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Introduction - - - -- - -- - - - - - - - - - - -- - - - - - - - - - -- - - - - - - - - - -- - - - - - - - - - - -- 0-2
How to use this manual - - - - -- - - - - - - - - - -- - - - - - - - - - -- - - - - - - 0-3
Safety label - - - -- - -- - - - - - - - - - - -- - - - - - - - - - -- - - - - - - - - - -- - - - - - - - - - - -- 0-5
Guides on use - - - - - - - - - - -- - - - - - - - - - - -- - - - - - - - - - -- - - - - - - - - - - -- - - 0-12
Integrated call center - - - - - - - - -- - - - - - - - - - -- - - - - - - - - - - -- - - - - - 0-14
Sales distributors - - - - - - - - - -- - - - - - - - - - - -- - - - - - - - - - -- - - - - - - - -- - 0-15
Authorized service shops - - - - -- - - - - - - - - - - -- - - - - - - - - - -- - - 0-16
Parts distributors - - - - - -- - - - - - - - - - - -- - - - - - - - - - -- - - - - - - - - - - -- - - - 0-17
1. Daily inspection -- - - - - - - - - - - -- - - - - - - - - - -- - - - - - - - - - -- - - - - 1-1
2. Do's and don'ts - - - - - - - - -- - - - - - - - - - - -- - - - - - - - - - -- - - - - -- - 1-2
3. Seat belts -- - - - - - - - -- - - - - - - - - - - -- - - - - - - - - - -- - - - - - - - - - - -- - - - - 1-4
4. No riders - -- - - - - - - - -- - - - - - - - - - -- - - - - - - - - - - -- - - - - - - - - - -- - - -- - 1-5
5. Pedestrians - - - - - - - - - - -- - - - - - - - - - -- - - - - - - - - - - -- - - - - - - - - -- - 1-6
6. Operator protection -- - - - - - - - - - -- - - - - - - - - - - -- - - - - - - - - - 1-7
7. Fork safety -- - - - - - - - - - -- - - - - - - - - - - -- - - - - - - - - - -- - - - - - - - - -- - - 1-8
8. Pinch points - - - - - - - - - - -- - - - - - - - - - - -- - - - - - - - - - -- - - - - - - - -- - - 1-9
9. Travel - -- -- - - - - - -- - - - - - - - - - -- - - - - - - - - - - -- - - - - - - - - - -- - - - - - - - - - - 1-10
10. Grades, ramps, slopes and inclines - - -- - - 1-11
11. Tip over - -- - -- - - - - - - - - - - -- - - - - - - - - - -- - - - - - - - - - - -- - - - - - - - - - -- - 1-12
12. Surface and capacity -- - - - - - - - - - - -- - - - - - - - - - -- - - - - - - 1-14
13. Parking - -- - - - - - - - -- - - - - - - - - - -- - - - - - - - - - -- - - - - - - - - - - -- - - - - - - - - 1-15
14. Lifting, jack-up and blocking - - - - - - - - - - - -- - - - -- - - 1-16
15. Lifting of forklift truck - - - - - - - - - - -- - - - - - - - - - -- - - - - - -- - - 1-21
16. Side shift and fork positioner (optional) - - - - - 1-22
1. Loose loads - - - - - - - -- - - - - - - - - - - -- - - - - - - - - - -- - - - - - - - - - - --- - 2-1
2. Long and wide loads - - - - - - - - -- - - - - - - - - - -- - - - - - - - - - - 2-2
3. Rear swing - - - - - - - - - - -- - - - - - - - - - - -- - - - - - - - - - -- - - - - - - - - - -- - 2-2
4. Low overhead clearance - - - - - - - - - - -- - - - - - - - - - --- - 2-3
5. Fast turns and high loads - - - - - - - -- - - - - - - - - - -- -- - - 2-3
6. Drop-offs - - - - - - -- - - - - - - - - - - -- - - - - - - - - - -- - - - - - - - - - -- - - - - - - - - - 2-4
7. Right angle stacking - -- - - - - - - - - - -- - - - - - - - - - - -- - - - - - - 2-4
8. Chain slack - - - - - - - - - - -- - - - - - - - - - -- - - - - - - - - - - -- - - - - - - - - -- -- 2-5
9. Pallets and skids -- - - - - - - - - - -- - - - - - - - - - - -- - - - - - - - - - -- - - 2-5
10. Caution for electrical lines - - - - - - - - -- - - - - - - - - - --- - 2-6
11. Solid tire --- -- -- -- -- --- -- -- -- -- --- -- -- -- -- --- -- -- -- -- --- -- -- - 2-7
12. Weight indicator (option) -- -- -- --- -- -- -- -- --- -- -- - 2-7
1. General locations -- -- --- -- -- -- -- --- -- -- -- -- -- --- -- -- -- 3-1
2. Name plate -- -- -- -- -- --- -- -- -- -- -- --- -- -- -- -- --- -- -- -- -- -- 3-2
3. Cab devices - -- -- -- -- -- --- -- -- -- -- --- -- -- -- -- --- -- -- -- -- -- 3-3
4. Cluster - --- -- -- -- -- --- -- -- -- -- --- -- -- -- -- --- -- -- -- -- -- --- -- -- - 3-4
5. Switches and levers -- -- -- -- --- -- -- -- -- --- -- -- -- -- -- - 3-12
6. Cab control devices - -- -- -- -- --- -- -- -- -- --- -- -- -- -- -- 3-18
7. Battery cover - -- -- --- -- -- -- -- -- --- -- -- -- -- --- -- -- -- -- --- - 3-19
8. Air conditioner and heater (optional) - -- --- 3-19
1. Daily safety inspection -- -- -- -- --- -- -- -- -- --- -- -- -- - 4-1
2. Apparent shape inspection - --- -- -- -- -- --- -- -- -- 4-2
3. Function inspection --- -- -- -- -- --- -- -- -- -- -- --- -- -- -- - 4-3
4. Actions on inspection results -- -- -- -- --- -- -- -- - 4-3
5. 5. STARTING AND OPERATING PROCEDURES
STARTING AND OPERATING PROCEDURES
1. Before operating the truck - -- -- -- -- --- -- -- -- -- --- 5-1
2. Starting from a safe condition - -- -- --- -- -- -- -- - 5-1
3. Traveling of the truck - -- -- --- -- -- -- -- -- --- -- -- -- -- -- 5-2
4. Speed adjusting --- -- -- -- -- --- -- -- -- -- --- -- -- -- -- --- -- - 5-4
5. Brake operation - -- -- -- -- --- -- -- -- -- -- --- -- -- -- -- --- -- -- 5-4
6. Plugging -- -- -- -- --- -- -- -- -- --- -- -- -- -- --- -- -- -- -- --- -- -- -- -- 5-4
7. Operating safely - -- -- -- --- -- -- -- -- --- -- -- -- -- --- -- -- -- - 5-5
8. Load handling -- -- -- -- --- -- -- -- -- --- -- -- -- -- --- -- -- -- -- -- 5-7
9. Shut down procedure -- -- -- -- --- -- -- -- -- -- --- -- -- -- 5-13
1. Hauling - -- -- -- -- --- -- -- -- -- --- -- -- -- -- --- -- -- -- -- --- -- -- -- -- - 6-1
2. Emergency mast lowering - -- -- --- -- -- -- -- --- -- - 6-3
7. 7.
1. Introduction --- -- -- -- -- -- --- -- -- -- -- --- -- -- -- -- --- -- -- -- -- - 7-1
2. Safe maintenance practices -- --- -- -- -- -- --- -- - 7-2
3. Basics - -- --- -- -- -- -- --- -- -- -- -- --- -- -- -- -- --- -- -- -- -- -- --- -- -- 7-4
4. Parts positions - -- -- -- --- -- -- -- -- -- --- -- -- -- -- --- -- -- -- -- 7-7
CONTENTS
CONTENTS
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Table of Contents
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Summarization of Contents
Introduction to Lift Truck Operation
Routine Servicing and Maintenance
Regular maintenance for economy, utilization, and essential safety.
Operator Daily Inspection
Pre-operation check to ensure safe operation. OSHA requirement.
Planned Maintenance Program
Recommended periodic inspection by trained personnel for safety & efficiency.
Safety Labels Overview
Location and Description of Safety Labels
Details and placement of various warning and safety labels on the truck.
Guide to Truck Information
Direction, Serial Number, and Symbols
Explains truck direction indicators, serial number identification, and symbols.
Vibration on Whole Body
Specifies vibration levels according to EN13059 standards for truck body.
Chapter 1 Safety Hints
Daily Inspection Procedures
Procedures for inspecting the truck at the beginning of each shift.
Do's and Don'ts for Safe Operation
Visual guidelines for safe operation and prohibited actions.
Seat Belt Importance
Importance of wearing seat belts for injury prevention.
No Riders Policy
Rules against carrying passengers on the truck.
Pedestrian Safety
Safety procedures for interacting with pedestrians in the work area.
Operator Protection Measures
Keeping oneself within the truck's confines and under the overhead guard.
Fork Safety Precautions
Warnings against walking under raised forks or using forks as elevators.
Pinch Point Hazards
Precautions regarding moving parts of the mast and avoiding repairs.
Safe Travel Practices
Safe travel practices, including load position and visibility.
Grades, Ramps, and Inclines Safety
Safe operation guidelines for inclined surfaces.
Tip Over Prevention and Response
Causes and prevention of lateral and longitudinal tip-overs.
Surface and Capacity Awareness
Avoiding hazardous surfaces and understanding load capacity limits.
Parking Procedures
Steps for safely parking the lift truck.
Lifting, Jack-Up, and Blocking
Procedures for safely lifting, jacking, and blocking the truck for maintenance.
Lifting of Lift Truck
Safe methods for lifting the entire lift truck using cranes or other equipment.
Side Shift and Fork Positioner Operation
Safe operation guidelines for side shift and fork positioner attachments.
Chapter 2 Operating Hazards
Loose Loads and Load Stability
Dangers of carrying loose or unbalanced loads and precautions.
Long and Wide Loads Handling
Safety considerations for handling extra-long or wide loads.
Rear Swing Awareness
Awareness of rear swing during turns to avoid collisions.
Low Overhead Clearance Hazards
Importance of checking overhead clearances to prevent tip-overs or spills.
Fast Turns and High Loads Risks
Hazards associated with sharp turns or high loads, increasing tip-over risk.
Drop-Offs and Trailer Safety
Precautions for operating near trailer edges or drop-offs.
Right Angle Stacking Safety
Safe practices for right-angle stacking, avoiding sharp turns.
Chain Slack Warning
Identifying chain slack as a potential issue and raising forks before moving.
Pallet and Skid Safety
Warnings against using damaged pallets or skids.
Caution for Electrical Lines
Safety distances required when operating near electrical power lines.
Solid Tire Limitations
Limitations and precautions when operating with solid tires.
Weight Indicator (Option) Function
Device to prevent overload work or rollover by measuring load.
Chapter 3 Know Your Truck
General Locations of Components
Identification of major truck components and their locations.
Name Plate Information
Understanding the information on the truck's identification and capacity plate.
Cab Devices and Controls
Locations and functions of switches, levers, and controls within the operator's cab.
Cluster Indicators and Buttons
Explanation of LED indicators, LCD display, and buttons on the truck's cluster.
Switches and Levers Operation
Detailed descriptions of various switches and levers for truck operation.
Brake Pedal, Steering Wheel, and Lift/Tilt Levers
Operation of essential control levers and pedals like brake, steering, lift, and tilt.
Side Shift and Fork Positioner Levers
Operation of levers for side shift and fork positioner functions.
Operator's Seat and Seat Belt
Adjustments for operator comfort and safety, including seat belt usage.
Battery Cover and Climate Control
Accessing the battery cover and operating the optional air conditioner and heater.
Chapter 4 Operator Maintenance and Care
Safety Inspection Procedures
Operator's responsibility to check the truck's condition before operation.
Visual Checks of Components
Performing a visual inspection of the truck's components and safety features.
Functional Checks of Systems
Testing the operation of controls, systems, and safety equipment.
Concluding the Inspection Process
Recording inspection results and reporting any issues found.
Chapter 5 Starting and Operating Procedures
Before Operating the Truck
Prerequisites and checks before starting truck operation.
Starting from a Safe Condition
Ensuring safe conditions and proper control positioning before starting.
Traveling and Direction Changes
Procedures for moving the truck forward, backward, and changing direction.
Stop and Parking Procedures
Steps to safely stop and park the lift truck.
Speed Adjustment and Brake Operation
How to adjust speed and properly use the brake pedal.
Plugging Function Operation
Using plugging for direction changes and its associated care.
Operating Safely Guidelines
General rules for safe operation, including awareness and protection.
Grades, Ramps, and Inclines Safety
Safe practices for operating on inclines and ramps.
Practice Safe Operation Always
Emphasizing continuous safe driving and hazard awareness.
Load Handling Procedures
Procedures for safely handling, picking, and moving loads.
Shut Down Procedure
Steps for safely shutting down and leaving the lift truck unattended.
Chapter 6 Emergency Procedures
How to Tow a Disabled Truck
Step-by-step instructions for safely towing a disabled lift truck.
Emergency Mast Lowering
Procedure for manually lowering the mast in case of controller failure.
Chapter 7 Planned Maintenance and Lubrication
Introduction to Planned Maintenance
Overview of planned maintenance importance and procedures.
Safe Maintenance Practices
General safety guidelines for performing maintenance and repairs.
Instructions Before Maintenance
Precautions and preparation steps before starting maintenance.
Major Component Locations for Maintenance
Identifying key components for planned maintenance procedures.
Daily Maintenance Checklist
Items to check daily or every 10 hours for routine maintenance.
Periodical Maintenance Checklist
Scheduled maintenance checks based on hourmeter readings.
Performing Planned Maintenance
Specific procedures for performing lubrication and checks on various systems.
Lift Chain Maintenance
Procedures for inspecting, measuring, lubricating, and replacing lift chains.
Visual Inspection of Parts
Detailed visual checks for forks, wheels, tires, and hydraulic systems.
Hydraulic Oil and Consumables Change
Procedures for changing hydraulic oil, filters, and air breathers.
Torque Checks for Components
Importance of maintaining correct torque on critical fasteners.
Air Cleaning Procedures
Guidelines for cleaning the truck using compressed air.
Battery Maintenance Guidelines
Safety and procedures for battery charging, handling, and replacement.
Lithium Ion Battery (OPT) Details
Structure and inspection procedures for the optional lithium-ion battery system.
Lithium Ion Battery Charger (OPT)
Operation, installation, and safety precautions for the lithium-ion battery charger.
Storage Procedures
Procedures for short-term and long-term storage of the lift truck.
Lubricants for New Truck
Recommended lubricants and oils for new trucks.
Recommended Lubricant Guide
Detailed guide for selecting lubricants based on ambient temperature.
Chapter 8 Specifications
Specification Table
Technical specifications and dimensions for various truck models.
Specification for Major Components
Detailed specifications for controllers, motors, batteries, chargers, pumps, and axles.
Fastening Torque Values
Specific torque values for various mounting bolts and nuts.
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