• Author / Uploaded
• Luis Bomfim

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OPERATING MANUAL

DO NOT REMOVE THIS MANUAL FROM THIS UNIT Part No. 4046068

10/11

• This manual describes instructions for proper handling of the HYSTER forklift truck as well as daily lubrication and maintenance check methods. To ensure safe and highly efficient work through correct operation and servicing, please read this manual thoroughly before using the truck. • This manual has been prepared for the standard model. Please contact the company-designated service center for details on options, special specifications and any other unclear points. This manual is subject to change with changes in the truck specifications. • The following marks are used in this manual to show important items related to safety, etc. Read this points carefully in addition to the text. Indicates items to be observed to prevent accidents that could lead to fatalities or personal injuries. Indicates items to be observed to prevent personal injuries or damage to the truck or surroundings. Items that should be followed to prevent accidents and trouble, and to allow the lift truck to be used safely for a long time.

Make sure that this operator manual is included when transferring ownership of the lift truck.

This operator manual describes the following truck models. Battery size

STD

Truck type

Model

Max. load

Volt

MIN. Ah/hr

MAX. Ah/hr

Standard chassis

J1.50EX

1500

440/5

600/5

J1.75EX

1750

440/5

600/5

Large Battery chassis

J2.00EX

2000

560/5

700/5

J2.50EX

2500

560/5

700/5

i

48V

CONTENTS 1

Introduction .........................................................................................

1

■ Pre-operation and Periodic Inspections ■ Chassis Number and Serial Number Locations ■ Handling of New Vehicle 2

For Safety Operation........................................................................... ■ Before Starting Work ■ During Travel ■ Parking

3

■ On The Vehicle ■ During Work

3

Safety Labels / Plates Installation Positions ....................................

12

4

Main Components ...............................................................................

14

5

Operating System and Display ..........................................................

16

6

Handling of Each Device ....................................................................

17

■ Key Switch ■ Indication of Display Devices ■ Levers ■ Light Switch ■ Standard Seat ■ Forks 7

How to Drive ........................................................................................ ■ Before Driving ■ Plug Braking ■ After Operation

8

■ Display ■ How to Set Various Modes ■ Pedals ■ Steering Wheel ■ Suspension Seat (Optional) 35

■ Starting and Traveling ■ Temporary Stop and Parking

Vehicle Structure and Stability...........................................................

38

■ Load and Vehicle Stability ■ Center of Gravity Position and Stability ■ Range of Center of Gravity Stability ■ Reference Load Center and Capacity Chart 9

Load Handling ..................................................................................... ■ Picking up Load from The Ground ■ Destacking from High Place ■ Unloading

ii

40

CONTENTS (Continued) 10

Exchanging of Battery ........................................................................

43

■ Exchanging The Battery Using a Hoist 11

How to Use The Battery ......................................................................

45

■ How to Use The Battery ■ Bulk Water Replenisher (Optional) 12

Pre-operation Inspection ....................................................................

51

■ Pre-operation Inspection 13

Post-operation Inspection and Storage ............................................

60

■ Post-operation Inspection ■ Daily Storage ■ Long-term Storage 14

Periodic Inspection .............................................................................

61

■ Periodic Inspection and Servicing ■ Weekly Inspection (Every 50 Hours) ■ Monthly Inspection (Every 200 Hours) 15

Work Items ...........................................................................................

70

■ Opening/Closing the Battery Cover ■ Adjusting The Parking Brake Lever Operating Force ■ How to Use Coupler Pin ■ Changing Tires ■ Replacing, Repairing Simple Parts ■ Replacing Bulb (If Equipped) ■ Replacing Fuse 16

Service Data.........................................................................................

79

■ Adjustment Value ■ Fuse Capacity ■ Bolt Tightening Torque 17

Inspection, Lubrication and Periodic Replacement Parts............... ■ Inspection, Lubrication and Periodic Replacement Parts Table ■ Inspection and Lubrication Chart ■ Periodic Replacement of Safety Parts ■ Lubricants List

iii

81

CONTENTS (Continued) 18

Freezer/Refrigerator Specified Vehicles............................................ ■ Freezer/Refrigerator Specified Vehicles

iv

85

Introduction

1

■ Pre-operation and Periodic Inspections It is important to conduct periodic inspections without fail to secure the safety of your forklift truck during use and to provide economically feasible operation.



Pre-operation inspection ................This daily inspection must be conducted before starting work with the forklift truck.



Post-operation inspection...............This inspection is carried out when the daily operation and work have been completed.



Periodic self-inspection ..................This self-inspection must be conducted periodically within a period not exceeding one month (monthly inspection).



Specific self-inspection ...................This self-inspection must be conducted periodically within a period not exceeding one year (annual inspection).

For our customers, the company provides the above inspection service (excluding daily inspection) at the designated service shops. It is recommended to use our periodic inspection service system for the safe and long-term use of your forklift truck.

■ Chassis Number and Serial Number Locations The chassis number of the vehicle is stamped at the location shown in the figure below. The model number, chassis number and serial number are stamped on the nameplate located on the right-side of the operator’s seat. Please inform our company of these numbers when making inquiries regarding repairs, etc.

-1-

1

Introduction

■ Handling of New Vehicle Vehicles are thoroughly inspected, adjusted, and tested before delivery, but a certain amount of time will be necessary to break the vehicle in completely. Careful breakingin of the new vehicle will lead to a long-term fault-free operation. For the first two weeks of use, take special care not to apply excessive loads, and pay attention to the following points.

• Avoid high-speed operation, and keep the load to 70 to 80% of the rated load. • Check the loosening of bolts, nuts and hydraulic joints during the break-in period. If any looseness is found, stop the vehicle and retighten the loose part. • Take time to train in the usage of each device on the vehicle before starting full operation. Even after getting used to the handling, be careful during the actual operation to prevent personal accidents or physical accidents. • Even if the vehicle has the same specifications, each vehicle will have its own characteristics in terms of brakes, accelerators, and load handling devices. Always feel the vehicle out before starting use. Take special care to get a feel of the brakes.

-2-

For Safety Operation

2

It is important for the forklift operator and supervisor to observe various rules to prevent work-related disasters during transfer work. Please observe the following items and carry out the operation and work safely.

■ Before Starting Work

Only operators who have completed the forklift truck operation skill training may operate this truck

Wear designated work clothes and protective devices. • Wear work clothes that have well closed cuffs and collars. • Always wear safety shoes and a protective helmet.

Take sufficient time to discuss the work before starting. • Discuss the work with the work leader before starting work, and always follow the work plan.

Inspect the forklift truck before starting work. • If any abnormality is found, contact the supervisor immediately. Do not operate the truck until the defect has been corrected.

Do not modify or repair the forklift truck on the site. • Contact the company-designated service center when the vehicle must be modified or repaired. -3-

2

For Safety Operation

If overhead guards, back rests or any other defects are found in the safety devices, repair them immediately before starting operation. • Do not remove the overhead guard. • Do not use vehicles that are not provided with the company-designated overhead guard and/or back rest.

Do not use the vehicle for purposes other than those specified. • Do not open or close the doors of railway cars or warehouses. • Do not push other vehicles. • Do not attach a wire rope onto the fork to suspend items. • Do not tow anything using the coupler pin.

■ On The Vehicle

Always fasten seat belt while operating the vehicle

If the vehicle is about to tip sideways, stay in the vehicle, grasp the steering wheel tightly with both hands, and plant your feet firmly to hold your body securely.

-4-

For Safety Operation

■ During Travel

Always operate the vehicle within the specified speed limit. • Set a safety speed limit for both when the vehicle is loaded and unloaded considering the working environment. • Observe the work site rules and operate the vehicle safely.

A forklift truck is built for only one person - the operator. It is dangerous for anyone to ride on the forks, counterweight or any other place.

Assign a guide at narrow places for safe operation. • When assigning a guide, make sure to predetermine signals to be used. • The operator must follow the signals given by the guide.

If the view is obstructed, always stop once and confirm the safety on the left and right before proceeding.

-5-

2

2

For Safety Operation

When traveling on a slope while carrying a load, drive forward when going up and backward when going down the slope. Never travel across a slope or change directions on a slope as the vehicle could tip over.

A forklift truck is steered by the rear wheels, so when making a turn, bring its inner side as close to the inside corner as possible. This is opposite of normal passenger cars.

When driving the forklift truck at night, the distance of objects and road levels can be easily mistaken. Always turn on both front and rear lights or other means of lighting. Take caution to persons and obstacles in the surrounding area.

Be careful of the height of the upper part of the forklift truck when entering or exiting a warehouse or other buildings, so that the truck will not catch.

The forklift truck is more likely to tip over when it has no load, so take care when driving.

-6-

For Safety Operation

Take special care when carrying a long or wide load. • Lift or lower the load slowly while confirming the surrounding safety. • Be careful of the balance of the load. Always work with the load at a low position. • Confirm the surrounding safety when turning, and operate the forklift truck slowly to prevent the load from shifting.

Do not drive over wood pieces or other objects scattered on the ground. Doing so may cause the load to shift or the operator to lose control.

Traveling on the very edge of the road may cause the vehicle to tip over. Always keep a safe distance from the edge.

Take care of the road condition while traveling. • Confirm the strength of the floor. • Travel on slippery surfaces can cause the vehicle to slip. If this is unavoidable, slow down. • Avoid traveling on weak or nonprepared ground.

-7-

2

2

For Safety Operation

■ During Work

Do not travel with an excessive load that causes the rear tires to float. • Follow the load table and carry out the work.

Do not use the tip of the forks as a lever to raise a heavy load. Do not push a load with the tip of the forks and do not use the tilt cylinder to pull a load.

Use pallets and skids suitable for the load. • Use pallets and skids that can withstand the weight of the load. • Do not use damaged, deformed or decayed pallets and skids.

Stack the load on the pallet or skids safely and properly. • To prevent eccentric loads, take care of the center of gravity of the load. • If the load might become unstable, bind the load with a rope (binder) or use other preventive measures. The worker in charge of loading must not get on the fork or hold the load during travel. • Do not carry unstable loads.

-8-

For Safety Operation

Do not travel or turn with the forks higher than 30cm from the ground or in a vertical position or tilted forward.

Do not advance suddenly, apply the brakes suddenly or make a sharp turn. If the brakes are applied suddenly while traveling forward, the load may fall off or the vehicle may tip over. • The stopping distance will increase while traveling down a slope or on a wet surface. Always provide an allowance when braking.

Do not place hands or feet on the cross members of the mast. Your hand may be severed if the mast is lowered while your hand is on it.

Before loading onto or unloading from a truck, always confirm that the truck’s parking brakes are applied and that the wheels are chocked.

-9-

2

2

For Safety Operation

Before moving backward, tilt the forks back completely and confirm that the load is safe. Drive carefully when backing. • When moving backward, do not depend on the rear-view mirror. Move backward while looking with your neck turned.

If the range of vision is poor due to a large load, follow the instructions given by the guide.

• Do not suddenly tilt when the forks are completely raised. • Never leave the forklift truck with a load lifted.

Never enter under the load or forks.

- 10 -

For Safety Operation

• Keep the elbows and feet within the vehicle body during operation. Otherwise, they may be caught by an obstacle. • Stay under the overhead guard during operation. • Always operate the forklift truck at the operator’s seat.

■ Parking

When leaving the forklift truck, always carry out the following: • Park the truck in a safe area where other work will not be obstructed. • Lower the forks until the tips touch the ground. • Apply the parking brakes securely. • Set the shift lever to neutral. • Turn the key switch “OFF” and remove the key. • When parking on a slope is unavoidable, always chock the wheels.

- 11 -

2

3

Safety Labels/Plates Installation Positions

Safety labels and other plates are attached to the positions shown below. Carefully read them to well understand the details before starting work for safe operation and driving of the vehicle without accidents.

- 12 -

Safety Labels/Plates Installation Positions

If any label or plate is no longer readable or missing, replace it with a new one. Use conforming labels and plates. - 13 -

3

4

Main Components

Link

1. 2. 3. 4. 5. 6.

Elevating Back Rest Fork Carriage Fork Tilt Cylinder Battery Cover

7. 8. 9. 10. 11. 12.

- 14 -

Seat Seat Belt Overhead Guard Front Light Turn Signal Light Battery (inside the cover)

Main Components

13. 14. 15. 16. 17. 18.

Rear Combination Lamp Counter Weight Rear Tire Side Cover Front Tire Mirror

19. 20. 21. 22. 23. 24.

- 15 -

Floor Plate Disconnect Lever Stationary Chain Lift Cylinder Rear Cover

4

5

Operating System and Display

Link

1. 2. 3. 4. 5. 6. 7. 8.

Steering Wheel Shift Lever (optional) Parking Brake Steering Wheel Tilt Lever Brake Pedal MONOTROL® Pedal Key Switch Tilt Lever

9. 10. 11. 12. 13. 14. 15.

- 16 -

Lift Lever Display Direction Indicator Lever Light Switch Horn Button Control Valve Tilt Lever Accelerator Pedal (optional)

Handling of Each Device

6

This section describes various devices required for driving and operating a forklift truck. To carry out safe and comfortable operation, it is important for users to correctly understand how to operate these devices and display details.

■ Key Switch A two-position ON/OFF key switch. Put the forklift truck in the neutral position, release the monotrol pedal (or accelerator pedal if applicable), and then turn the key “ON”. If these conditions are not met, the vehicle will not travel even if the key switch is turned “ON”.

Automatic power “OFF” function If the key switch is turned “ON” and left with no operator input for more than about 15 minutes, traveling and load handling functions will be automatically stopped. To restart operation, turn the key switch “OFF” once.

- 17 -

6

Handling of Each Device

■ Display

1. 2. 3. 4. 5.

Down Arrow Button Up Arrow Button Warning Indicator Mode Select Button LCD Panel 1. Battery Discharge Indicator 2. Power Mode Level Indicator 3. Hour Meter, Odometer 4. Current Speed Limit 5. Status Icons 6. Speed Limit Mode

- 18 -

Handling of Each Device

6

■ Indication of Display Devices 1. Battery discharge indicator Indicates the discharge level of the battery. While the key switch is turned “ON”, all the bars will be black when the battery is fully charged. The bars become empty sequentially from the top as the battery discharges.

When all of the bars are empty and a message appears that reads “CHARGE REQ’D” in the center of the LCD screen, promptly charge the battery.

BDI interrupt Lift operation is disabled when the message “CHARGE REQD” is displayed.

In this case, charge the battery immediately. 2. Power mode level indicator Indicates a combined set level for traveling and load handling power. The indication level changes as shown below by pressing the Mode button.

 : Level 1  : Level 2  : Level 3 HYPER: Hyper mode MY MODE: My mode

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6

Handling of Each Device

3. Stationary Screen In the normal display mode when the truck is stationary, the screen displays the total, travel, and hydraulic hour meters.

4. Traveling Screen In the normal display mode while the truck is traveling, the truck displays a speedometer. 5. Hour meter, odometer The following can be displayed in the advisory windows of the normal display mode: • Hour Meter – Total operating hours: TOTAL HOURS • Hour Meter – Total load handling hours: HYD HOURS • Hour Meter – Total travel hours: TRAVEL HOURS • Odometer – Total Travel Distance: ODOMETER • Odometer - Trip Travel Distance: TRIP ODO • Hour Meter – Key ON hours: KEYSW HOURS • Speed Limit Mode 6. Error Indicator Error indication There are two modes for warning icons, red and yellow. When a fault has caused a vehicle operation to be stopped, the icon will glow red. When vehicle performance is reduced or attention of the operator, the icon will glow yellow. Red is highest priority and will override the yellow indication.

When an error is indicated, inform a designated service shop of the error code and the message.

- 20 -

Handling of Each Device

6

7. Icons: In addition to a glowing warning icon, an error indicator screen will appear with an error icon. Error icon displayed differs according to the faulty section and detail of abnormality. Wrench - Indicates there is a fault that requires maintenance.

Rotating Wheel - Indicates a fault is related to the Traction System.

Fork - Indicates a fault is related to the Hydraulic System.

Steering Wheel - Indicates a fault is related to the Steering System.

Thermometer - Indicates a fault is related to Temperature.

Battery - Indicates a low battery condition or a fault that is battery related.

- 21 -

6

Handling of Each Device

8. Status Messages: For the five most common messages the operator will see, a Chinese message will be displayed in place of the numeric speed just above the advisory window. At the same time, the English equivalent message will appear in the message center. Charge Required - This image is shown any time the vehicle performance is reduced due to a low battery or because the Battery Discharge Indicator has reached the lift lockout threshold. Call for Service - This image is shown anytime there is an active fault that requires a maintenance technician to correct the issue. Cool Down - This image is shown anytime the performance is reduced because of excessive over temperature. Accelerator & Brake - This image is shown anytime the traction is disabled due to the accelerator and brake pedals are depressed at the same time for more than 10 seconds. Starting Sequence - This image is shown if the key is turned while the throttle is depressed and/or direction is out of neutral. It will also be shown if the key is turned and the seat switch is disengaged (optional).

When an error is indicated, inform a designated service shop of the error code and the message.

If the warning indication still remains after a while, immediately contact a designated service shop.

- 22 -

Handling of Each Device

■ How to Set Various Modes 1. Hour Meter, Odometer Pressing the DOWN Arrow for less than 2 seconds in the normal display mode shifts the indication sequentially as shown below. • Hour meter – Total Operating Hours: TOTAL HOURS • Hour meter - Total Load Handling hours: HYD HOURS • Hour meter – Total Travel Hours: TRAVEL HOURS • Odometer – Total Travel Distance: ODOMETER • Odometer - Trip Travel Distance: TRIP ODO • Hour meter – Key ON hours: KEYSW HOURS If the DOWN Arrow is held for more than 2 seconds while the trip odometer is displayed, the trip odometer will be reset.

- 23 -

6

6

Handling of Each Device

2. Speed Limit Setting Pressing the UP Arrow switches the speed limit modes • When the rabbit icon is displayed, the truck is in maximum speed limit mode using the value set in the Truck Speed Limit (TRUCK SPD LMT) setting. • When the turtle icon is displayed, the truck is in speed limit mode using the value set in the Speed Limit Mode (SPEED LMT MODE) setting.

3. Power Mode Setting Respective settings for travel and load handling can be switched at a time in accordance with the work level. Pressing the Mode button for less than 5 seconds changes the power mode indication as follows:

- 24 -

Handling of Each Device

6

 :Level 1 Energy saving mode  :Level 2 Standard mode  :Level 3 Power mode HYPER: Hyper mode A high-power mode with a speed equivalent to engine-driven vehicles MY MODE: My mode A mode in which the operator can set desired items in the operator set mode described on the following page.

• When Level 3 (power mode) and/or HYPER (hyper mode) are used, the work speed increases, but the operating time decreases. If these modes are not necessary, it is recommended to use the forklift truck in Level 1 (energy saving mode) or Level 2 (standard mode). • Travel acceleration and load handling acceleration levels are properly set in accordance with respective set levels. (For detail, see the Operator Set Mode in the following.) 4. Operator Set Mode Pressing the Mode button for 5 seconds enables the user to set desired travel or load handling characteristics. Each pressing of the Mode button changes the screen to the following set screens. a. Exit Menu b. Speed Limit Mode c. MY MODE Acceleration Rate d. Lift Speed e. Tilt Speed f. MY MODE Hydraulic Acceleration g. LCD Contrast h. Password Entry Enable The Operator Menu adjustment will display ‘—‘ in place of the numeric value if the setting is not available to the user. a. Exit Menu Select this to exit the Operator Set Mode

- 25 -

6

Handling of Each Device

b. Speed Limit Mode This setting is used to set the maximum vehicle traction speed while in Speed Limit mode (turtle) up to but not above the Truck Speed Limit (TRUCK SPD LMT) setting. Speed is set in 1 KPH increments. Minimum Setting = 04 KPH Maximum Setting = 20 KPH

This setting is effective only while the traveling speed limit function is activated (tortoise mark displayed). (See “Speed Limit Settings” on page 24.) c. MY MODE Acceleration Rate This setting is used to set the maximum allowable traction acceleration rate for the vehicle while operating in MY MODE. Settings are available from 1 to 10 in increments of 1 where: Setting of 1 = Lowest Acceleration Setting of 10 = Highest Acceleration d. Lift Speed This setting is used to set the maximum allowable speed for the hydraulic motor when lifting. Settings are available from 1 to 10 in steps of 1 where: Setting of 1 = Slowest Speed Setting of 10 = Fastest Speed e. Tilt Speed This setting is used to set the maximum allowable motor RPM when the Tilt Switch is activated. Settings are available from 1 to 10 in steps of 1 where: Setting of 1 = Slowest Speed Setting of 10 = Fastest Speed

- 26 -

Handling of Each Device f. MY MODE Hydraulic Acceleration This setting is used to set the maximum allowable hydraulic acceleration rate for the vehicle while operating in ‘MY MODE’ Settings are available from 1 to 10 in steps of 1 where: Setting of 1= Lowest Acceleration Setting of 10 = Highest Acceleration g. LCD Contrast This setting adjusts the LCD contrast for the display. Settings are available from 96 to 127 in steps of 1 where: Setting of 96 = lightest contrast setting Setting of 127 = darkest contrast setting h. This setting is used to enable/disable the operator password function. A setting of ‘ON’ enables the feature A setting of ‘OFF’ disables the feature Password Entry Enable If passwords are enabled, the user cannot set the PW ENTRY to off. If passwords are disabled, the operator can turn the PW ENTRY to on.

5. Initial Set Values The standard values set at the factory shipment are as follows: a. Speed Limit Mode: 7 b. MY MODE Acceleration Rate: 5 c. Lift Speed: 8 d. Tilt Speed: 4 e. MY MODE Hydraulic Acceleration: 6 f. LCD Contrast: 100 g. Password Entry Enable: ‘ON’

- 27 -

6

6

Handling of Each Device

For changing values other than those shown here (including brake feeling and attachment spread), consult a designated service shop.

■ Levers 1. Shift Lever (Option) The shift lever is used for switching between forward and backward moves. When the lever is pushed forward and the accelerator pedal is pressed, the forklift truck moves forward. When the lever is pushed backward and the accelerator pedal is pressed, the truck moves backward. When the lever is pushed to the opposite direction during traveling, the electric motor is used to slow the movement. After the vehicle stops once, it begins to move in the opposite direction.

Turning the key switch “ON” does not make the forklift truck move, if the shift lever is not in the neutral position or the accelerator pedal is being pressed. The Chinese message and corresponding English message “Starting Sequence” appears on the display. Set the lever to the neutral position once and release the accelerator pedal. Then the message disappears and the vehicle is ready to move. 2. Parking brake lever This brake is used for parking the vehicle. Pull this brake up to the maximum when parking. Also by turning the grip, the braking response can be adjusted. (For how to adjust, read the descriptions on page 71)

- 28 -

Handling of Each Device

6

• When using the parking brake, pull the lever while pressing the brake pedal. This will make the parking brake operation lighter. • Always pull the lever when parking or stopping. 3. Lift lever Pull this lever toward you to lift the fork upward. Push it forward to lower it. Adjust the rising/lowering speed with the lever tilting degree. The maximum lowering speed is maintained at a constant speed by the flow regulator valve. 4. Tilt lever Pull this lever toward you to tilt the mast backward. Push it forward to tilt the mast forward. Adjust the forward/ backward tilting speed with the lever tilting degree. A built-in tilt-lock device is provided to prevent the mast from tilting forward when the key switch is “OFF”. 5. Direction indicator lever Push this lever forward to flash the left turn signal light, and pull backward to flash the right turn signal light. This lever is used to indicate the vehicle turning direction.

- 29 -

6

Handling of Each Device

6. Steering wheel tilt lever Tilting of the steering wheel can be adjusted in four steps from front to back. a. The front/back position of the steering wheel can be adjusted by raising the lever left to the steering column (lock release). b. Release the lever at a desired position to lock the steering wheel there (positive locking). c. After the adjustment, check that the steering wheel position is locked.

Do not adjust the steering wheel position when the vehicle is moving. Adjustment must be done when the vehicle is stopped. 7. Disconnect lever This lever is equipped to disconnect the battery plug from the plug on the body. Tilt the lever backward to disconnect the plug. To reconnect the plug, connect the battery plug by hand.

• Connect the battery plug securely. Improper connection may cause a fault. • Always disconnect the battery plug before checking the electrical system. • When any abnormality has occurred during operation and the battery plug has to be disconnected, promptly tilt the lever backward to shut off the power from the battery. • Do not touch this lever during operation except for an emergency. Otherwise, this may cause faults in the electrical system. • If this lever is operated during travel, the power steering will be disabled, making the steering wheel heavier.

- 30 -

Handling of Each Device

6

8. Control valve tilt lever This lever is used to tilt the control valve lever forward or backward. Tilt the lever backward when getting on and off from right-hand side. And tilt forward when open the cover battery. To tilt the control valve lever, pull up this lever first, and tilt forward or backward.

Lower the fork onto the floor and turn off the key switch before operating this control valve tilt lever.

■ Pedals 1. MONOTROL® Pedal The MONOTROL® pedal is used for both forward and backward movement of the forklift truck. When the left half of the pedal is pressed (indicated by a forward facing arrow) the forklift truck moves forward. When the right half of the pedal is pressed (indicated by a backward facing arrow) the forklift truck moves backward. When the pedal is pressed to the opposite direction during traveling, the electric motor is used to slow the movement. After the vehicle stops once, it begins to move in the opposite direction. 2. Brake pedal Press the brake pedal to brake the vehicle. While the pedal is pressed, the brake lamps light up. 3. Accelerator pedal (option) Slowly pressing the accelerator pedal starts the drive motor and the vehicle starts moving. Continuously variable speed can be adjusted by the degree of force applied to the pedal.

- 31 -

6

Handling of Each Device

• Stopping distance increases when traveling on a down slope or wet surface. Always provide an allowance when braking to avoid a sudden stop. • Do not depress the brake pedal and the accelerator pedal simultaneously to prevent overload on the drive motor. • When depressing the brake and accelerator pedals continues for a long time, a warning message “ACCEL AND BRK” appears together with warning sound.

■ Light Switch (48V truck: Standard). Rotate Light Switch to turn lights on.

■ Steering Wheel To steer the vehicle, hold the sub-handle knob with your left hand. When advancing, turn the steering wheel in the same direction as the turning direction. When backing, turn the steering wheel in the opposite direction of the turning direction. The vehicle is provided with power steering system which makes light turn operation possible. To sound horn, press the horn button at the center of the steering wheel.

It is quite dangerous to make a sharp steering during travel. This may cause the load to fall and the vehicle to tip over. Always slow down and turn the steering wheel slowly.

- 32 -

Handling of Each Device

■ Standard Seat The seat position is adjustable 140mm in the front/back direction. Adjust it to an easy-to-drive position. By pulling the seat position adjustment lever upward, the seat lock is released and the seat position can be adjusted.

■ Suspension Seat (Optional) The seat position is adjustable 140mm in the front/ back direction. By pulling the seat position adjustment lever upward, the seat lock is released and the seat position can be adjusted. Also seat cushion can be adjusted with the knob at the front right of the seat according to the operator’s weight (50 to 120kg).

Adjust the seat position with the key “OFF”. After adjustment, return the seat position adjustment lever and check that the seat is securely locked.

- 33 -

6

6

Handling of Each Device

■ Forks The forks can be moved to a desired position by pulling out the upper anchor pin. Always fix the right and left forks so that they are symmetrical to the center of the chassis. Be careful so that the load is not eccentric (unbalanced). After moving the fork, securely insert the anchor pin in the fork carriage groove to lock movement.

To make this operation easier, control the tilt lever to make a forward tilting state.

• Adjust the fork position according to the size of load to be handled. • Do not hold the fork when moving the fork. This may cause your fingers to be caught. Push and slide the fork from behind.

- 34 -

How to Drive

■ Before Driving Before getting into the operator’s seat, carry out the pre-operation checking described in Section 12. Never fail to carry out this checking for your safety even when in a hurry. 1. Make sure that the battery charging cord power plug is disconnected from the charger and that the vehicle is in operable state. Securely lock the cover lock at the front of the battery cover. 2. Get into the operator's seat and turn the key switch “ON”. Is the battery charged fully? Check the battery capacity gauge.

Always operate the key switch from the operator’s seat.

■ Starting and Traveling 1. Always fasten the seat belt. 2. Check the surrounding safety before starting. 3. Lift the forks approx. 15 to 20cm from the ground, and fully tilt the mast backward. 4. (If equipped with standard accelerator pedal) While depressing the brake pedal, put the shift lever to the forward or backward position. 5. Release the parking brake and release the brake pedal. Then slowly push the right side of MONOTROL® pedal for Reverse and the left side of MONOTROL® pedal for Forward motion. The vehicle will start to move smoothly. 6. Traveling speed can be changed by adjusting the pressure onto the accelerator pedal.

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7

7

How to Drive

• The rear-wheel power steering is adopted, so the vehicle can be easily steered by turning the steering wheel. Take care not to turn the steering wheel suddenly during travel. • Do not turn the key switch “OFF” during travel. If the key switch is turned “OFF” during travel, the steering wheel will become heavy.

Securely put the shift lever into the forward or reverse position. Pay attention to the following points during travel for safe operation.

• Remain focused during operation. Always pay attention to pedestrians, workers and obstacles in the area. • Lower the speed and confirm the surrounding safety when traveling in places where the field of vision is poor. Do not pass other vehicles. • When traveling down a slope, decelerate the vehicle speed sufficiently while applying the brake. And when carrying a load, travel in the backward direction. When there is no load, travel in the forward direction. • When going up a sharp slope, take care so that the end of the fork or the base of the pallet will not contact the ground. And when carrying a load, go forward. When there is no load, go backward.

■ Plug Braking If the opposite direction on the MONOTROL® pedal is pressed during travel, electric motor braking will be activated. The vehicle will stop once and then will start smoothly in the opposite direction.

Do not apply excessive pressure on the MONOTROL® pedal. This may cause sudden braking. Be careful that plug braking does not work if there is no pressure on the MONOTROL® pedal. Adjusting the braking settings can affect electric motor braking performance.

- 36 -

How to Drive

7

■ Temporary Stop and Parking 1. When stopping the forklift truck, release your foot from the accelerator pedal and press the brake pedal to slow down. 2. When parking, lower the fork to the ground or floor surface, tilt the mast forward, put on the parking brake, and then put the shift lever into neutral. 3. When leaving the truck, turn the key switch “OFF” and remove the key without fail.

• Always park at a designated place. • Do not park on a slope. If parking on a slope is unavoidable, securely chock the tires. • Park the vehicle in a safe place where traffic will not be obstructed. Install a cautionary sign, signal light or fences as required near the parking place. • Select sufficiently hard surface for parking, and make sure that the tires will not slip or sink into the ground. • Always lower the forks to the ground. If the forks cannot be lowered because of a fault or other reasons, wrap the fork ends with cloth or the like, and park in a place with the forks facing a direction where persons and vehicles will not pass. • Get off the vehicle after it has completely stopped while facing its direction. • Never jump off the vehicle because it is dangerous.

■ After Operation After operating the vehicle, always carry out the post-operation checking (see Section 13). Do not forget to charge the battery.

- 37 -

8

Vehicle Structure and Stability

To safely operate the forklift truck, it is essential to understand the structure and stability of the vehicle.

■ Load and Vehicle Stability The forklift truck stability is like that of a seesaw, where stacked load and rear tire load are balanced while the front tire works like the fulcrum of a seesaw. If the load center of the stack is far from the front tires, the stackable load weight will decrease. Thus, always take care of the load center to keep the balance. If a load exceeding the balance is stacked, safe work will be obstructed.

■ Center of Gravity Position and Stability The stability of the forklift truck is determined by the composite center of gravity position of the vehicle’s and the load’s center of gravity. When there is no load, only the vehicle’s center of gravity is used, and when a load is stacked, the composite center of gravity of the vehicle and load will be used. Since the load center of gravity varies according to the mast tilting (forward or backward) and the mast up/down position, the composite center of gravity will also change.

- 38 -

Vehicle Structure and Stability

8

■ Range of Center of Gravity Stability For vehicle stability, the composite center of gravity position must be within the stability range created by left and right front tire grounding points and rear wheel suspension pin point (triangular zone). If the composite center of gravity position is ahead the front tires, the vehicle is tilted forward with the front tires as a fulcrum. If the composite center of gravity position moves outside the stability range of center of gravity, the vehicle will tilt in the direction of the movement.

■ Reference Load Center and Capacity Chart Load Capacity Table is affixed at the operator’s seat. Observe the allowable load for safe operation. The Load Capacity Table shown here is an example. ① Allowable load: Stackable load limit ② Load center: The distance from the vertical front surface of the fork to the center of gravity of the load on the fork. ③ Maximum fork height

If a load exceeding the load capacity specified in the Load Capacity Table is stacked, the rear tires may float during travel and the steering may not function creating a very dangerous state. The risk of tipping over will also increase. Always observe the allowable load limit when stacking.

- 39 -

9

Load Handling

■ Picking up Load from The Ground When picking up loads from the ground or floor, observe the following procedure: 1. Decelerate the vehicle to a safe speed when approaching the load to be carried. 2. Stop the vehicle once in front of the load. 3. Tilt the mast forward to the vertical position, and direct the forklift truck straight toward the load. Confirm the fork insertion position, slowly advance, and insert the forks into the pallet completely.

• Always keep the forks parallel to the pallet and insert them completely while taking care not to brush against the pallet. • Do not lift the forks with the forks tilted forward. • Do not insert the forks roughly into the pallet. 4. Lift the load 5 to 10cm and make sure that the load is stable.

Keep the load height up to the back rest height. Do not carry loads if they are raised higher than the back rest.

5. Hold the load in contact with the back rest, lift the forks 15 to 20cm above the ground, and tilt the mast backward to the maximum.

- 40 -

Load Handling

9

Do not place a weight on the rear of the vehicle, which will exceed the allowable limit. (See the Load Capacity Table.)

• Never travel, turn or tilt the forks forward with load lifted, because the load becomes unstable and the vehicle may tip over. • If the load blocks the front view, travel backward.

■ Destacking from High Place When destacking loads from a high place, observe the following procedure: 1. Decelerate the vehicle to a safe speed when approaching the load to be destacked. 2. Stop the vehicle once in front of the load. 3. Tilt the mast forward to the vertical position, and direct the forklift truck straight toward the load. Confirm the fork insertion position, slowly advance, and insert the forks into the pallet completely.

Always keep the forks parallel to the pallet and insert them completely while taking care not to brush against the pallet. 4. Lift the load 5 to 10cm, retract 10 to 20cm, and then lower the load once. 5. Insert the forks fully again, lift the load 5 to 10cm, slowly back away, and then lower the load to a safe height.

- 41 -

9

Load Handling

If the forks are slanted forward while the load is lifted, tilt the mast backward to maintain load stability. 6. Lower the forks to 15 to 20cm from the ground, fully tilt the mast backward, and travel to the destination.

■ Unloading 1. Decelerate the vehicle speed to a safe level when the vehicle comes near the destination. 2. Stop the vehicle once in front of the unloading place.

When stacking onto a shelf, carefully operate so as not to hit the shelf. 3. Set the mast to the vertical position and lift the load to a position slightly higher than the unloading level. 4. Confirm the stacking position, and slowly lower the forks. 5. Gently pull out the forks so as not to drag the load.

- 42 -

Exchanging of Battery

10

■ Exchanging The Battery Using a Hoist 1. Turn the key switch “OFF” and push the control valve tilt lever forward to tilt the hydraulic levers forward. 2. Release the cover lock and open the battery cover. 3. Remove the side door and valve cover. 4. Disconnect the battery plug. 5. Remove the stopper pin on the right rear side (1.50–1.75-ton trucks: left rear). 6. Put the shackles into the battery case holes (4 places). 7. Slowly hoist the battery and put it on a flat surface. 8. Put the shackles into the battery case holes of a new battery. 9. Slowly hoist the new battery and put it in the truck body. 10.Attach the stopper pin on the right rear side (1.50–1.75-ton trucks: left rear). 11.Connect the battery plug. 12.Attach the side door and valve cover. 13.Close the battery cover and lock it securely. 14.Tilt hydraulic levers back. 15.Return the steering wheel tilt lever to the previous position.

- 43 -

10

Exchanging of Battery

• Always remount the battery on a flat surface with no load on the vehicle. • Make sure that all the caps are tight so that the electrolyte will not spill, then slowly hoist the battery. • The battery must be hoisted by an operator who has completed sling and hoist skill training. • When hoisting the battery, do not hit it against the vehicle body, etc. • Use a sufficiently strong wire rope with no damage. • Pay attention so that the wire rope does not tangle with the overhead guard, etc. • The battery weight is given below. Use a hoist, wire rope, and hooks that are sufficiently strong. 1.5–1.75 ton 2.0 ton 1.5–1.75 ton 2.0–2.5 ton 1.5–2.5 ton 2.0–2.5 ton

48V 48V 48V 48V 48V 48V

390Ah 440Ah 525Ah 565Ah 700Ah 725Ah

. . . . . . . . . . . . . . . . . 685kg . . . . . . . . . . . . . . . . . ·805kg . . . . . . . . . . . . . . . . . 840kg . . . . . . . . . . . . . . . . · 1085kg . . . . . . . . . . . . . . . . ·1180kg . . . . . . . . . . . . . . . . ·1600kg

After the battery is remounted, attach the stopper pin on the rear side of the battery and securely lock the battery cover without fail.

• Connect the battery plug securely. Improper insertion may cause failures in electrical parts. • When remounting the battery, do not twist the battery cable.

- 44 -

How to Use the Battery

■ How to Use The Battery 1. Do not overdischarge the battery. If the battery power is used until the vehicle no longer moves, the life of battery will be shortened. Charge the battery immediately when the bottom bar of the battery discharge indicator lights.

2. Do not run out of electrolyte. When the battery is charged, only the water content of the electrolyte (dilute sulfuric acid) is consumed. Before charging, always replenish water to the adequate electrolyte level (electrolyte level check). In addition, about the VCH type battery, please replenish water after charging. VCH type battery (Only 72V battery for premium models)

Model 1-2.5 ton

Battery capacity 320AH, 360AH, 465AH, 525AH, 600AH

• Electrolyte level drop due to missing water supply may result in short life, overheating and burning of the battery. • If the electrolyte overflows, be sure to wipe it off thoroughly. Otherwise, overheating or explosion due to short-circuiting may occur. • Before cleaning the battery, disconnect the power plug without fail.

Always use distilled water or purified water for replenishment. 3. Keep the battery clean. The top surface and connectors of the battery should be clean and dry. Tighten the fluid plugs securely.

• Before starting inspection, disconnect the power plug without fail. • Wear insulating protectors such as rubber gloves during inspection for protection from electric shock. • Never sprinkle water on the battery plug. - 45 -

11

11

How to Use the Battery

Do not clean the battery with dry cloth or fabricated fiber cloth or by dusting it. Doing so may cause static electricity and may lead to an explosion. Always use moist cloth. 4. Keep the battery away from fire. Never let fire come close to the battery any time because explosive gas is generated from the battery. 5. Do not overcharge the battery. Always charge the battery following the charger handling procedure. 6. Handling during winter time The freezing temperature of the electrolyte is approx. 35°C when the battery is fully charged. The specific gravity of the electrolyte when fully charged is 1.280 (at 20°C). Since the electrolyte is easier to freeze when its specific gravity drops after discharging. Therefore, keep a good charge condition. Especially, when it is very cold, remove the battery plugs and cover the battery or take other warming measures to prevent discharging. 7. Handling during summer time Since water content of the electrolyte is likely to evaporate during summer time, check the electrolyte level frequently and replenish distilled water as specified. Note that overfilling will lead to overflow of the electrolyte during operation, which may cause corrosion or electrical leak.

- 46 -

How to Use the Battery

11

■ Bulk Water Replenisher (Optional; GS Yuasa Corporation Product) 1. Structure a. As shown in an example below, this device has a structure that connects the fluid plug of each cell using a tube and replenishes distilled water from the water supply port to each cell for each group.

b. As shown in the figure on the right, each fluid plug is equipped with a valve interocked with the float. When water is replenished to the electrolyte level limit, the water supply port is closed to stop water replenishment. c. As shown in the figure, each fluid plug is equipped with a visible fluid level indication bar. d. Gas and acid fog generated in the battery is individually exhausted from each fluid plug. The generated gas and acid fog do not enter the tube. e. Each fluid plug is also equipped with a measuring port for measuring the specific gravity of the electrolyte and battery temperature. 2. Handling a. Electrolyte level check cycle. Water content in the electrolyte decreases due to water decomposition during charging and natural evaporation. If the battery is used with the electrolyte extremely decreased, electrode plate degradation will occur and the battery life is shortened substantially. Furthermore, this may cause explosion or burning of the battery, so check the electrolyte level once a week without fail. b. Check method. The electrolyte level can be checked by horizontally viewing the top of the level indicator bar (red) in the fluid plug. When the level is very low and the top of the bar is invisible or in a similar state, replenish distilled water following the method below. If even one cell shows the lowest level when checking, replenish water.

- 47 -

11

How to Use the Battery

c. Water replenishing method ○ Fill the water supply tank with distilled water. When small volume of distilled water is in the tank, the water pressure drops. Be careful so that the liquid level in the tank will not be lower than 10cm during replenishing. ○ As shown in the figure, adjust the water supply tank position so that the bottom of the water supply tank comes 50 to 100cm above the top of the cell lid. If the water supply tank position is outside the range, the water stop ability of the fluid plug will drop and the electrolyte will overflow. ○ Shake the hose gently to bleed air. Open the cock, make sure that distilled water gushes, and then close the valve. ○ Remove the brown cap attached to the fluid plug of the cell. Then, insert the water supply connector of the water supply tank into the fluid plug. ○ Open the cock of the water supply connector and start water supply. Be sure to open the cock to the maximum. ○ During water replenishing, do not touch the level indicator bar.

- 48 -

How to Use the Battery

11

○ When water is replenished, the red level indicator bar of each fluid plug rises. Keep watching while water is replenished. When the level indicator bars of all cells rise as shown in the figure, water supply is completed. (It takes about 1 to 2 minutes from the start of water replenishing.) Immediately close the cock of the water supply tank to stop water replenishing. If the battery is left for a long time, over-replenishing (overflow) may occur. ○ Pull the movable ring on the water supply connector of the water supply tank to disconnect the fluid plug of the cell from the water supply connector. Attach the brown cap on the water supply port as before. ○ Check rising of the level indicator bars of all cells. Confirm that water was normally replenished into all cells. If there is no problem, the water replenishment is completed. 3. Other handling. a. Measurement of the specific gravity of the electrolyte and battery temperature. ○ When you open the lid of the fluid plug, you can see a measuring opening as shown in the figure. The specific gravity and battery temperature can be measured by using the general suction gravimeter and bar thermometer. ○ When measurement is completed, securely close the lid of the fluid plug. b. Precautions when using battery in low-temperature ambiance. Since a water sealing chamber is provided in the fluid plug, water in the chamber may be frozen if the battery is used in a low-temperature ambiance below 0°C. If the water in the chamber is frozen, bulk replenishing is impossible. Therefore, move the battery into a high-temperature ambiance (15 - 40°C). After melting, carry out water replenishment. c. Other precautions ○ Do not remove any fluid plug from the cell. In case a fluid plug has to be removed from the cell, detach the water supply tube from the fluid plug, turn the adapter, and remove the fluid plug together with the adapter. ○ Do not get on the water supply equipment. - 49 -

11

How to Use the Battery

○ This device can be used for 2 to 4 years in the standard operation state. Since functional degradation will adversely affect the life of the battery, it is recommended to replace the equipment every 2 years. If the equipment used under heavy conditions, its filter may not function well early.

- 50 -

Pre-Operation Inspection

12

■ Pre-operation Inspection To maintain safe work and vehicle performance, it is required for operators to check the vehicle before starting daily work. This is a lawful requirement. If any abnormality is found during inspection, contact a designated service shop.

• Even small defects can lead to major accidents. If even a slight abnormality is found, do not operate the forklift truck until the defect is completely corrected. • Carry out the inspection at a flat place. The table below summarizes items to be checked. NO. 1

5

Check item Abnormality found on the previous day Oil leak from gear cases, cylinders and hoses Lubrication to specified positions Damage, wear and air pressure of tires Loose hub nuts

6 7

Abnormal sound Accelerator pedal operation

16 17

8 9

Brake pedal operation Brake fluid level

18 19

10

Parking brake performance

2

4

12

Mast

Overall

3

NO. 11

13 14 15

Gauges

Main body

20 Battery

- 51 -

21

Check item Damage and operation of mast Damage of back rest and overhead guard Installation of forks and attachment Chain tension Looseness of tilt cylinder rod Hydraulic fluid level Operation of direction indicator Operation of horn Operations of lamps and gauges/meters Dirt and angle adjustment of rear-view mirror Secure connection of battery plug

12

Pre-Operation Inspection

Before getting on the forklift truck, conduct inspection in the following procedure to make it efficient.

When carrying out checking or maintenance, park the forklift truck at a solid and level place. Lower the forks to the ground, turn the key “OFF”, put all the operation levers to neutral, and then pull the parking brake.

1. Entire body Check the whole forklift truck. a. Check for excessive damage of the body. b. Check the ground and inside the body for oil leak and water leak.

2. Tires and hub nuts a. Measure air pressure using a tire pressure gauge. Adjust the air pressure to the specified value.

If the air pressures of the left and right tires are not balanced, the balance and lateral stability of the vehicle will deteriorate, which may cause the operator to lose steering control.

- 52 -

Pre-Operation Inspection Tire air pressure table Front wheel Rear wheel

Single

1.5 ton 850kPa (8.5kgf/ cm2) 700kPa (7.0kgf/ cm2)

1.75 ton 625kPa (6.25kgf/ cm2) 900kPa (9.0kgf/ cm2)

2–2.5 ton 900kPa (9.0kgf/ cm2) 700kPa (7.0kgf/ cm2)

b. Check for loose hub nuts. If loose, tighten hub nuts uniformly.

For the reference hub nut tightening torque, see the table on page 74. c. Check tires for damage, cracks and abnormal wear. d. Check wheels for damage and warp. 3. Lamps (If equipped) Check the lenses of lamps for damage and dirt. 4. Rear-view mirror (If equipped) Check the rear view mirror for damage and dirt. Adjust the mirror angle to provide good rear view.

- 53 -

12

12

Pre-Operation Inspection

5. Load handling equipment a. Check the mast for strain, biting and cracks. b. Check the chains for lubrication. c. Check that the fork anchor pin is firmly engaged with the notched portion in the fork carriage. d. Check that the right and left chain tensions are even.

If the tensions of the right and left chains are not even, adjust the tensions using the anchor bolt nut. 6. Back rest and overhead guard a. Check the back rest and overhead guard for deformations and cracks. b. Check for loose bolts and nuts.

- 54 -

Pre-Operation Inspection 7. Hydraulic oil With the forks lowered to the lowest position, pull out the level gauge, clean it with clean cloth, and insert it to the original position. Then slowly pull out the gauge again and measure the hydraulic fluid level. When the level is between H and L of the level gauge, the level is adequate. If the oil is contaminated, change it.

• Always check the hydraulic fluid at a flat place. • Completely wipe off any spoiled oil.

The periodic replacement cycle of hydraulic oil is 6 months. Clean the oil suction strainer and replace the oil return filter element every 6 months. 8. Brake fluid Check whether the brake fluid level is within the specified range. Always keep the brake fluid level filled to the level line. If the brake fluid is contaminated, change it.

The periodical change cycle of brake fluid is 6 months.

- 55 -

12

12

Pre-Operation Inspection

• When replenishing brake fluid, prevent any foreign matter from falling through the oil inlet. • Always keep the cap clean to prevent the ventilation hole from clogging. • Always use genuine brake fluid. Mixing different types of brake fluid may deteriorate brake performance. • If the brake fluid level decreases quickly, there is a leak somewhere. Contact a designated service shop. On-vehicle inspection. Now you may get into the vehicle. 9. Seat adjustment and seat belt checking Adjust the seat to the best operating position. Check the seat for damage and installation looseness.

• Check the seat belt for damage and secure fastening. • Check that the battery cover is securely locked.

- 56 -

Pre-Operation Inspection

12

10.Brake pedal a. While depressing the brake pedal, check for snagging or abnormal resistance. b. Check that the pedal height is the specified value. c. Check that the pedal play is within the specified range while pressing the pedal by hand until you feel a resistance.

If the pedal play is large, pedal movement is abnormal or the brakes do not work well, consult a designated service shop for inspection and repair. 11.Accelerator pedal. Check that the accelerator pedal moves smoothly when it is pressed and then released. 12.Parking brake. a. Check that the brake securely works when the parking brake lever is pulled, and that the brake is released when the lever is returned. Push the release button to release the lever. b. Check the lever operating force when the lever is pulled to the maximum. Lever operating force: 1.5–2.5 ton 200 to 250 N (20 to 25kgf) If the operating force is not within the specified range, adjust the brake. (See page 71 for adjustment method.) 13.Confirm that the shift lever is in neutral and then turn the key switch “ON”.

- 57 -

12

Pre-Operation Inspection

14.Display and safety parts a. Check that the display panel lights up when the key switch is turned “ON”. (See page 17.) b. Check that the hour meter functions correctly. c. Check the display for damage and dirt.

15.Lights Check that the front light, direction indicator light, brake light, tail light and backup light turn on when respective switches are turned on. 16.Horn Press the horn button and check that the horn sounds. 17.Load handling equipment a. Slowly move the forks from the lowest level to the maximum height 3 times, and check that the forks and mast move smoothly with no creak. b. Slowly move the mast back and forth 3 times, and check that the mast moves smoothly with no difference between right and left movements.

If there is any difference between right and left movements of the mast, check for looseness of the tilt cylinder rod and, if necessary, adjust the rod. Inspection during slow travel When no abnormalities are found in the above inspections, move the vehicle slowly. Do not travel fast. 18.Brakes a. Depress the brake pedal and check that the brake works normally and evenly on right and left tires. b. Pull on the parking brake lever and check that the vehicle stops and can keep the stop position.

Any abnormality in the brake system is very dangerous. If any abnormality is found, consult a designated service shop for inspection and repair. - 58 -

Pre-Operation Inspection

12

19.Steering wheel a. Set the rear wheels in the straight travel state, and check the play of the steering wheel. Play amount: 20 to 60mm b. Operate the steering wheel and confirm that it works smoothly. c. Move the steering wheel up and down and check for looseness. 20.Abnormal noise a. Check that the drive motor is generating no abnormal sound. b. Check that both pump and pump motor are generating no abnormal sound. c. Check that electrical parts are generating no abnormal sound.

If you hear abnormal sound, do not operate the forklift truck until the defect is completely rectified. Forklift truck operation shall not be started unless all the above check results are normal.

- 59 -

13

Post-Operation Inspection and Storage

■ Post-operation Inspection After work clean the outside and inside of the vehicle and check the following: 1. 2. 3. 4. 5.

Check any abnormal points found during operation. Check for visible damage and missing bolts. Check for fluid leakage. Check tires for abnormalities. Check bolts and hydraulic piping for looseness.

• Repair defects, if any, on the same day. • Always make the forklift truck ready to operate at any time.

■ Daily Storage 1. 2. 3. 4. 5.

Park at a dry and flat place. Pull on the parking brake without fail. Tilt the mast to the vertical position and lower the fork to the ground. Turn the key switch OFF and remove the key. Move the lift lever and tilt lever back and forth 3 or 4 times to release the pressure remaining in the cylinder piping.

■ Long-term Storage Pay attention to the following points in addition to those above when storing the forklift truck for a long time: 1. Disconnect the battery plug to prevent discharge and store the vehicle in a dark place. 2. Apply anti-rust grease to shafts, rods and other exposed parts. 3. Cover the breather and other openings where moisture may enter. 4. Cover the entire vehicle with a sheet or the like. 5. Lubricate all lubrication points. 6. Set air pressures of all tires to the specified value (for vehicles with pneumatic tires only). 7. Make the vehicle ready to operate at least once a week and check all operations. 8. Measure the specific gravity and level of the battery electrolyte at least once a month. Charge the battery or replenish water as required.

- 60 -

Periodic Inspection

14

■ Periodic Inspection and Servicing Complete periodic inspection prevents malfunctions and lengthens the life of your forklift truck. The periods given in this section apply for standard use, and differ according to usage conditions. Service your forklift truck according to the usage conditions. Precautions for inspection and servicing

• • • • • • • • •

• •

•

Always use the genuine parts for the replacement parts. Always use the genuine oil and grease. Park the forklift truck at a rigid and flat place. When conducting inspection indoor, make the place well ventilated. When working with other person(s), confirm each step with signals. Always use proper tools. Never use makeshift tools. Wear protective gear (helmet, safety boots, goggles, gloves, etc.). Lower the fork to the ground before starting inspection. Confirm that all operation levers are in neutral. When inspecting under lifted forks is required, place and fasten a wood block or the like between forks, mast inner frame and ground or floor so that the forks or mast inner frame will not drop. Do not place your foot under the fork. If even a slight abnormality is found through the inspection, report it to the supervisor, and never operate the vehicle until the defect is completely rectified. Improper disposal (in drainage or ground, burning, etc.) of waste oil generated through the inspection may pollute the surrounding (water, soil or atmosphere). This may be banned by law.

■ Weekly Inspection (Every 50 Hours) Conduct the following weekly inspection every 50 hours in addition to the daily inspection. 1. Lubrication a. Clean the grease nipples and their peripheries with clean cloth, and apply grease to the following points using a grease gun. Usable grease: Albania EP2

- 61 -

14

Periodic Inspection

Apply grease until it overflows and then wipe off the excess. b. Apply grease to the following points using a brush or the like. ○ Lift chains ○ Fork slide section ○ Mast roller sliding surface.

- 62 -

Periodic Inspection

14

• Wipe off old grease with clean cloth or the like. • If oil or grease gets on the operator's seat, hand rails or steps, wipe it off immediately. Failure to do so may cause the operator to slip and fall. c. Lubricate the following locations with machine oil using an oiler.

• After lubrication, wipe off any oil that leaks out. • Always use clean oil and grease as well as containers to prevent dusts from entering.

2. Battery Daily handling and management of battery greatly affect its performance and life. Therefore, always conduct inspection and maintenance completely to keep the battery in the best condition.

Do not place a wrench or other metals on top of the battery.

- 63 -

14

Periodic Inspection

• Always wear protective goggles, rubber gloves and rubbersoled shoes during maintenance and inspection. Directly touching conductive parts may cause electric shock. • Remove static electricity from your body before inspection. • Disconnect the battery plug before checking the battery electrolyte level. • Replenish distilled water before charging. • If too much electrolyte is put in the battery, it will overflow during charging and lead to corrosion. a. Check whether the electrolyte is insufficient referring to the figure below. ○ Open the cap. When the white line of the red float drops, replenish water. ○ Replenish water until you see the white line.

- 64 -

Periodic Inspection

14

For the daily inspection, randomly select several cells to understand the conditions of all cells. Change the inspection batteries at least once a month. Always record and save the inspection results.

If the electrolyte continues to overflow during charging although its level was within the specified range before charging, the battery discharges too fast, the electrolyte temperature increases abnormally, or the electrolyte decrease is remarkable (in certain cells), contact a designated service shop. b. Check terminals for looseness. c. Check cells, terminals and cables for rusts, corrosion or cracks. d. Check whether the battery is dirty or not. If dirty, current leakage will occur. So, wash the battery with water and then dry by air blow or using clean moist cloth.

Measure the specific gravity and temperature of each cell using a hydrometer and thermometer. Convert the specific gravity to find the specific gravity at 20°C. When electrolyte temperature exceeds 20°C: The specific gravity when electrolyte temperature is 20°C = Measured specific gravity + @. For example, when the measured specific gravity is 1.260 (electrolyte temperature is 30°C), the specific gravity when electrolyte temperature is 20°C will be 1.267(1.260 + 0.007), because @ is 0.007 according to the table below.

- 65 -

14

Electrolyte temp. (°C) 21, 22 23 24 25, 26 27 28, 29 30

Periodic Inspection

@ 0.001 0.002 0.003 0.004 0.005 0.006 0.007

Electrolyte temp. (°C) 31, 32 33 34 35, 36 37 38, 39 40

@ 0.008 0.009 0.010 0.011 0.012 0.013 0.014

Electrolyte temp. (°C) 41, 42 43 44 45, 46 47 48, 49 50

@ 0.015 0.016 0.017 0.018 0.019 0.020 0.021

When electrolyte temperature is below 20°C: The specific gravity when electrolyte temperature is 20°C = Measured specific gravity– @. For example, when the measured specific gravity is 1.270 (electrolyte temperature is 10°C, the specific gravity when electrolyte temperature is 20°C will be 1.263 (1.270– 0.007), because @ is 0.007 according to the table below. Electrolyte temp. (°C) 0 1, 2 3 4, 5 6

@ 0.014 0.013 0.012 0.011 0.010

Electrolyte temp. (°C) 7 8, 9 10 11, 12 13

@ Electrolyte temp. (°C) 0.009 0.008 0.007 0.006 0.005

@ 14, 15 16 17 18, 19

0.004 0.003 0.002 0.001

e. Check that the specific gravity is 1.280±0.01 when fully charged at 20°C. If the charging is insufficient after the first charging, carry out supplementary charging. Specific gravity at the end of charging: 1.280 (20°C) Specific gravity when completely discharged: Approx. 1.150 (20°C) f. Check for unevenness in the specific gravity among cells. If the unevenness still remains or some cells have low specific gravity even after uniform charging, specific gravity adjustment or other necessary treatment is required. Contact a designated service shop. Precautions for handling battery electrolyte Pay sufficient attention when handling the battery electrolyte, because dilute sulfuric acid is used. If an accident occurs, immediately take the following first-aid measures, and have a medical specialist diagnose the problem. Failure to do so may cause burns or blindness.

- 66 -

Periodic Inspection

14

• If the electrolyte contacts your skin, immediately wash it off with plenty of water (tap water, etc.) and then wash well with soap. • If the electrolyte splashes into your eyes, immediately rinse affected eye with plenty of clean water for about 15 minutes. • If the electrolyte is taken orally, immediately gargle with plenty of clean water repeatedly. Then drink a large amount of milk or clean water and rest. • If the electrolyte contacts your work clothes, take off the clothes immediately. Wash them with water and then completely neutralize using low-alkaline soap solution. • If a large amount of electrolyte splashes around or flows out, immediately neutralize with an acid neutralizer (sodium bicarbonate, calcium hydroxide or carbonated soda, etc.) and then wash off with water.

■ Monthly Inspection (Every 200 Hours) a. Existence of abnormalities in the braking devices, clutches and steering equipment. b. Existence of abnormalities in the load handling equipment and hydraulic equipment. c. Existence of abnormalities in the overhead guard and pack rest. Also check the following during the monthly inspection. 1. Checking the differential gear oil and transmission. Pull out the oil level gauge and check the oil level. When it is insufficient, replenish oil. When the oil is contaminated, replace it.

Replace the oil for the first time after 6 months of use, and after that replace it every 12 months.

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14

Periodic Inspection

2. Checking the mast trunnion cap bolt Refer to the lubricant table (page 82). Bolt tightening torque. 1.5–1.75 ton

71–86N·m (729–875kgf·cm)

2–2.5 ton

176–212N·m (1,800–2,160kgf·cm)

3. Lubricating the trail axle link. Trail axle link. Refer to the lubricant table (page 82).

4. Lubricating the trail axle king pin. Refer to the lubricant table (page 82).

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Periodic Inspection 5. Lubricating the control valve lever

6. Checking the overhead guard Check the overhead guard and its installation section for loose screws and damage. 7. Checking the lift lever potentiometer and tilt lever switch Operate these levers to check: a. whether the potentiometer and switch functions correctly, and b. whether the hydraulic motor is rotating after the lever is put to neutral. 8. Cleaning electrical equipment and checking installation Disconnect the battery plug and then remove dust with compressed air.

Never use a steam cleaner.

Avoid all electrical parts from getting wet. This may cause failures and malfunctions. a. Check for loose plugging and wiring. b. Check for excessively worn contactor contacts. c. Check for loose bolts.

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14

15

Work Items

■ Opening/Closing the Battery Cover 1. Opening a. Slide the operator's seat back to the maximum. b. Release the cover lock at the front of battery cover and lift the cover. c. Open the cover fully and check that the gas damper is securely locked.

Do not set the battery cover free before confirming that the gas damper is securely locked.

2. Closing a. Press and release the lock while supporting the battery cover by hand. b. Close the cover slowly and lock the cover lock securely.

• When closing the battery cover, do not place your hand on the cover. Otherwise, your hand will be caught by the cover.

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Work Items

■ Adjusting The Parking Brake Lever Operating Force 1. Attach a spring gauge in the middle of the parking brake lever grip. While pulling the gauge, measure the operating force of the lever. 2. If the operating force is not within the specified range, release the parking brake and then adjust the brake lever. Turn clockwise: Operating force increases. Turn counterclockwise: Operating force decreases. Operating force: 1.5–2.5 ton ···· 200–250 N (20–25kgf)

■ How to Use Coupler Pin Use the coupler at the back of weight when the forklift can no longer move as the tire is caught in mud. The pin can also be used when loading the forklift truck into another truck.

Do not use the coupler pin for towing other vehicles or towing the forklift truck.

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15

15

Work Items

■ Changing Tires 1. Preparation a. Prepare tools, jack, stoppers and new tires. b. Remove load, move the vehicle to a level and rigid place, and pull on the parking brake. c. Put the stoppers on the tire diagonal to the one to be changed. 2. Setting the jack a. Changing front tires Set the jack underneath the mast bottom or hoist the upper part of the mast or use hydraulic equipment.

b. Changing rear tires Set the jack underneath the counterweight. 1.5-1.75 ton

3 tons or more

2-2.5 ton

5 tons or more

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Work Items

• Use a jack having a capacity higher than the specified capacity. • Put the jack up piece right on the jack seat underneath the counterweight. • Check that the mast trunnion bolt is tightened in normal state. • Use a sufficiently strong wire rope with no damage.

Never hoist the vehicle by hooking the overhead guard or frame. When the vehicle must be hoisted, consult a designated service shop. 3. Tire change a. Jack up until the tire is barely off the ground. b. For joint rim tire, completely bleed the air. c. Loosen the hub nuts. Do not remove the tire at this point.

• Check that the wheel joint bolt is not loose and then loosen the hub nuts. • Differentiate the hub nut from the wheel joint nut before starting work.

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15

15

Work Items

4. Jack up until the tire gets off the ground. Remove the hub nuts and the wheel.

Do not put any part of your body under the truck while jacking up. If the jack comes off, it is very dangerous.

• Remove load from the vehicle and put stoppers on the tire before jacking up. • Get off the operator's seat before jacking up. • After jacking up, put a wood block or the like to secure safety. • Ask a specialist for disassembling/reassembling a tire. 5. Mount a new tire and tighten nuts with hand as much as possible. The flat surface of the nut must be on the outside. Tighten the nut so that the tapered section of the wheel nut comes in contact uniformly with the seat of the rim. 6. Lower the jack and torque the hub nuts in the order shown below.

Hub nut tightening torque Model Front Single wheel Rear wheel

1.5-1.75 ton 2–2.5 ton 196–216N·m 196–216N·m (2,000–2,200kgf·cm) (2,000–2,200kgf·cm) 98–118N·m 114–136N·m (1,000–1,200kgf·cm) (1,160–1,390kgf·cm)

7. Checking tire air pressure (See page 53). After the tire is installed, check the air pressure and adjust to the specified value. The standard air pressure is indicated on the specification plate on the battery cover to the right of the operators seat. 8. After the tire change, run the vehicle for a short distance and then tighten the hub nuts again. - 74 -

Work Items

15

Cautions for tire disassembly and reassembly • Ask a specialist for disassembling/reassembling a tire, tube, rim, etc. and also for air pumping. Since the tire air pressure for the forklift truck is set to high, it is dangerous to adjust the tire air pressure. A certificate of special training is required for air pumping work. • Start pumping air into tires off the truck after checking tire, rim, bolts and nuts. Put the tire in a safe fence when pumping air. Never raise the air pressure over the standard value.

• Wear protective goggles when pumping air to protect your eyes from dusts when they are blown off by compressed air.

■ Replacing, Repairing Simple Parts If faults listed below occur during daily work, check the vehicle to identify the cause according to the check points shown below. If the cause is not clear, contact a designated service shop.

Always turn the key switch OFF and disconnect the battery plug before starting inspection. Problem The vehicle does not run.

The battery cannot be charged.

Check point • Check whether the control circuit fuse is blown. • Check whether the travel circuit fuse is blown. • Check whether the battery connection plug is loose. • Check whether the power circuit fuse is blown. • Check whether the charge cord plug is disconnected or loose. • Check whether the charger fuse is blown.

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15

Work Items

■ Replacing Bulb (If Equipped) When a lamp does not light up, the fuse may be blown or the lamp may be dead. Use the following procedure when replacing a bulb. 1. Turn the key switch “OFF”. 2. Remove the screw fixing the lens, and then the remove the lens. 3. Press the bulb lightly and turn it to remove it. Light name Front light Front direction indicator light Rear combination lamp

Capacity 48V·40W 48V·25W

Tail light/brake 48V·10W/20W light Rear direction indicator light

48V·25W

Backup light

48V·10W

Use a bulb with the same rating for replacement.

■ Replacing Fuse Fuses are installed inside the rear cover. When a fuse is blown, remove the cause and then replace the fuse.

• Always disconnect the battery plug before replacing a fuse. • Always use fuses with the specified capacity. • Pay attention not to short circuit between terminals with a wrench or other metal tools during replacement. • If the fuse is still blown after being replaced or the cause is not clear, contact a designated service shop.

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Work Items 1.5 - 1.75 Ton

1. 2. 3. 4.

Traction Controller Hydraulic Controller Power Steering Fuse Fuse #4

5. 6. 7.

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Fuse #3 Fuse #2 Fuse #1

15

15

Work Items

2.0 - 2.5 Ton

1. 2. 3. 4.

Traction Controller Hydraulic Controller Power Steering Fuse Fuse #4

5. 6. 7.

Fuse #3 Fuse #2 Fuse #1

A high voltage is alive in the control unit. There is danger of electric shock when in contact.

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Service Data

16

■ Adjustment Values Item Power steering motor brush

1.5–1.75 ton

Model New part

2–2.5 ton

mm

20

Wear remaining limit mm

10

Steering wheel play

mm

20–60

Standard brake pedal height

mm

149–159

Standard brake play

mm

3–6

Specific gravity of electrolyte

(20°C)

1.28

■ Fuse Capacities

Model Main Circuit

Operation Circuit

1.5-1.75 Ton

2-2.5 Ton

48V

48V

Power Steering

40A

40A

Auto-Off (Fuse #1)

10A

10A

Control Circuit (Fuse #2)

10A

10A

Accessory Circuit (Fuse #3)

10A

10A

Accessory Circuit (Fuse #4)

5A

5A

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16

Service Data

■ Bolt Tightening Torques N·m (kgf·cm)

4.8

8.8

M

Bolt size 6

3.0–3.6 (31–37)

8.5–10.2 (87–104)

10.9 –

M

8

7.4–8.9 (76–91)

20.7–24.8 (211–253)

30.7–36.8 (313–375)

M

10

14.7–17.6 (150–180)

40.9–49.0 (417–500)

60.8–72.9 (620–744)

M

12

25.7–30.8 (262–314)

71.4–85.8 (729–875)

106–127 (1,080–1,296)

M

16

63.5–76.1 (648–777)

176–212 (1,800–2,160)

263–315 (2,680–3,216)

M

20

124–149 (1,270–1,524)

346–415 (3,530–4,236)

513–615 (5,230–6,276)

M

24

215–258 (2,190–2,628)

597–716 (6,090–7,308)

886–1,060 (9,040–10,848)

M

30

426–512 (4,350–5,220)

1,190–1,420 (12,100–14,520) 1,750–2,110 (17,900–21,480)

Remarks

Unless otherwise specified, tighten all meter bolts and nuts to the tightening torque specified above. Appropriate tightening torque is determined according to the strength indicated on the bolts and nuts. When replacing bolts and nuts, always use Hyster Forklift genuine parts (same size).

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Inspection, Lubrication and Periodic Replacement Parts

17

The table below lists parts required for pre-operation inspection and periodic inspection. 1. Carry out pre-operation inspection in the order described in Section 12. The order makes the work completed within a short time. 2. Details of periodic inspection is described in Section 14.

■ Inspection, Lubrication and Periodic Replacement Parts Table Daily Check Check

Weekly (50H)

Battery

Check

Electrolyte level, specific gravity, terminals, cables

Meters Safety parts (horn, lamps, etc.) Controller Contactor Drive motor Pump motor, power steering motor Wiring, battery plugs Transmission and differential gear oil

Check Check

Tires and wheel nuts King pin Bell crank Tie rod end Power steering Steering wheel

Check

Shift lever linkage Accelerator pedal linkage

Check Check

Lubricate Lubricate

Brake oil Brake pedal linkage Parking brake Parking cable Brake master cylinder cups Wheel cylinder cups Hoses

Check Check Check

Lubricate Grease

Hydraulic oil Fluid suction strainer Fluid return filter Lift lever, tilt lever Tilt pivot Mast roller rolling surface Lift chain Fork sliding section Trunnion cap bolt Entire mast Mast trunnion Pump drive Hoses O-rings

Check

Item

Others

Load handling device

Braking device

Operation Steering Tire Drive device device related conveyance

Electric equipment

Entire vehicle

Overhead guard

Monthly (200H)

6 months (1,200H)

12 months (2,400H)

Replace contactor tips if roughness is remarkable.

Check Check Check Check

Check Check Check Check

Grease Grease Grease

Initial oil change

Remarks

Check wear of brush. (power steering motor only)

Oil change

Oil quantity: 4liters (1t), 4.5 liters (2t, 2.5t)

Exchange right and left

Check Check

Replace

Replace

Replace every 2 years

Replace Replace every 2 years Replace Clean Replace

Oil quantity: 14 liters (1.5–2.5t)

Grease Check Check

Grease Grease Grease Grease

Replace every 2 to 4 years

Check Check Grease Grease Check

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Replace every 1 to 2 years Replace every 6 months to 2 years

17

Inspection, Lubrication and Periodic Replacement Parts

• The Inspection, Lubrication and Periodic Replacement Parts Table shows the required intervals under general usage conditions (operation of about 200 hours a month). Use an interval that matches the usage conditions of your vehicle. Doing so will reduce faults and extends the life of the vehicle. • *Use special grease for the items with an asterisk mark. Please feel free to contact a designated service shop if you have any questions.

■ Inspection and Lubrication Chart

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Inspection, Lubrication and Periodic Replacement Parts

17

The quick-reference table below summarizes the Inspection, Lubrication and Periodic Replacement Parts Table and the Inspection and Lubrication Table. This table does not include the initial replacements. For the initial replacements, see pages 81 and 82. Replacement part

Replacement time

[Lubrication related] Hydraulic oil Hydraulic oil return filter element Transmission oil Differential gear oil Brake oil

Every 6 months or 1,200 hours Every 6 months or 1,200 hours Every 12 months or 2,400 hours Every 12 months or 2,400 hours Every 6 months or 1,200 hours

[Hydraulics related] O-rings

Every 6 months to 2 years

[Electric devices] Contactor tips

Every 1 to 3 years Replace when remarkably rough. Every 6 months to 2 years Replace when wear limit is reached.

Power steering motor brush [Braking device] Parking cable

Every 2 years

■ Periodic Replacement of Safety Parts Periodically replace the parts listed below related to safe operation of the forklift truck. In order to maintain safety functions, replace these parts after their specified periods have passed even if no abnormalities are found during the period. If any problem is found with the parts even before the specified replacement period, repair or replace the parts. Note that the periodic replacement and warranty process are not related. No.

Part name

Years

1

Cups of master cylinder and wheel cylinder, dust seals, etc.

2

Brake hose or tube

1–2

3

Brake reservoir tank tube

2–4

4

Lift chain

2–4

5

Hydraulic hose for load handling

1–2

6

Power steering hose

2

7

Rubber parts of power steering system

2

1

(Source: Standard of Japan Industrial Vehicle Association)

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17

Inspection, Lubrication and Periodic Replacement Parts

■ Lubricants List Application

Transmission oil

Differential oil

Brake oil

Hydraulic oil

Type

Applicable Temperature

SAE 80

30°C or less

SAE 90

30°C or above

SAE 80

30°C or less

SAE 90

30°C or above

DOT 3

 Shell Spylux 80EP Shell Spylux 90EP  Shell Spylux 80EP Shell Spylux 90EP Seiken Genuine BF3-N

VG 32 Anti-wear hydraulic oil

NM Super Highland 32

Grease Special grease

Lubricant Brand (used at shipment)

Albania EP2 Molybdenum disulfide grease

- 84 -

SUMICO Mori LG Grease

Refrigerator/Freezer Specified Vehicles

18

■ Freezer/Refrigerator Specified Vehicles The freezer/refrigerator-specified vehicle is a counterbalance-type battery operated forklift truck that is designed and manufactured for load handling work under sever conditions in a refrigerator. There are two types; one is for working with a temperature down to –35°C, and the other down to –45°C. 1. –35°C type This type is designed for work inside and outside of –35°C-class refrigerator and for 3-hour continuous work in a refrigerator at –25°C. When working with a –35°C-class refrigerator, the indoor and outdoor work time ratio is should be nearly fifty-fifty and continuous indoor work must be within 1 hour. As for a –25°C class refrigerator, continuous indoor work must be within 3 hours then work outdoor or take a break for about 30 minutes. 2. –45°C type This type is designed for work inside and outside of –45°C-class refrigerator and for 3-hour continuous work in a refrigerator at –35°C. When working with a –45°C-class refrigerator, the indoor and outdoor work time ratio is should be nearly fifty-fifty and continuous indoor work must be within 1 hour. As for a –35°C class refrigerator, continuous indoor work must be within 3 hours then work outdoor or take a break for about 30 minutes.

• Do not leave the forklift truck inside the refrigerator (both –35°C and –45°C types). • Any other types of forklift truck shall not enter a refrigerator. • Always charge the battery of the vehicle outside the refrigerator. Rustproof and low-temperature measures are provided for electrical parts and some other parts of this type of forklift trucks. Take special care of the daily lubrication, maintenance and inspection. 3. Rustproof measures When the vehicle enters and exits a refrigerator, water will condense on the vehicle due to the sharp change in temperature. This will cause rust to form easily. Therefore, special rustproof paint has been applied on the vehicle mast and parts where rust will form easily. When repairing the vehicle body or mast because of damage, pay special attention to painting agent to be used. Furthermore, stainless steel bolts and nuts are used at portions where rust will form easily. The other bolts, nuts, springs, etc. are plated, so take care when replacing them.

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18

Refrigerator/Freezer Specified Vehicles

4. Low-temperature measures a. Hydraulic oil Hydraulic oil that has superior performance even at low temperatures is used. Use the oil listed below when replacing the oil. Oil for freezer/refrigerator specified vehicles Application

Application

Lubricant brand (used at shipment)

Hydraulic oil

Anti-wear hydraulic oil

–35°C spec

Shell Tellus Oil T15

–45°C spec

Shell Tellus Oil T15

b. Electric parts Waterproof and rustproof parts are used to ensure the vehicle performance even at low temperatures.

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Part No. 4046068

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