MasterMover SmartMover SM60+ User manual

2
Original Instructions in UK English
Revised / Reprinted 29th June 2017
Manual revision: REV1
MasterMover Part No. 011–46900 Standard Operator’s Manual (English)
General Sales and Service Contact Information:
MasterMover Ltd.
Airfield Industrial Estate,
Moor Farm Road,
Ashbourne,
Derbyshire.
DE6 1HD
UK
T+44 (0) 1335 347700
Wwww.mastermover.com
Copyright © 2008-2017 MasterMover Ltd. All rights reserved.
No part of this publication may be reproduced or distributed in any form or by any means,
electronic or mechanical, including photocopying, recording or any other information storage or
retrieval system, without prior permission in writing from MasterMover Ltd.
MasterMover®is a Registered Trade Name.
MasterMover Ltd. Registered in England No. 6776797
VAT No. 974 8546 62

Contents
i
ABOUT THIS OPERATOR MANUAL 1
Maintenance 1
Disclaimer 1
HEALTH & SAFETY 2
Warning Labels 2
Safety Warnings in this Manual 3
If you Suspect a Fault 3
Safety Precautions 3
Preparation 4
Unpacking 4
Lighting in the Work Area 4
Safety Do’s 5
Safety Don’ts 5
GENERAL INFORMATION 6
Storing the Machine 6
Model Names 6
Noise Levels 6
IP rating 6
Cleaning 6
CONTROLS & INDICATIONS 7
Control Head 7
Key Switch 8
Emergency Stop 8
Automatic Parking Brake 8
Anti-Crush Button 9
Hydraulic Coupling Switch 9
Warning Horn 9
Forward/Reverse Throttle and Brake Lever 10
Battery Discharge Indicator (BDI) 10
MACHINE OPTIONS 12
Option Contents 13
BATTERIES 14
Battery Care & Life 14
Lead Acid - Sealed and Vented 14
Lithium 14
Battery Do’s 15
Battery Don’ts 15
Battery Safety Labels 16
Interchangeable Battery Pack 16
Disposing of Used Batteries or Packs 16

Contents
ii
CHARGING 17
Charging with the External Charger 17
Charging with the Internal Charger 17
Charger Indicator Lights 18
MACHINE CHECKS 20
Pre-Shift Checks 20
Weekly Checks 20
Monthly Checks 20
TRAINING & SERVICING 21
Training 21
Regular Service 21
Sales & Service Contacts 22
Warranty 22
FAQS AND TROUBLESHOOTING 23

About this Operator Manual
1
About this Operator Man ual
This manual provides general machine instructions and
guidance for our machines. Please also refer to your machine
Bolt-On manual supplied.
In the interests of Safety, please make sure that you read and
understand both manuals before using your MasterMover
machine.
Maintenance
This manual does not cover maintenance other than basic cleaning and checking for signs of a
problem. In the event of a fault, please contact your supplier or MasterMover Ltd –see page 22.
Disclaimer
The purpose of this manual is to provide general, non-machine specific instructions and guidance
for our machines.
Nothing contained in this manual constitutes a warranty of any kind in respect of the machine or
of the results to be achieved by its use. The only warranties given by MasterMover in respect of
any machine are those expressly given by MasterMover or your supplier in the contract under
which it sells the machine to its purchaser.
The information contained in this manual is believed to be accurate at the date of publication.

Health & Safety
2
Health & Safety
Warning Labels
Some of the following symbols may be used on your machine. Please study them and learn their
meaning.
Refer to instruction
manual/booklet
Wear eye protection
Wear safety footwear
Disconnect mains plug
from electrical outlet
General warning sign
Warning; Battery charging
Warning; Explosive
material
Warning; Crushing of feet
or limbs
Warning; Flammable
material
Warning; Corrosive
substance
Warning; Electricity
Warning; Toxic materials
Warning; Crushing of
hands or limbs
No children allowed
No open flame; Fire,
open ignition source
and smoking
prohibited
Recycle the batteries –
they contain Lead (Pb)
Battery power-
disconnect
Waste Electronic and
Electrical Equipment
(WEEE) symbol. Recycle
in the correct manner
Company ISO 9001
quality assurance in
production,
installation and
servicing
Manufacturer's
declaration that the
product meets the
requirements of the
applicable EC directives

Health & Safety
3
Safety Warnings in this Manual
In this manual, we indicate potential safety issues by the Warning/Caution
symbol. Please read the safety information before you do any task preceded by
this symbol.
There are two levels of safety message: WARNINGS and CAUTIONS:
WARNING: Failure to observe a WARNING could result in death or serious
injury.
CAUTION: Failure to observe a CAUTION may cause minor injury or damage
to equipment.
If you Suspect a Fault
If you notice a fault, or if the machine does not operate as described:
1. STOP the machine and turn the key switch to OFF.
2. Disconnect the battery.
3. REPORT the problem immediately to your supervisor/manager, or directly to
MasterMover.
CAUTION: SERVICING SAFETY
In the interests of safety only authorised, trained personnel may service or
repair MasterMover machines.
Safety Precautions
Please follow these precautions when using the machine:
Do not switch the machine on until you are ready.
Make sure the working area is safe and clear of obstacles.
Wear suitable non-slip, safety footwear with protective toecaps.
Be very careful how you move the machine, how you drive it from its packing crate, etc.
If necessary, ask someone to help you or use lifting equipment.
Always follow your company’s Health and Safety Regulations.

Health & Safety
4
WARNING: MACHINE WEIGHT
Our machines are very heavy and could easily injure someone if incorrectly
used.
Preparation
The machine is supplied ready for use, although in some cases you may need to fit the coupling
you have chosen (fitting the coupling is simple and requires only a few basic hand tools).
At the MasterMover factory:
We set the acceleration and speed. Note, this can be altered.
We provide and attach the chosen machine Options (some simple assembly may be
required in the case of certain options).
We send the unit with a fully-charged battery pack.
Unpacking
Check that you have received all the parts shown on the itemised delivery note. If anything is
missing, please contact your supplier immediately.
IMPORTANT:
FAILURE TO COMPLY WITH THE FOLLOWING POINTS COULD RESULT IN
SERIOUS DAMAGE TO EQUIPMENT AND POTENTIALLY CAUSE SEVERE INJURY
OR DEATH OF THE OPERATOR OR THOSE AROUND
Lighting in the Work Area
The working area must be sufficiently well lit so that the operator and all other pedestrians in the
area can clearly see:
The load and your immediate surroundings.
The route ahead that the load will be travelling through.
The condition of the ground/surface where the machine and load will move.
All possible obstructions.

Health & Safety
5
Safety Do’s
When pulling a load, DO walk beside the machine when possible, for safety. If you
need to walk backwards when pulling a load, DO make sure that you are not walking
into an obstruction.
DO use the warning horn to make people aware of your movements.
DO take care to avoid people, objects, equipment, cables on the floor etc.
DO check the coupling for wear or damage (including cracks/deformation).
DO remove the key when machine is not in use - store in a secure place.
DO keep the machine clean and free of dirt and grease.
DO take extra care on slopes and loose surfaces.
DO keep your feet clear of the machine when moving the machine.
Safety Don’ts
DON’T use the machine if the battery state meter shows a low or uncharged state.
Recharge immediately.
DON’T use the machine unless properly trained.
DON’T use the machine for anything other than its intended use.
DON'T try to ride on the machine.
DON'T attempt to turn the castor wheel using feet/hands.
DON’T use pressure washers to clean the machine, water can easily get into the
battery compartment through the ventilation slots.
DON’T detach the machine from the load if on a slope. The load could easily roll away
and injure someone.
DON’T try to modify the machine yourself. This includes changes affecting for
example, stability, capacity, braking, steering, visibility and the addition of any
removable attachments.

General Information
6
General Information
Storing the Machine
It is important to have a designated storage and charging area, in a dry place indoors. Store in a
suitable place away from aisles and passageways as to avoid it being an obstacle and trip
hazard.
Model Names
The first two or three letters of the machine model indicate which family it is part of. If it has a
plus ‘+’ symbol at the end, this denotes it has hydraulic functionality.
Abbreviated family name
Full family name
SM
SmartMover
MT
MasterTug
AT
All Terrain
AT TOW
All Terrain Tow
MH
MasterHandler
MP
MasterPusher
GBM
Gas Bottle Mover
TMS
Trailer Moving System
CEM
Cummins Engine Mover
RCM
Roll Cage Mover
Noise Levels
This is a quiet, electrically-operated machine. These are the typical noise levels at the operator’s
position:
Noise level
Decibels (dBA)
Motor operation in high
speed mode, at maximum
speed
≤ 80*1
Flashing safety light and
motion bleeper
80
Horn output
95
*1 Tested on concrete floor
IP rating
The IP rating varies from machine to machine –please refer to page 1 of your machine Bolt-On
manual for more information.
Cleaning
When cleaning your MasterMover (including Stainless Steel machines), do not use solvents or
pressurised water*2as this can damage the machine and the internal components invalidating
your warranty. Instead we recommend to use a damp, non-abrasive cloth or sponge with a mild
detergent or soap. Avoid cleaning pastes and detergents containing chloride.
*2 Only the MT5/400+SS IP55 can be subjected to pressurised water.

Controls & Indications
7
Controls & Indications
Control Head
The Control Head is the steering wheel of the MasterMover machine. There are two variants:
Two button configuration
1
2
3
4
5
6
3
Six button configuration
1
2
7
8
3
4
5
9
10
6
3
1. Steering handles
2. Two speed selector switch (Option): See page 12
3. Forward/reverse throttle and brake lever (referred to as throttle lever)
4. Anti-crush button
5. Warning horn
6. Hydraulic coupling switch: See page 9
7. Dependant on application
8. Dependant on application
9. Dependant on application
10. Dependant on application

Controls & Indications
8
Key Switch
The key switch is located on the front or top of the machine. When you
insert the key and turn it ON, the battery discharge indicator will display
the charge level - this confirms that the machine is now “live”.
We supply two keys with the machine. Extra keys are available to order,
please contact your dealer or MasterMover Technical Support.
Note: You can only remove the key in the OFF positon.
Emergency Stop
The Emergency Stop is a red button usually located on the tiller
arm. When the emergency stop button is pressed, it activates a
cut-out for the machine and all controls are disabled. To release
the button, turn the button 90oclockwise and this will activate
the machine again.
Automatic Parking Brake
The machines are equipped with an automatic parking brake - there is
no separate manual brake control. The brake is automatic and releases
when you move the throttle lever. A constant electric current holds the
parking brake OFF while the machine is moving. When it comes to a
complete stop, the brake applies automatically.
Note: If you turn the key switch OFF, or if the battery becomes fully
discharged, the motor stops and the parking brake applies
automatically.

Controls & Indications
9
Anti-Crush Button
At the front centre of the control head is a red Anti-
Crush button which overrides the throttle levers when
pressed.
In the unfortunate event of being trapped while the
machine is reversing, this button will activate an
emergency stop and move forward slowly. If pressed
while moving forwards, the machine will perform an
emergency stop and will not move until the throttle
lever has returned to its neutral position first.
Hydraulic Coupling Switch
This activates the hydraulic pump on the machine to either raise/lower the coupling mast or to
clamp/unclamp the coupling, allowing you to connect to the load. See ‘Coupling to the Load’
in your machine Bolt-On manual.
Lower/Clamp
Raise/Unclamp
Warning Horn
Use the horn to give audible warning when you
approach corners or to let other people know that a
moving load is coming.

Controls & Indications
10
Forward/Reverse Throttle and Brake Lever
Forward, reverse and brakes are controlled by the throttle levers. This is a variable speed
control: you can accelerate and decelerate gently.
Using the Throttle:
To push the load away from you, push either lever UP away from you.
To pull the load towards you, press either lever DOWN towards you.
These levers are mechanically linked so you can use either side.
How to Stop:
Release the throttle levers and they spring to a central, neutral position. The motor slows the
load to a stop. When stationary, the parking brake applies automatically.
Battery Discharge Indicator (BDI)
The Battery Discharge Indicator (BDI) shows you the charge level of the battery pack as a
percentage. It will also display any fault code the machine might have (model dependant).
100% charged.
31 –40% charged.

Controls & Indications
11
For those machines with the circular BDI, the following indications
are to be observed when switching on and during use of the
machine:
1. When you first switch the machine ON, all 3 LEDs
illuminate briefly (green, yellow and red) to indicate that
they are all working, then they switch off.
2. Next, the green light shows. The meter displays “Traction
Hours” for a moment, then a number. This number
displayed is the total number of hours that the machine
has been moving.
3. Next, the yellow light shows and after a few moments
switches off. The display shows the battery charge level
and will continue to show this during use.
The yellow light will also show the following Low Battery
Indications:
Yellow light ON - battery 35%.
Yellow light FLASHING - battery 25%.
Yellow light FLASHING and text reading “Low BDI” - battery
20%. Recharge the battery pack immediately, or the
battery may fail.
4. If the red light is FLASHING then there is a fault and the
display will show a fault code number. If this happens,
report the fault and code to your supervisor.
Additional information:
Check that the battery pack is well charged before use.

Machine Options
12
Machine Options
Option –flashing safety light and motion
bleeper
Option –two speed selector switch
Option –wireless control handset
Option –lifting and anchoring points
Option –wheel protectors
Option –forward facing LED
Option –headlights
Option –no horn
Option –drive wheel
Option –mast steering lock
Option –roll cage pivot link bar - sunlight
Option –roll cage pivot link bar - universal
Option –XrissXcross roll cage connection
straps
Option –air compressor

Machine Options
13
Option Contents
MasterMover
Model
Option - flashing safety light and motion bleeper
Option - two speed selector switch
Option - lifting and anchoring points
Option - wireless control handset
Option - wheel protectors
Option - forward facing LED
Option - headlights
Option - no horn
Option - Drive
Wheel
Option - mast steering lock
Option - roll cage pivot link bar - sunlight
Option - roll cage pivot link bar- universal
Option - XrissXcross roll cage connection straps
Option - air compressor
Extra grip
316 stainless steel
316 stainless steel extra grip
SmartMover
SM60+
SM100+
SM100
SM100 TOW
MasterTug
MT200
MT300+
MT400+
MT600+
MT800+
MT1000+
MT1200+
MT1500+
MT2000+
All Terrain
ATP400
ATT400
ATT400+
AT200 TOW
AT300 TOW
Stainless Steel Machines
SM60+ SS
SM100+ SS
MT5/400+ SS
IP44 & IP55
MH400+ SS
IP44
MT20 SS IP44
MasterPusher
MP400
Trailer Moving System
TMS
MasterHandler
GBM16
GBM20
MH400+
MH TOW
MasterTug (pre 2014)
MT20/1500
extended body
MT30/2000+
PAS

Batteries
14
Batteries
Battery Care & Life
Lead Acid - Sealed and Vented
To prolong battery life of your machine, read this carefully:
For the first 15 charges, discharge the battery until the meter shows the remaining
charge as BDI = 30%, but not lower.
Note: It is very important that you follow this procedure for the first charge cycles on the
battery; otherwise the battery life can be severely affected. After these initial charges, we
recommend you charge when the BDI shows 30-50%.
Always recharge the battery to 100% regardless of the current battery charge level.
Lithium
To prolong battery life of your machine, read this carefully:
Unlike Lead-Acid, Lithium batteries are designed to be regularly charged for short periods
of time, a charge pattern often referred to as ‘opportunity charging’.
It does not need to be fully recharged every time. There is no minimum charge time
required.
30% capacity can be returned to the battery in 30mins. Full charge in 1.5 hours.
The battery does not give off gas when on charge, therefore the charger can be mounted
wherever is convenient.
The battery must receive a full charge every three months. This is true whether the
machine has been used during this time or not. Failure to do this may lead to irreparable
damage to the battery.
IMPORTANT: BATTERY LEVELS
Lead Acid and Lithium batteries: If the battery indicator shows 30% or less
stop using the machine and recharge as soon as possible, otherwise the
machine may stall while connected to a load. Do not leave a battery fully
discharged. This can damage the battery, impair performance and shorten its
life.
Additional Information:
Machine batteries are consumable items and have a certain life. They will need replacing
from time to time.
You must only fit a new battery pack that is approved by MasterMover or by your local
service partner. Warranty restrictions apply.

Batteries
15
Battery Do’s
Wear suitable hand and eye protection when you change batteries. Battery acid is
poisonous and corrosive should it accidently leak.
Keep the top of the battery clean and dry.
Switch off the charger before connecting or disconnecting the battery.
Check that the battery terminal connections are tight, using insulated tools. Keep
terminals clean and greased with petroleum jelly or light/medium grease.
When changing batteries, take proper care and use correct safety procedures.
Batteries are very heavy and can be dangerous to handle.
Charge the battery when the BDI shows between 30-50% charge.
Only use the charger supplied by MasterMover. An incorrect charger can damage the
batteries and invalidate the warranty.
Always store the machine at full charge to avoid degradation of the battery.
When charging always recharge to 100%.
Battery Don’ts
Do not discharge the battery below 30%, or battery life will deteriorate and it may fail
completely. This is not covered by warranty. Recharge immediately.
Do not put metal objects on top of the battery. Beware of metal tools and jewellery.
Do not allow corrosion around terminals. Clean and re-grease.
Do not store the battery below 0oC.

Batteries
16
Battery Safety Labels
On the machine, regardless of battery option, the power pack information and safety labels will
either be mounted on top of the battery cover or on the battery itself.
Interchangeable Battery Pack
The interchangeable battery pack means you can have any number spare for your machine,
some on charge whilst one is in use. As the recharge time is typically 6-7 hours, by changing the
battery pack you can maintain high productivity.
Fixed battery setups and internal chargers are also available.
Disposing of Used Batteries or Packs
If a MasterMover representative replaces the batteries, they will remove the old batteries and
dispose of them correctly.
If you replace batteries, then please ensure that you dispose of them correctly according to local
rules and regulations.