UniCarriers 1F4 Series Operator's Manual

With zd30 engine, platinum g04 series heavyweight pneumatic tire engine powered/epa tier 4 diesel

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OPERATOR'S MANUAL

MODEL 1F4 WITH ZD30 ENGINE

Platinum G04 Series Heavyweight Pneumatic Tire

Engine Powered/EPA Tier 4 Diesel

8,000-11,000 lb. Capacities

OPERATOR

Printing: October 2015 (01)

Publication No.: 0M5UC-1F4ZD

Printed in Marengo IL USA

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Page 1 OPERATOR’S MANUAL MODEL 1F4 WITH ZD30 ENGINE Platinum G04 Series Heavyweight Pneumatic Tire Engine Powered/EPA Tier 4 Diesel 8,000-11,000 lb. Capacities OPERATOR Printing: October 2015 (01) Publication No.: 0M5UC-1F4ZD Printed in Marengo IL USA...
Page 2 Reliability. It’s the de ning trait of our company and our forklifts. UniCarriers’ roots extend back over 100 years, and over that time, strong, reliable performance has always been the hallmark of our organization, our people and our equipment. Today, our unrivaled reliability continues to provide UniCarriers’ customers with a competitive edge.
Page 3: Warnings
UNICARRIERS AMERICAS OPERATOR’S MANUAL MODEL 1F4 SERIES WITH ZD30 ENGINE WARNING • This Original Manual contains important safety information and must be made available to the operator. • Keep this manual on the truck at all times. • Do not operate the forklift unless you have reviewed and fully understand the Operator’s Manual. Failure to follow all of the instructions in this manual could be a violation of the Occupational Safety and Health Act.
Page 4 Failure to follow all instructions in this manual could be a violation of the Occupational Safety and Health Act. Disclosure of Regulation Applicability for California customers only • To owner/operators of UniCarriers industrial trucks in California: ARB Regulation 2449(d)(3) June 2008: Starting June 15, 2008 the California Air Resources Board (CARB) placed a limit in idling time for in use off road diesel powered equipment.
Page 5: A Word To Unicarriers Forklift Operators
UniCarriers industrial truck. on the latest data obtainable at the time of publication. UniCarriers We urge you to read this manual carefully before operating a UniCarriers Americas Corporation, hereafter referred to as UCA, reserves the right industrial truck to familiarize yourself with the safety instructions.
Page 6: Table Of Contents
Safety Rules and Practices Operator Quali cations Only in the event that UniCarriers Americas Corporation is no longer Safety Guards in business and there is no successor to the business, the user may Personal Protective Equipment for Operating Forklift...
Page 7 Ultra Low Sulfur Fuel Only Decal Speed Limit High/Low Operating Controls and Functions Malfunction and Warning Indications Applications Mast Interlock Warning Application Area for UniCarriers Trucks Torque Converter Fluid Temp Warning Prohibited Applications for UniCarriers Trucks Radiator Level Warning Main Components Air Cleaner Warning...
Page 8 TABLE OF CONTENTS TABLE OF CONTENTS SUBJECT PAGE SUBJECT PAGE Operating Controls and Functions (cont'd) Operating the Truck (cont'd) Switches Loading Horn Button Transporting Loads Rear Right Grip with Horn Button (option) Unloading Ignition Switch Climbing Lighting Switch and Turn Signal Switch Stopping and Parking the Truck Back-Up Operation Lamp Switch (option) Forks...
Page 9 TABLE OF CONTENTS TABLE OF CONTENTS SUBJECT PAGE SUBJECT PAGE General Care and Maintenance (cont'd) General Care and Maintenance (cont'd) Maintenance and Inspection (cont'd) Maintenance and Inspection (cont'd) Automatic Transmission Fluid Level Lubrication Chart Re lling Automatic Transmission Fluid Recommended Lubricants Hydraulic Oil Level Putting Forklift in Storage Re lling Hydraulic Oil...
Page 10: Introduction
MAINTENANCE AND SERVICING UniCarriers model 1F4 series industrial trucks meet all applicable UniCarriers industrial trucks are built to be dependable, but as with requirements of ITSDF B56.1 at the time of manufacture. UCA will not any industrial truck, they are only as ef cient as the operator and the assume, and expressly disclaims, any liability for injuries or damage persons responsible for maintaining them.
Page 11: How To Use This Manual
Only the intelligence, good judgement and care of the operator, along with proper planned maintenance, will help assure that the unit Description of each major component of the 1F4 series forklifts and operates correctly. It is important to have only trained, reliable personnel how the instruments, gauges, and controls operate.
Page 12: Safety Signs And Safety Messages
SAFETY SIGNS AND SAFETY MESSAGES WARNING SYMBOLS & LEVELS Safety signs and Safety messages are placed in this manual and on the Always follow the warnings in this Operator’s Manual and any located truck to provide instruction and identify speci c areas where potential on the truck to help avoid accidents and/or injuries from occurring.
Page 13: Operator Qualifications
SAFETY RULES AND PRACTICES OPERATOR QUALIFICATIONS SAFETY GUARDS WARNING WARNING • Operator must be trained, evaluated and authorized to drive • An overhead guard is intended to offer protection from falling the forklift and must understand safety techniques and rules objects but cannot protect against every possible impact.
Page 14: Safety Rules And Practices
SAFETY RULES AND PRACTICES PERSONAL PROTECTIVE EQUIPMENT FOR DAILY INSPECTION OPERATING FORKLIFT WARNING Helmet • OSHA 1910.178 requires a daily or per shift inspection. Safety Muffs Glasses Inspect the forklift before operating. Do not operate the forklift if it is in need of repair. If it is in need of repair, tag the forklift, remove the key and report the condition to the proper Dust Mask...
Page 15: Operator Responsibility
SAFETY RULES AND PRACTICES OPERATOR RESPONSIBILITY WARNING • Safe operation is the responsibility of the operator. • The operator shall develop safe working habits and also be aware of hazardous conditions in order to protect himself, other personnel, the truck, and material being handled. •...
Page 16 SAFETY RULES AND PRACTICES GENERAL (cont’d) WARNING • A powered industrial truck is unattended when the operator is more than 8 m (25 ft) from the truck which remains in his view, or whenever the operator leaves the truck and it is not in his view.
Page 17: No Riders
SAFETY RULES AND PRACTICES GENERAL (cont’d) NO RIDERS WARNING • Care shall be taken not to contact overhead installations such as lights, wiring, pipes, sprinkler systems, etc. WARNING • Do not sit on the forks (when loaded or not) or get under the •...
Page 18: Traveling
SAFETY RULES AND PRACTICES TRAVELING WARNING • Observe all traf c regulations including authorized plant speed limits. Under normal traf c conditions, keep to the right. Maintain a safe distance, based on speed of travel, from the truck ahead; and keep the truck under control at all times.
Page 19 SAFETY RULES AND PRACTICES TRAVELING (cont’d) WARNING • Under all travel conditions, operate the truck at a speed that will permit it to be brought to a stop in a safe manner. • Travel with load-engaging means or load at lowered height except during stacking operation.
Page 20: Loading
SAFETY RULES AND PRACTICES TRAVELING (cont’d) LOADING WARNING • Handle only stable or safely arranged loads. WARNING a. When handling off-center loads that cannot be centered, operate with extra caution. • Before driving over a dockboard or bridge plate, be sure that it is properly secured.
Page 21: Dockboards (Bridge Plates), Trucks And Railroad Cars
SAFETY RULES AND PRACTICES LOADING (cont’d) DOCKBOARDS (BRIDGE PLATES), TRUCKS AND RAILROAD CARS WARNING • When attachments are used, extra care shall be taken in securing, manipulating, positioning, and transporting the load. Operate trucks equipped with attachments as partially loaded trucks when not handling a load. •...
Page 22 SAFETY RULES AND PRACTICES DOCKBOARDS (BRIDGE PLATES), TRUCKS AND RAILROAD CARS (cont’d) WARNING • All types of dockboards shall have a high friction surface designed to reduce the possibility of employees or trucks slipping and shall be designed and maintained so that one end will have a substantial contact with the dock (or loading platform) and the other end with the transport vehicle to prevent the dockboard from rocking or sliding.
Page 23: Fuel Handling
SAFETY RULES AND PRACTICES FUEL HANDLING WARNING • Do not breath exhaust gasses: they contain colorless and odorless carbon monoxide. Carbon monoxide is a dangerous gas and can cause unconsciousness or death. • Do not run the forklift in closed spaces or poorly ventilated areas.
Page 24: Installation Of Attachments
INSTALLATION OF ATTACHMENTS IN CASE OF TIP-OVER WARNING • The 1F4 series forklifts have been designed for attachments (refer to "Truck Modi cations" on page 4). • Before installing hook-on attachments, be sure to read the installation manual issued by the attachment manufacturer to assure correct and proper installation.
Page 25 SAFETY RULES AND PRACTICES TRANSPORTING FORKLIFT APPROACH ANGLE, DEPARTURE ANGLE AND GANGWAY WARNING Ramp breakover angle Approach angle 1. Tilt the mast back to the maximum without load. 2. Check the approach and departure angles to make sure the underside of the forklift does not come into contact with the load carrying platform or the ground.
Page 26: Transporting Forklift (Cont'd)
SAFETY RULES AND PRACTICES TRANSPORTING FORKLIFT (cont’d) WARNING HOISTING (LIFTING) UP THE FORKLIFT • Make sure that the cables/wire ropes WARNING do not interfere with the overhead guard while lifting the forklift. • Only use this method as a last resort to move the forklift if •...
Page 27: Function Tests
SAFETY RULES AND PRACTICES TRANSPORTING FORKLIFT (cont’d) TRACTION BAR The traction bar should be used only for FUNCTION TESTS pulling the forklift out of ditches or muddy The functional tests are carried out to check whether the forklift roads. functions correctly after it has been transported (over land or water), or after it has been taken out of storage.
Page 28: Position Of Data & Capacity Plates And Decals
SAFETY RULES AND PRACTICES POSITION OF DATA & CAPACITY PLATES AND DECALS WARNING • When data & capacity plates or warning & caution decals are damaged such that they cannot be read or have peeled off, they should be immediately replaced with new ones to ensure that they are constantly maintained in a legible condition.
Page 29 SAFETY RULES AND PRACTICES POSITION OF DATA & CAPACITY PLATES AND DECALS Lateral tip-over can occur if truck is improperly operated. Don’t risk injury or death. Buckle up belt WARNING Slow down before turning! Stay in seat IN CASE OF TIP-OVER Follow these Hold on DANGER...
Page 30: Data & Capacity Plates And Decals
SAFETY RULES AND PRACTICES DATA & CAPACITY PLATES AND DECALS Actual Capacity will vary with forklift con guration and load center. Mast con guration will determine the maximum lifting distance. These values are stamped on the data plate. Know your unit. The data plate indicates all necessary information regarding the type of attachments, lifting capacity, etc.
Page 31: Identi Cation Numbers
SAFETY RULES AND PRACTICES The engine serial number is stamped as shown below. DATA & CAPACITY PLATES AND DECALS (cont’d) ZD30 IESEL NGINE DENTIFICATION UMBERS The serial number of the forklift is stamped on the front panel. Truck Serial Number D1F4 95XXXX DG1F4...
Page 32: Caution Drive Decal (In Case Of Tip-Over)
SAFETY RULES AND PRACTICES DATA & CAPACITY PLATES AND DECALS (cont’d) ARNING RIVE ECAL RAINED AND UTHORIZED AUTION RIVE ECAL ASE OF ECAL WARNING • Operator must be trained and authorized to drive the forklift, and must understand safety techniques and rules for the WARNING forklift operation.
Page 33: Caution Fork Decal
SAFETY RULES AND PRACTICES DATA & CAPACITY PLATES AND DECALS (cont’d) AUTION RIVE ECAL PERATION AUTION ECAL WARNING/ATTENTION/ACHTUNG/ATENCION Label part No. 97837 FK100 WARNING Do not stand on or underneath forks. • Riding on the forks is strictly prohibited. Furthermore, do not stand immediately underneath the forks.
Page 34: Cooling Fan Warning Decal
SAFETY RULES AND PRACTICES SAFETY RULES AND PRACTICES DATA & CAPACITY PLATES AND DECALS (CONT’D) LTRA ULFUR ECAL OOLING ARNING ECAL WARNING • Never touch the cooling fan while it is turning. Touching the cooling fan while it is turning may result in injury to your ngers, and in the worst case, may CAUTION sever the ngers.
Page 35: Operating Controls And Functions
APPLICATION AREA FOR UNICARRIERS TRUCKS • Do not use as a towing truck for trailers UniCarriers industrial trucks are solely designed and manufactured • Not to be used for pushing applications to handle goods. The truck should only be tted with the appropriate accessories relevant to the application.
Page 36: Main Components
OPERATING CONTROLS AND FUNCTIONS 1. Mast Upright: The mast upright is the lifting device for the forks. MAIN COMPONENTS The lifting is done through hydraulic lift cylinders and chains. 2. Lift Cylinders: The cylinders are used to lift the forks up and down.
Page 37: Meters, Indicators And Lamps
OPERATING CONTROLS AND FUNCTIONS METERS, INDICATORS AND LAMPS METER DISPLAY NOTE: • Even if the battery is removed, the display time and date will not be The operator compartment contains the 1F4 main functional controls reset for 20 days. If 20 days elapse after the battery is removed, it to operate the truck in a safe and controlled manner.
Page 38: Meters, Indicators And Lamps (Cont'd)
OPERATING CONTROLS AND FUNCTIONS METERS, INDICATORS AND LAMPS (cont’d) OIL PRESSURE WARNING LIGHT This warning illuminates when the oil pressure is low. MALFUNCTION INDICATOR LIGHT-ENGINE CHECK WARNING CAUTION This warning illuminates when there is a malfunction with an engine • If the light illuminates under ordinary operating conditions, sensor or air-fuel ratio control, or other engine emission control issues.
Page 39: Date And Time/Engine Oil Level
OPERATING CONTROLS AND FUNCTIONS METERS, INDICATORS AND LAMPS (cont’d) Engine oil level 11. DATE AND TIME/ENGINE OIL LEVEL OIL HI Ex 1) Setting the date and time OIL LO Ex 2) METER DISPLAY NOTE: • Even if the battery is removed, the display time and date will not be reset for 20 days.
Page 40: Water Temperature Gauge
OPERATING CONTROLS AND FUNCTIONS METERS, INDICATORS AND LAMPS (cont’d) 13. FUEL GAUGE Indicates the current fuel level in levels 0 - 5. 12. WATER TEMPERATURE GAUGE When level 5 is indicated, the fuel tank is Indicates the current water temperature in levels 0 - 4. full.
Page 41: Hour Meter/Odometer/Dpf Accumulation Level
OPERATING CONTROLS AND FUNCTIONS METERS, INDICATORS AND LAMPS (cont’d) 15. SPEEDOMETER/LOAD METER When the speedometer and load meter 14. HOUR METER/ODOMETER/DPF ACCUMULATION LEVEL are set to display, the load meter displays Hour Meter/Odometer after the startup screen is displayed. When the forklift is driven, the meter Use FN2 button to change display.
Page 42: Error Code/Warning Symbol/Service Reminder
OPERATING CONTROLS AND FUNCTIONS METERS, INDICATORS AND LAMPS (cont’d) 17. ERROR CODE/WARNING SYMBOL/SERVICE REMINDER Displays when malfunction occurs 16. FORWARD/REVERSE LEVER POSITION (cont’d) When a controller malfunction occurs, ’11.04/01-13:23 an error code is displayed. km/h If the display shown at right appears, •...
Page 43: Power/Eco Mode
OPERATING CONTROLS AND FUNCTIONS METERS, INDICATORS AND LAMPS (cont’d) 19. SPEED LIMIT HIGH/LOW This standard setting is for 18. POWER/ECO MODE maximum speed between RABBIT (high speed mode) and TURTLE This standard setting is for (low speed mode). Press FN3 changing acceleration rate.
Page 44: Torque Converter Fluid Temp Warning
OPERATING CONTROLS AND FUNCTIONS MALFUNCTION AND WARNING INDICATIONS NOTE (cont'd): • This 1F4 will reduce engine speed to creep home mode when uid temperature warning illuminates. RADIATOR LEVEL WARNING This warning illuminates when the engine coolant level is low, add coolant (refer to page 77).
Page 45: Driver Recognition Mode
OPERATING CONTROLS AND FUNCTIONS DRIVER RECOGNITION MODE Registering a password can restrict the drivers of the forklift. You can register a password for up to 5 people (A to E). Contact your Local Authorized Dealer for information about the registration of the password.
Page 46: Horn Button
OPERATING CONTROLS AND FUNCTIONS SWITCHES HORN BUTTON Pushing the button in the center of the steering wheel will sound the 1. Horn button horn, regardless of ignition switch position. 2. Ignition switch 3. Lighting switch and Turn signal switch 4. Back-up operation lamp switch (option) REAR RIGHT GRIP WITH HORN BUTTON (OPTION) 5.
Page 47: Ignition Switch
OPERATING CONTROLS AND FUNCTIONS SWITCHES (cont’d) Diesel Forklift Do not operate the starter for more than 30 consecutive seconds. If the IGNITION SWITCH engine does not start wait for at least 30 seconds and then try again, Insert the ignition key into the ignition starting with preheating.
Page 48: Lighting Switch And Turn Signal Switch
OPERATING CONTROLS AND FUNCTIONS BACK-UP OPERATION LAMP SWITCH (OPTION) SWITCHES (cont’d) This switch is used to turn on and off LIGHTING SWITCH AND TURN SIGNAL SWITCH the rear operating light that illuminate Lighting Switch rearward for nighttime operation or Position bar To turn on one of the lamps in the table, operation in poorly illuminated areas.
Page 49: Diesel Particle Filter (Dpf)
OPERATING CONTROLS AND FUNCTIONS 2. DPF regeneration method (cont'd) SWITCHES (cont’d) b. Start DPF regeneration by pressing the DPF switch on the DIESEL PARTICLE FILTER (DPF) instrument panel (engine revolution will increase to approx. 1,600 rpm). c. When regeneration is complete, engine revolution will return to idling and all indicators will turn off.
Page 50: Operating Controls
OPERATING CONTROLS AND FUNCTIONS OPERATING CONTROLS FORWARD-REVERSE LEVER 1 Speed 1. Forward-reverse lever This lever is used to change the driving 2. Parking brake lever direction of the forklift (forward or 3. Inching brake pedal reverse). Push the lever away from you 4.
Page 51: Parking Brake Lever
OPERATING CONTROLS AND FUNCTIONS OPERATING CONTROLS (cont’d) PARKING BRAKE LEVER To set the parking brake, fully pull FORWARD-REVERSE LEVER (cont’d) Release Parking position position the lever towards you. To release the Button CAUTION parking brake, push down the button on top of the lever and then push •...
Page 52: Inching Brake Pedal
OPERATING CONTROLS AND FUNCTIONS OPERATING CONTROLS (cont’d) WARNING INCHING BRAKE PEDAL • During deceleration on any grade, only use the brake pedal The inching brake pedal allows or increase or decrease the speed by using the accelerator you to nely adjust the forward and pedal.
Page 53: Accelerator Pedal
OPERATING CONTROLS AND FUNCTIONS OPERATING CONTROLS (cont’d) WARNING ACCELERATOR PEDAL • Always sit in the operator's seat when operating any lever. This pedal allows you to adjust the engine speed (RPM's). The engine • Operating the control lever without properly sitting in the speed changes according to the operator's seat causes the loading interlock warning light to degree to which the accelerator pedal...
Page 54 OPERATING CONTROLS AND FUNCTIONS OPERATING CONTROLS (cont’d) Control of lowering speed: The speed can be changed only by controlling the tilt angle of the lever, do not depress the accelerator CARGO-HANDLING CONTROL LEVER (cont’d) pedal. Twin Control Lever Type Control of forward and backward tilting speeds: For both forward and This method uses two levers: a lift lever backward tilts, the speed can be changed by controlling the tilt angle for moving the fork up and down and a...
Page 55 OPERATING CONTROLS AND FUNCTIONS OPERATING CONTROLS (cont’d) Loading condition Forward tilt operation of mast Without load Automatically stops in the horizontal fork CARGO-HANDLING CONTROL LEVER (cont’d) position. Single-Lever Type (cont'd) With load • No automatic forward stop to horizontal • No movement when turning on the tilt- WARNING horizontal switch •...
Page 56: Ansi/Itsdf Standards For Forklift Clamp
OPERATING CONTROLS AND FUNCTIONS OPERATING CONTROLS (cont’d) ANSI/ITSDF STANDARDS FOR FORKLIFT CLAMP ATTACHMENTS The ANSI/ITSDF Standards regarding forklift mounted clamp attachments took effect for trucks shipped on or after October 7, 2010. This current standard affects lift trucks equipped with a load bearing clamp (paper roll clamp, carton clamp, etc.) and requires the operator to perform two distinct motions before opening (releasing) the clamp.
Page 57: Operating The Truck
OPERATING THE TRUCK The following are the recommended procedures that should be followed PRECAUTIONS FOR COLD AND HOT WEATHER before and while operating a UniCarriers forklift. In Cold Weather Since the Occupational Safety and Health Act (OSHA) • Oil and Grease 29CFR1910.178(I) requires that “only trained and authorized...
Page 58: Operational Procedures
OPERATING THE TRUCK OPERATIONAL PROCEDURES WARNING There are certain hazards that cannot be avoided solely by mechanical • Do not turn the ignition switch ON unless the FORWARD- means in the everyday use of material handling trucks. Only the REVERSE lever is in neutral. intelligence, good sense, and care of the operator, along with proper maintenance, will assure that the trucks are operated properly.
Page 59: Diesel Forklift Starting
OPERATING THE TRUCK OPERATIONAL PROCEDURES (cont’d) 4. When the glow pilot light has turned off, turn the ignition switch to the START position while fully depressing the accelerator pedal, DIESEL FORKLIFT STARTING until the engine starts. WARNING NOTE: • Do not breathe exhaust gases, they contain a mixture of Do not operate the starter for more than 30 consecutive seconds.
Page 60 OPERATING THE TRUCK OPERATIONAL PROCEDURES (cont’d) WARNING DIESEL FORKLIFT STARTING (cont’d) • Avoid quick steering or acceleration as this may cause an 7. Check horn operation; if it does not work do not operate the truck. accident, which could result in serious injury or death. Always sound horn at blind corners and intersections before •...
Page 61: Procedure For Jump Starting Efi Engines
OPERATING THE TRUCK PROCEDURE FOR JUMP STARTING EFI ENGINES CAUTION WARNING • Always connect positive (+) to positive (+) and negative (-) to body ground (for example, strut mounting bolt, engine lift • Always follow the instructions below. Failure to do so could bracket, etc.) not to the battery.
Page 62: Automatic Transmission
OPERATING THE TRUCK PROCEDURE FOR JUMP STARTING EFI ENGINES AUTOMATIC TRANSMISSION (cont’d) 9. To start the engine with a booster battery, the following warnings must be followed. Forward WARNING Reverse • If done incorrectly, jump starting can lead to a battery explosion, resulting in severe injury or death.
Page 63 OPERATING THE TRUCK AUTOMATIC TRANSMISSION (cont’d) 6. Precautions: • When starting on slopes, be sure to apply the parking brake to Starting the forklift from the stopped condition: hold the forklift and then start, even if the slopes are gentle. 1.
Page 64: Loading
OPERATING THE TRUCK CLIMBING LOADING For safety reasons, when driving a loaded forklift up a steep grade, it Adjust distance between the forks so that they are at or near the same must be driven forward with the load in front; park on a downgrade, distance to the centerline of the forklift.
Page 65: Forks
OPERATING THE TRUCK FORKS SEAT ADJUSTMENT The fork-to-fork distance can be Suspension Seat Operator’s Weight Adjustment properly adjusted by unlocking Adjust the suspension seat to the the lock pins on the forks. These operator’s weight by turning the weight pins are unlocked by pulling them adjustment dial at the front side of the up and turning them 90°...
Page 66 OPERATING THE TRUCK SEAT ADJUSTMENT (cont’d) Lumbar Adjustment To expand the lumbar turn the Backrest Inclination Adjustment knob counterclockwise. To Adjust the backrest to the desired collapse the lumbar turn the knob angle while pushing the lever located clockwise. to the left of the seat. Release the lever to lock the backrest.
Page 67: Seat Belt
OPERATING THE TRUCK SEAT BELT WARNING 1. Holding the tongue pull out the seat belt gently. • Tightly wrap the seat belt around the hipbone as low as possible. If the seat belt comes off the hipbone and it wraps 2.
Page 68: Top Panel
OPERATING THE TRUCK Close Operation TOP PANEL 1. Depress the top panel. Since there is reaction of the gas stay, The top panel can be opened toward the rear of the forklift. depress the top panel while pressing its front top until it is completely locked.
Page 69: Top Panel Lock
OPERATING THE TRUCK TOP PANEL LOCK TILT STEERING WHEEL The position of the steering wheel can WARNING be adjusted. To adjust, push down on the tilt lever (black) located on the left • Do not open the top panel with the engine running. Do not side of the steering column, and move place hands near the cooling fan because it rotates at a high the wheel to the desired position.
Page 70: Radiator Cover
OPERATING THE TRUCK RADIATOR COVER REARVIEW MIRROR (OPTION) The radiator cover can be Adjust the right and left rearview removed with the top panel mirrors respectively by hand so that closed. both ensure the best view to the rear. Rearview mirror For inspection of the radiator or replenishment of the engine coolant, loosen the right and left...
Page 71: General Care And Maintenance
GENERAL CARE AND MAINTENANCE WET CELL BATTERY CARE AND MAINTENANCE WARNING CAUTION • Only trained and authorized personnel should conduct any maintenance or servicing of this unit and its battery. The following information is general information regarding the best methods for using and maintaining the battery, and it in no way can •...
Page 72 GENERAL CARE AND MAINTENANCE WET CELL BATTERY CARE AND MAINTENANCE Battery Fluid Level (cont’d) WARNING Proper area • Do not place tools or other metallic objects on the top surface of the battery where they may come in contact with the battery terminals and cause an electrical short.
Page 73: Battery Speci C Gravity
GENERAL CARE AND MAINTENANCE BATTERY SPECIFIC GRAVITY 1.30 1.28 1.26 1.24 1.22 1.20 1.18 1.16 1.14 1.12 1.10 –10 ˚C (14) (32) (50) (68) (86) (104) (122) (˚F) Electrolyte temperature The battery should not be left in the discharged state. When battery performance becomes questionable, check the speci c gravity of the electrolyte, terminals of battery and alternator.
Page 74: Daily Inspection
GENERAL CARE AND MAINTENANCE 11. Check for full motion and proper function of all the steering and DAILY INSPECTION travel controls. To maintain your forklift in proper condition and ready for safe operation, 12. Check steering wheel play. be sure to perform the daily checks indicated below. If you note any 13.
Page 75 GENERAL CARE AND MAINTENANCE DAILY INSPECTION (cont’d) WARNING • Do not open the top panel with the engine running. Do not place hands near the cooling fan because it rotates at a high speed and may cause injury. When opening the hood, be sure to turn off the engine.
Page 76: Operator's Daily Checklist (Sample)
GENERAL CARE AND MAINTENANCE OPERATOR'S DAILY CHECKLIST (SAMPLE) WARNING • Carry out the daily checks as per “Daily Inspection” in this Operator’s Manual on page 72 and the applicable provisions of laws and regulations of your country (In U.S. OSHA 29CFR1910.178). I .T.A.
Page 77: Maintenance And Inspection
GENERAL CARE AND MAINTENANCE If the fuel cap has the optional lock and key, insert the key into the MAINTENANCE AND INSPECTION keyhole on the fuel cap and turn the key clockwise for locking or turn it FUEL RECOMMENDATION counterclockwise to unlock. The ZD30 diesel engine is designed to run only on ultra low sulfur diesel fuel with at least a minimum of 42 cetane rating and maximum After re lling, be sure to turn the fuel cap...
Page 78: General Care And Maintenance (Cont'd)
GENERAL CARE AND MAINTENANCE REFILLING ENGINE OIL MAINTENANCE AND INSPECTION (cont’d) 1. For re lling the engine oil tank with engine oil, remove the oil ller ENGINE OIL LEVEL cap and slowly pour genuine OEM motor oil into the tank while For diesel engines, the level checking the oil level with the oil level gauge until the oil reaches gauge is located on the left side...
Page 79: Engine Coolant Level
GENERAL CARE AND MAINTENANCE REFILLING ENGINE COOLANT MAINTENANCE AND INSPECTION (cont’d) 1. Remove the reservoir tank ller cap and add coolant until the ENGINE COOLANT LEVEL "MAX" level is reached (refer to page 78 for proper mixing ratio). Visually check the amount of coolant 2.
Page 80: Cooling System Bleeding Instructions
GENERAL CARE AND MAINTENANCE MAINTENANCE AND INSPECTION (cont’d) 1. Remove the radiator cover and open the engine hood. Remove the radiator cap. COOLING SYSTEM BLEEDING INSTRUCTIONS 2. Place an appropriate size container under the radiator. Open the Antifreeze drain cock of the radiator and extract the coolant. Applicable Capacity LLC Density...
Page 81: Brake Fluid Level
GENERAL CARE AND MAINTENANCE MAINTENANCE AND INSPECTION (cont’d) REFILLING BRAKE FLUID Turn the brake reservoir tank cap counterclockwise to remove it. Gently BRAKE FLUID LEVEL pour the brake uid into the tank until the uid level reaches the "MAX" Check the brake uid level in the level (refer to page 105).
Page 82: Automatic Transmission Fluid Level
GENERAL CARE AND MAINTENANCE MAINTENANCE AND INSPECTION (cont’d) REFILLING AUTOMATIC TRANSMISSION FLUID Automatic transmission uid can be added through the level gauge AUTOMATIC TRANSMISSION FLUID LEVEL hole. Checking the uid level with the level gauge, pour OEM uid into the level gauge hole until the uid level is in the proper range (refer to page 105).
Page 83: Hydraulic Oil Level
GENERAL CARE AND MAINTENANCE REFILLING HYDRAULIC OIL MAINTENANCE AND INSPECTION (cont’d) Remove the hydraulic oil ller cap. While checking the hydraulic oil level with the level gauge, pour the speci ed hydraulic oil into the oil ller until HYDRAULIC OIL LEVEL the oil level is in the proper area (refer to page 105).
Page 84: Wheel And Tire
GENERAL CARE AND MAINTENANCE MAINTENANCE AND INSPECTION (cont’d) • If the tire pressure is not correct it can affect the stability of the forklift, potentially resulting in a tip-over. It can also cause WHEEL AND TIRE rupturing, premature tire wear or explosive separation of the multi-piece rim set.
Page 85 GENERAL CARE AND MAINTENANCE MAINTENANCE AND INSPECTION (cont’d) TIRE REPLACEMENT (cont'd) NOTE: The pneumatic type cushion tire without inner tube (so-called tubeless tire or non-puncture tire) is supplied. This type of tire does not need to have a tire pressure check performed. Vehicle Tire size Tire pressure...
Page 86 GENERAL CARE AND MAINTENANCE MAINTENANCE AND INSPECTION (cont’d) Front Tire: 1. Place the forklift on a level and solid surface. TIRE REPLACEMENT (cont'd) 2. Start the engine and raise the carriage about 250 mm (9.84 in). 3. Place chocks behind the rear wheels to prevent movement of the CAUTION forklift.
Page 87 GENERAL CARE AND MAINTENANCE MAINTENANCE AND INSPECTION (cont’d) 10. Start the engine and remove the wood blocks from the underside of the frame. TIRE REPLACEMENT (cont'd) 11. Lower the forklift slowly by tilting the mast fully backward. Remove the wood blocks from under the mast and remove the chocks. CAUTION 12.
Page 88 GENERAL CARE AND MAINTENANCE MAINTENANCE AND INSPECTION (cont’d) WARNING TIRE REPLACEMENT (cont'd) Rear Tire: • Use a jack with a capacity of 4.0 tons or more. 4. Loosen the wheel nuts one or WARNING two turns each by turning them Wheel Nuts counterclockwise.
Page 89 GENERAL CARE AND MAINTENANCE MAINTENANCE AND INSPECTION (cont’d) Tightening torque: Unit: ft-lb (N-m) TIRE REPLACEMENT (cont’d) Model 3.5 & 4.0 4.5 & 5.0 Rear Tire: (cont'd) 6. Remove the wheel nuts and replace the rear tire. 398 - 462 Single tire (539 - 627) WARNING 398 - 462...
Page 90: Checking Mast
GENERAL CARE AND MAINTENANCE MAINTENANCE AND INSPECTION (cont’d) CHECKING LIFT CHAIN CHECKING MAST WARNING Check the mast to ensure that: a. No oil leakage occurs at or around the lift and tilt cylinders. • Use extreme care when checking lift chain tension. b.
Page 91: Fork Inspection
GENERAL CARE AND MAINTENANCE MAINTENANCE AND INSPECTION (cont’d) FORK REPAIR Repair - Only the manufacturer of the fork or an expert of equal FORK INSPECTION competence shall decide if a fork may be repaired for continued use, Ensure the forks are secured in their proper position and they are not and the repairs shall only be carried out by such parties.
Page 92: Checking Horn
GENERAL CARE AND MAINTENANCE MAINTENANCE AND INSPECTION (cont’d) CHECKING PARKING BRAKE LEVER Make sure the parking brake works properly CHECKING HORN when pulled and then returns to its original Check the horn for proper operation. (release) position. CHECKING LIGHTS Pulling force at gripping position is 245 - 295 Mark sure that lights illuminate when switches are placed into the "ON"...
Page 93: Checking Air Cleaner
GENERAL CARE AND MAINTENANCE MAINTENANCE AND INSPECTION (cont’d) CHECKING FAN BELT CHECKING AIR CLEANER Check the belt de ection by applying moderate thumb pressure at Remove the three clamps securing a point midway between the pulleys. If necessary, adjust the belt Clamp the air cleaner case and take the de ection.
Page 94: Checking Accessory Belt
GENERAL CARE AND MAINTENANCE MAINTENANCE AND INSPECTION (cont’d) CHECKING ACCESSORY BELT Due to automatic adjustment by the automatic tensioner, it is not necessary to check the tension of the accessory belt. Visually inspect the following parts. • Visually inspect the entirety of the belt perimeter including the inside and sides to ascertain that there is no wear, damage or cracks.
Page 95: Drainage/Replacement Of Sedimenter Filter
GENERAL CARE AND MAINTENANCE MAINTENANCE AND INSPECTION (cont’d) CAUTION DRAINAGE/REPLACEMENT OF SEDIMENTER FILTER Drainage • Parts may remain very hot immediately after the engine has stopped. Wear protective gloves and perform the operation If the water collected in carefully so as not to touch possible hot parts around the the sedimenter exceeds water drain cock.
Page 96: Inspection/Replacement Of Fuel Filter
GENERAL CARE AND MAINTENANCE MAINTENANCE AND INSPECTION (cont’d) REPLACEMENT OF FUEL FILTER DRAINAGE/REPLACEMENT OF SEDIMENTER FILTER (cont'd) CAUTION Replacement of Sedimenter Filter • After replacement, securely install the fuel lter so as not to 1. Disconnect the sedimenter’s sensor allow fuel to leak. Any fuel leakage leads to a re accident. connector (1).
Page 97: Fuel System Air Bleeding
GENERAL CARE AND MAINTENANCE FUEL SYSTEM AIR BLEEDING 4. Open drain on fuel lter (4). CAUTION 5. Squeeze the priming pump until fuel comes out and close the drain. • During replacement of the fuel lter and water drainage, 6. When all the air has been bled, the priming pump will become installation and removal or replacement of the fuel hose may hard to squeeze.
Page 98: Periodic Maintenance And Lubrication Schedule
GENERAL CARE AND MAINTENANCE PERIODIC MAINTENANCE AND LUBRICATION SCHEDULE Before delivery of your new forklift, your dealer provides a pre-delivery inspection and adjustment service speci ed by the factory and designed to ensure satisfactory performance. The following tables list the servicing required to keep your forklift operating in good mechanical condition. The forklift should be attended to as indicated, preferably by your Local Authorized Dealer.
Page 99 GENERAL CARE AND MAINTENANCE PERIODIC MAINTENANCE AND LUBRICATION SCHEDULE (cont’d) Interval Months How to Inspection Items check Hundreds of hours Battery: mounting, level and speci c gravity Visual/Test Harness and connectors Visual Fuses If Necessary Visual Relays Visual Switches Test Lights (all) Test Horn/Buzzer...
Page 100 GENERAL CARE AND MAINTENANCE PERIODIC MAINTENANCE AND LUBRICATION SCHEDULE (cont’d) Interval Months How to Inspection items check Hundreds of hours Wheel bearing for looseness Test/Adjust Wheel bearing grease (repack) Replace Wheel bearing for looseness Test/Adjust Steer axle adjustment If Necessary Adjust Wheel play Test...
Page 101 GENERAL CARE AND MAINTENANCE PERIODIC MAINTENANCE AND LUBRICATION SCHEDULE (cont’d) Interval Months How to Inspection items check Hundreds of hours Wheel operation effort Test Steering uid pressure If Necessary Test Steering wheel (movement and play) Test Function of brake system Test Brake uid level Replace...
Page 102 GENERAL CARE AND MAINTENANCE PERIODIC MAINTENANCE AND LUBRICATION SCHEDULE (cont’d) Interval Months Inspection items Hundreds 12 14 16 18 20 Check of hours Hydraulic pressure If Necessary Test Hydraulic oil level Visual Hydraulic oil replacement Replace Micron oil lter Replace Suction lter Clean Movement and connection of levers...
Page 103 GENERAL CARE AND MAINTENANCE PERIODIC MAINTENANCE AND LUBRICATION SCHEDULE (cont’d) Interval Months How to Inspection items Check Hundreds 10 12 of hours Function of mast Test Mast system (damage/cracks/wear) Visual Clearance of each stage If Necessary Measure Mast rail Grease Mast/carriage rollers If Necessary Visual/Test...
Page 104 GENERAL CARE AND MAINTENANCE PERIODIC MAINTENANCE AND LUBRICATION SCHEDULE FOR EMISSION CONTROL SYSTEM Before delivery of your new forklift, your dealer provides a pre-delivery inspection and adjustment service speci ed by the factory and designed to ensure satisfactory performance. The following tables list the servicing required to keep your forklift operating in good mechanical condition. The forklift should be attended to as indicated, preferably by your Local Authorized Dealer.
Page 105 GENERAL CARE AND MAINTENANCE PERIODIC MAINTENANCE AND LUBRICATION SCHEDULE FOR EMISSION CONTROL SYSTEM (cont’d) Interval Months 12 18 How to Inspection items Check Hundreds 10 12 24 36 of hours Intake & exhaust valve Adjust clearance (operating temp) Drive belt tension Visual Engine oil Replace...
Page 106: Lubrication Chart
GENERAL CARE AND MAINTENANCE LUBRICATION CHART ZD30 engine ZD30...
Page 107: Recommended Lubricants
GENERAL CARE AND MAINTENANCE RECOMMENDED SAE RECOMMENDED LUBRICANTS VISCOSITY CHART System/component Applicable model Oil and grease Capacity With oil lter 10.8 (11-1/2, 9-1/2) Engine ZD30 engine CJ-4 8 EO L (US qt, Imp qt) Without oil lter 9 (9-1/2, 7-7/8) Automatic transmission 1 speed 13 (13-3/4, 11-1/2)
Page 108: Putting Forklift In Storage
GENERAL CARE AND MAINTENANCE STORAGE OVER A LONG PERIOD OF TIME PUTTING FORKLIFT IN STORAGE When the operation of the forklift is completely suspended for a given Putting the forklift in storage involves storing the forklift at the end of period of time, take the following measures and store the forklift in a dry each working day or storing the forklift over a long period of time.
Page 109: Servicing The Forklift In Storage
GENERAL CARE AND MAINTENANCE PUTTING FORKLIFT IN STORAGE (cont’d) SIDE SHIFT (OPTION) SERVICING THE FORKLIFT IN STORAGE SLING POINT FOR HOOK-ON TYPE SIDE SHIFT 1. Periodically check the speci c gravity and level the battery uid. Charge and replenish as necessary. Sling point 2.
Page 110: Overview Of Side Shift
The following is the standard amount of side shift. Model Variation Side Shift Distance 1F4 series Each to right/left 100 mm (3.94 in)
Page 111: Main Terms Used In This Section
GENERAL CARE AND MAINTENANCE SIDE SHIFT (OPTION) (cont’d) SAFETY RULES AND PRACTICES WARNING 1. Shift to right. • Do not make sudden and quick shifts with the forks loaded or 2. Shift to left. raised. MAIN TERMS USED IN THIS SECTION Shift: To move the forks or load to the right or the left.
Page 112 GENERAL CARE AND MAINTENANCE SIDE SHIFT (OPTION) (cont’d) WARNING SAFETY RULES AND PRACTICES (CONT'D) • Do not travel unstable or loads unsecured. WARNING • Do not use the shift function to push or pull loads or pallets. Do not travel with loads shifted to one side. When loads are shifted (off centered) they will be less stable.
Page 113: Operation Of The Control Lever For Side Shift
GENERAL CARE AND MAINTENANCE SIDE SHIFT (OPTION) (cont’d) When you pull the lever toward When you push the lever the operator, the shift nger forward, the shift nger bar (with OPERATION OF THE CONTROL LEVER FOR THE SIDE SHIFT bar (with forks mounted) shifts forks mounted) shifts (moves) to (moves) to the right.
Page 114: Side Shift Operation
GENERAL CARE AND MAINTENANCE SIDE SHIFT (OPTION) (cont’d) CAUTION SIDE SHIFT OPERATION • Do not shift the forks while the forks are inserted into the pallet. This could cause the load to shift if the pallet is 1. Pallet pushed. 2.
Page 115: Daily Checks And Simple Maintenance
GENERAL CARE AND MAINTENANCE SIDE SHIFT (OPTION) (cont’d) DAILY CHECKS AND SIMPLE MAINTENANCE WARNING • If any abnormality is noted in the daily checks, immediately report it to the appropriate personnel or contact your Local Authorized Dealer for repair. Do not operate the forklift until the malfunctions is repaired.
Page 116: Speci Cations
SPECIFICATIONS MODEL VARIATION (LONG MODEL CODE) BREAKDOWN - 1F4 SERIES ☐ DESTINATION V: U.S.A. and Canada (except California) FUEL TYPE ☐: Diesel engine LOAD CAPACITY RANGE 35: 3.5 Ton (8,000 lb) model 40: 4.0 Ton (9,000 lb) model 45: 4.5 Ton (10,000 lb) model 50: 5.0 Ton (11,000 lb) model...
Page 117: Main Truck
SPECIFICATIONS MAIN TRUCK - 1F4 BASED ON 2W330 MAST, 1220MM FORKS AND MINIMUM BATTERY SPECIFICATIONS Model code Item MD1F4A35V MD1F4F35V MD1F4A40V MD1F4F40V Rated Load Capacity lb (kg) Refer to Truck Data Plate Load center in (mm) 24 (600) Overall Length (to face of forks) in (mm) 121.8 (3095) 123.1 (3130)
Page 118 SPECIFICATIONS MAIN TRUCK - 1F4 BASED ON 2W330 MAST, 1220MM FORKS AND MINIMUM BATTERY SPECIFICATIONS (cont’d) Model code Item MD1F4A35V MD1F4F35V MD1F4A40V MD1F4F40V Approach Angle Not Available Grade Clearance Ramp Breakover Angle Not Available Departure Angle 40.0 38.0 Full Load fpm (mm/sec) 98.4 (500) Empty...
Page 119 SPECIFICATIONS MAIN TRUCK - 1F4 BASED ON 2W330 MAST, 1220MM FORKS AND MINIMUM BATTERY SPECIFICATIONS (cont’d) Model code Item MD1F4A35V MD1F4F35V MD1F4A40V MD1F4F40V Truck Weight lb (kg) Refer to Truck Data Plate Model ZD30 Classi cation Engine Rated Output - SAE Gross hp (kW) @ rpm 73.7 (55) @ 2400 Rated Torque - SAE Gross...
Page 120 SPECIFICATIONS MAIN TRUCK - 1F4 BASED ON 2W330 MAST, 1220MM FORKS AND MINIMUM BATTERY SPECIFICATIONS (cont’d) Model code Item MD1F4A45V MD1F4F45V MD1F4A50V MD1F4F50V Rated Load Capacity lb (kg) Refer to Truck Data Plate Load center in (mm) 24 (600) Overall Length (to face of forks) in (mm) 126.3 (3210) 131.5 (3340)
Page 121 SPECIFICATIONS MAIN TRUCK - 1F4 BASED ON 2W330 MAST, 1220MM FORKS AND MINIMUM BATTERY SPECIFICATIONS (cont’d) Model code Item MD1F4A45V MD1F4F45V MD1F4A50V MD1F4F50V Approach Angle Not Available Grade Clearance Ramp Breakover Angle Not Available Departure Angle 36.0 Full Load fpm (mm/sec) 84.6 (430) 82.7 (420) Empty...
Page 122 SPECIFICATIONS MAIN TRUCK - 1F4 BASED ON 2W330 MAST, 1220MM FORKS AND MINIMUM BATTERY SPECIFICATIONS (cont’d) Model code Item MD1F4A45V MD1F4F45V MD1F4A50V MD1F4F50V Truck Weight lb (kg) Refer to Truck Data Plate Model ZD30 Classi cation Engine Rated Output - SAE Gross hp (kW) @ rpm 73.7 (55) @ 2400 Rated Torque - SAE Gross...
Page 123: Mast Speci Cations
SPECIFICATIONS MAST - 1F4 3.5 - 4.0 TON Overall Height Free Lift Maximum Fork Tilt Angle without Lowered Mast Position Extended Mast Position Mast Name Height Forward/ Backrest in (mm) in (mm) in (mm) Backward in (mm) Top of OHG Mast (OHL) With Backrest Without Backrest...
Page 124 SPECIFICATIONS MAST - 1F4 4.5 - 5.0 TON Overall Height Free Lift Maximum Fork Tilt Angle without Lowered Mast Position Extended Mast Position Mast Name Height Forward/ Backrest in (mm) in (mm) in (mm) Backward in (mm) Top of OHG Mast (OHL) With Backrest Without Backrest...
Page 125: Fuel & Oil Capacity
SPECIFICATIONS FUEL & OIL CAPACITY Model 1F4 3.5-4.5 ton 1F4 5.0 ton Fuel Tank 94.8 (25, 20-7/8) (Standard tank) 110.4 (29-1/8, 24-1/4) (Long Tank) (US gal, lmp gal) Hydraulic Oil Tank (20-1/8, 16-3/4) (23-1/2, 19-5/8) (US gal, lmp gal) Transmission Oil 13.0 (13-3/4, 11-1/2) (US qt, lmp qt)
Page 126: Engine
SPECIFICATIONS ENGINE Model ZD30 with Turbocharger Type Diesel Cylinder Arrangement 4-cylinder, in-line Valve Mechanism Double Overhead camshaft type Bore x Stroke 96.0 x 102.0 mm (in) (3.780 x 4.016) Total Displacement 2,953 cm (cu in) (180) Compression Ratio 15.5 Firing Order 1-3-4-2 ENGINE OIL CAPACITY Model...
Page 127: Bulbs
SPECIFICATIONS NOISE LEVEL BULBS The values are the A-weighted sound pressure level at the Item Wattage operator's position, L and the uncertainty value, K according to Headlamp EN12053:2001. Front Turn Signal Lamp Item Rear Combination Lamp For Europe 80 dB (A) (standard speci cation) Stop / Tail Lamp Except Europe 84 dB (A) (standard speci cation)
Page 128: Index
INDEX Checking Accessory Belt ......92 Checking Air Cleaner ......... 91 A Word to UniCarriers Forklift Operators ..3 Engine Coolant Level ......... 77 Checking Brake Pedal ....... 90 Accelerator Pedal ........51 Engine Coolant Re lling ......77 Checking Cargo-Handling Control Air Cleaner Warning ........
Page 129 Operation Buttons ........35 Procedure for Jump Starting EFI Engines ... 59 LCD ............35 Operation of the Control Lever for Prohibited Applications for UniCarriers Lighting Switch .......... 46 Side Shift (Option) ....... 111 Trucks ..........33 Load Meter ..........39 Operational Procedures ......
Page 130 INDEX Speed Limit High/Low ....... 41 Speedometer ..........39 Radiator Cover .......... 68 Warning Drive Decal (Trained and Steering Wheel Play ........81 Radiator Level Warning ......42 Authorized) ........... 30 Stopping and Parking the Truck ....62 Radiator Warning Decal ......31 Warning Symbol ........
Page 132: Genuine Parts
This way you can ensure that your UniCarriers industrial truck will always perform at its best. This is one of the many things that make UniCarriers Genuine Forklift Parts the best choice to help maintain the value of your UniCarriers industrial truck.
Page 133 ©UniCarriers Americas Corporation 240 N. Prospect Street, Marengo, IL 60152 USA Tel: +1-815-568-0061 Fax: +1-815-568-0179 www.unicarriersamericas.com UniCarriers® is a registered trademark of UniCarriers Corporation...

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Md1f4a35v Md1f4f35v Md1f4a40v Md1f4f40v