forbidden application of the truck The truck is designed for handling goods indoors. It is not permitted to use the truck for other purposes including the following: - In areas that contain dust or gases which can cause fires or explosions - As a tow-truck for trailers - To tow other trucks - To transport/lift passengers - To drive on gravel or grass

© BT Industries AB 208591-040 14

Presentation of the truck

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

Truck type

LW 13

Rated capacity, kg

1300

Lift height, mm

205

Travel speed without load, km/h

5,4

Travel speed with rated load, km/h

4,0

Gradient with rated load, %

5

Weight without battery, kg

200

Weight with battery, kg

236

Turning radius (Wa), mm

1410

Continuous noise level according to CE prEN 12053, dB A

66

Continuous noise level according to ASME B56.11.5_1992, db A

59

Permitted drive wheel, material

Tractothan

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

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Presentation of the truck

Truck dimensions The illustration shows external dimensions for the truck in its standard design.

LW 13

1243

678

420

910 - 1220

156

700

450,520,685

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Presentation of the truck

Identification plate The illustration shows the identification plate used on the truck.

A

Item

Text

B C

A

MODEL

B

SERIAL NO.

C

RATED CAPACITY

kg

D

WEIGHT WITHOUT BATTERY

kg

E

BATTERY WEIGHT

F

BATTERY VOLTAGE

G

BATTERY TYPE ACCORDING TO ASME-NORM UL583 (ONLY ASME)

D E E F G

© BT Industries AB 208591-040 17

Unit

MAX MIN

kg kg V

Main components

Main components 1. Tiller arm: The truck is manoeuvred by the driver while walking. 204 degree steering area.

The brakes are applied in the tiller arm’s upper and lower positions.

2. Covers: Easily removable, providing good accessibility for battery replacement.

3. Start block and charging plug The battery is charged via the in-built charger.

4. Electric panel: Removable, which provides good access when servicing. 24 volt electrical supply. The speed is variably controlled by means of a transistor.

5. Hydraulic unit: Pump motor and pump are integrated in a compact unit.

6. Drive unit with brake: Fixed drive unit with electromagnetic brake, travel motor, gear and drive wheel combined into a compact unit. Steering bearings between motor and gears.

7. Serial number: The serial number plate fitted to the chassis.

8. Support castor wheels Two support castor wheels to ensure stability 9. Battery: 24 V using two 12 V batteries.

10. Fork carriage: The forks are held horizontally by a link system. The fork carriage can be lubricated via the push rods.

11. Identification plate: With model designation, serial number, year of manufacture, weight without battery, battery weight, rated capacity, battery voltage and manufacturer.

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Main components 1

11

2

3 4

5

6 10

9 8

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7

Controls and instruments

Controls and instruments 1.

2.

3.

4.

5.

6.

7.

8.

9.

Switch for safety reversing Travel direction selector and speed control Control for lifting and lowering the forks Horn LED to indicate start/battery status Start block and charging plug Key switch Emergency switch off Tiller arm and brake

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Controls and instruments

1 2

4

3

9

5

6

7

8

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Controls and instruments

Switch for safety reversing (1) To prevent crush injuries to the operator the truck moves in the direction of the forks when the switch M is pushed in. When the switch is no longer pushed in the truck stops. The operator must move the travel direction selector to its neutral position to start the truck again.

M

Travel direction selector and speed control (2) • Select the travel direction by moving the control (R) in the required direction. On transistor controlled trucks the speed is infinitely variable depending on the position of the control. On resistor controlled trucks the speed increases in three steps depending on the position of the control.

R

Control for lifting and lowering the forks (3)

B A

The control buttons activate a microswitch to start the pump motor with lifting and to control the solenoid valve when lowering. The lowering speed of the forks is controlled by a flow valve.

The diagram illustrates the controls, seen from the operator’s position.

• Lift the forks by pressing A and lower by pressing B. NOTE: The forks cannot be lowered with the key in the 0 position.

Horn (4) The horn sounds as long as the button is pressed.

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Controls and instruments

LED to indicate start/battery status (5) The LED has two functions: one as a start indicator and the other as a battery status indicator.

When the truck is started the LED lights and then immediately goes out.

As the battery status indicator the LED shows the battery capacity as follows: - The LED flashes when the capacity is approx. 40 %.

- The LED ligths when the capacity is approx. 20 %.

Start block and charging plug (6) • Pull out the charging plug (see diagram) in order to cut the power supply: - When charging the battery.

- In the event of an accident.

- Welding work.

NOTE! The battery can be damaged.

When welding using a electric power source the welding current can enter the battery.

It is necessary to disconnect the battery.

When charging, the charging plug should be pulled out and connected to a 230 V main supply socket.

The LED on the battery charger lights yellow when charging starts. When charging is complete and during maintenance charging one LED lights yellow and one LED green. The charger plug must be reconnected to the start block once charging is complete in order to drive the truck.

Key switch (7) The main power switch for the control current.

0

The current is cut and the start indicator LED if off.

1

The current is on and the start indicator LED lights during the start procedure.

The control current is fed to all electrical components.

© BT Industries AB 208591-040 23

Controls and instruments

Emergency switch off (8) The truck is equipped with emergency switch off (see illustr.).

Press in the emergency switch off to cut the power supply in the event of: - An accident.

- Emergency situation, risk of an accident.

- With welding work.

• Release the emergency switch off by turning the knob in the direction of the arrow.

Tiller arm and brake (9) • Operate the truck with the tiller arm in the centre position, F. The brake is activated mechanically by the tiller arm/brake lever.

The brakes are applied in two positions, B1 and B2.

Parking brake (B1): The arm automatically returns to position B1 when released.

Travel brake (B2): Brake by pressing the tiller arm downwards.

© BT Industries AB 208591-040 24

Accessories

Accessories The truck can be fitted with accessories to increase your safety when using the truck.

Load support The load support increases the stability of the load when handling high loads. The load support has different heights to suit the height of the load being handled.

© BT Industries AB 208591-040 25

Driving

Driving Starting the truck • Check that the start block has not been disconnected.

• Turn thr ignition key to the l position. The instrument lighting comes on. First after a few seconds, when the lighting has gone out, can the truck be driven.

• A flashing red light indicates a low charge status.

NOTE! Low charge level.

A low charge level can result in damage to the battery with prolonged operating.

Do not drive without first charging the battery.

• Move the tiller arm to the drive position (F). The parking brake is released automatically when the travel direction selector/ speed control is activated.

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

WARNING! Function failure.

Safety can be jeopardised.

Always check the following safety functions before starting the day’s work.

- That the horn functions correctly.

- That the steering functions correctly.

- That the brakes function correctly.

- That the hydraulic functions are operational.

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

WARNING! Dangerous driving.

Accidents can occur.

Always drive with care, good judgement and responsibility as set out in the general safety regulations.

Braking • Brake by moving the tiller arm to the B2 position. When you release the tiller arm it automatically returns to the parking brake position.

© BT Industries AB 208591-040 26

Driving

Deceleration The speed of the truck can also be reduced by means of the electric drive motor by turning the travel direction selector to the opposite travel direction. Control the braking force by the position of the speed control.

The truck is equipped with so called automatic speed reduction, which means that the speed is automatically reduced as soon as the speed control is released and returns to the neutral position.

Steering • Steer by means of the tiller arm.

• If the truck gets caught against an obstacle, do not use more force to steer than used when steering the truck under normal conditions. If this is the case, try to come free by carefully driving forwards and backwards while carefully moving the steering wheel/tiller arm.

WARNING! Risk of slipping.

You can lose control of the truck if your hands or shoes are oily.

Always dry your hands and shoes before driving.

Parking the truck • Stop the truck and disengage the travel direction selector.

• Release the tiller arm. The arm returns automatically to the parking brake position and the brake is applied.

• Lower the forks fully to the floor.

• Turn the key to the 0 position.

WARNING! Unauthorised use.

Accidents can happen.

Always remove the ignition key when the truck is left unattended.

© BT Industries AB 208591-040 27

Transporting loads

Transporting loads The weight of the load should be within the truck’s permitted lifting capacity. See the truck’s identification 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.

WARNING! Lost stability.

High loads can fall when cornering at high speed.

Drive slowly and carefully when cornering.

WARNING! Protruding loads.

The load can collide with personnel, fixed or moving objects.

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

• 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.

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

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 travelling downhill.

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

• Before you drive the truck into a lift, ensure that the lift is approved for the total weight of the truck, the load and the operator. Enter with the load first. No other personnel should be in the lift.

WARNING! Risk of overloading the lift.

An overloaded lift can fall out of control down the lift shaft.

Always check the capacity of the lift before driving in with the truck. © BT Industries AB 208591-040 28

Transporting loads • Before you drive the truck on a loading ramp, ensure that the ramp is correctly secured and that is has the necessary bearing capacity. The truck should be driven slowly and carefully across the ramp and at a safe distance from the edge.

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 edge.

Loading and unloading • Always wear protective footwear when loading and unloading.

• Never stand with your feet under the forks.

WARNING! Risk of crushing under the forks There is a risk of injury due to crushing with unintentional lowering of the forks or a fault with the hydraulic system.

Never stand with your feet under the forks.

• Do not load over the battery cover's top edge if the truck is not equipped with an appropriate load support.

• Ensure the load is secured on a pallet.

Collecting a load • Lower the forks and carefully position the forks under the load.

• Lift the forks. Do not drive at the same time as you lift the forks.

CAUTION! Lost stability.

Lifting a loaded pallet when the truck is still moving can result in the load falling off of the pallet.

Never lift a load if the truck is moving.

• Start slowly and then increase the speed.

© BT Industries AB 208591-040 29

Transporting loads

Depositing a load • Stop the truck and lower the forks. Do not lower the forks until the truck has come to a standstill.

• Leave the load so that it does not block, e.g. truck aisles or emergency exits.

CAUTION! Lost stability.

Lowering a loaded pallet when the truck is still moving can result in the load falling off the pallet.

Never lower a load if the truck is moving.

• Start slowly and then increase the speed.

© BT Industries AB 208591-040 30

Battery

Battery The truck is designed in such a way that is receives its power supply from two traction lead batteries. If any other type of battery or power source is used, measures must be taken to ensure that the battery voltage during operations always exceeds 70% of the nominal voltage, 17 volt for a 24 volt system. This is essential for the truck to function as designed.

• Check that the batteries in the truck are 2 x 12 V traction batteries with minimum and maximum weights that correspond with the data on the truck’s type 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 identification plate.

WARNING! Risk of moving the centre 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 identification plate.

When changing the battery proceed as follows: • Pull out the start block.

• Remove the battery hoods.

• Disconnect the battery cables from the batteries.

• Lift the batteries out of the truck.

• Lift in the new batteries.

WARNING! Falling battery.

The battery can fall when releasing the lifting hook if it is not secured using a trestle or other supporting material of the right height.

Check the height of the supporting material before removing the lifting hook.

• Connect the battery cables.

• Always make sure that the polarity is correct before connecting the battery cables.

• Replace the battery hoods.

• Ensure the ignition key is in the 0 position.

• Replace the start block.

• Test the truck before using it. © BT Industries AB 208591-040 31

Battery

Charging the battery GENERAL PROHIBITION When charging the battery it is absolutely forbidden to smoke or use a naked flame.

The truck’s mains lead can be connected to the mains supply whenever the truck is not in use to ensure the batteries are always fully charged. The charging process is gentle and consequently does not shorten the life of the battery. It is also beneficial if the truck can be recharged over night or for 12 hours at least once a week.

Charging instructions

A

1. Remove the charging plug (A) from the truck’s start block.

2. Pull out the spiral cable and connect the plug to a 230V wall socket. The charging process starts and continues fully automatically.

3. When the main charge is in progress, only a yellow LED (B) is lit on the charger. The LED on the charger can be seen through the hole for the main cable on the truck’s electrical panel.

B 4. When the main charge is complete, a yellow and green LED is lit on the charger. This indicates maintenance charging and equalizing charging.

5. When the truck is to be used, return the spiral cable and reconnect the charging plug in the truck’s start block.

The charger has a charging current as set out in the following table:

Battery (Ah)

Charger (A)

50

7

WARNING! Corrosive acid.

The battery fluid contains sulphuric acid. Fluid spilt on the 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!

© BT Industries AB 208591-040 32

Battery

© BT Industries AB 208591-040 33

Daily service and function checks

Daily service and function checks • The operator is responsible for the daily service and care of the truck.

• Carry out the daily service at the start of the working day or shift, before the truck is used. The daily service is a function control as set out in the checklist below.

• 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.

WARNING! Never neglect the daily service and function checks.

Serious accidents can occur.

Always report any faults or damage to the management without delay. Never use a truck that has faults.

Pos no

Check points

Action

1

Hydraulic functions

Check its function

2

Operating control

Check its function

3

Switch for safety reversing

Check its function

4

Horn

Check its function

5

Steering

Check its function

5

Brakes

Check its function

6

Drive unit

Inspect abnormal noises and oil leakage

7

Hydraulic system

Check the oil level and for oil leakage

8

Wheels

Check for damage, remove oil, metal chips and the like

9

Chassis

Check for damage, remove dirt and the like

10

Fork carriage

Check for damage and wear

11

Battery

Check the mountings

© BT Industries AB 208591-040 34

Daily service and function checks 3 2 1

4

5

11

10

6

9 8

© BT Industries AB 208591-040 35

7

Maintenance

Maintenance Ensure the truck is given a regular maintenance service according to the Maintenance chart (p. 40). 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.

BT recommends that you contact your closest BT representative to sign a service and maintenance agreement to ensure the 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 authorised 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.

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

• Never wear loose objects or jewellery when working on the truck.

WARNING! Short-circuiting/Burns.

When working with the truck’s electrical system, shortcircuiting/burns can occur if a metal object comes into contact with live electrical connections.

Remove watches, rings or other types of metal jewellery.

• Always disconnect the battery by pulling out the emergency disconnector when carrying out maintenance work on the truck unless otherwise stated in this publication or the Service Manual.

• Always switch off the truck’s power supply before opening the covers on the drive unit or electrical system.

• Relieve the system pressure slowly before starting work on the truck’s hydraulic system.

• 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.

WARNING! Risk of burns.

Hot transmission and hydraulic oil.

Let the truck cool before changing the oil.

© BT Industries AB 208591-040 36

Maintenance • Only fill the hydraulic system with new and clean oil.

WARNING! The hydraulic system can be damaged.

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

WARNING! The hydraulic system can be damaged.

The hydraulic components can be damaged if different hydraulic fluids are used.

Always use the same type of hydraulic fluid as before when topping up or changing fluid in the hydraulic system.

• Store and dispose of changed oil in accordance with local directives.

• Do not release solvents and the like, which are used for cleaning/washing, into drains that are not intended for this purpose. Follow the local directives that apply for disposal.

• Disconnect the battery when welding on the truck.

NOTE! The battery can be damaged.

When welding using an electric power source the welding current can enter the battery.

The battery should therefore be disconnected.

• Remove at least 100 mm (4”) of paint around the welding/ grinding area through sand-blasting or the use of a paint stripper when welding or grinding on painted surfaces.

CAUTION! Harmful gases.

Paint that is heated gives off harmful gases.

Remove 100 mm (4”) of paint from the work area.

• 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 trestleblocks and secured by a lifting device.

Maintenance work that is to be carried out by the operator Daily service and function checks as set out in the checklist in chapter Daily service and function checks.

Maintenance points with intervals 1 day, 1 week and 1 month as set out in the maintenance chart may be carried out by the operator.

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. © BT Industries AB 208591-040 37

Maintenance

Maintenance work that may be carried out by trained maintenance personnel All maintenance points as set out in the maintenance chart.

With uncertainty regarding working procedures, consult the Service Manual for the 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.

Cleaning and washing Cleaning and washing of the truck is important to ensure the truck’s reliability.

• 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 emergency disconnector.

External cleaning • Remove rubbish, etc. from the wheels daily.

• Use a well-known degreasing agent, diluted to a suitable concentration.

• Rinse off loose grime using tepid water.

NOTE! Jamming, corrosion.

Mechanical components can be damaged.

After washing, the truck should be lubricated as set out in the lubrication chart in chapter Maintenance.

Cleaning the motor compartment • Cover the electric motors, connections and valves before washing.

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 well-known degreasing agent, diluted to a suitable concentration.

• Rinse off loose grime using tepid water. © BT Industries AB 208591-040 38

Maintenance

Electrical components • Blow electric motors down using compressed air.

• Clean the electrical panels, electronic boards, contactors, connections, solenoid valves, etc. using a damp cloth and a cleaning agent.

NOTE! Risk of short-circuiting.

Electrical components can be damaged.

Do not break the guarantee seal on the electronic board.

© BT Industries AB 208591-040 39

Maintenance

Maintenance chart I: Inspect, correct and replace if necessary. T: Tighten C: Clean L: Lubricate M: Measure, correct if necessary

Pos. no.

0000.

0000.1 0000.2 0000.3 0000.4 0000.5 0380 0380.1 0380.2 0380.3 0380.4 1700.

1700.1 1700.2 1700.3 1700.4 1700.5 2550.

2550.1 2550.2 2550.3 2550.4 3100 3100.1 3100.2 3100.3 3500.

3500.1 3500.2 3500.3 3500.4

Work to carry out Interval in days/weeks/months - may vary due to application Chassis Check all links and locking pins Check wear on battery locking Check of cracking and damage Check signs and stickers Check the mounting, lock and function of the covers Fork carriage Check for crack formation and damage Check clearance in bushes and links Press grease into grease nipples Check the lift limit switch Drive motor Check clearance in connections Check the carbon brushes in the drive motor Clean the drive motor Re-tighten the attachment bolts Check for abnormal noise in bearing Drive gear Check for leakage Check for abnormal noise Check the attachment and clearance in steering bearing Change the grease in the drive gear Brake Clean Check for wear on the brake disc Check the function of the brake Wheels Remove string and other rubbish Check the drive wheel for wear and the tightening torque on bolts Check that the support wheel turns and rotates freely Check for wear on the support wheel

© BT Industries AB 208591-040 40

1d

1w

12 m

36 m

I I I I I I I I/L I I/T1 M C T2 I I4 I I L C M M I I/T3 I I

Maintenance I: Inspect, correct and replace if necessary. T: Tighten C: Clean L: Lubricate M: Measure, correct if necessary

Pos. no.

4110.

4110.1 4110.2 4110.3 5000.

5000.1 5000.2 5000.3 5000.4 5000.5 5000.6 5000.7 5110.

5110.1 5110.2 5110.3 5400 5400.1 5400.2 5400.3 5400.4 5400.5 5700 5700.1 6100.

6100.1 6100.2 6100.3 6100.4 6100.5 6600.

6600.1 6600.2

Work to carry out Interval in days/weeks/months - may vary due to application Tiller arm Check the mountings Check the power in the gas damper Check the touching protection Electrical functions Check the function of the brake microswitch Check the function of the collision safety switch Check the function of the horn Check for wear on cabling Check the function of the driver’s control Check the emergency switch off Check the charging plug and start block Battery Check connections to battery, truck and charger Check that the cell and pole guards are undamaged Check the battery locking Power system Cleaning and checking of mounting in chassis Re-tighten cable connections Check the contactor points on K10 and K30 Check the movement of the contactors Check the cable insulation Electronic circuit board Check connectors and cables Hydraulic system Check hoses and connections for wear Check hoses for wear and damage Check the oil tank for cracks, leakage and damaged mountings Check that the oil level is correct Change the oil and clean the filter Lift cylinder Check for leakage Check the mountings

© BT Industries AB 208591-040 41

1d

1w

12 m

I I I I I I

I I I I I I

I I I I I

I C/T1 T1 I I I T1 I I I I

I L5 I I

36 m

Maintenance 1 = Retighten connections every 12 months.

2 = Retighten securing bolts to 45 Nm every 12 months.

3 = Wheel replacement takes place when the wheel diameter is <235 mm. Wheel bolts are retightened to 20 Nm after 12 months.

4 = Check for leakage when changing the grease for the first time.

5 = The oil is replaced and the filter cleaned for the first time after 12 months then after every 24 months.

When points are carried out according to higher hour intervals, even the points at lower time intervals are to be carried out, unless otherwise stated above.

© BT Industries AB 208591-040 42

Maintenance

5000 5000 4110

5000

0380

0000

3500 5110 5700 6100

6600

5400

3100 2550 1700

© BT Industries AB 208591-040 43

Maintenance

Lubrication chart Pos no

Service point

Interval/Running hours 12 m

0380

Lubricating nipples

L

2550

Drive gear

C

6100

Hydraulic system

O5

L= Lubrication

C = Check

Lubricant

36 m D G4

C B

O = Oil change

G = Grease change

4 = The grease is changed every 36 months.

5 = The oil is changed and the filter cleaned for the first time after 12 months and then every 24 months.

Oil and grease specification Lubricant

Specification

Application area

>0° C A

Grease

BT 26777 (Spray)

Bearings and bushings

B

Hydraulic oil

ISO-L-HM32

Hydraulic system

C

Grease

SHELL RETINAX G

Gears

D

Grease

BT 73942XX5 TOTAL N3942

Grease nipples

© BT Industries AB 208591-040 44

Maintenance

0380

6100

2550

© BT Industries AB 208591-040 45

Transporting and storing the truck

Transporting and storing the truck The truck’s dimensions and weight as standard NOTE! the truck’s dimensions and weight can vary with different accessories.

The truck’s dimensions and weight

LW 13

Height

mm

With folded tiller arm

1243

Width

mm 700

Length

mm

Fork length = 1150 mm

1570

Permitted battery weight (Ah)

kg 2 x 18 (50)

Weight without battery (Ah)

kg 200

© BT Industries AB 208591-040 46

Transporting and storing the truck

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

• Before lifting, make sure that the forks are raised to the maximum lifting height.

WARNING! Risk of overturning.

The truck can overturn if it is lifted from the wrong lifting points.

Always lift the truck from the marked lifting points.

NOTE: Always check that the lift cylinder is in the correct position before the truck is used again.

• Lift from the truck’s centre of gravity when using another fork lift truck.

• Before lifting, make sure that the forks are raised to the maximum lifting height.

• Secure the truck to the lifting truck’s forks.

© BT Industries AB 208591-040 47

Transporting and storing the truck • Lift with the greatest of care.

WARNING! Risk of overturning.

The truck can overturn if it is lifted incorrectly.

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

NOTE: Always check that the lift cylinder is in the correct position before the truck is used again.

Towing and transporting a defective truck The towed truck shall always have an operator who can steer and apply the brake when towing using a tow-truck and towrope.

Tow or transport a defective truck to a repair station as follows: • Move the tiller arm to the drive position and move the truck by hand. The travel brake can still be used.

WARNING! Personal injury.

The truck can start to roll when the parking brake is disconnected.

Never leave the truck with the parking brake disconnected, chock the wheels in a satisfactory manner.

• Tow the truck using a tow-truck and trailer if the truck’s drive wheel is jammed. The truck’s drive wheel must be lifted off the ground.

Storing the truck Take the following action if the truck is not used for a long period of time:

Battery • Recharge the battery fully and carry out usual battery maintenance.

Hydraulic system • Change the oil in the hydraulic system when stored for periods longer than one year, see the oil specification in the Lubrication chart in chapter Maintenance.

© BT Industries AB 208591-040 48

Transporting and storing the truck

Drive unit • Block up the truck’s drive section to take the load off the drive wheel, when stored 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 set out in the chapter Daily service and function checks.

• When stored for a period greater than three months carry out preventive maintenance as set out in the instructions.

© BT Industries AB 208591-040 49

Recycling/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 sign on the battery) for disposal/recycling. You can also return batteries to your local BTrepresentative 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 subsystems.

Chassis Chassis

Steel

Drive unit

Steel and cast material

Bushings

Polyamide

Finish

Epoxy-polyester

Wheels

Polyurethane

© BT Industries AB 208591-040 50

Recycling/discarding

Hydraulic system Oil tank

Polythene

Pump unit

Steel and aluminium

Hoses

Rubber and steel

Cylinders

Cast iron and steel

Electrical system Cables

Copper cores with PVC sheaths

Electronic board

Reinforced glass fibre circuit board laminate

Motors

Steel and copper

© BT Industries AB 208591-040 51

Recycling/discarding

© BT Industries AB 208591-040 52