Operator’s Manual Operator’s Manual

OE35 OE35
Electric Counterbalanced Order Selector Electric Counterbalanced Order Selector
Effective Serial Number OE35027319000 Effective Serial Number OE35027319000

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

WARNING Keep this OPERATOR’S MANUAL with unit WARNING Keep this OPERATOR’S MANUAL with unit
at all times in place provided when not in use. at all times in place provided when not in use.
WARNING DO NOT operate this equipment unless all WARNING DO NOT operate this equipment unless all
factory installed guards and shields are factory installed guards and shields are
properly secured in place. properly secured in place.

Part no: 29296-03 Date: November 15, 1997 Part no: 29296-03 Date: November 15, 1997
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 Operator’s warning Operator’s warning

IMPORTANT NOTICE IMPORTANT NOTICE

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

Before operating the truck: Before operating the truck:

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

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

BEFORE OPERATING TRUCK BEFORE OPERATING TRUCK

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

LEARN AND PRACTICE USE OF LEARN AND PRACTICE USE OF

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

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

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 Foreword Foreword
It is important that you read and understand this It is important that you read and understand this
Operator’s Manual for your own safety and the Operator’s Manual for your own safety and the
safety of those who work with you! safety of those who work with you!
Before you start to use this truck it is of extreme importance Before you start to use this truck it is of extreme importance
that you have read the contents of the entire Operator’s that you have read the contents of the entire Operator’s
Manual to be able to use the truck in a safe and efficient Manual to be able to use the truck in a safe and efficient
manner. manner.
This Operator’s Manual contains information on how you This Operator’s Manual contains information on how you
should use the truck and how to keep the truck in a safe should use the truck and how to keep the truck in a safe
condition by following daily service routines. condition by following daily service routines.
Only personnel that have been trained as a truck operator, for Only personnel that have been trained as a truck operator, for
this type of truck, are permitted to use this truck. this type of truck, are permitted to use this truck.
It is your employer’s responsibility to ensure that you have It is your employer’s responsibility to ensure that you have
been trained to use your truck safely. Contact your supervisor been trained to use your truck safely. Contact your supervisor
if you feel uncertain about how to use this truck. if you feel uncertain about how to use this truck.
Always follow the warnings given in this Operator’s Manual Always follow the warnings given in this Operator’s Manual
and on the truck to avoid accidents. and on the truck to avoid accidents.

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

California Proposition 65 California Proposition 65

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

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 Table of Contents Table of Contents
Safety regulations ............................................................. 5 Safety regulations............................................................. 5
Warning symbols.............................................................. 5 Warning symbols.............................................................. 5
Prohibitory symbols .......................................................... 6 Prohibitory symbols .......................................................... 6
General safety regulations ............................................... 7 General safety regulations ............................................... 7

Warning and information signs ...................................... 18 Warning and information signs ...................................... 18

Presentation of truck ....................................................... 21 Presentation of truck ....................................................... 21

Application areas for BT’s trucks ..................................... 22 Application areas for BT’s trucks..................................... 22
Prohibited applications for BT’s trucks ............................ 22 Prohibited applications for BT’s trucks ............................ 22
Truck data ....................................................................... 23 Truck data ....................................................................... 23
OE35 truck dimensions ................................................... 24 OE35 truck dimensions ................................................... 24
Data plate ........................................................................ 25 Data plate ........................................................................ 25
U.L. construction type...................................................... 26 U.L. construction type...................................................... 26

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

Controls and instruments ............................................... 30 Controls and instruments ............................................... 30

Control for raising the forks ............................................. 31 Control for raising the forks ............................................. 31
Control for lowering the forks .......................................... 31 Control for lowering the forks .......................................... 31
Horn................................................................................. 32 Horn ................................................................................ 32
Travel direction selector and speed control ..................... 32 Travel direction selector and speed control..................... 32
Braking using plugging function ...................................... 33 Braking using plugging function ...................................... 33
Parking brake pedal ........................................................ 34 Parking brake pedal ........................................................ 34
Drive wheel indicator ....................................................... 35 Drive wheel indicator ....................................................... 35
Key switch (toggle switch) ............................................... 35 Key switch (toggle switch) ............................................... 35
Start switch button........................................................... 36 Start switch button........................................................... 36
Emergency disconnect button ......................................... 37 Emergency disconnect button ......................................... 37
Hydraulic emergency release valve ................................ 37 Hydraulic emergency release valve ................................ 37
Pallet clamp control ......................................................... 38 Pallet clamp control ......................................................... 38
BDI/Hourmeter with travel interrupt ................................. 39 BDI/Hourmeter with travel interrupt ................................. 39
Battery discharge indicator (BDI) .................................... 39 Battery discharge indicator (BDI) .................................... 39
Hourmeter ....................................................................... 40 Hourmeter ....................................................................... 40
Dash display.................................................................... 41 Dash display.................................................................... 41
Dash display status codes............................................... 42 Dash display status codes............................................... 42

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 Table of Contents Table of Contents
Driving............................................................................... 43 Driving ............................................................................... 43
Starting the truck ............................................................. 44 Starting the truck.............................................................. 44
Braking ............................................................................ 46 Braking............................................................................. 46
Steering ........................................................................... 47 Steering............................................................................ 47
Parking the truck ............................................................. 48 Parking the truck .............................................................. 48

Transporting loads .......................................................... 49 Transporting loads ........................................................... 49

General............................................................................ 49 General ............................................................................ 49
Loading and unloading .................................................... 51 Loading and unloading..................................................... 51
Collecting a load.............................................................. 52 Collecting a load .............................................................. 52
Leaving a load ................................................................. 53 Leaving a load.................................................................. 53

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

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

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

Maintenance ..................................................................... 65 Maintenance ...................................................................... 65

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

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

Recycling/discarding ....................................................... 81 Recycling/discarding........................................................ 81

Discarding the battery ..................................................... 81 Discarding the battery ...................................................... 81
Scrapping the truck ......................................................... 81 Scrapping the truck .......................................................... 81

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 Safety regulations Safety regulations
Warning symbols Warning symbols
Always follow the warnings given in this Instruction Always follow the warnings given in this Instruction
Manual and on the truck to avoid accidents from Manual and on the truck to avoid accidents from
occurring. occurring.
Warning levels Warning levels
Warning texts are given in four levels and provide information Warning texts are given in four levels and provide information
on the risks, describe the consequences, and instruct how to on the risks, describe the consequences, and instruct how to
avoid accidents. avoid accidents.

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

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

CAUTION CAUTION
Warns that an accident can occur if the instructions are Warns that an accident can occur if the instructions are
not followed. not followed.
The consequences are personal injury and/or material The consequences are personal injury and/or material
damage. damage.
NOTE! NOTE!
Marks the risk of a crash/breakdown if the instructions Marks the risk of a crash/breakdown if the instructions
are not followed. are not followed.

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 Safety regulations Safety regulations
Prohibitory symbols Prohibitory symbols

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

OPEN FLAMES PROHIBITED OPEN FLAMES PROHIBITED

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

GENERAL PROHIBITION GENERAL PROHIBITION

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

Ordinance symbols Ordinance symbols

SAFETY SHOES SAFETY SHOES

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

PROTECTIVE GLASSES PROTECTIVE GLASSES

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

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

General safety regulations General safety regulations

Control Control

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

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

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

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

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 Safety regulations Safety regulations
General safety regulations General safety regulations
Operating the truck Operating the truck

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

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

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

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

- As a towing truck for trailers. - As a towing truck for trailers.

- To tow other trucks. - To tow other trucks.

- To transport/lift passengers. - To transport/lift passengers.

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 Safety regulations Safety regulations
General safety regulations General safety regulations
Operator’s responsibility Operator’s responsibility

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

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

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

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

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

• Local regulations regarding personal safety equipment • Local regulations regarding personal safety equipment
shall be followed. shall be followed.

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

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

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 Safety regulations Safety regulations
General safety regulations General safety regulations
Working area Working area

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

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

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

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

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

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

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

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 Safety regulations Safety regulations
General safety regulations General safety regulations
Driving and conduct while driving Driving and conduct while driving

• Always drive the truck from the normal operator position. • Always drive the truck from the normal operator position.

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

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

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

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

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

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

• Keep a safe distance from all vehicles ahead. • Keep a safe distance from all vehicles ahead.

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

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

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

• Never allow passengers to ride on the truck. • Never allow passengers to ride on the truck.

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

• Keep hands and feet clear of controls other than those in • Keep hands and feet clear of controls other than those in
use. use.

• Lift and lower with caution. Make sure there are no • Lift and lower with caution. Make sure there are no
obstructions under, or in the path of, the lifting mechanism. obstructions under, or in the path of, the lifting mechanism.

• Make sure the lifting mechanism is operating smoothly. • Make sure the lifting mechanism is operating smoothly.

• Whenever truck is driven ON and OFF semi-trailers not • Whenever truck is driven ON and OFF semi-trailers not
coupled to a tractor, supports may be needed to prevent coupled to a tractor, supports may be needed to prevent
upending or corner dipping. upending or corner dipping.

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

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

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

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

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

• DO NOT smoke while working around truck. • DO NOT smoke while working around truck.

• Always wear tether line and safety belt. • Always wear tether line and safety belt.

• Never get ON or OFF a moving truck. • Never get ON or OFF a moving truck.

• DO NOT BYPASS LIMIT SWITCHES. Doing so will result • DO NOT BYPASS LIMIT SWITCHES. Doing so will result
in server INJURY OR DEATH. in server INJURY OR DEATH.

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 Safety regulations Safety regulations
General safety regulations General safety regulations
Handling loads Handling loads

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

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

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

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

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

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

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

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

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

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 Safety regulations Safety regulations
General safety regulations General safety regulations
Parking the truck Parking the truck

• Always park in designated areas if available. • Always park in designated areas if available.

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

• Never park the truck on an incline. • Never park the truck on an incline.

• Never park the truck so that it obstructs emergency exits. • Never park the truck so that it obstructs emergency exits.

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

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 Safety regulations Safety regulations
General safety regulations General safety regulations

Handling the battery Handling the battery

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

• Always wear protective glasses when working with the • Always wear protective glasses when working with the
battery. battery.

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

• Make sure the battery is secured in its compartment. • Make sure the battery is secured in its compartment.

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 Safety regulations Safety regulations
General safety regulations General safety regulations
Maintenance and repair Maintenance and repair
Maintenance instructions should be followed to prevent faults Maintenance instructions should be followed to prevent faults
and accidents. See the chapter covering Maintenance. Only and accidents. See the chapter covering Maintenance. Only
qualified and trained personnel are permitted to maintain, qualified and trained personnel are permitted to maintain,
adjust, or repair the truck. adjust, or repair the truck.
All replacement parts shall be BT approved spare parts. All replacement parts shall be BT approved spare parts.
Modifications and additions which affect capacity and safe Modifications and additions which affect capacity and safe
operation shall not be performed by the customer or user operation shall not be performed by the customer or user
without manufacturer’s prior written approval. Capacity, without manufacturer’s prior written approval. Capacity,
operation, and maintenance instruction plate, tags, or decals operation, and maintenance instruction plate, tags, or decals
shall be changed accordingly. shall be changed accordingly.

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 Warning and information signs Warning and information signs
Warning and information signs Warning and information signs
The figure shows the position and significance of the signs’ The figure shows the position and significance of the signs’
location on the truck. location on the truck.
1. Emergency disconnect button 1. Emergency disconnect button
2. Do not walk under an elevated load. 2. Do not walk under an elevated load.
3. Pinch points: Do not reach through uprights. 3. Pinch points: Do not reach through uprights.
4. Hydraulic controls: Raising 4. Hydraulic controls: Raising
5. Horn button 5. Horn button
6. Hydraulic controls: Lowering 6. Hydraulic controls: Lowering
7. Important decal: Special fluids for freezer application. 7. Important decal: Special fluids for freezer application.
8. Emergency valve lowering instructions. 8. Emergency valve lowering instructions.
9. Start button (this button is depressed after the key switch 9. Start button (this button is depressed after the key switch
is turned to the ON position to start truck operation). is turned to the ON position to start truck operation).
10. Warning decal: Safety belt must be worn when operating 10. Warning decal: Safety belt must be worn when operating
this truck. this truck.
11. List of warnings 11. List of warnings
12. U.L. listed (24 Volt only) 12. U.L. listed (24 Volt only)
13. Truck data plate 13. Truck data plate

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 Warning and information signs Warning and information signs

2 2

3 3
1 1

13 13
4 4

6 5 6 5

7 7

12 12

11 11

8 8

9 9
10 10

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 Warning and information signs Warning and information signs
Warning decals Warning decals
Clean or replace all safety and instruction decals that cannot Clean or replace all safety and instruction decals that cannot
be read. be read.
When you clean decals use only a cloth, soap, and water. DO When you clean decals use only a cloth, soap, and water. DO
NOT use solvent, gasoline, etc. NOT use solvent, gasoline, etc.
You must replace a decal if the decal is damaged, missing, or You must replace a decal if the decal is damaged, missing, or
cannot be read. cannot be read.
If a decal is on a part that is replaced make sure you install a If a decal is on a part that is replaced make sure you install a
new decal on the new part. New warning decals can be new decal on the new part. New warning decals can be
obtained from your BT dealer at NO charge. obtained from your BT dealer at NO charge.

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 Presentation of truck Presentation of truck
Presentation of truck Presentation of truck
BT’s truck program is intended for handling pallets indoors or BT’s truck program is intended for handling pallets indoors or
alternatively other types of loads using other load carriers. alternatively other types of loads using other load carriers.
This truck is operated in a standing position. This BT truck has This truck is operated in a standing position. This BT truck has
available different fork lengths and mast heights. Refer to the available different fork lengths and mast heights. Refer to the
truck’s data plate for this information. truck’s data plate for this information.
The truck has a maximum lifting capacity of 3000 lb. Refer to The truck has a maximum lifting capacity of 3000 lb. Refer to
the truck’s data plate for this information on lifting capacities. the truck’s data plate for this information on lifting capacities.
The trucks are equipped with a 24 volt or optional 36 volt The trucks are equipped with a 24 volt or optional 36 volt
electrical system and the speed is regulated by means of a electrical system and the speed is regulated by means of a
SCR controller to provide gentle control of acceleration and SCR controller to provide gentle control of acceleration and
speed while operating. speed while operating.
The forks are raised by means of an electric powered The forks are raised by means of an electric powered
hydraulic pump unit. Both raising and lowering are done hydraulic pump unit. Both raising and lowering are done
electrically with separate push buttons on the control handle. electrically with separate push buttons on the control handle.
The truck can be specially equipped to work in cold The truck can be specially equipped to work in cold
conditions. conditions.

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 Presentation of truck Presentation of truck
Application area for BT’s trucks Application area for BT’s trucks
BT’s trucks are solely designed and manufactured to handle BT’s trucks are solely designed and manufactured to handle
goods indoors. The truck should be fitted with the appropriate goods indoors. The truck should be fitted with the appropriate
accessories relevant to the application. accessories relevant to the application.
Prohibited applications for BT’s trucks Prohibited applications for BT’s trucks
The trucks are designed for handling goods indoors. It is not The trucks are designed for handling goods indoors. It is not
permitted to use the trucks for other purposes including the permitted to use the trucks for other purposes including the
following: following:

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

- Do not use as a towing truck for trailers - Do not use as a towing truck for trailers

- Do not use to tow other trucks - Do not use to tow other trucks

- Do not use to transport/lift passengers - Do not use to transport/lift passengers

- Do not use to drive on gravel or grass - Do not use to drive on gravel or grass

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

Truck type 24 Volt 36 Volt Truck type 24 Volt 36 Volt

Operating speed without load Operating speed without loa

Below 24 in. 5.4 mph 5.8 mph Below 24 in. 5.4 mph 5.8 mph
24 in. to 150 in. 2.5 mph 2.5 mph 24 in. to 150 in. 2.5 mph 2.5 mph
151 in. and 225 in. 1.0 mph 1.0 mph 151 in. and 225 in. 1.0 mph 1.0 mph
Above 225 in. 0 mph 0 mph Above 225 in. 0 mph 0 mph

Operating speed with classified load Operating speed with classified load
Below 24 in. 4.6 mph 5.2 mph Below 24 in. 4.6 mph 5.2 mph
24 in. to 150 in. 2.2 mph 2.2 mph 24 in. to 150 in. 2.2 mph 2.2 mph
151 in. and 225 in. 0.08 mph 0.08 mph 151 in. and 225 in. 0.08 mph 0.08 mph
Above 225 in. 0 mph 0 mph Above 225 in. 0 mph 0 mph

Maximum operating gradient with load, % 0 Maximum operating gradient with load, % 0

Continuous noise level. dB (A) <80 Continuous noise level. dB (A) <80

The truck’s lifting capacity and weight can be found on the The truck’s lifting capacity and weight can be found on the
truck’s data plate. truck’s data plate.
Above 150 in. (381 mm) Above 150 in. (381 mm)
10° 10° 10° 10°

The truck will not travel if turned more then 10 degrees either The truck will not travel if turned more then 10 degrees either
side of center while platform is in a raised position of 150 in. side of center while platform is in a raised position of 150 in.
(381 mm) or more. To resume travel either lower the platform (381 mm) or more. To resume travel either lower the platform
below 150 in. (381 mm) or turn the steering wheel to the below 150 in. (381 mm) or turn the steering wheel to the
center position center position.

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 Presentation of truck Presentation of truck
OE35 truck dimensions OE35 truck dimensions
The following diagrams show external dimensions for OE35 The following diagrams show external dimensions for OE35
trucks in its standard design. trucks in its standard design.

42.0” 24.0” Minimum 42.0” 24.0” Minimum

4.0” 30.0” Maximum 4.0” 30.0” Maximum

Platform -- 40” wide Platform -- 40” wide

70” Turning Radius 70” Turning Radius

60.0” 76.0” 60.0” 76.0”

Picking or Picking or
Height 80.0” Height 80.0”

OALH OALH
36.0” 36.0”
41.0” 7.5” 41.0” 7.5”
33.0” 33.0”
2.0” 2.0”
27.0” 27.0”

58.2” 2.5” 58.2” 2.5”

76.0” (2-Stage) Fork 76.0” (2-Stage) Fork
77.0” (3-Stage) Length 77.0” (3-Stage) Length

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 Presentation of truck Presentation of truck
Data plate Data plate
The following diagram shows the data plate used on the truck. The following diagram shows the data plate used on the truck.

Legend Legend

1. Truck model number 1. Truck model number

2. Truck serial number 2. Truck serial number
3. Truck capacity 3. Truck capacity
4. Mast serial number 4. Mast serial number
5. Attachments 5. Attachments
6. Truck type 6. Truck type
7. Truck weight (less battery) 7. Truck weight (less battery)
8. Back tilt degree (NOT USED ON THIS TRUCK) 8. Back tilt degree (NOT USED ON THIS TRUCK)
9. Minimum battery weight 9. Minimum battery weight
10. Maximum battery weight 10. Maximum battery weight
11. Battery maximum AMP hours 11. Battery maximum AMP hours
12. Battery voltage 12. Battery voltage
13. Battery type 13. Battery type

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

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 Presentation of main components Presentation of main components
Presentation of main components Presentation of main components
1. Steering wheel 1. Steering wheel
The truck is to be controlled by the operator with 180 The truck is to be controlled by the operator with 180
degree steering angle. degree steering angle.
2. Parking brake pedal 2. Parking brake pedal
The brake is applied in the up position. The brake is applied in the up position.
3. Key switch (toggle switch) 3. Key switch (toggle switch)
Shuts off electrical power to control system. Shuts off electrical power to control system.
4. Emergency stop switch 4. Emergency stop switch
The emergency stop switch will stop all control functions. The emergency stop switch will stop all control functions.
5. Pallet clamp 5. Pallet clamp
Applies clamping to retain pallets to lift platform. Applies clamping to retain pallets to lift platform.
6. Start switch 6. Start switch
Pressed after key switch is turned on to start truck’s Pressed after key switch is turned on to start truck’s
operation. operation.
7. Steering direction indicator 7. Steering direction indicator
Displays the direction the transmission is headed. Displays the direction the transmission is headed.
8. Fork lower switch 8. Fork lower switch
The forks will lower when switch is pressed or until lower The forks will lower when switch is pressed or until lower
stops are reached. stops are reached.
9. Fork raise switch 9. Fork raise switch
The forks will raise when switch is pressed or until lift stops The forks will raise when switch is pressed or until lift stops
are reached. are reached.
10. Horn switch 10. Horn switch
The horn sounds to warn others of your position. The horn sounds to warn others of your position.
11. Hydraulic electric pump unit 11. Hydraulic electric pump unit
Pump motor and pump are an integrated unit. Pump motor and pump are an integrated unit.
12. Hydraulic electric solenoid valve 12. Hydraulic electric solenoid valve
For controlling lifting and lowering function with electric For controlling lifting and lowering function with electric
solenoid valve. solenoid valve.
13. Battery 13. Battery
24V or optional 36V with different capacities and weights. 24V or optional 36V with different capacities and weights.
Return 27 27
 Presentation of main components Presentation of main components
14. Drive unit with brake 14. Drive unit with brake
Drive motor, gears, drive wheel, and brake combined in Drive motor, gears, drive wheel, and brake combined in
the drive unit. the drive unit.
15. Data plate 15. Data plate
Contains data designation, manufacturing number, year of Contains data designation, manufacturing number, year of
manufacture, service weight, battery weight, classified manufacture, service weight, battery weight, classified
lifting capacity, battery voltage, and manufacturer. lifting capacity, battery voltage, and manufacturer.
16. Cover 16. Cover
Hinged to provide good access for servicing. Hinged to provide good access for servicing.
17. Load wheel 17. Load wheel
Lubricate load wheels to prevent wheels from locking up. Lubricate load wheels to prevent wheels from locking up.
18. Instrument (accessory) 18. Instrument (accessory)
Combined hourmeter/battery indicator, hourmeter/battery Combined hourmeter/battery indicator, hourmeter/battery
indicator with lift interrupt, or hourmeter only. indicator with lift interrupt, or hourmeter only.
19. Electronics 19. Electronics
All the electronics are collected in a protected All the electronics are collected in a protected
compartment. compartment.
20. Circuit fuses 20. Circuit fuses
15A, BT Control fuse part number 201324 15A, BT Control fuse part number 201324
400A, 24 volt BT Pump fuse part number 25094-03 400A, 24 volt BT Pump fuse part number 25094-03
300A, 36 volt BT Pump fuse part number 25094-04 300A, 36 volt BT Pump fuse part number 25094-04
300A, BT Drive fuse part number 25094-04 300A, BT Drive fuse part number 25094-04
21. Travel speed / direction selection 21. Travel speed / direction selection
To select direction rotate in the direction you wish to move. To select direction rotate in the direction you wish to move.
The further in that direction you rotate the faster you move. The further in that direction you rotate the faster you move.
22. Mast 22. Mast
Covered by a finger protection which covers the operator’s Covered by a finger protection which covers the operator’s
normal range of reach from the operating position. normal range of reach from the operating position.

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 Presentation of main components Presentation of main components

22 22

18 18
7 7
9 9
11 11
1 1
3 3
18 18
16 16
14 4 12 14 4 12
8 8
6 19 6 19
20 20

2 15 2 15
10 10

5 5
21 16 13 21 16 13
17 17

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

WARNING DO NOT operate this equipment unless all WARNING DO NOT operate this equipment unless all
factory installed guards and shields are factory installed guards and shields are
properly secured in place. properly secured in place.
Decals are also provided to warn of potential danger as well Decals are also provided to warn of potential danger as well
as to display special operating procedures. as to display special operating procedures.

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

Drive wheel indicator Directional Drive wheel indicator Directional

control handle control handle
Battery Battery
discharge discharge
indicator indicator

Hourmeter Hourmeter
Steering Steering
wheel wheel
Emergency Emergency
disconnect disconnect

Key switch Key switch

Start switch Start switch

Pallet clamp Pallet clamp

release lever release lever

Pallet clamp Pallet clamp

Parking brake pedal foot control Parking brake pedal foot control

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 Controls and instruments Controls and instruments
Control for raising the forks Control for raising the forks

A A

The control button activates a micro switch to start the pump The control button activates a micro switch to start the pump
motor with lifting. motor with lifting.
The diagram illustrates the controls as seen from the The diagram illustrates the controls as seen from the
operator’s position. Lift the forks by pressing ‘A’. operator’s position. Lift the forks by pressing ‘A’.

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

Control for lowering the forks Control for lowering the forks

E E

Lower the forks by pressing ‘E’. The lowering speed of the Lower the forks by pressing ‘E’. The lowering speed of the
forks is controlled by a flow control valve. forks is controlled by a flow control valve.

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

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 Controls and instruments Controls and instruments
Horn Horn

Horn Horn

The horn sounds as long as the button is pressed. The horn sounds as long as the button is pressed.

Travel direction selector and speed control Travel direction selector and speed control

R R

Select the travel direction by rotating ‘R’ in the required Select the travel direction by rotating ‘R’ in the required
direction. The speed is controlled variably based on the direction. The speed is controlled variably based on the
position of the handle. position of the handle.
Rotating control in the forward or rearward direction will select Rotating control in the forward or rearward direction will select
that direction of travel. The truck speed will progressively that direction of travel. The truck speed will progressively
increase as the control is rotated. Reversing the control can increase as the control is rotated. Reversing the control can
be used to quickly decrease speed or brake the truck. be used to quickly decrease speed or brake the truck.

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 Controls and instruments Controls and instruments
Braking using plugging function Braking using plugging function

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

• As the truck comes to a full stop the operator may choose • As the truck comes to a full stop the operator may choose
to continue holding the controls in the opposite direction to continue holding the controls in the opposite direction
and thus start the truck moving in that direction, or the and thus start the truck moving in that direction, or the
operator may release the handle and allow the truck to operator may release the handle and allow the truck to
come to a complete halt. Releasing the steering control come to a complete halt. Releasing the steering control
handle will allow the parking brake to become handle will allow the parking brake to become
automatically applied. automatically applied.
THE CONTROL HANDLE MUST NOT BE PLACED IN THE THE CONTROL HANDLE MUST NOT BE PLACED IN THE
BRAKE POSITION DURING THE PLUG BRAKING BRAKE POSITION DURING THE PLUG BRAKING
OPERATION. OPERATION.

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

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 Controls and instruments Controls and instruments
Parking brake pedal Parking brake pedal

Parking Brake Parking Brake

Pedal Pedal

Power steering operates full time when key switch is in the Power steering operates full time when key switch is in the
“ON” position and brake pedal is depressed. The parking “ON” position and brake pedal is depressed. The parking
brake is applied when brake pedal is in the normal position brake is applied when brake pedal is in the normal position
(raised). Depressing brake pedal releases brake and closes a (raised). Depressing brake pedal releases brake and closes a
switch in control circuit that allows operation on unit. The switch in control circuit that allows operation on unit. The
parking brake foot pedal is physically located on floor of parking brake foot pedal is physically located on floor of
operator compartment. operator compartment.
The brake pedal and brake interlock switch must always be The brake pedal and brake interlock switch must always be
checked prior to operation of unit. checked prior to operation of unit.

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 Controls and instruments Controls and instruments
Drive wheel indicator Drive wheel indicator

Drive wheel Drive wheel

indicator indicator

The position of the drive wheel and the truck’s direction of The position of the drive wheel and the truck’s direction of
travel are indicated by the arrow in the gauge. travel are indicated by the arrow in the gauge.

Key switch (toggle switch) Key switch (toggle switch)

Key switch Key switch

A key switch is provided to prevent unauthorized use of this A key switch is provided to prevent unauthorized use of this
unit. The key switch is located on the control panel cover. unit. The key switch is located on the control panel cover.
The key switch has two (2) positions: OFF and ON. The key switch has two (2) positions: OFF and ON.

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

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

NOTE! The start switch button must be pressed NOTE! The start switch button must be pressed
before electrical power is available to the before electrical power is available to the
control circuit. control circuit.

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

Start switch button Start switch button

Start Start
switch switch
button button

The start switch button is used to supply electrical power, after The start switch button is used to supply electrical power, after
the key switch is in the ON position, to the unit when pushed. the key switch is in the ON position, to the unit when pushed.
The start switch button is black in color and is physically The start switch button is black in color and is physically
located on the bottom and in the center of dash below located on the bottom and in the center of dash below
emergency disconnect button. emergency disconnect button.

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 Controls and instruments Controls and instruments
Emergency disconnect button Emergency disconnect button

Emergency Emergency
disconnect disconnect
button button

The emergency disconnect button is used to cut all electrical The emergency disconnect button is used to cut all electrical
power to the unit when button is pushed. To reset emergency power to the unit when button is pushed. To reset emergency
disconnect button turn key switch to the “OFF” position, repair disconnect button turn key switch to the “OFF” position, repair
emergency, turn key switch to the “ON” position and press emergency, turn key switch to the “ON” position and press
the start switch button. the start switch button.

Hydraulic emergency release valve Hydraulic emergency release valve

The hydraulic emergency release valve is physically located The hydraulic emergency release valve is physically located
on the control valve in the drive unit compartment. To operate on the control valve in the drive unit compartment. To operate
this unit you must raise drive unit cover. Push in and rotate the this unit you must raise drive unit cover. Push in and rotate the
red emergency lowering screw counterclockwise on the red emergency lowering screw counterclockwise on the
control valve to lower the platform. The lift platform will lower control valve to lower the platform. The lift platform will lower
after about 2-4 seconds. To stop lowering push in and rotate after about 2-4 seconds. To stop lowering push in and rotate
emergency lowering screw clockwise. emergency lowering screw clockwise.

NOTE! After lowering to platform using the emergency NOTE! After lowering to platform using the emergency
lowering screw, the screw must be reset by lowering screw, the screw must be reset by
pushing in and rotating clockwise, release pushing in and rotating clockwise, release
after rotating. after rotating.

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 Controls and instruments Controls and instruments
Pallet clamp controls Pallet clamp controls
This pallet clamp only works on pallets with a center brace. This pallet clamp only works on pallets with a center brace.
The pallet clamp control is used to secure a pallet to the The pallet clamp control is used to secure a pallet to the
platform. The pallet clamp jaws are physically located platform. The pallet clamp jaws are physically located
between the forks on the platform. between the forks on the platform.
The pallet clamp foot control is located on the right side at the The pallet clamp foot control is located on the right side at the
floor of the platform. floor of the platform.
The pallet clamp release control lever is located below the The pallet clamp release control lever is located below the
direction control handle on the platform. direction control handle on the platform.
To operate pallet clamp controls To operate pallet clamp controls

1. Push down on the pallet foot control to clamp pallet. 1. Push down on the pallet foot control to clamp pallet.

2. To release pallet, push down on the pallet clamp 2. To release pallet, push down on the pallet clamp
release lever. release lever.

Pallet Clamp Pallet Clamp Pallet Clamp Pallet Clamp

Jaws Release Lever Jaws Release Lever

Pallet Clamp Pallet Clamp

Foot Control Foot Control

Pallet Clamp Control Location Pallet Clamp Control Location

Return 38 38
 Controls and instruments Controls and instruments
BDI/Hourmeter with travel interrupt BDI/Hourmeter with travel interrupt
1 Fully-charged battery 1 Fully-charged battery
1/2 Half-charged battery 1/2 Half-charged battery
0 Discharged battery 0 Discharged battery

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

Battery discharge indicator (BDI) Battery discharge indicator (BDI)

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

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 Controls and instruments Controls and instruments
Hourmeter Hourmeter

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

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 Controls and instruments Controls and instruments
Dash display Dash display
The dash display is a four segment light emitting diode (LED) The dash display is a four segment light emitting diode (LED)
display that displays the status codes, hourmeter readings, display that displays the status codes, hourmeter readings,
and battery discharge indication from the controller. and battery discharge indication from the controller.
Checking hourmeter reading Checking hourmeter reading
1. Turn on the key switch. 1. Turn on the key switch.
2. Push start switch button and hold in. 2. Push start switch button and hold in.
3. The display is hourmeter LED reading. 3. The display is hourmeter LED reading.
Checking battery condition reading. (BDI) Checking battery condition reading. (BDI)
1. Turn on the key switch. 1. Turn on the key switch.
2. Push start switch button and do not hold in. 2. Push start switch button and do not hold in.
3. Depress foot brake pedal and hold down. 3. Depress foot brake pedal and hold down.
4. The display is percent of battery discharge. 4. The display is percent of battery discharge.
5. The battery condition is displayed anytime unit is in 5. The battery condition is displayed anytime unit is in
the operating mode. the operating mode.
Checking status code reading. (wrench) Checking status code reading. (wrench)
1. Turn on the key switch. 1. Turn on the key switch.
2. Push start switch button and do not hold in. 2. Push start switch button and do not hold in.
3. The display is a status code for failure with unit. 3. The display is a status code for failure with unit.
The dash display is physically located on the cross member The dash display is physically located on the cross member
on the mast upright. The display is viewed through windshield on the mast upright. The display is viewed through windshield
when platform is in the fully lowered position. when platform is in the fully lowered position.

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 Controls and instruments Controls and instruments
Dash display status codes Dash display status codes
The following status codes are items that operator should The following status codes are items that operator should
check. If any other status codes appear your BT dealer check. If any other status codes appear your BT dealer
should be contacted to solve problem. should be contacted to solve problem.
Status code -01 Status code -01

Indicates that brake foot switch is not closed. Make Indicates that brake foot switch is not closed. Make
sure the brake foot pedal is depressed. sure the brake foot pedal is depressed.

Status code -02 Status code -02

Indicates forward switch was closed before the key Indicates forward switch was closed before the key
switch or start switch or brake switch was closed. With switch or start switch or brake switch was closed. With
key switch on and start switch pressed, return key switch on and start switch pressed, return
directional switch to neutral, then select direction. directional switch to neutral, then select direction.

Status code -03 Status code -03

Indicates rearward switch was closed before the key Indicates rearward switch was closed before the key
switch or start switch or brake switch was closed. With switch or start switch or brake switch was closed. With
key switch on and start switch pressed, return key switch on and start switch pressed, return
directional switch to neutral, then select direction. directional switch to neutral, then select direction.

Status code -04 Status code -04

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

Status code -05 Status code -05

Indicates brake foot switch is not closed. Make sure Indicates brake foot switch is not closed. Make sure
brake foot switch is closed. brake foot switch is closed.

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

Travel Travel

Proper operation of this unit is with forks trailing when Proper operation of this unit is with forks trailing when
possible. Steering the truck is easier with the forks trailing. possible. Steering the truck is easier with the forks trailing.
Always look in the direction of travel. Always look in the direction of travel.
This unit has been designed for level floor operation and This unit has been designed for level floor operation and
should be operated in accordance with instructions. should be operated in accordance with instructions.
Operate the unit from the operator’s position after assuring Operate the unit from the operator’s position after assuring
that the operation will not endanger the operator or any other that the operation will not endanger the operator or any other
person. Do not operate a truck in hazardous areas. Make sure person. Do not operate a truck in hazardous areas. Make sure
that the forks and/ or load have clearance to lower and do not that the forks and/ or load have clearance to lower and do not
“hang-up”. “hang-up”.
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 Driving Driving
Starting the truck Starting the truck

Steering Directional Steering Directional

wheel control handle wheel control handle

Platform Platform
side bars Key switch side bars Key switch

Parking Parking
brake brake
pedal pedal

• Ensure the battery connector is connected to the truck. • Ensure the battery connector is connected to the truck.

• Enter the operator’s compartment, lower the platform side • Enter the operator’s compartment, lower the platform side
bars, and put on the safety belt. The truck will not operate bars, and put on the safety belt. The truck will not operate
with platform side bars in the raised position. with platform side bars in the raised position.

NOTE! This unit will not operate with the platform NOTE! This unit will not operate with the platform
side bars in the raised position. side bars in the raised position.

• Turn the key switch to the ON position and press the start • Turn the key switch to the ON position and press the start
button. button.

• Make sure the battery indicator indicates a sufficient • Make sure the battery indicator indicates a sufficient
charge level (1/2 - 1) to operate the truck. charge level (1/2 - 1) to operate the truck.
NOTE! NOTE!
Low charge level. Low charge level.
Prolonged operation with a low battery charge level can Prolonged operation with a low battery charge level can
result in damage to the battery. result in damage to the battery.
Do not drive without first recharging the battery. Do not drive without first recharging the battery.
Return 44 44
 Driving Driving
• Disengage the parking brake by placing your foot on the • Disengage the parking brake by placing your foot on the
parking brake pedal and press down. parking brake pedal and press down.

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

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

WARNING Function failure. WARNING Function failure.

Safety can be jeopardized. Safety can be jeopardized.
Always complete the daily operator’s Always complete the daily operator’s
checks before starting the day’s work. checks before starting the day’s work.

- That the horn functions correctly. - That the horn functions correctly.

- That the steering functions correctly. - That the steering functions correctly.

- That the brakes function correctly. - That the brakes function correctly.

- That the hydraulic functions are operational. - That the hydraulic functions are operational.

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

WARNING Dangerous driving. WARNING Dangerous driving.

Accidents can occur. Accidents can occur.
Always drive with care, good judgment, Always drive with care, good judgment,
and responsibility. and responsibility.

Return 45 45
 Driving Driving
Braking Braking

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

• As the truck comes to a full stop the operator may choose • As the truck comes to a full stop the operator may choose
to continue holding the controls in the opposite direction to continue holding the controls in the opposite direction
and thus start the truck moving in that direction, or the and thus start the truck moving in that direction, or the
operator may release the handle and allow the truck to operator may release the handle and allow the truck to
come to a complete halt. Releasing the steering control come to a complete halt. Releasing the steering control
handle will allow the parking brake to become handle will allow the parking brake to become
automatically applied. automatically applied.
THE CONTROL HANDLE MUST NOT BE PLACED IN THE THE CONTROL HANDLE MUST NOT BE PLACED IN THE
BRAKE POSITION DURING THE PLUG BRAKING BRAKE POSITION DURING THE PLUG BRAKING
OPERATION. OPERATION.

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

Return 46 46
 Driving Driving
Steering Steering

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

WARNING Risk of slipping. WARNING Risk of slipping.

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

Return 47 47
 Driving Driving
Parking the truck Parking the truck
Directional Directional
Steering Steering
control handle control handle
wheel wheel

Platform Platform
side bars side bars
Key switch Key switch

Parking Parking
brake brake
pedal pedal

• Rotate directional control to the NEUTRAL position and • Rotate directional control to the NEUTRAL position and
use plug braking to stop all travel. use plug braking to stop all travel.

• Engage the parking brake by raising your foot from brake • Engage the parking brake by raising your foot from brake
pedal. pedal.

• Lower the platform fully to the floor. • Lower the platform fully to the floor.

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

WARNING Unauthorized use. WARNING Unauthorized use.

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

• Remove safety belt and raise platform side bars. • Remove safety belt and raise platform side bars.

Return 48 48
 Transporting loads Transporting loads
Transporting loads Transporting loads

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

WARNING Risk of overturning. WARNING Risk of overturning.

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

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

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

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

WARNING Lost stability. WARNING Lost stability.

High loads can fall when cornering at high High loads can fall when cornering at high
speed or cause tipover. speed or cause tipover.
Drive slowly and carefully when cornering Drive slowly and carefully when cornering
and travel with loads in lowered position. and travel with loads in lowered position.

WARNING Protruding loads. WARNING Protruding loads.

The load can collide with personnel, fixed, The load can collide with personnel, fixed,
or moving objects. or moving objects.
A truck with a protruding load requires A truck with a protruding load requires
more room when cornering. more room when cornering.

Return 49 49
 Transporting loads Transporting loads

NOTE! NOTE!
Increased machine width. Increased machine width.
The load can collide with fixed objects. The load can collide with fixed objects.
A truck with wide loads requires a greater operating A truck with wide loads requires a greater operating
area. area.

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

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

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

• Before the truck is driven into an elevator ensure that the • Before the truck is driven into an elevator ensure that the
elevator is approved for the overall load (the truck’s weight elevator is approved for the overall load (the truck’s weight
and the load). Enter with the load first. DO NOT permit and the load). Enter with the load first. DO NOT permit
other personnel to be in the elevator while entering or other personnel to be in the elevator while entering or
leaving. leaving.

WARNING Risk of overturning. WARNING Risk of overturning.

A loaded truck can overturn when A loaded truck can overturn when
attempting to turn on an incline. attempting to turn on an incline.
Never turn a loaded truck on an incline. Never turn a loaded truck on an incline.

WARNING Increased braking distance. WARNING Increased braking distance.

The braking distance is increased when The braking distance is increased when
traveling downhill. traveling downhill.
Drive at a reduced speed using the truck’s Drive at a reduced speed using the truck’s
motor brake. motor brake.

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 Transporting loads Transporting loads

WARNING Risk of overloading the elevator. WARNING Risk of overloading the elevator.
An overloaded elevator can fall out of An overloaded elevator can fall out of
control down the elevator shaft. control down the elevator shaft.
Always check the capacity of the elevator Always check the capacity of the elevator
before driving in with the truck. before driving in with the truck.

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

WARNING Risk of tipping. WARNING Risk of tipping.

The truck can tip over. The truck can tip over.
Always check the ramp’s load bearing Always check the ramp’s load bearing
capacity and that it is secured correctly. capacity and that it is secured correctly.
Drive at a safe distance from the edges. Drive at a safe distance from the edges.

Loading and unloading Loading and unloading

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

• Never stand with your feet under the forks. • Never stand with your feet under the forks.

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

• Ensure the load is secured on a pallet. • Ensure the load is secured on a pallet.

• Ensure the pallet is securely clamped to lift platform. • Ensure the pallet is securely clamped to lift platform.

• Always wear safety belt and lanyard. The lanyard is to be • Always wear safety belt and lanyard. The lanyard is to be
attached to overhead guard. attached to overhead guard.

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 Transporting loads Transporting loads
Collecting a load Collecting a load

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

• Lift the forks to the required position. • Lift the forks to the required position.

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

• Lift the platform so that forks clear the load. • Lift the platform so that forks clear the load.

• Slowly drive the truck forward to clear the rack. • Slowly drive the truck forward to clear the rack.

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

NOTE! Forks not horizontal. NOTE! Forks not horizontal.

The load can slide off the forks or catch on the The load can slide off the forks or catch on the
rack. rack.
When the load is left or collected the forks should When the load is left or collected the forks should
always be positioned horizontally. always be positioned horizontally.

• Start slowly and then increase the speed. • Start slowly and then increase the speed.

CAUTION Lost stability. CAUTION Lost stability.

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

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 Transporting loads Transporting loads
Leaving a load Leaving a load

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

• Lift the platform to the required lifting position. • Lift the platform to the required lifting position.

• Drive the truck rearward so that the load is positioned • Drive the truck rearward so that the load is positioned
correctly on the rack. correctly on the rack.

• Lower the platform so that forks clear the load. • Lower the platform so that forks clear the load.

• Slowly drive the truck forward to clear the rack. • Slowly drive the truck forward to clear the rack.

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

NOTE! Forks not horizontal. NOTE! Forks not horizontal.

The load can slide off the forks or catch on the The load can slide off the forks or catch on the
rack. rack.
When the load is left or collected the forks should When the load is left or collected the forks should
always be positioned horizontally. always be positioned horizontally.

• Start slowly and then increase the speed. • Start slowly and then increase the speed.

CAUTION Lost stability. CAUTION Lost stability.

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

Return 53 53
 Battery Battery
Battery Battery

Type of battery Type of battery

• Check that the battery used in this truck is the correct • Check that the battery used in this truck is the correct
voltage as shown on the truck’s data plate. Use a traction voltage as shown on the truck’s data plate. Use a traction
battery having a weight within the minimum/maximum battery having a weight within the minimum/maximum
values stated on the data plate. values stated on the data plate.

Changing the battery Changing the battery

• Only replace the battery with a battery of the same weight • Only replace the battery with a battery of the same weight
as the original. The battery weight affects the truck’s as the original. The battery weight affects the truck’s
stability and its braking capacity. Information on the lowest stability and its braking capacity. Information on the lowest
permitted battery weight can be found on the truck’s data permitted battery weight can be found on the truck’s data
plate. plate.

WARNING Risk of moving the center of gravity. WARNING Risk of moving the center of gravity.
A battery weight that is too low gives A battery weight that is too low gives
impaired stability and braking capacity. impaired stability and braking capacity.
The battery weight must be in accordance The battery weight must be in accordance
with the information on the truck’s data plate. with the information on the truck’s data plate.

When changing the battery proceed as follows: When changing the battery proceed as follows:

• Park truck at battery removal station. • Park truck at battery removal station.

• Turn OFF key and remove. • Turn OFF key and remove.

• Push the emergency disconnect button to the OFF position • Push the emergency disconnect button to the OFF position
to stop hourmeter from running. to stop hourmeter from running.

• Disconnect the battery connector from the battery. • Disconnect the battery connector from the battery.

• Remove battery stops. • Remove battery stops.

Return 54 54
 Battery Battery
• Slide out the discharged/old battery, then slide in the new • Slide out the discharged/old battery, then slide in the new
battery. battery.

• Connect battery and truck connectors. • Connect battery and truck connectors.

• Connect the battery connector and truck connector. • Connect the battery connector and truck connector.

WARNING Risk of short-circuiting. WARNING Risk of short-circuiting.

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

• Push the emergency disconnect button to the ON position. • Push the emergency disconnect button to the ON position.

• Install battery stops. • Install battery stops.

WARNING Falling battery. WARNING Falling battery.

If the truck should tip over the battery can If the truck should tip over the battery can
fall out if the battery stops have not been fall out if the battery stops have not been
installed. installed.
Make sure the battery stops have been Make sure the battery stops have been
installed. installed.

WARNING Falling battery. WARNING Falling battery.

When charging the battery, it can be When charging the battery, it can be
dropped. dropped.
Always lift battery using an approved Always lift battery using an approved
lifting device, and use a battery yoke lifting device, and use a battery yoke
intended for the battery. intended for the battery.

Return 55 55
 Battery Battery
Charging the battery Charging the battery

General prohibition General prohibition

When recharging the battery it is absolutely forbidden to When recharging the battery it is absolutely forbidden to
smoke or use an open flame. smoke or use an open flame.
Use an automatic charger intended for recharging traction Use an automatic charger intended for recharging traction
batteries. batteries.
The charger must have an automatic maintenance charging The charger must have an automatic maintenance charging
feature for a certain period after the main charging period has feature for a certain period after the main charging period has
been completed. This eliminates the risk of over charging the been completed. This eliminates the risk of over charging the
battery and the need to monitor the charging procedure is battery and the need to monitor the charging procedure is
reduced to a minimum. reduced to a minimum.
The charger shall have a minimum charging current of: The charger shall have a minimum charging current of:

Battery (Ah) Charger (A) Battery (Ah) Charger (A)

300-480 50-70 300-480 50-70

480-730 80-110 480-730 80-110
730-900 130-150 730-900 130-150

WARNING Corrosive acid. WARNING Corrosive acid.

The battery fluid contains sulfuric acid. The battery fluid contains sulfuric acid.
Fluid spilled on skin should be rinsed Fluid spilled on skin should be rinsed
OFF immediately. Wash thoroughly with OFF immediately. Wash thoroughly with
soap and water. soap and water.
If the fluid has come into contact with the If the fluid has come into contact with the
eyes, wash the eyes immediately using an eyes, wash the eyes immediately using an
eye shower. Contact a doctor. eye shower. Contact a doctor.

ALWAYS WEAR PROTECTIVE GLASSES ALWAYS WEAR PROTECTIVE GLASSES

AND PROTECTIVE GLOVES WHEN AND PROTECTIVE GLOVES WHEN
CHECKING THE BATTERY. CHECKING THE BATTERY.
Return 56 56
 Battery Battery
Pre-charging Pre-charging

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

• Ensure nothing prevents ventilation above the battery. • Ensure nothing prevents ventilation above the battery.

• Turn key switch to the OFF position. • Turn key switch to the OFF position.

• Remove the battery connector from the truck’s connector. • Remove the battery connector from the truck’s connector.

• Make sure the battery charger is switched OFF. • Make sure the battery charger is switched OFF.

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

• Never connect charger connector to truck connector. • Never connect charger connector to truck connector.

• Switch ON the battery charger. • Switch ON the battery charger.

WARNING During the charging process oxygen and WARNING During the charging process oxygen and
hydrogen gases are always formed in the hydrogen gases are always formed in the
battery. battery.
Short circuits, open flames, and sparks in Short circuits, open flames, and sparks in
the vicinity of the battery can cause an the vicinity of the battery can cause an
EXPLOSION. EXPLOSION.
Always switch OFF the charger current Always switch OFF the charger current
BEFORE removing the battery connector. BEFORE removing the battery connector.
Provide good ventilation, especially if the Provide good ventilation, especially if the
battery is recharged in a confined area. battery is recharged in a confined area.

During charging During charging

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

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 Battery Battery
After charging After charging

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

• Switch OFF the charger. • Switch OFF the charger.

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

Risk of short circuiting. Risk of short circuiting.

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

Return 58 58
 Battery Battery
Battery maintenance Battery maintenance
Carry out battery maintenance after recharging. Carry out battery maintenance after recharging.

WARNING Corrosive acid. WARNING Corrosive acid.

The battery fluid contains sulfuric acid. The battery fluid contains sulfuric acid.
Fluid spilled on skin should be rinsed Fluid spilled on skin should be rinsed
OFF immediately. Wash thoroughly with OFF immediately. Wash thoroughly with
soap and water. soap and water.
If the fluid has come into contact with the If the fluid has come into contact with the
eyes, wash the eyes immediately using an eyes, wash the eyes immediately using an
eye shower. Contact a doctor. eye shower. Contact a doctor.

ALWAYS WEAR PROTECTIVE GLASSES ALWAYS WEAR PROTECTIVE GLASSES

AND PROTECTIVE GLOVES WHEN AND PROTECTIVE GLOVES WHEN
CHECKING THE BATTERY. CHECKING THE BATTERY.

Each week: Each week:

• Remove all cell caps. • Remove all cell caps.

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

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

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

• Refit all of the cell caps. • Refit all of the cell caps.

• Rinse off and dry the battery. • Rinse off and dry the battery.

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 Battery Battery
Each month: Each month:

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

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

• Adjust specific gravity with temperatures based on the • Adjust specific gravity with temperatures based on the
chart below. chart below.

Temperature Gravity Temperature Gravity

77°F [25.2°C] 1.280 77°F [25.2°C] 1.280

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

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 Daily service/safety checks Daily service/safety checks
Daily service/safety checks Daily service/safety checks

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

• Carry out the daily service at the start of the day or shift, • Carry out the daily service at the start of the day or shift,
before the truck is used. The daily service is a simple before the truck is used. The daily service is a simple
safety and function control as set in the check list below. safety and function control as set in the check list below.

• You need no tools to carry out the service checks. • You need no tools to carry out the service checks.

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

WARNING Never neglect the daily service and safety WARNING Never neglect the daily service and safety
checks. Serious accidents can occur. checks. Serious accidents can occur.
Always report any faults or damage to Always report any faults or damage to
your supervisor without delay. Never use your supervisor without delay. Never use
a truck that does not function properly. a truck that does not function properly.

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 Daily service/safety checks Daily service/safety checks

21 23 24 21 23 24
5 5
19 3 19 3
2 2
7 7
6 6
8 4 8 4
18 18
1 1
9 9
17 17
22 10 22 10

16 11 16 11
12 12
9 9

14 14
20 15 13 20 15 13

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

Item Item
Check points Action Check points Action
# #

1 Direction / accelerato Check its function 1 Direction / accelerator Check its function
2 Horn Check its function 2 Horn Check its function
3 Steering wheel Check its function 3 Steering wheel Check its function
4 Key switch (toggle) Check its function 4 Key switch (toggle) Check its function
5 Hydraulic function Check its function 5 Hydraulic function Check its function
6 Running time Inform your supervisor if your truck is 6 Running time Inform your supervisor if your truck is
ready for a schedule maintenance ready for a schedule maintenance
check. Se “Maintenance” chapter. check. See “Maintenance” chapter.
7 Emergency stop button Check its function 7 Emergency stop button Check its function

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 Daily service/safety checks Daily service/safety checks

Item Item
Check point Action Check points Action
# #

8 Start button Check its function 8 Start button Check its function
9 Pallet clamp Check its function and adjustment 9 Pallet clamp Check its function and adjustment
10 Hydraulic system Check for oil leakage, hoses, and 10 Hydraulic system Check for oil leakage, hoses, an
floor floor
11 Battery Check acid level, charge, an 11 Battery Check acid level, charge, and
condition (see battery maintenance) condition (see battery maintenance)
12 Battery cables and Check for breakage, cutting, or 12 Battery cables an Check for breakage, cutting, or
connections damage connections damage
13 Drive unit Inspect abnormal noises and leakage 13 Drive unit Inspect abnormal noises and leakag
14 Chassis Check for damage, remove dirt and 14 Chassis Check for damage, remove dirt an
debris debris
15 Wheels Check for damage, remove oil, metal 15 Wheels Check for damage, remove oil, metal
chips, and debris chips, and debris
16 Parking brake Check its function 16 Parking brake Check its function
17 Platform side bar Check its function 17 Platform side bar Check its function
18 Hydraulic cylinder Check for damage and leakage 18 Hydraulic cylinder Check for damage and leakag
19 Platform overhead Check for damage, ensure placement 19 Platform overhead Check for damage, ensure placement
guard and covers guard and covers
20 Forks Check for damage and alignment of 20 Forks Check for damage and alignment of
forks forks
21 Safety belt and lanyard Check for damage, ensure placement 21 Safety belt and lanyar Check for damage, ensure placement
22 Warning light (optional) Check its function 22 Warning light (optional) Check its function
23 Drive wheel indicator Check its function and alignment 23 Drive wheel indicator Check its function and alignment
24 Battery discharge Check its function 24 Battery discharge Check its function
indicator (optional) indicator (optional)

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

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

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 Maintenance Maintenance
Maintenance Maintenance

General information General information

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

• Only use BT approved spare parts when service and • Only use BT approved spare parts when service and
repair work are carried out. repair work are carried out.

• BT recommends that you contact your BT representative • BT recommends that you contact your BT representative
to set up a service and maintenance agreement to ensure to set up a service and maintenance agreement to ensure
your truck’s operating economy and safety. your truck’s operating economy and safety.

Safety regulations with maintenance work Safety regulations with maintenance work

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

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

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

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

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 Maintenance Maintenance

WARNING Short-circuiting/burns. WARNING Short-circuiting/burns.

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

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

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

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

• Use paper or a rigid sheet of cardboard when checking for • Use paper or a rigid sheet of cardboard when checking for
oil leakage. Never use your hand. oil leakage. Never use your hand.

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

WARNING Risk of burns. WARNING Risk of burns.

Hot transmission and hydraulic oil. Hot transmission and hydraulic oil.
Let the truck cool before changing the oil. Let the truck cool before changing the oil.

• Only fill the hydraulic system with new clean oil. Oil should • Only fill the hydraulic system with new clean oil. Oil should
meet BT cleanliness specification 12-00-002. Contact your meet BT cleanliness specification 12-00-002. Contact your
BT representative for assistance or more information. BT representative for assistance or more information.

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 Maintenance Maintenance

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

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

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

• When working underneath the truck support the truck on • When working underneath the truck support the truck on
trestle-blocks. trestle-blocks.

WARNING Risk of crushing. WARNING Risk of crushing.

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

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 Maintenance Maintenance
Maintenance work that can be carried out by you Maintenance work that can be carried out by you
The Daily service/Safety checks as set out in the check list. The Daily service/Safety checks as set out in the check list.
Maintenance points with intervals 1 day, 1 week, and 1 Maintenance points with intervals 1 day, 1 week, and 1
month as set out in the Maintenance chart may be carried month as set out in the Maintenance chart may be carried
out by the driver without more knowledge than that provided out by the driver without more knowledge than that provided
by the Operator’s Manual. by the Operator’s Manual.
Other maintenance points as set out in the Maintenance Other maintenance points as set out in the Maintenance
chart may only be carried out by personnel who have chart may only be carried out by personnel who have
completed maintenance training for this type of truck. completed maintenance training for this type of truck.

Maintenance work that may be carried out by Maintenance work that may be carried out by
trained maintenance personnel trained maintenance personnel
All maintenance points as set out in the Maintenance chart. All maintenance points as set out in the Maintenance chart.
If you are uncertain regarding working procedures consult the If you are uncertain regarding working procedures consult the
Service Manual for the truck. Service Manual for the truck.

Other service and repair work Other service and repair work

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

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 Maintenance Maintenance
Cleaning and washing Cleaning and washing

General General
Cleaning and washing the truck is important to ensure the Cleaning and washing the truck is important to ensure the
truck will operate safely and reliably. truck will operate safely and reliably.

• Carry out general cleaning and washing weekly. • Carry out general cleaning and washing weekly.

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

External cleaning External cleaning

• Remove debris, etc. from the wheels daily. • Remove debris, etc. from the wheels daily.

• Use a degreasing agent diluted to a suitable concentration. • Use a degreasing agent diluted to a suitable concentration.

• Rinse off loose grime using warm water. • Rinse off loose grime using warm water.

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

Cleaning the motor compartment Cleaning the motor compartment

• Cover the electric motors, electrical compartments, • Cover the electric motors, electrical compartments,
connectors, and valves before washing. connectors, and valves before washing.

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 Maintenance Maintenance
• Clean carefully using the minimum of water and detergent. • Clean carefully using the minimum of water and detergent.
Never pressure wash or steam clean in the Never pressure wash or steam clean in the
compartments. compartments.

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

• Clean the motor compartment using a degreasing agent • Clean the motor compartment using a degreasing agent
diluted to a suitable concentration. diluted to a suitable concentration.

• Rinse off loose grime using warm water. • Rinse off loose grime using warm water.

Electrical components Electrical components

• Blow electric motors dry using compressed air. • Blow electric motors dry using compressed air.

WARNING Compressed air used for cleaning MUST WARNING Compressed air used for cleaning MUST
be reduced to less than 30 psi, and then be reduced to less than 30 psi, and then
only with effective chip-guarding and only with effective chip-guarding and
personal protective equipment. personal protective equipment.

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

• Do not spray or pressure wash in the compartment. • Do not spray or pressure wash in the compartment.

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

Return 70 70
 Maintenance Maintenance
Maintenance chart Maintenance chart
PM Interval: PM Interval:
A=5 Hours or 1 Day E=500 Hours or 6 Months A=5 Hours or 1 Day E=500 Hours or 6 Months
B=20 Hours or 1 Week F=1000 Hours or 12 Months B=20 Hours or 1 Week F=1000 Hours or 12 Months
C=80 Hours or 1 Month G=3000 Hours or 36 Months C=80 Hours or 1 Month G=3000 Hours or 36 Months
D=250 Hours or 3 Months D=250 Hours or 3 Months
No. Action A B C D E F G No. Action A B C D E F G
1.0 Chassis 1.0 Chassis
1.1 Check that the truck’s data plate is X 1.1 Check that the truck’s data plate is X
legible legible
1.2 Check the cover screws X 1.2 Check the cover screws X
1.3 Check door lock X 1.3 Check door lock X
1.4 Check for damage and crack formation X 1.4 Check for damage and crack formation X
1.5 Check fork frame mounting X 1.5 Check fork frame mounting X
2.0 Motors 2.0 Motors
2.1 Check for loose connections X 2.1 Check for loose connections X
2.2 Clean motor X 2.2 Clean motor X
2.3 Check mounting bolts X 2.3 Check mounting bolts X
2.4 Check for abnormal bearing noise X 2.4 Check for abnormal bearing noise X
2.5 Check brush wear X 2.5 Check brush wear X
3.0 Drive unit 3.0 Drive unit
3.1 Check for leakage X 3.1 Check for leakage X
3.2 Check oil level X 3.2 Check oil level X
3.3 Check for noises X 3.3 Check for noises X
3.4 Check the mounting on support X 3.4 Check the mounting on support X
4.0 Wheels 4.0 Wheels
4.1 Remove string and debris X 4.1 Remove string and debris X
4.2 Check all wheels for wear X 4.2 Check all wheels for wear X
4.3 Check that all wheels rotate and axles X 4.3 Check that all wheels rotate and axles X
are fitted correctly are fitted correctly
4.4 Check drive wheel for loose screws X 4.4 Check drive wheel for loose screws X
4.5 Grease load wheel bearings X 4.5 Grease load wheel bearings X

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 Maintenance Maintenance
No. Action A B C D E F G No. Action A B C D E F G
4.6 Grease caster and caster wheels X 4.6 Grease caster and caster wheels X
4.7 Dismantle and lubricate all wheel X 4.7 Dismantle and lubricate all wheel X
bearings. bearings.
5.0 Brake 5.0 Brake
5.1 Check brake operation X 5.1 Check brake operation X
6.0 Electrical panel 6.0 Electrical panel
6.1 Clean and check the mounting X 6.1 Clean and check the mounting X
6.2 Tighten cable connections X 6.2 Tighten cable connections X
6.3 Check contactor tips X 6.3 Check contactor tips X
6.4 Check the contactor tips for free X 6.4 Check the contactor tips for free X
movements movements
6.5 Check all cable insulation for damage X 6.5 Check all cable insulation for damage X
7.0 Electronic control system 7.0 Electronic control syste
7.1 Check for connections in harness X 7.1 Check for connections in harness X
connectors connectors
7.2 Check control wiring harness for X 7.2 Check control wiring harness for X
proper routing proper routing
7.3 Warning light X 7.3 Warning light X
8.0 Battery 8.0 Battery
8.1 Check electrolyte level, 1/2 -5/8 in. X 8.1 Check electrolyte level, 1/2 -5/8 in. X
(10-15mm above cell plate) (10-15mm above cell plate)
8.2 Check the connections on battery, X 8.2 Check the connections on battery, X
truck, and charger truck, and charger
8.3 Check all cells and pole guards X 8.3 Check all cells and pole guards X
8.4 Check the fluid density and X 8.4 Check the fluid density and X
temperature temperature
8.5 Check power cables are not cut or X 8.5 Check power cables are not cut or X
frayed frayed
9.0 Hydraulic system 9.0 Hydraulic system
9.1 Check hoses and connections for X 9.1 Check hoses and connections for X
leakage leakage
9.2 Check hoses for wear and damage X 9.2 Check hoses for wear and damage X
9.3 Check oil tank for cracks, leaks, and X 9.3 Check oil tank for cracks, leaks, and X
mounting mounting

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 Maintenance Maintenance
No. Action A B C D E F G No. Action A B C D E F G
9.4 Check oil level X 9.4 Check oil level X
9.5 Change oil X 9.5 Change oil X
10.0 Cylinders 10.0 Cylinders
10.1 Check for leakage X 10.1 Check for leakage X
10.2 Check the mountings X 10.2 Check the mountings X
11.0 Lifting device 11.0 Lifting device
11.1 Check for damage and cracks X 11.1 Check for damage and cracks X
11.2 Check mast mounting bolts torque X 11.2 Check mast mounting bolts torque X
11.3 Check for play on rollers X 11.3 Check for play on rollers X
11.4 Check the electrical limit switch X 11.4 Check the electrical limit switch X
function function
11.5 Check the platform side bar switches X 11.5 Check the platform side bar switches X
11.6 Check for wear and stretch on the X 11.6 Check for wear and stretch on the X
chains and sheaves chains and sheaves
11.7 Check hoses and couplings for X 11.7 Check hoses and couplings for X
leakage, cuts, and other damage leakage, cuts, and other damage
118 Check for wear to the forks and other X 118 Check for wear to the forks and other X
lifting devices lifting devices
11.9 Lube all grease fittings X 11.9 Lube all grease fittings X
12.0 Controls 12.0 Controls
12.1 Check steering wheel mounting X 12.1 Check steering wheel mounting X
12.2 Check the parking brake switch X 12.2 Check the parking brake switch X
12.3 Check travel direction/speed control X 12.3 Check travel direction/speed control X
12.4 Check horn button function X 12.4 Check horn button function X
12.5 Check hydraulic button functions X 12.5 Check hydraulic button functions X
12.6 Check the start switch X 12.6 Check the start switch X
12.7 Check key switch (toggle) X 12.7 Check key switch (toggle) X
12.8 Check brake switch X 12.8 Check brake switch X
12.9 Check the pallet clamp X 12.9 Check the pallet clamp X
13.0 Gauge 13.0 Gauge
13.1 Check dash display X 13.1 Check dash display X
13.2 Check hourmeter X 13.2 Check hourmeter X

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 Maintenance Maintenance
No. Action A B C D E F G No. Action A B C D E F G
13.3 Check drive wheel indicator X 13.3 Check drive wheel indicator X
13.4 Check battery discharge indicator X 13.4 Check battery discharge indicator X
14.0 Emergency stop switch 14.0 Emergency stop switch
14.1 Check the emergency stop switch X 14.1 Check the emergency stop switch X
14.2 Check mast chain slack switch X 14.2 Check mast chain slack switch X
15.0 Safety device 15.0 Safety device
15.1 Check safety belt and lanyard for X 15.1 Check safety belt and lanyard for X
damage and wear damage and wear

15 13 13 15 13 13

11 11

14 12 14 12

10 10

9 9
6, 7 6, 7

5 5
8 8

1 1
4 3 2 4 3 2

Maintenance chart Maintenance chart

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 Maintenance Maintenance
Lubrication chart Lubrication chart

Interval/Running hours Interval/Running hours

Pos Pos
Service point Lubricant Service point Lubricant
No. No.
500h 1000h 3000h 500h 1000h 3000h

1 Wheel bearings L A 1 Wheel bearings L A

2 Hydraulic system C O B 2 Hydraulic system C O B

3 Parking brake C 3 Parking brake C

4 Drive gear C O C 4 Drive gear C O C

5 Hinges L D 5 Hinges L D

6 Steering bearings L A 6 Steering bearings L A

7 Gear ring L A 7 Gear ring L A

L=Lubrication C=Check O=Oil change L=Lubrication C=Check O=Oil change

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 Maintenance Maintenance
Approved oils and grease Approved oils and grease

Pos. Lubricant Specification Application Pos. Lubricant Specification Application

> 5°F-15°C < 5°F-15°C <-10°F-23°C area > 5°F-15°C < 5°F-15°C <-10°F-23°C area
A Grease Tex. Ref. C & Tex. Ref. C & Tex. Ref. C & Bearings and A Grease Tex. Ref. C & Tex. Ref. C & Tex. Ref. C & Bearings and
C #880 C #880 C #880 bushings C #880 C #880 C #880 bushings
B Hydraulic oil Sunoco TH Sunoco TH Texaco 15 Hydraulic B Hydraulic oil Sunoco TH Sunoco TH Texaco 15 Hydraulic
system system
C Transmission SAE 80W/90 SAE 75W SAE 75W Gears C Transmission SAE 80W/90 SAE 75 SAE 75 Gears
oil oil
D Motor oil SAE 40 SAE5W-20 SAE5W-20 Hinges D Motor oil SAE 40 SAE5W-20 SAE5W-20 Hinges
E Grease Molykote Molykote Molykote Mast rails E Grease Molykote Molykote Molykote Mast rails
200025 200025 200025 200025 200025 200025
F Grease 49670-00 49670-00 49670-00 Mast rails F Grease 49670-00 49670-00 49670-00 Mast rails

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

E E

B B
F F
C C

D D

A A
Lubrication chart location points Lubrication chart location points

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

Truck’s dimensions and weight Truck’s dimensions and weight

Truck type 2 Stage 3 Stage Truck type 2 Stage 3 Stage

Height Mast lowered height Height Mast lowered height

Width (platform - 40 in. wide) 42 in. (1067 mm) Width (platform - 40 in. wide) 42 in. (1067 mm)
Length without forks 76 in. 77 in. Length without forks 76 in. 77 in.
(1930 mm) (1956 mm) (1930 mm) (1956 mm)
Minimum battery weight 1100 lb Minimum battery weight 1100 lb
Service weight without battery 5200 lb 5500 lb. Service weight without battery 5200 lb 5500 lb.
(this weight is with 48 in. forks) (this weight is with 48 in. forks)

Lifting the truck Lifting the truck

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

WARNING Risk of overturning. WARNING Risk of overturning.

The truck can overturn if lifted from the The truck can overturn if lifted from the
wrong lifting points. wrong lifting points.
Always lift the truck from the marked lifting Always lift the truck from the marked lifting
points. points.

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 Transporting and storing the truck Transporting and storing the truck

WARNING Risk of overturning. WARNING Risk of overturning.

The truck can overturn if lifted incorrectly. The truck can overturn if lifted incorrectly.
Always lift the truck secured to, and with the Always lift the truck secured to, and with the
center of gravity between, the lifting truck’s center of gravity between, the lifting truck’s
forks. forks.

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 Transporting and storing the truck Transporting and storing the truck
Towing and transporting a disabled truck Towing and transporting a disabled truck

WARNING DO NOT tow a disabled truck. WARNING DO NOT tow a disabled truck.

It is not recommended to tow a disabled lift truck. It is not recommended to tow a disabled lift truck.

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 Transporting and storing the truck Transporting and storing the truck
Storing the truck Storing the truck
Take the following action if the truck is not used for one week Take the following action if the truck is not used for one week
or more: or more:
Battery Battery

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

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

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

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

Starting after a period of disuse Starting after a period of disuse

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

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

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 Recyling/Discarding Recyling/Discarding

Recycling/Discarding Recycling/Discarding
Batteries are hazardous to the environment and should be Batteries are hazardous to the environment and should be
returned to the manufacturer for recycling. returned to the manufacturer for recycling.
Discarding the battery Discarding the battery

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

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

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

Chassis Chassis
Chassis Steel Chassis Steel
Battery cover Steel Battery cover Steel
Mast Steel Mast Steel
Drive unit Steel and cast material Drive unit Steel and cast material
Bushings Iron/copper Bushings Iron/copper
Finish Epoxy-polyester Finish Epoxy-polyester
Wheels Polyurethane Wheels Polyurethane

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 Recyling/Discarding Recyling/Discarding

Hydraulic system Hydraulic system

Oil tank Polythene Oil tank Polythene
Pump unit Steel and aluminium Pump unit Steel and aluminium
Hoses Rubber and stee Hoses Rubber and steel
Cylinders Steel Cylinders Stee

Electrical system Electrical system

Cables Copper cores with PVC Cables Copper cores with PVC
sheaths sheaths
Electronic board Reinforced fiberglass circuit Electronic board Reinforced fiberglass circuit
board laminate board laminate
Motors Steel and copper Motors Steel and copper

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