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UniCarriers FD160-2, Operation & Maintenance Manual

The UniCarriers FD160-2 Operation & Maintenance Manual is essential for proper care and operation of your equipment. This comprehensive manual covers all aspects of using and maintaining the FD160-2 for optimal performance. Download your free manual from manualshive.com to ensure the longevity of your investment.

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PERIODIC INSPECTION

4-23

 

■

GREASING POINTS

MAST AND STEERING SYSTEM

  1.  Outer mast upper thrust roller (2)
  2.  Lift bracket thrust roller (4)
  3.  Inner mast lower thrust roller (2)
  4.  Tilt cylinder pin (4)
  5.  Mast support (2)
  6.  Valve control lever (*)
  7.  Propeller shaft (3)
  8.  Cradle pin (2)
  9.  King pin (4)
10.  Steering cylinder (2)
11.  Steering shaft (2)
* The number varies with the installation of attachments.

Summary of Contents for FD160-2

Page 1: ...T TRUCK It is the responsibility of the Operator and Supervisor to read and understand this manual Protect the earth and be kind to your lift truck OPERATION MAINTENANCE MANUAL Diesel Powered FD160 2...

Page 2: ......

Page 3: ...about the safe operation and maintenance of the UniCarriers forklift truck Read this manual thoroughly and become completely familiar with the lift truck before using it If you have any questions see...

Page 4: ......

Page 5: ...EA 1 3 PROPER AND IMPROPER USES 1 6 TYPES OF VEHICLES AND LOADS 1 7 INSPECTION 1 10 INSPECTION TRANSPORTING THE LIFT TRUCK 1 11 TRAVELING ON PUBLIC ROADS 1 13 HOW THE LIFT TRUCK WORKS 1 14 TRAVELING 1...

Page 6: ...which are primarily the responsibility of supervisory personnel Pages 1 2 through 1 13 contain instructions which should be enforced by the personnel supervising the operation of the lift truck Please...

Page 7: ...of a fire or accident All personnel should understand the location and use of emergency equipment TRAIN OPERATOR TO STACK SAFELY Stacking Unstacking Stacking means piling up a palleted load or materi...

Page 8: ...AN AND DISCUSS IT Before using the lift truck plan out the travel routes and operating procedures and thoroughly discuss the details with all involved personnel MARK THE TRAVEL LANES Designate the tra...

Page 9: ...ICLES OUT No en try of un au th or ize d ve hi cle s Unauthorized vehicles must be kept out of the load handling areas Post signs or give signals as required ASSIGN TRAFFIC GUIDES TO CONGESTED AREAS P...

Page 10: ...mpact of an object falling from overhead but it cannot withstand every impact If a heavy object seems likely to fall on the truck make every effort to prevent it from doing so KEEP THE GROUND LEVEL AN...

Page 11: ...ing a person elevating a person and towing another vehicle are examples of the improper use of a lift truck Uses which this manual specifies as improper must never be requested or permitted under any...

Page 12: ...describe safety precautions and operating instructions Replace any damaged or missing decals Check that the decals are legible during regular inspections NO OPERATION WITHOUT LIGHTS OVERHEAD GUARD OR...

Page 13: ...ion tires engine type or battery type Both are compact For outdoor use pneumatic tires work well Solid cushion tires with the same dimensions as pneumatic tires may be the best choice in cases where t...

Page 14: ...e strong enough to withstand the heavy weights of loading and unloading Remove or repair any damaged pallet STACK LOADS SECURELY When stacking loads place them in a stable manner that they will not ea...

Page 15: ...mended replacement interval year 1 Master cylinder and wheel cylinder cups and dust seals 1 2 Power steering hose 2 3 Reserve tank tubing 2 4 4 Fuel hose 2 4 5 Torque converter rubber hose 2 6 Rubber...

Page 16: ...erious injury TRANSPORTING THE LIFT TRUCK Use a level hard road surface when loading the truck onto or unloading from a trailer and when unloading it Be certain that the ramps have sufficient length a...

Page 17: ...of the truck falling If hoisting the lift truck is necessary for any reason use optional Lifting Eyes WARNING Observe the following conditions when lifting the lift truck Use optional Lifting Eyes Use...

Page 18: ...It is usually illegal to carry a load on a public road It is also not allowed to make a sideways travel or tow another vehicle on a public road with the possible exception of a disabled vehicle Never...

Page 19: ...e of load HOW THE CENTER OF GRAVITY SHIFTS Lift truck viewed from front The higher the load the higher the truck s center of gravity Truck s center of gravity with truck tilted Truck s center of gravi...

Page 20: ...further forward than the front wheels the truck will tip forward with the front wheels as the fulcrum If the overall center of gravity moves outside the triangle to the right or the left the truck wi...

Page 21: ...a momentary forward force As a result if the brakes are applied suddenly there is a very strong hazard that the forward force will become strong enough for the truck to tip forward Likewise when the...

Page 22: ...ent might occur After adjustment make sure they are securely locked 4 Seat yourself in the operator s seat and fasten the seat belt 5 Press the clutch pedal trucks with clutch or brake pedal trucks wi...

Page 23: ...aveling when loaded in particular keep the forks 20 cm above the floor or ground and tilted back so as to lower the truck s center of gravity as far as possible Never use man as an additional counterw...

Page 24: ...ad There is a fear of the edge of a soft ground breaking Stay away from such a place Keep appropriate distance from the edge of a narrow road or a platform Do not travel over a floor or ground surface...

Page 25: ...ntersections corners narrow aisles and other locations where your vision is restricted Slow down at corners Slow down and sound horn at intersections and other locations where your vision is restricte...

Page 26: ...an appropriate ground clearance height When operating an unloaded truck on grades have the rear end of your truck pointed up hill When operating a loaded truck on grades have the rear end of your truc...

Page 27: ...edal is pressed Engine powered trucks When the inching pedal is pressed to the bottom the brake is applied to the truck but engine braking is not available because the clutch unit is disengaged When d...

Page 28: ...practice safe driving and load handling techniques Even after getting familiar with the operation of the truck operate the truck carefully reckless driving and operation will cause a personal injury...

Page 29: ...nother vehicle using the draw bar Do not push or pull loads with forks otherwise the load might fall off or get damaged In particular the truck with the max lift height of more than 150 cm might tip o...

Page 30: ...hands or feet might be cut if the mast moves unexpectedly WARNING Never elevate a man WARNING Never allow other person s to ride on the forks He might fall off the forks getting injured Never lift a...

Page 31: ...handling loose loads make sure they are stable enough before lifting Use special caution when stacking or unstacking loads When stacking or unstacking loads stabilize them with ropes or others to prev...

Page 32: ...is over stack otherwise the truck might tip over Do not lift or start with mast tilted forward When the mast is tilted forward do not perform the following operations lifting the forks and starting a...

Page 33: ...o turn over Use a hook attachment or crane arm attachment to hang loads Make sure that the wire ropes are strong enough to withstand the weight of the load and properly attached The length of the rope...

Page 34: ...n a slope apply the parking brake securely and block the wheels Do not park near flammables When parking a faulty truck F a u lt y When it is not possible to lower the forks on the ground due to a fau...

Page 35: ...fic area and lower the forks on the ground 2 Tilt the mast a little forward and make the fork tips in contact with the ground surface 3 Apply the parking brake Engine powered trucks 4 Place the shift...

Page 36: ...ver working indoors Know how to use it Wipe any spilt oil or grease Wipe any spilt oil or grease If the truck is contaminated with oil or grease it is difficult for you to find possible cracks or othe...

Page 37: ...e powered trucks Unless otherwise specified inspection or maintenance should be performed with the engine shut off Unless otherwise specified turn off the key switch Electric trucks Unless otherwise s...

Page 38: ...hands or feet Do not use the mast as a ladder You might fall down from the mast leading to a serious accident Shut down the engine before working on rotating parts Engine powered trucks Use due cauti...

Page 39: ...ece of cardboard or wood High pressure oil penetrates the skin It can cause blindness Checking of accumulator and piping is hazardous Inspection of piping where an accumulator is installed is hazardou...

Page 40: ...under it Before jacking up the truck remove the loads from the truck When jacking up the truck the operator must leave the truck Lift the truck a little off the ground surface and put supports at both...

Page 41: ...es used for electric trucks are high voltages more than 48 V If anyone touches it inadvertently he can get an electrical shock accident or burn No fire Since explosive hydrogen gases are always being...

Page 42: ...aps are securely tightened Static electricity is hazardous Static electricity is generated when cleaning the top surface or connections of the battery with a dry cloth or covering the battery with a v...

Page 43: ...ty glasses and mask When inflating tires wear safety glasses and mask because dust might get into your eyes or mouth Do not loosen the wheel assembly nuts when changing a tire The wheel assembly is lo...

Page 44: ...tires An improperly reassembled tire might cause explosion to let parts fly into pieces resulting in a serious personal injury Keep the tension of the right and left chains even Uneven tension of the...

Page 45: ...im into fresh air seek medical attention as required and contact your employer so he can monitor threshold limit values Consid eration should be given to shutting off the operator s internal combustio...

Page 46: ...C For hook mast and counterweight E Caution against catching fingers F Danger and warning against fan and rotating part G Load chart I Warning decal against getting caught by tire J Warning decal agai...

Page 47: ...Mast warning O Brake oil warning P Air tank drain Q Diesel oil decal S Brake oil decal D B P O Q S L A H CAUTION The instructions on the caution plates carried in this manual may differ from those on...

Page 48: ...ruck if it tips Do not tilt overweight or loose loads Move slowly with wide high or long loads Keep forks wide and fully under loads Travel in reverse if loads block view Attachments require special t...

Page 49: ...and rotating part I Warning decal against getting caught by tire J Warning decal against radiator cap G Load chart H List of lubrication points K Caution against burning L Mast warning Use caution no...

Page 50: ...CAUTION PLATES 1 45 M Hook and counter weight decal N Brake operation O Brake oil warning P Air tank drain Q Diesel oil decal UniCarriers R Hydraulic oil decal S Brake oil decal...

Page 51: ...h side shifter U Fork extension sleeve operation decal for trucks with fork extension sleeve V Hydraulic oil level decal W Name plate C This mark is certifying confirming to EEC directive MODEL SERIAL...

Page 52: ...conducting part with bare hands will cause an electric shock accident Do not connect or disconnect the battery plugs during the battery turned ON otherwise you might get burnt or an explosion might oc...

Page 53: ...with operating checking and servicing This manual and decals affixed to the truck use the following safety alert indications SIGNAL WORD CLASSIFICATION DANGER Failure to follow the instructions in the...

Page 54: ...WHEEL DRIVE WHEEL REAR WHEEL Note The operator s cab with head lights wiper air conditioner high lift mast and side shifter are optionally available REAR UNDER MIRROR MUFFLER OPERATOR S CAB MAST BATTE...

Page 55: ...PICTORIAL NOMENCLATURE 2 2 REAR COMBINATION LAMP COUNTERWEIGHT TILT CYLINDER OPERATOR S CAB FUEL TANK CAP BRAKE AIR TANK...

Page 56: ...INSTRUMENTS AND CONTROLS 2 3 Fwd travel Rev travel Detail of Detail of...

Page 57: ...22 Hour meter 37 Defroster selection switch option 8 Accelerator pedal 23 Brake air pressure gauge 38 Front windshield wiper switch option 9 Brake pedal 24 Warning light air cleaner 39 Rear windshield...

Page 58: ...start a cold engine turn the starter switch to the PREHEAT position to preheat the engine for about 20 seconds Preheating the engine is not necessary when the weather is warm The key will automaticall...

Page 59: ...ad light OFF OFF ON NOTE The above lights turn on or off regardless of the starter switch Remember to turn them off when leaving the truck TURN SIGNAL SWITCH Use the turn signals front and rear to ind...

Page 60: ...ing lamp goes out AUTOMATIC TRANSMISSION MODE SELECTOR SWITCH Press POW to select the power mode The transmission will automatically shift from the 1st 2nd and to 3rd speed Press ECO to select the eco...

Page 61: ...ke The truck usually won t move when the parking brake is applied If the truck needs to be moved in an emergency with the parking brake applied turn on the switch and move the truck The truck will mov...

Page 62: ...nge If the pointer enters the red range stop the truck immediately let the engine run at low rpm to cool it down and check the engine for overheating NOTE Do not shut off the engine even if the pointe...

Page 63: ...ine starts up it suggests that the fan belt is loose or broken or that the power generating system is defective Stop the operation immediately and consult your local UniCarriers dealer BRAKE AIR PRESS...

Page 64: ...drops below the specified level If light comes on add brake oil and check the brake line INDICATORS TURN SIGNAL INDICATORS RIGHT AND LEFT Either of the turn signal indicators blinks when the turn sig...

Page 65: ...IFT LEVER CAUTION Seat yourself in the operator s seat and make sure there is no one around the truck before operating the lift lever Pull back on the lever to raise the forks and push forward on it t...

Page 66: ...uring operation Adjust the steering column angle according to the individual operator s physique Turn the lever in the direction B and adjust the steering column angle properly and then turn the lever...

Page 67: ...vidual operator s physique To unlock pull up the lever After adjustment try to move the seat back and forth to make sure that the seat is securely locked DOCUMENTS POCKET AND MAGAZINE BOX The driver s...

Page 68: ...and adjust the seat height according to the individual operator s physique Usually set the seat height to the right end or the second from the right end marking The suspension stroke will be automati...

Page 69: ...VERHEAD GUARD WARNING The overhead guard is an important safety device which protects the operator from falling objects Make sure it is securely installed Do not use the truck with the overhead guard...

Page 70: ...ps tail lamps brake lamps back up lamps turn signals and rear reflector at its rear The license number plate lamp is optionally available SIDEVIEW MIRRORS AND UNDER MIRROR CAUTION When traveling in re...

Page 71: ...truck front area in engine room DRAWBAR CAUTION Do not use the drawbar for towing another vehicle or for being towed by another vehicle Use the drawbar for the following cases When the truck has bogge...

Page 72: ...IR TANK The brake oil reservoir tank is located at the left side area inside the engine room The brake oil level should be between the upper and lower markings on the tank RADIATOR RESERVOIR TANK The...

Page 73: ...the engine is hot Make sure the engine has cooled down completely and turn the cap counterclockwise a little to relieve the pressure in the radiator and then remove the cap The radiator cap is locate...

Page 74: ...before trying to travel the truck When opening the door from outside turn the door handle disengage the stopper and pull it outwards To open the door from inside turn the door handle to disengage the...

Page 75: ...the ceiling of the cabin The ON OFF switch is located near the light Remember to turn it off when leaving the truck WIPER SWITCH Front windshield wiper switch The switch is pulled out in 2 stages low...

Page 76: ...rly NOTE Do not operate the windshield wipers when the wiper fluid tank is empty otherwise the motor might get damaged REAR VIEW MIRROR CAUTION When traveling in reverse always look in the direction o...

Page 77: ...H Turn on and off the air conditioner FAN SWITCH The fan switch turns on and off the fan and controls the air volume in four stages LO HI TEMPERATURE CONTROL SWITCH Press the switch for cooling and th...

Page 78: ...FF desired setting desired setting defroster HI OFF or ON desired setting NOTE Warm up the engine sufficiently prior to operating the fan switch It is good practice to ventilate the driver s room if i...

Page 79: ...ST PURIFYING MUFFLER Use the exhaust purifying muffler to protect the environment MANUAL PUMP TYPE AUTOMATIC GREASTER Centralized lubrication can be performed through grease fittings by installing a g...

Page 80: ...MEMO...

Page 81: ...following symbols found throughout this manual alert you to potentially hazardous conditions to the owner and the operator Become completely familiar with the truck before proceeding with operating c...

Page 82: ...starts or turns Oil changes and lubrication are recommended to do earlier than specified Do not run the engine needlessly at high rpm without load RELATIONSHIP BETWEEN LOAD AND STABILITY OF TRUCK The...

Page 83: ...the standard truck a truck without any attachment for the following reasons Never exceed the allowable load indicated on the load chart attached onto the truck or attachment Reasons for a reduction i...

Page 84: ...ition This means that the forks are raised 30 cm 12 in above the ground or floor surface with a load placed at the basic load center position of the forks USING INCHING PEDAL The inching pedal works i...

Page 85: ...al noise or vibration during operation stop the operation immediately and have the engine inspected When shutting down the engine Make sure to let the engine run at idle rpm for a few minutes before s...

Page 86: ...key will automatically return to the ON position 4 After the engine has started do not increase the engine speed rapidly Warm up the engine and make sure the CHARGE warning light and ENGINE OIL PRESS...

Page 87: ...start the engine Do not keep the starter motor engaged for more than 10 seconds at a time After the engine has started release your hand from the key and it will automatically return to the ON positi...

Page 88: ...truck Using the automatic transmission mode selector switch you can start from the 1st speed P mode or 2nd speed E mode NOTE Do not keep your foot on the inching pedal after the truck has started othe...

Page 89: ...ble position the load handling means down hill and block the wheels to prevent accidental roll Park the truck in a designated area or out of traffic area If necessary put signposts or signal lights ar...

Page 90: ...e sure to once stop make sure to be safe and cross the railroad track at an angle wherever possible Go around obstacles such as rocks and stumps or pot holes If unavoidable reduce the speed and go ove...

Page 91: ...lammable Do not use open flame when adding changing or storing it The LLC is poisonous Lethal dose 100 cc Do not swallow it If anyone swallowed it accidentally induce vomiting immediately and get medi...

Page 92: ...ious amount of water immediately If electrolyte gets into your eyes wash your eyes with a copious amount of water immediately and get medical attention Battery care CAUTION Never pour hot water over t...

Page 93: ...fin and loose fan belt IN HOT WEATHER Cooling system CAUTION Make sure the engine is cold before opening or closing the radiator cap Hot cooling water might spout out to cause serious burns To get a...

Page 94: ...TACKING CAUTION Never tilt the mast forward with the load upraised except when the forks are over the rack or a stack Do not leave the truck with the load upraised 1 When approaching the deposit area...

Page 95: ...wly to insert the forks into the pallet as far as possible Stop the truck If the forks are hard to be fully inserted use the following procedure Move forward to insert 3 4 of the forks Raise the forks...

Page 96: ...general condition of the truck Especially check the truck body for dents or cracks the tires for wear or nails or stones in the tread Check the fuel level and add if necessary Check for leakage of hy...

Page 97: ...k in the operating state once a week and start the engine Warm it up sufficiently before moving the truck a little back and forth Avoid parking on a soft ground such as an asphalt ground in summer OPE...

Page 98: ...MEMO...

Page 99: ...hroughout this manual alert you to potentially hazardous conditions to the owner and the operator Become completely familiar with the truck before proceeding with operating checking and servicing This...

Page 100: ...el or employer is required to dispose of it properly GENERAL RULES ON INSPECTION Use UniCarriers genuine parts only Use UniCarriers genuine or recommended lubricants only Clean the oil fillers and gre...

Page 101: ...ght in the tread State of the truck Check the inclination of the truck If the truck is tilted to either side it suggests that the tires or wheels are defective Contact your local UniCarriers dealer Oi...

Page 102: ...to a serious accident If you find any failure contact your local UniCarriers dealer Overinflation Underinflation Good Keep the inflation pressure of the tires always at proper level The standard tire...

Page 103: ...truck to tip over Check the nuts for looseness If even a single nut is loose it is very dangerous Retighten to the specified torque securely Hub nut and tightening nut with wedge band Unit N m kgf m T...

Page 104: ...eck the cooling water level in the cooling water tank Make sure the level is between the FULL and LOW markings on the tank Usually you can check the cooling water level without removing the radiator c...

Page 105: ...is shut down Wait for about 10 minutes before checking the oil level Use caution not to get burnt When releasing the pressure use a thick rag Avoid putting on gloves since you might get burnt on your...

Page 106: ...le of proper oil level set for a lift height of 3 meters If level is low add hydraulic oil through the fill port at the center right area of the truck 10 HYDRAULIC OIL PIPING AND CYLINDERS HYDRAULIC P...

Page 107: ...hand from it 12 CARRIAGE Check the carriage for damage or loose or missing mounting bolt 13 HEAD LAMPS AND COMBINATION LAMPS Check for dirty or damaged lens of the head lamps Check also the combinatio...

Page 108: ...rs for contamination or damage Adjust the mirrors to gain full rearview when you are seated in the operator s seat Start the engine 16 SHIFT LEVER CAUTION Make sure the shift lever is in neutral and t...

Page 109: ...ur meter function properly 21 FUEL LEVEL Check the fuel level using the fuel level gauge on the instrument panel Make sure the fuel level is sufficient for the day s work or each shift 22 LIGHTS AND L...

Page 110: ...ft and tilt levers several times to check if the forks and mast operate smoothly without squeaking Check also each lever for looseness If the truck is equipped with a hydraulic attachment check the at...

Page 111: ...are very dangerous When starting the lift truck in an enclosed space make sure there is enough ventilation The exhaust gas check should be done outdoors Especially use caution to avoid fire hazards P...

Page 112: ...OOM BRAKE OIL TANK SIDE PANEL LEFT INLET MANIFOLD RADIATOR TANK HOT WATER HOSE FOR HEATER FUEL FILTER RADIATOR HOSE RADIATOR CAP RADIATOR GENERATOR DIPSTICK AIR CLEANER EXHAUST PIPE FILL PORT SIDE PAN...

Page 113: ...ate normally Whenever the fuel tank is drained water is removed or the filter element is replaced with a new one bleed air out of the fuel system in the following manner 1 Loosen the fuel filter conne...

Page 114: ...t Replace the blown fuse with a spare fuse of the same capacity and color If some of the components in a circuit do not function properly it suggests that a bulb has burnt out Replace the burnt bulb w...

Page 115: ...them attached to the truck or by putting in a safety cage even if you are qualified to inflate tires SAFETY CAGE Get tools and jack necessary for replacing tires Front wheel CAUTION When removing a t...

Page 116: ...ressure kPa kgf cm2 Nut torque Front wheel Rear wheel FD160 2 784 8 0 686 N m 70 kgf m 440 490 N m 45 50 kgf m FD180 2 809 8 25 FD200 2 882 9 0 FD230 2 882 9 0 After reinstalling the wheels be sure to...

Page 117: ...w the terminal of the booster cable to come in contact with the terminal of the booster cable 1 Make certain that auxiliary battery unit supplies 24 volts connect two 12 V batteries in series 2 Connec...

Page 118: ...more economical Preoperational checks the addition of oil grease and fuel and cleaning of filter elements should be carried out by the customer and other complicated checks and maintenance should be...

Page 119: ...inary maintenance whether they are beyond their respective service limits or not The safety parts must be replaced with new ones when their respective service limits have been reached even if their ap...

Page 120: ...ooseness Tire tread Check for wear or foreign matter Wheel bearing Check for looseness or noise Brake hose and pipe Check for damage oil leaks or interference Brake oil Check for leaks or contaminatio...

Page 121: ...he lift chain observe the following conditions 1 Loosen the chain sufficiently 2 After applying engine oil move the mast up and down at least 10 times NOTE If your lift truck is used near a port or co...

Page 122: ...rust roller 2 2 Lift bracket thrust roller 4 3 Inner mast lower thrust roller 2 4 Tilt cylinder pin 4 5 Mast support 2 6 Valve control lever 7 Propeller shaft 3 8 Cradle pin 2 9 King pin 4 10 Steering...

Page 123: ...for cracks or contamination Usually replace the air cleaner element with a new one every 2400 hours of operation In addition if the air cleaner element warning light comes on it is advisable to repla...

Page 124: ...dealer will undertake oil change job if required DRAIN PLUG OIL FILL PORT CAP DIPSTICK 1 Remove the engine oil fill port cap 2 Wipe the cap clean with shop rag 3 Put a pan under the drain plug of the...

Page 125: ...same brand of oil as being used OIL FILTER Replace the two cartridge filter elements with new ones To install new elements apply a small amount of engine oil on the O ring of each new element and tigh...

Page 126: ...ter every year when LLC is used Fuel filter cartridge Change Fuel tank Drain water Propeller shaft Check for looseness and loose mounting bolts Front axle differential and final reduction gear Check o...

Page 127: ...he engine and add cooling water again properly Radiator side drain cock DRAIN COCK RADIATOR SIDE Do not remove the radiator cap immediately after the engine is shut off otherwise you will get burnt by...

Page 128: ...s drained air may enter the piping to hinder the flow of fuel Be sure to bleed air out of the fuel system CHECKING DIFFERENTIAL OIL LEVEL DRAIN PLUG LEVEL PLUG Check the differential oil for level and...

Page 129: ...mal specific gravity of electrolyte is 1 260 when the temperature is 20 C See the conversion table when the temperature is other than 20 C For example if the hydrometer reads 1 250 when the temperatur...

Page 130: ...ange element at 200 hours of operation for the first time only Mast support cap bolt Check for looseness at 200 hours of operation for the first time only Hydraulic oil tank suction strainer Clean Hyd...

Page 131: ...TORQUE CONVERTER DRAIN PLUG Put an oil receiving pan under the filter and remove the drain plug of the transmission to drain the torque converter Remove the suction pipe and take out the suction strai...

Page 132: ...e level plug and run the truck for about 5 minutes to clean inside the differential Then drain the differential again install the drain plug and add new oil through the level plug to the specified lev...

Page 133: ...ction nozzle Check injection pressure and spray pattern Engine Check injection timing Feed pump Clean inlet strainer Water pump Change grease Parking brake Check for proper operation wear or damage Br...

Page 134: ...h new one If the desiccant is exhausted severely it is advisable to replace it earlier than specified at the next replacement CLEANING FEED PUMP INLET STRAINER STRAINER The strainer is incorporated in...

Page 135: ...cleaner element for contamination and clean if needed Visual Check valve clearance Thickness gauge Retighten cylinder head bolts No need to retighten except when disassembling and reassembling cylind...

Page 136: ...ern Nozzle tester Injection timing Operate Clean feed pump inlet strainer Operate Drain water from fuel tank Operate Clean inside fuel tank Operate Check fuel tank for level Visual Cooling system Chec...

Page 137: ...ch and test hammer Differential and final reduction gear Check for oil leaks Visual Check oil level Visual first time only Check for deformation cracks or damage Visual Check for loose mounting bolt T...

Page 138: ...heck for proper operation and installation Operate Check parking brake pad for wear or damage Check parking brake disk for wear or damage Check emergency brake for operation Operate Hose and pipe Chec...

Page 139: ...air desiccant Disassemble Replace rubber parts O ring and seals Disassemble LOAD HANDLING SYSTEM Checking item Service Required Tools Daily Monthly 200 hrs Trimonthly 600 hrs Semiannually 1200 hrs An...

Page 140: ...ension elongation deformation damage or corrosion Touch and gauge Lubricate chains Visual and operate Check connection between chain anchor pin and chain for looseness Visual Check sheaves for deforma...

Page 141: ...rol valve and tilt lock valve for operation Auditory Measure relief pressure Oil pressure gauge Return filter Change Operate first time only Hose piping hose reel and swivel joint Check for oil leaks...

Page 142: ...r oil leaks Visual Check for loose mounting our linkage Visual Check high pressure hose Operate 2 years ELECTRICAL SYSTEM Checking item Service Required Tools Daily Monthly 200 hrs Trimonthly 600 hrs...

Page 143: ...Operate Sideview mirrors Check for contamination or damage Visual Check for proper visibility Visual Meters Check for operation Visual Rear reflector license number plate Check for contamination or d...

Page 144: ...MEMO...

Page 145: ...amiliar with the truck before proceeding with operating checking and servicing This manual and decals affixed to the truck use the following safety alert indications SIGNAL WORD CLASSIFICATION DANGER...

Page 146: ...SPECIFICATIONS 5 1 Specifications are subject to change without notice...

Page 147: ...height mast F mm 3290 3540 3570 3580 overhead guard mm 3200 3230 3260 3260 Overall height mast raised G mm 4790 5040 5070 5080 Wheelbase H mm 3650 3650 3650 3650 Tread front I mm 2195 2195 2185 2185 r...

Page 148: ...ack up buzzer Horn Neutral switch Floor mat Engine hood damper stay Upward air intake port Radiator reservoir tank Tilt steering wheel Turn signal Hour meter Engine water temp gauge Fuel gauge Engine...

Page 149: ...of standard specifications and those with high mast whose lifting height is less than 6 m Note that load charts for lift trucks with a high mast whose lifting height is more than 6 m or those with an...

Page 150: ...ones after 5 times of removal or earlier Engine specifications Idling rpm 800 850 Non load max rpm 2450 2550 Fuel injection order 1 5 3 6 2 4 Fuel injection timing BTDC 12 Fuel injection start pressur...

Page 151: ...0W 40 C above SAE75W 4 Transmission torque converter 30 Engine oil 25 C above SAE10W ATF DEXRON 40 C above ATF 5 Radiator 32 UniCarriers Long Life Coolant concentration of 50 6 Fuel tank 400 Light oil...

Page 152: ...Dexron ESSO ESSO ATF CALTEX Texamatic Fluid Dexron II GEAR OIL Class Supplier API Class GL 4 and Higher GL 4 GL 5 MOBIL Mobilube 40 Series 75W 80W 90 Mobilube HD 75W 80W 80W 90 90 SHELL SHELL Spirax...

Page 153: ...rs lubricants for lubrication TRUCK SERIAL NUMBER The truck serial number is imprinted on the rear part of the frame at the left side of the truck ENGINE SERIAL NUMBER The engine serial number is impr...

Page 154: ...SERVICE 5 9 WRITE DOWN DATA OF YOUR TRUCK HERE TRUCK MODEL Truck Serial No Service Weight kg lbs Max Load mm in kg lbs ENGINE Manufacturer Model Engine Serial No DATE OF PURCHASE DEALER S NAME PHONE D...

Page 155: ...MEMO...

Page 156: ...ISSUED MAR 2003 REVISED MAY 2004 REVISED SEP 2015 1 2 Shin Ogura Saiwai ku Kawasaki Kanagawa 212 0031 Japan All rights reserved JB 1509001 AN Printed in Japan No OMFBE 8B8150...

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