Table of Contents
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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
Routine Servicing and Maintenance
Discusses regular maintenance for economy, utilization, and safety.
Operator Daily Inspection - Safety and Operating Checks
Emphasizes pre-operation checks for safety and proper function.
Planned Maintenance
Recommends periodic PM by trained mechanics for inspections and repairs.
Service Manual
In-depth service information for trained personnel.
Safety Labels
Location of Labels
Illustrates and lists the location of various safety labels on the truck.
Description of Safety Labels
Explains the meaning and purpose of various warning labels on the truck.
Guide
Direction
Explains truck directions (forward, backward, right, left) during travel.
Serial Number
Information on locating the truck's serial number for parts ordering.
Symbols
Explains important safety hints and useful information symbols used in the manual.
Safety Hints
Daily Inspection
Details the importance of daily truck inspection and reporting issues.
Do's and Don'ts
Lists essential safety precautions and actions to avoid.
Seat Belts
Emphasizes the importance of wearing seat belts for operator safety.
No Riders
States that only the operator should be on the truck to prevent accidents.
Pedestrians
Advises operators to watch for pedestrians in work areas and at intersections.
Operator Protection
Guides operators to stay within the overhead guard and seat confines.
Fork Safety
Warns against walking under raised forks and using forks as a work platform.
Pinch Points
Alerts operators to keep hands, feet, and legs clear of mast pinch points.
Travel
Provides guidelines for safe travel with loads, visibility, and load stability.
Grades, Ramps, Slopes and Inclines
Advises on safe operation on grades, inclines, and ramps.
Tip Over
Explains causes of lateral and longitudinal tip-overs and associated risks.
What to Do in Case of a Tip Over
Provides crucial steps to take if the truck begins to tip over.
Surface and Capacity
Warns about hazardous surfaces and knowing truck capacity to avoid tip-overs.
Parking
Details the correct procedure for safely parking the lift truck.
Lifting, Jack-up and Blocking
Outlines safe procedures for lifting, jacking, and blocking the truck.
Lifting of Lift Truck
Provides detailed instructions and safety precautions for lifting the truck.
Side Shift and Fork Positioner (OPT)
Discusses safe operation of side shift and fork positioner attachments.
Operating Hazards
Loose Loads
Warns about the dangers of carrying loose or unbalanced loads.
Long and Wide Loads
Advises on handling long/wide loads and understanding load capacity reduction.
Rear Swing
Warns about the rear swing during turns and watching for pedestrians.
Low Overhead Clearance
Emphasizes checking overhead clearance to prevent collisions or spills.
Fast Turns and High Loads
Warns that fast turns or high loads can cause tip-overs.
Drop-Offs
Provides precautions for operating near trailer edges or docks.
Right Angle Stacking
Advises caution during right angle stacking to avoid turns and collisions.
Pallets and Skids
Warns against using damaged pallets/skids to prevent falling materials.
Chain Slack
Explains that slack chains can indicate hang-ups and the need to raise forks.
Caution for Electrical Lines
Details safe working distances from electrical lines and actions if contact occurs.
Solid Tire
Advises against high speeds or driving on roads with solid tires.
Weight Indicator (Option)
Describes the function of the optional weight indicator for preventing accidents.
Know Your Truck
General Locations
Identifies major components of the lift truck with a diagram.
Name Plate of Lift Truck
Explains the information found on the truck's nameplate, including capacity.
Cab Devices
Identifies and describes various switches and levers within the operator's cab.
Cluster
Details the LED indicators and LCD display on the truck's cluster.
Warning Lamps
Explains the function of various warning lamps on the cluster.
Indicator Lamps
Explains the function of various indicator lamps like power modes and driving direction.
Buttons
Describes the function of various buttons on the control panel (Cancel, Home, OK, etc.).
Main Screen
Explains the battery level, speed mode, and other information displayed on the main screen.
Menus
Details how to access and adjust settings like display, unit, and language.
Warning Sound and Controller Information
Explains how to manage warning sounds and access controller information.
Switches and Levers
Start Switch
Explains the operation of the main start switch.
Emergency Stop Switch
Details the function and use of the emergency stop switch.
Headlight Switch
Explains how to operate the headlight switch.
Rear Work Lamp Switch (Optional)
Explains how to operate the rear work lamp switch.
Other Switches and Levers
Covers beacon lamp, FNR, auto tilt leveling, and horn switches.
Driving and Turning Controls
Explains the forward/reverse lever, turn signals, parking brake, and accelerator pedal.
Brake Pedal, Steering Wheel, and Lift Lever
Details the brake pedal, steering wheel adjustments, and lift lever operations.
Tilt and Side Shift Levers
Explains the tilt lever for mast movement and side shift lever for fork lateral movement.
Side Shift with Fork Positioner Lever
Describes operation of the side shift lever combined with fork positioner.
Fork Positioner and Seat Switch
Explains independent fork positioner control and the seat switch function.
Operator's Seat Adjustment
Seat Belt
Reinforces seat belt usage and maintenance recommendations.
Air-Conditioner and Heater (Optional)
AC/Heater Error Codes and Heater Operation
Covers troubleshooting AC/heater issues and heater operation.
Operator Maintenance and Care
Safety Inspection
Stresses operator's responsibility for pre-operation checks and reporting issues.
Visual Checks
Guides through visual inspection of truck components for damage and proper fitting.
Functional Checks
Details checks for operating controls, indicators, and systems.
Concluding the Inspection
Describes recording inspection results and handling out-of-service trucks.
Starting and Operating Procedures
Before Operating the Truck
Emphasizes reading the manual, being trained, and performing pre-operation checks.
Starting from a Safe Condition
Lists essential conditions to ensure before starting the truck.
Traveling
Explains how to start moving, control speed, and direction.
Changing Travel Direction
Details how turning direction affects truck movement and clearance.
Stop and Parking
Outlines the procedure for safely stopping and parking the truck.
Speed Adjustment
Explains how to adjust truck speed using the accelerator pedal.
Brake Operation
Details how to use the brake pedal to stop the truck safely.
Plugging
Describes the plugging function for changing direction and its safe usage.
Operating Safely
Provides general safety rules for operating the lift truck.
Grades, Ramps, and Inclines
Gives specific advice for operating on inclines and ramps.
Practice Safe Operation
Reinforces the importance of careful driving, following instructions, and observing truck functions.
Load Handling
General Load Handling Principles
Covers principles for handling loads within capacity, stability, and safe lifting.
Adjusting the Load Forks
Explains how to adjust forks for stability and safe load engagement.
Load on Forks
Warns against using one fork or the ends of forks, and proper load placement.
Traveling with Load
Provides guidance for safe travel with loads, including visibility and tail swing awareness.
Picking up and Moving Loads
Details procedures for safely picking up loads from the ground.
Unloading
Outlines the steps for safely unloading a load.
Stacking
Provides step-by-step instructions for safely stacking loads.
Moving a Load from a Stack
Details the procedure for safely removing a load from a stack.
Shut Down Procedure
Safety Rules for Parking
Lists essential safety rules to follow when leaving or parking the truck.
Steps Before Leaving Operator Position
Outlines critical steps to take before exiting the operator's seat.
Steps When Leaving Truck Unattended
Provides additional steps for securing the truck when left unattended.
Emergency Procedures
How to Tow a Disabled Truck
Provides instructions and safety guidelines for towing a disabled truck.
Emergency Mast Lowering
Explains how to manually lower the mast in case of controller failure.
Planned Maintenance and Lubrication
Introduction to Planned Maintenance
Introduces planned maintenance, its importance, and schedules.
Safe Maintenance Practices
Outlines safety standards and procedures for maintenance operations.
Instructions Before Maintenance
Covers preparation steps before starting maintenance work.
Precaution
General precautions for inspection and maintenance.
Proper Maintenance
Covers component replacement, using genuine parts, and correct procedures.
Hydraulic Hose/Pipe Installation Precautions
Advises on preventing damage and ensuring proper installation of hydraulic hoses and pipes.
Periodical Replacement of Safety Parts
Lists safety-critical parts and their recommended replacement cycles.
Major Component Locations
Shows locations of major components for maintenance procedures.
Service Locations
Identifies service points for various truck parts with a diagram.
Daily Maintenance Checklist
Provides a list of items to check daily or every 10 hours for truck maintenance.
Periodical Checklist
Details service intervals and types of checks for various truck components.
How to Perform Planned Maintenance
Explains how to check brake oil, hydraulic oil, and lift chain tension.
Checking Hub Nut
Details tightening procedures and torque for hub nuts.
Grease Applying
Guides on applying grease to various parts and specific points.
Drive Axle Oil Level
Explains how to check and maintain the drive axle oil level.
Truck Body Inspection
Advises inspecting the truck body for defects.
Fuse Exchange
Provides instructions for safely exchanging fuses.
Lift Chain Maintenance
Covers maintenance needs for lift chains to ensure safe operation.
Lift Chain Inspection and Measurement
Details procedures for inspecting lift chains for wear and damage.
Lift Chain Lubrication
Explains the importance and method of lubricating lift chains.
Lift Chain Wear and Replacement Criteria
Defines criteria for replacing lift chains and related procedures.
Visual Inspection
Details inspection of mast, rollers, chains, and cylinders for wear and leaks.
Overhead Guard
Instructions for checking the overhead guard for damage and security.
Backrest
Guidelines for inspecting the backrest for damage and proper positioning.
Mast
Details inspection of mast, rollers, chains, and cylinders for wear and leaks.
Lift Chain
Specific checks for lift chain wear, tension, and fasteners.
Forks
Covers inspection of forks for wear, damage, and proper alignment.
Wheel and Tires
Instructions for checking wheels, tires, and tire pressure for safe operation.
Hydraulic Oil and Consumables Change
Step-by-step guide for draining and refilling hydraulic oil.
Hydraulic Oil Return Filter Exchanging
Instructions for replacing the hydraulic oil return filter element.
Air Breather Element Replacement
Details the process for replacing the air breather element.
Torque Checks
Explains the importance of maintaining proper torque on critical fasteners.
Air Cleaning
Provides guidelines for cleaning the truck using compressed air.
Battery Maintenance
Lists mandatory facilities required for the battery shop.
Battery Handling Precautions
Highlights safety precautions due to battery weight and chemical content.
Battery Handling
Further details on handling batteries safely, including lifting tools and precautions.
Battery Charging
Explains how to use the charger and its indicator lamps.
Charger Installation
Guides on proper installation of the battery charger.
Normal Charging
Details the procedures for normal battery charging.
Even Charging
Explains the purpose and procedure for even charging to equalize cell capacities.
Makeup Charging
Advises on makeup charging when daily capacity is insufficient.
Charging Precautions
Lists essential precautions to observe during the charging process.
Battery Replacement
Covers general aspects and safety for replacing the truck battery.
Cautions on Battery Replacement
Provides specific cautions to follow during battery replacement.
Replacement with Lift Truck
Details how to replace the battery using the lift truck itself.
Replacement with Palette Truck
Explains how to replace the battery using a palette truck and jigs.
Minimum Battery Lifting Height
Advises on minimum height requirements for lifting batteries safely.
Transportation of Battery
Provides safety guidelines for transporting the truck battery.
Battery Docking
Explains procedures for docking the battery onto a dock.
Battery Maintenance Precautions
Warns against fully discharging the battery to preserve its service life.
Prohibition of Over-Discharge
Warns against fully discharging the battery to preserve its service life.
Strict Prevention of Open Flame
Advises extreme caution regarding open flames near the battery due to flammable gas.
Makeup with Distilled Water
Explains how to maintain electrolyte level using distilled water.
Keeping Battery Clean
Stresses the importance of keeping the battery top clean and dry.
Lithium Ion Battery (Optional)
Details the structure of the battery pack and modules.
Lithium Ion Battery Inspection Procedures
Outlines procedures for inspecting lithium-ion battery components and terminals.
Lithium Ion Battery Charger (Optional)
Covers safe usage requirements and operations of the charger.
Power Connection
Instructions for connecting the charger to the power source.
Battery Connection
Details the procedure for connecting the battery to the charger.
Precaution During Charging
Lists critical precautions to observe during the charging process.
Storage
Warns about potential damage from improper storage.
Daily Storage
Provides instructions for short-term storage of the truck.
Long-Term Storage
Details procedures for storing the truck for extended periods.
Notes After Storage
Outlines checks and procedures after removing the truck from storage.
Notes During Storage
Tips for maintaining the truck during storage.
Lubricants for New Truck
Lists lubricants and oils used for new truck shipping.
Recommended Lubricant
Provides a table of recommended lubricants based on ambient temperature.
Specifications
Specification Table
Presents key specifications for different truck models in a table.
Specification for Major Components
Lists specifications for controller, motor, and battery systems.
Gear Pump and Main Control Valve Specifications
Provides specifications for the gear pump and main control valve.
Charger Specifications
Lists specifications for the battery charger.
Drive Axle Specifications
Details specifications for the drive axle.
Wheel Specifications
Provides specifications for wheels, including type and pressure.
Brake and Steering Systems Specifications
Lists specifications for the brake and steering systems.
Fastening Torque
Lists torque specifications for various fasteners used in assembly and maintenance.
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