Download PDF: BT VR Forklift Operator’s Manual SN401497AA

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

Operator’s Manual

GB

BT VR Valid from serial number: 401497AA-

Order number: 180115-040 Issued: 2000-12-14 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 180115-040 2

Table of Contents

Safety regulations ............................................................................... 5 Warning symbols .............................................................................. 5 General safety regulations ................................................................ 7 Warning and information plates and symbols ............................... 12 Presentation of BT’s narrow aisle trucks ........................................................................... 14 Application areas for BT’s reach trucks .......................................... 14 Prohibited applications for BT's narrow aisle trucks ....................... 15 Truck data ...................................................................................... 16 Truck dimensions ........................................................................... 17 Identification plate, truck ................................................................. 19 Capacity plate ................................................................................. 20 Modification plate ............................................................................ 20 Identification plate, mast ................................................................. 21 Main components ............................................................................. 22 Controls and instruments ................................................................ 24 Display and programming ............................................................... 35 Warning codes ................................................................................ 38 Error codes ..................................................................................... 40 Accessories ....................................................................................... 42 Seat belt ......................................................................................... 42 Warning light ................................................................................... 42 Working light ................................................................................... 42 Wire guidance ................................................................................. 43 Button for choice of whole or half pallet .......................................... 43 Camera equipment ......................................................................... 44 Height pre-selector ......................................................................... 45 BT TLS Truck Logging System ....................................................... 50 Collision sensor .............................................................................. 53 Driving ............................................................................................... 54 Starting the truck ............................................................................ 54 Braking ........................................................................................... 56 Deceleration ................................................................................... 56 Steering .......................................................................................... 57 Parking the truck ............................................................................. 60 Transporting loads ........................................................................... 61 Collecting a load ............................................................................. 62 Depositing a load ............................................................................ 63

© BT Industries AB 180115-040 3

Table of Contents

Battery ............................................................................................... 64 Changing the battery ...................................................................... 64 Charging the battery ....................................................................... 66 Battery maintenance ....................................................................... 67 Daily service and function checks .................................................. 70 Maintenance ...................................................................................... 73 Cleaning and washing .................................................................... 76 Maintenance chart .......................................................................... 78 Oil and grease specification ........................................................... 82 Transporting and storing the truck ................................................. 88 The truck’s dimensions and weight as standard ............................. 88 Lifting the truck ............................................................................... 88 Towing and transporting a defective truck ...................................... 89 Storing the truck ............................................................................. 90 Starting after a period of disuse ...................................................... 91 Recycling/discarding ........................................................................ 92 Discarding the battery ..................................................................... 92 Scrapping the truck ......................................................................... 92

© BT Industries AB 180115-040 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 180115-040 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 180115-040 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 collecting and leaving goods at different heights in narrow aisle warehouses.

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.

- For work on sloping floors.

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.

© BT Industries AB 180115-040 7

Safety regulations • 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.

• 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, walking or standing on the platform.

• 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.

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

• Always drive with the forks fully lowered when driving outside the narrow aisle, except for when collecting or leaving loads.

• 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.

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

© BT Industries AB 180115-040 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.

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

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

• When driving outside the narrow aisle, only drive with the forks raised when manoeuvring to collect or leave 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/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.

Parking the truck • Always park the truck with the load holder 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 180115-040 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 chapter covering 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 without written approval from BT Products AB.

© BT Industries AB 180115-040 10

Safety regulations

© BT Industries AB 180115-040 11

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.

Modification plate Identification plate Capacity plate Serial number Hydraulic oil filling Parking brake Lifting points Hydraulic controls: Lift-lower, fork traverse, rotation and auto-rotation 9. Do not walk under elevated load 10. Maximum height for rated capacity 11. Identification plate, mast 12. Risk of crushing

© BT Industries AB 180115-040 12

Warning and information plates and symbols

© BT Industries AB 180115-040 13

Presentation of BT’s narrow aisle trucks

Presentation of BT’s narrow aisle trucks BT VR is developed to meet the market's increased demands for efficient material handling equipment and high performance, good ergonomics and reliability.

BT VR is easy to manoeuvre in and out of warehouse aisles. It has a powerful drive motor which combined with the rigid mast provides safe and effective handling at high heights. This results in high performance and low handling costs.

BTs series of narrow aisle trucks are designed for the handling of pallets indoors in narrow aisle warehouses. The trucks are operated with the driver seated in a protected and ergonomic operator position. The operator's position can easily be adapted so that a good working position and a view of the load are comfortable and safe. They are available in different size categories and have a standard lifting capacity of up to 1500 kg and lifting height of up to 11 m.

The truck has a 48V electrical system. The travel and lifting speeds are regulated by means of a transistor controller to provide smooth driving. The travel function and the different hydraulic functions have additional controls which further enhance these features. Different speeds, fork movement and steering can be set using parameters to give the best possible individual setting for the functions.

By equipping the truck with different accessories its efficiency and safety can be increased over and above its already high standard.

Application areas for BT’s reach trucks The truck is designed and manufactured to handle indoor pallet handling in narrow aisle warehouses. The truck should be fitted with the appropriate accessories relevant to the application.

© BT Industries AB 180115-040 14

Presentation of BT’s narrow aisle trucks

Prohibited applications for BT's narrow aisle trucks BT’s narrow aisle trucks are designed for handling goods indoors. Unless the truck is specially equipped, it is not permitted to use the truck for other purposes including the following applications: - 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 - For work on sloping floors

© BT Industries AB 180115-040 15

Presentation of BT’s narrow aisle trucks

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

Truck type

VR

Lifting capacity classified load, kg

1500

Operating speed without load, m/s

3.3 or 2.52

Operating speed with classified load, m/s

3.3 or 2.52

Rate of lifting, without load, m/s

0.37

Rate of lifting, with rated load, m/s

0.29

Rate of lowering, without load, m/s

0.48

Rate of lowering, with rated load, m/s

0.50

Side shift of forks without load, m/s

0.21

Fork rotation 180 ° without load, s

7.5

Fork rotation 180 ° with max. classified load, s

9.5

Weight without battery, kg

4050 1

Battery (5h discharge)

480/600/720/900

Weight of battery, kg

940/1120/1306/ 1400

Continuous noise level, dB (A)

< 70

Vibration level, m/s2

0.8

1) Medium chassis, h23 = 7000 mm 2) 3.3 m/s for chassis width 1420 and 1520 mm with rail guidance.

2.5 m/s chassis width 1270 mm, or chassis width 1420 and 1520 mm with wire guidance.

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

© BT Industries AB 180115-040 16

Presentation of BT’s narrow aisle trucks

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

© BT Industries AB 180115-040 17

Presentation of BT’s narrow aisle trucks

Dimensions (mm) b1

Chassis width

1270/1420/1520

b5

Width across forks, min./max.

525-11601

e

Fork width

120/125

h6

Height over cab

2266

h7

Seat height

1100

h13

Fork height with forks lowered

80

l

Fork length

600-1800

I2

Truck length excl. forks

2125/2275/2425

I22

Boom length, min.

650

m2

Floor clearance

60

Wa

Turning radius

1960/2110/2260

x

Distance between wheel axle and fork carriage

172

1) Depending on boom length

Dimensions, depending on lift height (mm) h1, mm

2535

2735

2935

3135

3570

3770

3970

4170

4505

4705

5035

h2, mm

1570

1770

1970

2170

2604

2804

3004

3204

3538

3738

4070

h4, mm

5290

5890

6490

7090

7990

8590

9190

9790

10390 10990 11965

h23, mm

4300

4900

5500

6100

7000

7600

8200

8800

9400

© BT Industries AB 180115-040 18

10000 11000

Presentation of BT’s narrow aisle trucks

Identification plate, truck The illustration shows the identification plate for the truck in CE-design.

Item

Text

Unit

A

MODEL

B

SERIAL NO

C

RATED CAPACITY

kg

D

WEIGHT WITHOUT BATTERY

kg

E

BATTERY WEIGHT

kg kg

F

BATTERY VOLTAGE

MAX MIN

V

The illustration shows the identification plate for the truck in ASME-design.

A B C D E E F G

Item

Text

A

MODEL

B

NO

C

RATED CAPACITY

kg

D

WEIGHT WITHOUT BATTERY

kg

E

BATTERY WEIGHT

kg kg

F

BATTERY VOLTAGE

G

BATTERY TYPE ACCORDING TO ASME-NORM UL583

© BT Industries AB 180115-040 19

Unit

MAX MIN

V

Presentation of BT’s narrow aisle trucks

Capacity plate The illustration shows the capacity plate used on the truck.

Item

Text

Unit

H

SERIAL NO

I

LIFT HEIGHT

mm

J

ACTUAL CAPACITY

kg

K

LOAD CENTRE DISTANCE

mm

L

THE TRUCK MUST ALWAYS BE DRIVEN WITH LOWERED FORKS AND RETRACTED MAST EXCEPT WHEN PLACING OR REMOVING LOAD.

Modification plate The illustration shows the modification plate which is found on the truck if it is supplied as non-standard or if it has been modified after leaving the manufacturer. The plate includes information according to the table below.

Item

Text

A

Modification plate

B

Type

C

Serial number

D

Place of manufacture

E

Place of manufacture

F

Modification number

G

Date

© BT Industries AB 180115-040 20

Presentation of BT’s narrow aisle trucks

Identification plate, mast The illustration shows the mast identification plate which can be found on the side of the mast. The plate shows information according to the table below.

Item

Text

A

Type

B

Serial number

C

Date

© BT Industries AB 180115-040 21

Main components

Main components 1. Mast: The mast is a hi-lo model for minimal mast height, see measurement h1 on the dimension diagram, and is fitted with an information plate with model designation, serial number and year of manufacture.

2. Three-way fork carriage: The three-way fork carriage has two home positions that allow full speed, carriage shifted fully to the left or right and the forks turned in as shown in the illustration.

3. Battery: 48 V with different Ah values. The dimensions of the battery tray conform to DINstandards.

4. Recharging connector: The battery is charged using a permanent recharging connector which is connected to the battery, see chapter Battery for further details.

5. Control circuit fuse: 10A, BT part no. 161640-100.

Fuse for electrical steering wheel: 30 A, BT part no. 161640-300.

6. Hydraulic unit: Pump motor, pump and oil tank integrated in a compact unit.

7. Hydraulic valves: The hydraulic valves are located in two different places on the truck depending on their function.

The valves for the mast lift are fitted directly to the hydraulic pump and the valve pack for the fork functions are located under the cover on the three-way fork carriage.

8. Drive unit with brake: Drive motor, gears and drive wheel combined into a compact unit. Steering bearings between motor and gears as well as a 360° steering angle which facilitates the handling of loads.

9. Electrical steering motor: Mounted with the drive gear to provide a compact design.

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

11. Operator’s seat: The seat is fully adjustable to provide optimal operator comfort.

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

13. Cover: Easily swivelled to provide good access for servicing.

14. Pedals: Accelerator with optional direction selector, travel brake and safety pedal.

15. Control console: The control console can be adjusted to a suitable height and angle to obtain a comfortable working position. The steering, hydraulic functions, horn, weight indication, height pre-selector, travel direction and any extra hydraulic functions are all controlled from this console.

16. Instrument panel: This provides information on the truck’s running time, time indication, error codes, travel direction, parking brake, steering angle, operator identification and battery status. The instrument panel also houses the emergency switch off, ignition key, switches for accessories, indicator lamps for fork position and narrow aisle mode and buttons for operator parameters.

17. Roof panel: Panel with displays for height and length indication and push buttons for working lights and half pallet handling.

18. Electronics: Electronic equipment for lifting and driving functions is housed under the armrest panel. The electronic card for fork functions is fitted to the three-way fork carriage and the electronic card for the wire guidance option is located under the floor in the cab.

19. Drive motor fuse: 160 A BT part no. 29223.

20. Pump motor fuse: 300 A, BT part no. 29674.

© BT Industries AB 180115-040 22

Main components

© BT Industries AB 180115-040 23

Controls and instruments

Controls and instruments 1. Emergency switch off 2. Key switch 3. Display 4. Operator identification 5. Indicator lamps 6. Control console 7. Controls for control console position 8. Operator’s seat 9. Pedals 10. Cover lock 11. Height indicator

© BT Industries AB 180115-040 24

Controls and instruments

Emergency switch off (1) 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.

Note that it is still possible to steer the truck when the emergency switch is activated.

If the emergency switch has been pressed in, the ignition key must be turned off and on after the emergency switch has been reset.

NOTE! The battery can be damaged.

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

It is necessary to disconnect the battery.

Key switch (2) The main power switch for the control current.

0

The power is off and the display lamp is off (however, there is still voltage to some parts of the electronics).

1

The power supply is on. The display light is on and current is fed to all electronic components.

Display (3) Parking brake indicator (A) When the parking brake is applied, the indicator window (A) will light.

Direction indicator (B) When selecting the direction of travel an arrow will light indicating the selected direction.

Time display (C) A digital clock indicates the actual time. How to set the time is explained in the section Display and programming (p. 35).

© BT Industries AB 180115-040 25

Controls and instruments Display of hour meter reading/error codes (D) The character window (D) shows the time, load weight and error codes. When the time meter reading is displayed the indicator window (J) is lit. The time displayed is as follows:

Character

Time Key time

Total running time

Drive motor time

Pump motor time Remaining operating hours before next service When the warning/error codes are displayed the indicating window (G) will be lit. A character E/C will be displayed in the left-hand side of the character window and the error code in the right-hand side. The meaning of the codes is explained in the sections Warning codes and Error codes.

Operator identification (E) During operator selection, the number will be shown in the indicator window (E). To log in, see under Operator identification (p. 27) in this chapter.

Drive wheel indicator (F) The position of the drive wheel and the truck’s direction of travel are indicated by one of the arrows in the diagram. When the opposite direction is selected without changing the position of the drive wheel the opposite arrow will light.

Weight indication (H) When load weighing is ordered, indicator window (H) will light up.

• Start weighing by actuating the switch on the control console, see Weight indication (C) in the section Switches and indicator lamps.

Parameter control (I) When checking the set parameters the indicator window (I) will light. For checking procedures, refer to the section Display and programming (p. 35). © BT Industries AB 180115-040 26

Controls and instruments Battery controller (K) The battery controller indicates the current charge status of the truck’s battery.

1

Fully charged battery

1/2

Half-charged battery

0

Discharged battery

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

Operator identification (4) The truck can be adapted to suit the requirements of different operators as regards speed, acceleration, etc. See section Display and programming. These are activated by stating the operator number using push-buttons I-III. Two different alternatives are available: three or ten operators.

When the three-operator alternative is used, the operator number is determined by pressing the relevant push-button.

When the ten-operator alternative is selected, a 4-figure code is entered using the push-buttons, e.g. I, II, II, III. The code is programmed using a service instrument.

© BT Industries AB 180115-040 27

Controls and instruments

Indicator lamps (5) Pos.

Symbol

Function

A

Indicator lamp, forks in home position

B

Indicator lamp, truck in narrow aisle

C

Weight indication

D

Bypass lift

Indicator, forks in home position (A) A green lamp is lit when the forks are in the “home position”.

When the forks are not in the home position the travel speed of the truck is reduced.

When the function “Auto rotation straight ahead” is active (activated by service parameter 61), the position is also indicated by the lamp being lit: Forks 90° straight ahead/traversing half way.

This position is not, however, defined as the “home position” and the travel speed is reduced.

N.B. "The home position": Traversing to the left and the forks turned max. clockwise or traversing to the right and the forks turned max. anti-clockwise. Full speed is permitted.

Indicator, “truck in narrow aisle” (B) A green lamp is lit when the truck is in the narrow aisle.

Weight indication (C) The truck can show the actual weight on the forks within the free-lift zone if you collect a load with the forks and then press the switch. Then, lift the load until the weight is shown in the hour meter indicator window. The weight is shown to the nearest 50 kg. The hour meter display resets automatically after 10 seconds.

© BT Industries AB 180115-040 28

Controls and instruments Lift height limit override (D) When the forks have come up to the lift limit height, the lift is stopped. Press down switch (D) to override the lift height limit.

The lift should be started within 5 seconds and when the lift has stopped, continued lifting can take place within 15 seconds.

Two different lift limit heights can be programmed.

WARNING! Obstacles in the roof.

The truck can overturn and the load fall if the mast catches on an obstacle.

Pay extra attention to the top of the mast when operating the truck.

Control console (6) Steering (A) The steering characteristics are progressive. This means the higher the driving speed the lower the steering speed (sensitivity is reduced). When driving slowly you do not need to turn the steering wheel as many turns as when drive at a high speed.

The steering characteristics can be adapted to the operator’s experience and requirements. Steering sensitivity and progressiveness can be increased or decreased as is required. See section Display and programming.

The drive wheel has no end limit position, which allows steering through 360°.

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

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

WARNING! Lost stability.

The truck can overturn and the load fall if you turn the steering quickly at high speed.

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

Horn control (D) The horn sounds as long as the switch is pressed in.

© BT Industries AB 180115-040 29

Controls and instruments Hydraulic controls (F) On the control console there are a maximum of five mini-levers with which the hydraulic functions are controlled. The movement of the levers is processed on the logic-board which then sets the correct speed on the pump motor and oil flow via a proportional valve. Changes in function speed are attained by moving the levers forwards or backwards more or less.

Function Lever 1 -

Lower forks

+

Lift forks

Lever 2 -

Traversing, left

+

Traversing, right

Lever 3 -

Fork rotation, anti-clockwise

+

Fork rotation, clockwise

Lever 4 -

Auto-rotation, clockwise / accessory

+

Auto-rotation, anti-clockwise / accessory

Lever 5 -

Extra hydraulic function / accessory

+

Extra hydraulic function / accessory

Auto-rotation (lever 4) Auto-rotation can only be activated when the forks are in the home position and the indicator lamp is lit. If the lever is released during the rotation, or if lever 2 or 3 is activated, the auto-rotation will be stopped. The function is interrupted and cannot be restarted until the forks are manually returned to the home position.

When the lever is moved, + or -, more than 1/3 of its stroke length the forks will be fully traversed and rotated, from home position to home position.

An extra function, “Auto rotation straight ahead” can be connected by adjusting service parameter 61. The forks are rotated 90° straight ahead and traversing stops half way.

When the lever is moved more than half of its stroke length autorotation will position the forks straight ahead.

© BT Industries AB 180115-040 30

Controls and instruments Levers 4 - 5 can have other functions, e.g. fork spread and/or fork tilt. These functions are described in the chapter Accessories.

Those functions which may be use simultaneously are traversing and rotation of the forks.

The levers’ distance can be adjusted to suit the accompanying cover-plates. See Master Service Manual (MSM).

Note! No hydraulic functions can be used if the ignition key is in the 0 position or if the operator’s seat is empty.

Travel direction selector (G) Select the travel direction by pressing the switch in the direction you wish to travel.

• Release the parking brake by pressing the accelerator down gently. Then, hold the switch pressed down for more than two seconds and the truck will start to move at a crawling speed.

This function can be used advantageously when you wish to adjust the truck’s final position, e.g. when you are collecting or leaving a load.

Controls for control console position (7) The control console is adjustable to provide a comfortable operating position.

• Loosen knob (A) and the entire control console can be adjusted to a suitable height.

• Loosen knob (B) and the entire control console can be tilted in a suitable position.

• Do not forget to tighten knobs (A) and (B) after adjusting.

A

B

C

• Push the locking lever (C) to its rear position. The control console can now be moved forwards or backwards around its centre pivot. Lock the control console by moving the locking lever to its forward position.

NOTE! Overloading the mounting.

Do not use the control console as a handle when entering the cab.

Use the left-hand post by the truck’s entry.

WARNING Loose control console.

You can lose control of the truck if the control console is loose.

Tighten the knobs and move the locking lever to its rear position after adjusting.

© BT Industries AB 180115-040 31

Controls and instruments

Operator’s seat (8) The operator’s seat can be adjusted as required to attain the most comfortable operating position.

Adjustment: • To set the angle of the back rest, lift up the lever (A) at the same time as you push the seat forwards or backwards • To adjust the seat forwards or backwards, pull out the lever (B) and release the locking mechanism.

Use the lever (C) to set the seat’s spring force. Setting should be carried out with a load-free seat.

• Pull out the lever to the weight which corresponds to the operator’s weight.

To reset, pull the lever fully out and then release it. The set value is indicated on the dial.

The driver’s seat can be fitted with a seat belt to increase safety.

WARNING! Loose operator’s seat.

You can lose control of the truck if the operator’s seat is loose.

Ensure all levers are locked.

Left hand handle: When driving over long distances the left hand is placed on the handle and the right hand on the steering wheel and thereby increasing the operator’s comfort.

Pedals (9) Safety pedal (A) • Place your left foot on the safety pedal when you release the parking brake. This prevents your foot being crushed if the truck collides with an obstacle.

There is the possibility for two alternative functions on the left foot pedal: - a buzzer sounding or - a buzzer sounding and acceleration is stopped when the left foot is not placed on the pedal. However, the motor brake and the foot brake can be used.

© BT Industries AB 180115-040 32

Controls and instruments To change the function, contact a trained service technician.

NOTE! Risk of crushing Risk of crushing exists if any part of the body is outside of the operator’s cab.

Always sit with the whole of your body inside the protective cab.

The pedal stand can be adjusted longways to suit different operators.

Travel brake (B) • Use the travel brake to reduce the speed of the truck. The braking force is controlled by the pressure on the pedal.

If the travel brake pedal is pressed down when the truck has stopped, the parking brake is automatically applied.

Accelerator (C) The speed is infinitely variable depending on the pressure applied to the pedal.

When the accelerator is actuated, the parking brake is released automatically.

Cover lock (10)

• Loosen the handle and swing out the entire seat plate to inspect the motor compartment

© BT Industries AB 180115-040 33

Controls and instruments

Height indicator (11)

A The height indicator shows the forks’ actual height within the head lift area. The height is shown digitally on a display.

© BT Industries AB 180115-040 34

Controls and instruments

Display and programming It is possible to look in the machine-specific register, but not to re-programme. However, you can re-programme the operatorspecific parameters and the clock. The parameters can be found in the table. For further information regarding parameters and warning and error codes, see Master Service Manual (MSM).

Display Follow the instructions below to look into the operator and machine-specific register: • Switch on the ignition key to feed voltage to the electronics.

• State the number of the operator, using the switches I-III. • Then, hold switch I pressed in for 5 secs.

• Press switch I once more to scroll between the functions.

The indicator windows will present the functions: - Time of day (C) - Error codes (D) - Parameters (D) - Running times and service time (D) The address register’s ”No” will be shown on the left-hand side and ”the value” on the right-hand side.

Programming Clock When programming of the clock is possible, the indicator windows for hours will flash and after pressing switch I the minutes will flash.

• Change by scrolling up with switch II and down with switch III. • Store the programmed value and show the next function by pressing switch I.

Function

Value

Hours

09 = 9h

Minutes

35 = 35 min.

When the error codes are shown in the indicator window (D), indicator window (G) will light up and when parameters are shown in the indicator window (C), indicator window (I) will light up. However, parameters are not possible to re-programme in this position. If this function is required, see Operator parameters. © BT Industries AB 180115-040 35

Controls and instruments Quit programming by switching the ignition key off and on once.

Programming is also stopped if no button is pressed within twenty seconds.

NOTE. Truck handling.

The handling characteristics of the truck will change if you change any of the truck specific parameters. Do not change any parameters without possessing the necessary know-how.

Operator parameters To re-programme the operator parameters (if the change is permitted), carry out the following: • Switch on the ignition key to feed voltage to the electronics.

• Using the switches (I-III), enter the number of the operator for whom you wish to change the parameters.

• Turn off the ignition key so that the electronic board is dead.

• Press switch I at the same time as you turn the ignition key.

The operator number will be shown in the indicator window (E).

• Scroll using switch II (up) and switch III (down) to the parameter you want to change.

• Press down switch I (the parameter number flashes).

• Change the value using switches II and III. • Press down switch I to set the value (the parameter number stops flashing).

If you want to change several parameters, scroll with switches II and III to the parameter you want to change and repeat from “Press switch I (the parameter number flashes)”.

Conclude the programming by turning the ignition key off and on.

The common operator parameters can only be reprogrammed using a service instrument.

© BT Industries AB 180115-040 36

Controls and instruments

No.

Parameter type

1

Steering sensitivity

2

Drive motor, max. speed

3

Min./ Max.

Std. value

Notes

1-6

3

%

10 - 100

100

Drive motor, acceleration

%

10 - 100

100

4

Drive motor, automatic deceleration

%

0 - 100

50

5

Drive motor, max. reversing Max. speed in narrow aisle

%

10 - 100

80

1 = little sensitivity 5 = much sensitivity 6 = no progressiveness To the nearest whole value In percent of max. speed To the nearest 5th value In percent of max. acceleration To the nearest 5th value In percent of max. autobrake To the nearest 5th value 0 = no automatic deceleration Drive motor, max. reversing

%

10 - 100

100

6

Unit

In percent of max. narrow aisle speed.

To the nearest 5th value

Parameter 1 The higher the number entered, the fewer turns of the steering wheel are required to turn the drive wheel. Entering the number 6 will give steering with no progressiveness (less sensitivity at higher speed).

Parameter 2 This parameter is used to set the maximum permitted travel speed.

Parameter 3 The lower the number entered here, the longer time it will take to reach max. speed.

Parameter 4 This parameter is used to set the braking force to be applied when the accelerator pedal is released.

Note 1.

Driver 1 has 20%, drivers 2-10 have 50% as standard values.

Parameter 5 This parameter is used to set the braking force with which the truck is stopped when you change travel direction and use the drive motor to stop the truck.

Parameter 6 This parameter is used to set the maximum permitted travel speed in the narrow aisle.

© BT Industries AB 180115-040 37

Controls and instruments

Warning codes Character

Error Warning

When an error occurs a buzzer will sound and a code is displayed, during a 10 second period, on the right-hand side of the character window (C).

If the error remains after 1 minute the warning and buzzer will be reactivated for a further 2 second period.

This process continues until the fault is rectified, however, the truck can be driven with all functions as set out in the table.

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

WARNING! Ignoring error indications.

Truck safety in jeopardy.

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

Code No.

Error type

Probable cause

Effect on the truck

11

The servo electronics on the steering are too hot.

Jammed steering.

The steering and driving speed is reduced.

14

The seat switch is activated for more than 20 minutes without the machine being touched.

Faulty switch or broken cable.

None

15

The safety switch is activated for more than 20 minutes without the machine being touched.

Faulty switch or broken cable.

None

16

Accelerator pedal actuated when ignition key turned on.

Accelerator sensor actuated when ignition key turned on.

Driving stopped until the accelerator has come to neutral position.

17

Brake pedal actuated when ignition key turned on.

Brake sensor actuated when ignition key turned on.

Driving stopped until the brake pedal has come to neutral position.

18

The battery in the logic box has reached its lowest voltage level.

The battery has run down.

The data stored in the memory will be lost.

19

The truck’s parameter values are not OK, standard values entered.

© BT Industries AB 180115-040 38

Truck driving characteristics changed.

Controls and instruments

Code No.

Error type

Probable cause

Effect on the truck

21 - 24

Error signal from the hydraulic function sensors.

Faulty sensor, broken cable or sensor actuated when ignition key turned on.

Function depending on the cause of the error.

25

Electrical failure or shortcircuiting on a valve/support arm brake.

Faulty valve/support arm brake or broken cable.

Function depending on the cause of the error. Support arm brake error reduces the max. speed to 9 km/h.

26

Electrical failure on the sensor for hydraulics/accelerator.

Faulty potentiometer or broken cable.

Function depending on the cause of the error.

27

Incorrect battery supply.

The power supply cables to the battery supply are not connected to the battery.

No effect on the truck. The battery display flashes.

28

Emergency switch off has been activated.

29

Service counter at zero.

Service should be carried out.

Buzzer sounds every minute.

30

No signal from height pulse sensor when lowering forks above the fork reference switch.

Faulty pulse sensor or broken cable.

None

31

No pulses from sensor for traversing position.

Faulty pulse sensor or broken cable.

Fork movement reduced to creep speed.

32

Incorrect values from sensor for rotation angle.

Faulty/incorrectly adjusted sensor or broken cable.

Fork movement reduced to creep speed.

33

Incorrect parameter values for fork movement, standard values entered.

Altered characteristics for fork movement.

Fork movement reduced to creep speed.

34

Incorrect signals to/from valves for fork movement.

Communication fault between the truck’s electronics and the electronics in the three-way fork carriage.

Function depending on the cause of the error.

Traversing and rotation movements stopped.

Fork movement reduced to creep speed or stopped.

Travel speed reduced to creep speed.

40-47

High temperature in transistor panel or motor.

The truck is stopped.

Faulty valve Communication fault

One of the cooling fans has stopped.

© BT Industries AB 180115-040 39

Driving/hydraulics performance is reduced.

Controls and instruments

Error codes Character

Error Error

When an error occurs a buzzer will sound at the same time as an error code is displayed on the right-hand side of the character window (D). The buzzer will sound until the key is turned and the voltage to the truck is cut.

If the error remains when the key is turned on again the buzzer will sound and the error code displayed.

The truck cannot be used with the functions listed in the table.

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

WARNING! Ignoring error indications.

Truck safety in jeopardy.

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

Code No.

Error type

Probable cause

Effect on the truck

104

Error in parking brakes

Faulty electronics unit

Drive motor stopped

106 -108

Error in main contactor or main capacitor output

Faulty main contactor or cable

All functions stopped

111

Error in brake pedal potentiometer

Faulty potentiometer or cable

Drive motor stopped

112 120 -121 123 127 -140

Error in the electronics unit

Faulty electronics unit

Drive motor braked

122

Too much heat in the servo electronics.

Faulty electronics unit

All hydraulic functions except lowering the forks are stopped

125

Error in the steering generator.

Faulty generator or broken cable.

Drive motor stopped

126

Error in the steering motor

Faulty motor or broken cable.

Drive motor stopped

150-163

Error in CAN communication

Fault in component or cable

Function depending on the cause of the error

170

Error in wire guidance unit

© BT Industries AB 180115-040 40

Driving stopped Drive motor braked

Controls and instruments

Code No.

Error type

Probable cause

Effect on the truck

171

Wire guidance not requested in guided aisle

Switch for wire guidance not activated

Drive motor braked.

172

Wire not detected

Incorrect parameter values for wire guidance

Drive motor braked.

173

Truck has lost the guidance wire (derailment)

Incorrect parameter values for wire guidance

Drive motor braked

174

Too wide steering angle in guided aisle

Incorrect parameter values for wire guidance

Drive motor braked

175

Sensors for centre of aisle activated outside narrow aisle (narrow aisle sensors not activated)

Sensors faulty or subjected to mechanical interference

Drive motor braked

176

No communication with wire guidance unit at start up

Fault in component or cable

Drive motor stopped.

Restarting may solve the problem

177

No communication with wire guidance unit

Fault in component or cable

Drive motor braked. Restarting may solve the problem

200-215 220-235

Error indication from frequency converter

Fault in component or cable

Function depending on the cause of the error

© BT Industries AB 180115-040 41

Accessories

Accessories The truck can be fitted with different accessories to further increase your safety and make your work easier when using the truck. Accessories can be combined.

Seat belt The driver’s seat can be fitted with a seat belt to increase safety.

• Always wear the seat belt when driving the truck.

WARNING! Failure to use the seat belt.

You can be thrown from the truck when stopping suddenly.

Always wear a seat belt.

Warning light A warning light can be mounted on the truck and is used to warn persons in close proximity when you are driving in a certain direction.

Working light The working light is used to help the operator see in dark areas.

The light is turned on using the switch on the roof panel.

© BT Industries AB 180115-040 42

Accessories

Wire guidance

• Press button E when you enter a narrow aisle with wire guidance. The yellow lamp flashes when the truck is “seeking” the wire and will stop flashing and remain lit when the truck has found the wire.

• Indicator lamp B on the instrument panel is lit while the truck is in the narrow aisle.

Button for choice of whole or half pallet

• Press this button on the roof panel when you wish to change length of the fork stroke. One length of stroke matches a whole pallet, the other matches a half pallet.

© BT Industries AB 180115-040 43

Accessories

Camera equipment The truck can be fitted with a camera system to facilitate the positioning of the forks in the load holder.

Single camera

• The equipment consists of a TV monitor in the driver’s cab and a single camera mounted on the left-hand fork (when the forks are pointing straight ahead).

• Turn the camera on by pressing button A. NOTE! The camera moves with the forks when they turn.

When the forks are turned to the right the furthermost pallet tunnel is in view and when the forks are turned to the left the closest pallet tunnel is seen.

• The guide line on the monitor can be adjusted as an aid to finding the centre line of the pallet.

Adjusting the guide line • Turn the forks fully to the left.

• Position the tip of the fork in front of the opening of the closest pallet tunnel.

• Adjust the guide line to the centre of the pallet.

- Press button D to adjust the line to the left on the monitor.

- Press button E to adjust the line to the right on the monitor.

© BT Industries AB 180115-040 44

Accessories

Height pre-selector By using the height pre-selector the operator can lift and lower the forks to a maximum of 99 different programmable levels.

Based on height information obtained from the height meter, the lift and lowering mechanism is controlled to stop at the required level. Depositing or collecting of the load takes place manually.

The correct height for depositing or collecting the pallet is requested/programmed via the keyboard. The selected level can be read off on the display, which also indicates any error codes.

PROG

1

2

3

4

5

6

7

8

9

0

INFO

© BT Industries AB 180115-040 45

Accessories

Symbol

Function

0

Numerical push-buttons for setting height levels.

9 INFO

Push-button for control of the required height level, while driving.

STOP Push-button to delete, during automatic mode, incorrectly entered height levels, to cut programming and to cancel a stop due to an error.

Push-button for saving UPPER STOP during programming.

Push-button for saving LOWER STOP during programming.

LOAD. Push-button to indicate that the operator has a load on the forks when starting.

PROG

Push-button to access programming routines.

Character window for indicating height levels and error codes.

© BT Industries AB 180115-040 46

Accessories

Programming • Press the button PROG briefly to enter the programming mode. The LED in the button comes on and the display shows PL00 when programming routines have been started.

You can program new lifting heights, modify or remove programmed values.

Programming a level Programming of lift heights can take place within the truck’s entire lift zone.

”Collection level” • Press the PROG button briefly. State the required level (e.g.

1+5 = level 15). The numbers are shown on the display.

• Lift the forks to the required level and press the button LOWER STOP. The LED flashes.

”Leaving level” • Pick-up the load and wait three seconds. Lift the forks just enough so that the pallet can be removed from the rack.

Ensure that there is sufficient space for safe handling.

• Now press the UPPER STOP button and both LEDs for LOWER STOP and UPPER STOP will start to flash.

• Press the PROG button until both the LEDs go out and the display indicates PL00, storing information.

• Repeat from the first point to program more levels.

• Press STOP to return to the display mode.

Erasing programmed levels • Lower the forks to the free-lift zone when programmed lifting heights are to be erased.

• Enter the programming mode and state the required level (e.g. 1+5 = level15). The number is shown on the display.

• Press the LOWER STOP button (the LED flashes) and then press the UPPER STOP button (both LEDs start to flash).

• Press the PROG button until both LEDs (LOWER STOP and UPPER STOP) stop flashing and the display shows PL00 to erase the memory.

• Press the STOP button to return to the display mode.

© BT Industries AB 180115-040 47

Accessories

Automatic operations There are two different automatic operating modes, one where the forks are raised/lowered to the required level without a load and the other with a load.

Collecting a load • State the required height level using buttons 0 - 9, (e.g. 1+2 = level 12). The display will show LE12.

• Raise/lower the forks until they are automatically stopped by the electronics.

If the wrong direction is chosen no raise/lower movement will take place. The electronics expect the correct direction to be selected.

• When the forks stop and the LED, LOWER STOP comes on, the forks can be manoeuvred in under the load.

• Lift the forks until they are automatically stopped by the electronics and the LED, UPPER STOP comes on.

• Move the load from the rack. When the work cycle has been completed the LEDs will go out.

Leaving a load • Press the LOAD button (the LED now comes on).

• State the required height level using buttons 0 - 9, (e.g. 5 = level 05). The display will show LE05.

• Raise/lower the forks until they are automatically stopped by the electronics.

If the wrong direction is chosen no raise/lower movement will take place. The electronics expect the correct direction to be selected.

• When the forks stop and the LED, UPPER STOP comes on, the forks can be manoeuvred out from under the load.

• Lower the forks until they are automatically stopped by the electronics and the LED, LOWER STOP comes on.

• Remove the forks from the rack. When the work cycle has been completed the LEDs will go out.

Control • Press the button INFO to check the required “UPPER STOP/ LOWER STOP level”. The value will be shown for 3 seconds on the display.

© BT Industries AB 180115-040 48

Accessories Error Codes

Error code

Remark

Err 1

The requested height level is not programmed or is incorrect.

Err 2

The forks have stopped outside of the tolerance area.

Err 9

Incorrect values stated when programming.

Err flashes

Communication error between the height preselector and the truck computer

• Four lines light up when started. This indicates that no communication has been established between the height preselector and the main electronics. These go out when contact between the two units has been established.

• Four points are lit on the display when the forks are below the truck’s height reference switch.

• If the points are flashing this indicates that the reference switch was already activated when the truck was started. If the points continue to flash when the forks are lowered there could be a fault in the cable or the height reference switch.

© BT Industries AB 180115-040 49

Accessories

BT TLS Truck Logging System BT TLS Truck Logging Systems (EV 1 and EV 16) are designed so that only qualified truck drivers can start the truck. The truck is started by entering your personal code on the keyboard or by using your personal code card, depending on the system used.

The truck can be driven after you enter the correct code. The display lights or another visual indication is given when the correct code has been entered.

The time that the truck has been in use is recorded in the truck log.

Keyboard version Logging using a code (5 digit) 7

4

1 * C

LR

Login

8

9

5

6

2

• You must enter your five digit personal code each time you start the truck.

3

#

ENT

• Enter your personal code using the keyboard, 12345 for EV 16 and 54312 for EV 1 (standard codes the first time you log in).

• Press # to start the truck.

If you enter the code incorrectly press * and start again.

WARNING! Unauthorised operating.

Accidents can occur and errors in the truck log can be recorded.

Never give your personal code to any other person.

Logout When you leave the truck you must always logout.

• Press * to logout and make the truck undrivable.

Never press * while working with the truck.

WARNING! Unauthorised operating.

Accidents can occur and errors in the truck log can be recorded.

Always logout when leaving the truck.

© BT Industries AB 180115-040 50

Accessories If you do not logout by using *, TLS will automatically logout after a preset time.

WARNING! Unauthorised operating.

Accidents can occur and errors in the truck log can be recorded.

Avoid letting the automatic logout come into force.

Login with fault reporting (5+1 digit) Only valid for EV 16 Truck logging can be programmed so that it allows you to record any faults on the truck when you start to use it (e.g. mechanical damage, battery acid level or another fault).

Login You must enter your five digit personal code plus an additional digit each time you start the truck.

• Enter your personal code using the keyboard, e.g. 12345.

7

8

4 1 * C

LR

9

5

6

2

3 #

• Enter a number between 0 and 9 depending on the fault detected in the truck. If no fault has been detected, enter the number for fault-free truck.

• Press # to start the truck.

ENT

If you enter the code incorrectly, press * and start again.

You must enter a number between 0 and 9 to start the truck.

Login with extra code (5+3 digit) Only valid for EV 16 In this mode you enter, e.g. your employment number as the first five digits and then a three digit personal code.

• Enter your five digit code using the keyboard, e.g. 12345.

• Then enter your three digit code.

• Press # to start the truck.

The first time you use the truck and have not programmed in a code the three digit code will be 000.

To change the code, see Changing the personal three digit code (p. 52).

WARNING! Unauthorised operating.

Accidents can occur and errors in the truck log can be recorded.

Never give your personal code to any other person. © BT Industries AB 180115-040 51

Accessories

Login with extra code and fault reporting (5+3+1 digit) Only valid for EV 16 • Enter your five digit code using the keyboard, e.g. 12345.

• Then enter your three digit code.

• Enter a number between 0 and 9 depending on the fault detected in the truck. If no fault has been detected, enter the number for fault-free truck.

• Press # to start the truck.

If you enter the code incorrectly, press * and start again.

You must enter a number between 0 and 9 to start the truck.

WARNING! Unauthorised operating.

Accidents can occur and errors in the truck log can be recorded.

Never give your personal code to any other person.

Changing the personal three digit code Only valid for EV 16 You can change your personal three digit as follows: • Enter your five digit code using the keyboard, e.g. 12345.

• Then enter your three digit code.

• Press 9 (green). This informs the truck log that you wish to change your code.

• Enter the new code, e.g. 678.

• Press 9 (green). This informs the truck log that this is the code you wish to use.

Code card Login • Pull the card with the magnetic strip facing the keyboard through the card reader (upwards or downwards).

• Press F4 to start the truck.

WARNING! Unauthorised operating.

Accidents can occur and errors in the truck log can be recorded.

Never give your personal card to any other person.

© BT Industries AB 180115-040 52

Accessories Logout • Press F3 to logout and make the truck undrivable.

Never press F3 while working with the truck.

WARNING! Unauthorised operating.

Accidents can occur and errors in the truck log can be recorded.

Always logout when leaving the truck.

If you do not logout by using *, TLS will automatically logout after a preset time.

WARNING! Unauthorised operating.

Accidents can occur and errors in the truck log can be recorded.

Avoid letting the automatic logout come into force.

Login with error reporting • Pull the card with the magnetic strip facing the keyboard through the card reader (upwards or downwards).

• Press F1 if you do not find a fault on the truck or F2 if you do find a fault on the truck that you wish to report.

• Press F4 to start the truck.

You must press either F1 or F2 to start the truck.

0

Collision sensor

1 Only valid for EV 16

The truck can be equipped with a collision sensor. If you should hit an object the collision sensor will register this, a buzzer sounds and the truck becomes undrivable. Resetting takes place using a key on the instrument panel, which is turned to 1 and then back to 0.

WARNING! Dangerous driving.

Accidents can occur.

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

© BT Industries AB 180115-040 53

Driving

Driving If the truck is to be used for other applications than it’s specified for, or if the truck is not to be used for long periods contact BT for more information.

NOTE: Drive the truck very carefully during the running-in period. The handling of the truck during the first few days can have a direct effect on the truck’s future maintenance costs.

Starting the truck When you sit in the driver’s seat a switch is activated which allows the truck to driven.

• Make sure the emergency switch off is not pressed in.

• Turn the ignition key to position l. The instrument lighting should come on.

• Check that the correct operator is selected, alternatively log in with your operator identification.

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

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.

• Place your left foot on the safety pedal.

• Always keep your left hand on the steering when driving outside of narrow aisles.

NOTE! Risk of crushing exist if any part of the body is outside of the operator’s cab.

Always sit with the whole of your body inside the protective cab.

© BT Industries AB 180115-040 54

Driving • Select the travel direction by momentarily activating the travel direction selector. The drive wheel indicator on the display panel shows the selected travel direction.

• Press down the accelerator pedal to release the brake and start the truck.

• Use the accelerator to regulate the driving speed.

• If you activate the travel direction selector for a longer period of time the creep speed function will be activated and travel speed will be limited to 2.5 km/h.

WARNING! Function failure.

Safety can be jeopardised.

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

- That the horn and emergency switch off function 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.

© BT Industries AB 180115-040 55

Driving

Braking • Control the braking force by pressing the brake pedal to the required position.

Avoid braking sharply as this quickly wears out the surface of the drive wheel.

Deceleration Deceleration can take place using the electric drive motor. This is done by actuating the travel direction selector in the opposite travel direction. Deceleration is controlled using the accelerator pedal. The maximal deceleration force can be set using an operator parameter, see Programming (p. 35) in the chapter Controls and instruments.

Deceleration can also take place by reducing the acceleration.

Moreover, through this deceleration it is also possible to bring the truck to a complete standstill. The deceleration force can be set using an operator parameter, see Programming (p. 35) in the chapter Controls and instruments.

End of aisle speed reduction (accessory) If the truck has a speed in excess of 2.5 km/h in a narrow aisle approx. 7 metres from the end of the aisle (=braking point), the truck’s speed is reduced automatically until it comes to a complete stop.

To continue driving you must release the accelerator fully before pressing it down again. If you continue driving out of the narrow aisle the max. speed is half speed, 4 km/h. If you re-enter the narrow aisle the max. narrow aisle speed is allowed, depending on the current lift height.

When the truck passes the braking point a warning signal will sound for approx. 2 seconds to inform you that you are nearing the end of the aisle.

WARNING! Driving without care.

Accidents can happen.

The end of aisle brake is not a safety system, exercise great care when driving out of narrow aisles.

© BT Industries AB 180115-040 56

Driving

Steering Outside of narrow aisles A B

The steering impulses are transmitted to an electric steering motor mounted in the motor compartment. The steering motor actuates the drive gear by means of a chain drive.

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

The drive wheel has no end limit position, which gives the possibility of steering through 360°. The drive wheel indicator on the display panel shows the current travel direction.

NOTE! The current travel direction will be the opposite to that which is selected using the travel direction control when the steering angle is greater than 180°.

You can change the direction of travel using the steering without activating the travel direction control.

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

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

• Steer the truck with the tips of the fingers on the steering hub (B) when driving at high speed (long transport, etc.).

WARNING! Lost stability.

The truck can overturn and the load fall if you turn the steering quickly at high speed.

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

© BT Industries AB 180115-040 57

Driving • 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.

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.

In narrow aisles with rails • Drive slowly towards the aisle. Lower the speed to creep speed or lower • Ensure the turret head is in the home position.

• Enter the narrow aisle as straight as possible. (use the drive wheel indicator on the display panel to help you.)

• When the entire truck is in the aisle this is registered by the magnetic sensor under the truck.

• The indicator lamp for truck in narrow aisle lights up.

© BT Industries AB 180115-040 58

Driving • The truck takes over the steering and you can no longer influence this. .

WARNING! Obstacles in the narrow aisle.

An accident could occur.

Keep the narrow track free from objects that could obstruct the movement of the truck.

WARNING! Spillage in the narrow aisle.

An accident could occur.

Keep the narrow track free from spillage, dust, ice etc. to avoid the risk of the truck skidding, especially when braking in an emergency.

In narrow aisles with wire guidance (accessory) If the truck is equipped with wire guidance it is automatically guided via the wire. Other functions such as, travel direction, lifting and lowering are controlled manually by the driver.

• Ensure the turret head is in the home position.

• Drive slowly towards the aisle and wire. Lower the speed to a crawling speed or lower and press the button for wire guidance. The yellow lamp in the button starts to flash.

• Enter the narrow aisle as straight as possible (use the drive wheel indicator on the display panel to help you.)

• The angle of the truck must not exceed 10° and the forks should be centralised above the wire. © BT Industries AB 180115-040 59

Driving • When the truck has found the wire the truck takes over the steering and you can no longer influence this.

• The truck is now being guided by the wire and the lamp stops flashing and remains lit.

• When the entire truck is in the aisle this is registered by the magnetic sensor under the truck and the indicator lamp for truck in narrow aisle lights.

WARNING! Obstacles in the narrow aisle.

An accident could occur.

Keep the narrow track free from objects that could obstruct the movement of the truck.

WARNING! Spillage in the narrow aisle.

An accident could occur.

Keep the narrow track free from spillage, dust, ice etc. to avoid the risk of the truck skidding, especially when braking in an emergency.

Parking the truck • Stop the truck carefully.

• Apply the parking brake by pressing down the brake pedal.

The parking brake is applied automatically when the operator climbs out of the cab.

• Lower the forks fully to the floor.

• Position the forks in the left or right-hand home position.

• Turn the key to the 0 position.

NOTE! Traversing of the forks will only be at creep speed when restarting if the forks are not in the home position when the ignition key is turned to the 0 position.

The traversing movements end position must be calibrated.

Calibrate the end position by moving the forks fully to the left or right, activate the lever fully for approx. 0.5 seconds to calibrate.

WARNING! Unauthorised use.

Accidents can happen.

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

© BT Industries AB 180115-040 60

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.

• Always drive with the forks in the home position except for when collecting or leaving a load.

The truck can be equipped with other pallet handling equipment, see the Accessories chapter.

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.

© BT Industries AB 180115-040 61

Transporting loads

Collecting a load Instructions relating to height pre-selection and weight indication are stated in the chapter Controls and instruments.

Outside of narrow aisles • Slow down and position the truck carefully in front of the rack.

• Lift the forks to the required position.

• Slide out the forks so that they come as far under the load as possible.

• Lift the forks so that the load is lifted free.

• Retract the forks so that the load clears the rack.

• Lower the load to the transporting position and drive carefully away from the rack.

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.

In the narrow aisle • The forks can be raised to the desired lift height while driving as soon as you enter the narrow aisle.

• Reduce speed and move into position in front of the pallet position.

• Slide out the forks so that they come as far under the load as possible.

• Lift the forks so that the load is lifted free.

• Retract the forks so that the load clears the rack.

• Start slowly and then increase the speed.

• Lower the load to the transporting position and drive carefully away from the rack.

© BT Industries AB 180115-040 62

Transporting loads

Depositing a load Instructions relating to height pre-selection and weight indication are stated in the chapter Controls and instruments.

Outside of narrow aisle • Slow down and position the truck carefully in front of the rack.

• Lift the forks to the required position.

• Slide out the forks so that the load is positioned correctly.

• Lower the forks so that they clear the load.

• Retract the forks.

• Lower the forks to the transporting position and drive carefully away from the rack.

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.

In the narrow aisle • The forks can be raised to the desired lift height while driving as soon as you enter the narrow aisle.

• Reduce speed and move into position in front of the pallet position.

• Slide out the forks so that the load is positioned correctly.

• Lower the forks so that they clear the load.

• Retract the forks.

• Start slowly and then increase the speed.

• Lower the load to the transporting position before driving out of the narrow aisle.

© BT Industries AB 180115-040 63

Battery

Battery The truck is designed so that it receives its energy supply from a so-called lead traction battery. If any other type of battery or energy source is used, measures shall be taken to ensure that the battery voltage during operation always exceeds 70% of nominal voltage: 17 volts for a 24 volt system and 34 volts for a 48 volt system. This is necessary in order for the truck to function as intended.

• Check that the battery in the truck is a 48 V traction battery having a weight within the minimum/maximum values stated on the 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: • Park the truck next to the battery changing table.

• Apply the parking brake.

• Turn off the ignition key.

• Press in the emergency switch off.

• Remove the battery covers.

• Turn the lock bolt (1) upwards and pull it out (2).

• Remove the locking plate (3) on the side of the battery.

• Disconnect the battery connector from the battery.

• Connect the extension cables between the battery and the truck.

© BT Industries AB 180115-040 64

Battery • Slide out the discharged/old battery and move the truck.

• Remove the extension cables and slide in the new battery.

• Connect the battery connector to the battery.

WARNING! Risk of short-circuiting.

The cables can be damaged and cause a short circuit.

Ensure the battery cables are not crushed.

• Assemble the locking plate for the battery and refit the battery covers.

• Release the emergency switch off.

• Turn on the ignition key.

WARNING! Falling battery.

The battery can fall out of the truck if the truck should tip over or when turning corners if the battery’s locking plate has not been refitted.

Ensure that the battery’s locking plate has been refitted.

WARNING! Falling battery.

When changing the battery, it can be dropped.

Always lift the battery using an approved lifting device and use a battery yoke intended for the battery.

© BT Industries AB 180115-040 65

Battery

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

Use an automatic battery charger intended for charging traction batteries.

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

The charger shall have a minimum charging current of:

Battery (Ah)

Charger (A)

300 - 480

50 - 70

480 - 730

80 - 110

730 - 900

130 - 150

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!

Before charging • Park the truck in the assigned charging area.

• Ensure nothing prevents ventilation above the battery.

• Turn the ignition key to the 0 position and remove the key.

• Open the battery cover and separate the battery plugs.

• Make sure the battery charger is switched off.

• Connect the battery charger to the permanently fitted battery connector.

© BT Industries AB 180115-040 66

Battery • Start the charging unit.

WARNING! Risk of EXPLOSION. During the charging process oxygen and hydrogen gases are always formed in the battery.

Short-circuits, naked flames and sparks in the vicinity of the battery can cause an EXPLOSION. Always switch off the charging current BEFORE removing the battery connector.

Provide good ventilation, especially if the battery is charged 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.

After charging • Make sure that the ammeter indicates an insignificant or no reading and that maintenance charge lamp is on, if fitted.

• Switch off the battery charger.

• Disconnect the battery charger from the permanently fitted battery connector.

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 maintenance Carry out battery maintenance after recharging: 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 180115-040 67

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.

• Fill using distilled water. The fluid level should be 10 - 15 mm above the cell plates.

• Refit all of the cell caps.

• Rinse off and dry the battery.

• Suck up the fluid through the pipe that juts out between the cells on the battery.

Each month: • 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.

Correct density values at different fluid temperatures for a fully charged battery:

Temperature °C

Density g/cm3

-15

1.31

0

1.30

+15

1.29

+30

1.28

+45

1.27

© BT Industries AB 180115-040 68

Battery

© BT Industries AB 180115-040 69

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.

• To gain access to the motor compartment, see the chapter Controls and instruments.

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 system

Check for oil leakage

2

Lifting device

Check for damage, remove dirt and the like

3

Chassis

Check for damage, remove dirt and the like

4

Wheels

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

5

Control console

Check its locking mechanism

6

Remaining operating hours before next service/ Running time

Carry out maintenance according to the table in the chapter Maintenance

7

Battery

Check charge level

8

Operating controls

Check the function for all operating controls

9

Parking brake

Check its function

10

Safety pedal

Check its function

11

Steering

Check its function and drive wheel indicator

12

Accelerator

Check its function, acceleration and deceleration

13

Travel brake

Check its function

14

Drive unit

Inspect abnormal noises and leakage

15

Horn

Check its function

16

Hydraulic functions

Check its function, max. lifting heights, height indicator/ height pre-selector, weight indicator and extra functions

17

Emergency switch off

Check its function

© BT Industries AB 180115-040 70

Daily service and function checks

© BT Industries AB 180115-040 71

Daily service and function checks

© BT Industries AB 180115-040 72

Maintenance

Maintenance Make sure that the truck is given a regular maintenance service after every 500 driving hours (total running time). The truck’s safety, efficiency and service life is dependant on the service and maintenance it receives.

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.

The time interval in the maintenance chart is based on singleshift usage with 8 hours working time and under normal working conditions. The service interval is shorter if the truck is used in tougher environments, e.g. cold storage rooms or dusty or corrosive areas.

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 connector when carrying out maintenance work on the truck, unless otherwise stated in this publication or in 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.

© BT Industries AB 180115-040 73

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

WARNING! Risk of burns.

Hot transmission and hydraulic oil.

Let the truck cool before changing the oil.

• Only fill the hydraulic system with new 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.

• 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 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 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.

• See chapter Controls and instruments for how to open the motor compartment.

© BT Industries AB 180115-040 74

Maintenance

Maintenance work that is to be carried out by the operator Daily service and function checks as set out in the checklist (p. 70).

Maintenance points marked with U 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.

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.

Other service and repair work.

In addition to the maintenance points in the maintenance chart, all service and repair work should be carried out by personnel with special training for this type of truck.

© BT Industries AB 180115-040 75

Maintenance

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, without abrasives, diluted to a suitable concentration.

WARNING! Risk for wear.

Degreasing agents containing abrasives increase the risk for wear and tear of the lifting chains and gear transmissions.

Never use degreasing agents containing abrasives when cleaning the truck. Always check the contents on the packaging.

© BT Industries AB 180115-040 76

Maintenance • 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.

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 180115-040 77

Maintenance

Maintenance chart Pos. no.

0000

Work to carry out Intervals in hours

5

20

80

250 500 1000 3000

Intervals in Days/Weeks/Months

1 D 1 W 1 M 3 M 6 M 12 M 36 M

Chassis

0000.1 Check for damage and crack formation

U

X

0340.1 Check the door lock and oil the hinges 0390.1 Check that the battery locks attachment and for signs of wear

A U

X

0620.1 Check the seat mounting and the setting devices

X

0640.1 Check the function of the driving controls

U

X

0640.2 Check the function of the steering wheel

U

X

0640.3 Check the function of the brakes

U

X

0640.4 Check the function of the pedals

U

X

0640.5 Check the function of the horn

U

X

0810.1 Check the machine housing and safety roof mounting

X

0840.1 Check the function of the emergency switch off U 1700

X

Electrical motors

1700.1 Check for loose connections

X

1700.2 Check the mounting bolts

X

1700.3 Check for abnormal bearing noise

X

1730.3 Check the steering motor carbon brushes

X

1800

Hydraulic motors

1820.1 Check the mounting, tighten mounting bolts

X

1820.2 Check for leakage 2550

X

Drive unit

2550.1 Check the oil level

X C2

2550.2 Change the oil 2550.3 Check for abnormal noise and leakage

U

C X

2550.4 Check the mounting on the support arm

X

2550.5 Lubricate the gear ring

H

© BT Industries AB 180115-040 78

Maintenance

Pos. no.

3370

Work to carry out Intervals in hours

5

20

80

250 500 1000 3000

Intervals in Days/Weeks/Months

1 D 1 W 1 M 3 M 6 M 12 M 36 M

Brakes

3370.1 Check the brake disc for wear

X

3370.2 Check for play in the released position

X

3370.3 Check the brake torque

X

3500

Wheels

3530.1 Remove string and other rubbish

U

X

3530.2 Check for drive wheel wear and the bolts

U

X

3550.1 Remove string and other rubbish

U

X

3550.2 Check the support arm wheels’ rotation and mounting

U

X

3550.3 Check support arm wheel for wear

U

X

4100.1 Check the mounting and control console locking mechanism.

U

X

4100.2 Check the gas cartridge’s capacity and locking mechanism

U

X

4100

5000

Control console

Electrical panel

5000.1 Clean and check the mounting

X X4

5000.2 Tighten cable connections

X

5000.3 Check the emergency operation functions 5000.4 Check the error code log and running times

X U

X

5190.1 Check contactor points

X

5190.2 Check the contactor’s movement

X

5280.1 Check the electrical limit functions 5110

X

Battery

5110.1 Check the electrolyte level (10-15 mm above the cell plates)

U

X

5110.2 Check the connections on the battery, truck and charger

U

X

5110.3 Check the cell and pole guard

U

X

5110.4 Check the fluid density

U

X

5110.5 Check the temperature

U

X

5110.6 Extract excess fluid from the battery tray

U

X

© BT Industries AB 180115-040 79

Maintenance

Pos. no.

6000

Work to carry out Intervals in hours

5

20

80

250 500 1000 3000

Intervals in Days/Weeks/Months

1 D 1 W 1 M 3 M 6 M 12 M 36 M

Hydraulic system

6110.1 Check the tank for leakage and its mountings

X

6110.2 Check the oil level

X

6110.3 Clean or change oil

B

6120.1 Check hoses, pipes and couplings

U

X

6120.2 Check the hoses on the mast and fork carriage for wear

X X1

6130.1 Check hoses, pipes and couplings

X

6170.1 Check overflow pressure 6600

X

Cylinders

6600.1 Check for leakage.

U

X

6600.2 Check the mountings.

7100

X

Mast

7100.1 Check for damage and crack formation

X

7110.1 Lubricate mast beams on runners and rails in the reach carriage

A

7120.1 Check for wear on the lifting chains and sprockets

X

7120.2 Check the lift chains adjustment. Check the chain bolts and mountings.

Tighten locking nuts and inspect the safety pin.

X

7120.3 Lubricate the lift chains

D

7150.1 Check for play on the rollers

X X3

7190.1 Tighten the mast mounting

X

7190.2 Check the mast stay's fixation points

X

7200.1 Check extra functions

F

7400.1 Check for wear to the forks

U

© BT Industries AB 180115-040 80

X

Maintenance

Pos. no.

7700

Work to carry out Intervals in hours

5

20

80

250 500 1000 3000

Intervals in Days/Weeks/Months

1 D 1 W 1 M 3 M 6 M 12 M 36 M

Reach carriage

7700.1 Lubricate the turning chain

D

7700.2 Lubricate gear axle/gear rod

F

7700.3 Lubricate turning bearings 7700.4 Lubricate contact surfaces on guide rollers 7700.5 Check the drive axles flank clearance

I F X

1) Change filter after 50 - 100 hrs, and then every 1000 hrs.

2

) Change oil after 50 -100 hrs, and then every 3000 hrs.

3

) Check after 50 -100 hrs, and then every 1000 hrs.

4) Check after 50 -100 hrs, and then every 500 hrs.

U represents what is found in the chapter Daily service and function checks and must be carried out during the 500 hour service.

X shows what is to be done upon the different service occasions.

Other letters show grade of oil or grease.

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 180115-040 81

Maintenance

Oil and grease specification Pos. Lubricant A B C

Grease Hydraulic oil Transmission oil

D

Grease

E F

Fluid Grease

G

Grease

H

Grease

I

Grease

Specification > - 15°C BT 26777 (Spray) ISO-L-HM32 Hypoid oil SAE 80W/90 BT 73040 or 68101 (Spray) DOT 3 - 4 Grafloscon C-SG 2000 Ultra (Klüber) Topas NB 52 Grafloscon A-G1 (Klüber) BT 171536 Polylube GLY 801 (Klüber)

Application area < - 15°C BT 26777 (Spray) ISO-L-HV32 Hypoid oil SAE 75W BT 163588 (Spray) DOT 3 - 4 Klüber paste 46 MR 401 (Klüber)

Bearings and bushings Hydraulic system Gears

Topas NB 52 Grafloscon A-G1 (Klüber) BT 171536 Polylube GLY 801 (Klüber)

Steering motor gear

© BT Industries AB 180115-040 82

Chains Travel brake Gear rods and contact surfaces of guide rollers

Gear ring Turning gears

Maintenance

© BT Industries AB 180115-040 83

Maintenance

© BT Industries AB 180115-040 84

Maintenance

© BT Industries AB 180115-040 85

Maintenance

© BT Industries AB 180115-040 86

Maintenance

© BT Industries AB 180115-040 87

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 Height, truck without mast, mm

2266

Height, truck with mast (dependent on the mast height), mm

2535-4705

Width, mm

1270/1420/1520

Length excl. forks, mm

2125/2275/2425

Weight without battery, kg

4050 lh=7000

Lowest battery weight, kg 480 Ah

940

600 Ah

1120

720 Ah

1306

900 Ah

1400

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

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.

© BT Industries AB 180115-040 88

Transporting and storing the truck • Lift from the truck’s centre of gravity using another fork lift truck.

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

• 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.

Towing and transporting a defective truck Tow or transport a defective truck to a repair station as follows:

Release of parking brake The emergency operating switch for releasing the parking brake is located under the armrest panel.

• Press the switch to position I to release the brake.

• 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.

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

WARNING! Risk for injury to persons.

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

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

© BT Industries AB 180115-040 89

Transporting and storing the truck Lowering the forks If the forks can not be lowered by activating the hydraulic lever they can be lowered manually by opening the return tap on the valve block by the pump motor.

WARNING! Lost stability.

The load can slide off the forks or catch on the rack since the lowering valve is fully open during emergency operation.

Do not lower the load if it is not correctly positioned on the forks or if there is a risk that the load can catch on the rack.

Emergency steering of truck If the truck can not be steered, emergency steering can take place by using a reversible battery-driven drill with an extension tool.

• Stick the tool through the cover plate and connect it to the steering motor axle. Then operate the drill in one or another direction in order to turn the drive wheel.

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.

• Maintenance charge the battery every third month and check the fluid level.

Hydraulic system • Change the oil in the hydraulic system when the truck is stored for periods longer than one year, see the oil specification in the Maintenance chart and Oil and grease specification in chapter Maintenance.

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.

© BT Industries AB 180115-040 90

Transporting and storing the truck

Starting after a period of disuse Before the truck is put into operation after a period of disuse it should undergo a function and safety check as 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, 500 hours interval.

© BT Industries AB 180115-040 91

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

Mast

Steel

Reach carriage

Steel

Instrument panels

Polypropylene

Seat cushions

Polyurethane

Drive unit

Steel and cast material

Bushings

Polyamide

Finish

Epoxy-polyester

Wheels

Polyurethane

Counter balance

Steel

© BT Industries AB 180115-040 92

Recycling/discarding

Hydraulic system Oil tank

Polythene

Pump unit

Steel and aluminium

Hoses

Rubber, steel and plastic

Cylinders

Cast iron and steel

Valve

Aluminium and steel

Electrical system Cables

Copper cores with PVC sheaths

Electronic board

Reinforced glass fibre circuit board laminate Can contain lithium battery

Motors

Steel, copper and aluminium

Frequency converter

Aluminium, polycarbonate and glass fibre FR 4

Electronics box

Aluminium

© BT Industries AB 180115-040 93

Recycling/discarding

© BT Industries AB 180115-040 94