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UniCarriers FD20 Series, Operation & Maintenance Manual

The UniCarriers FD20 Series is a reliable and efficient forklift that is essential for your warehouse operations. Ensure smooth performance and longevity by referring to the Operation & Maintenance Manual. Download the manual for free from manualshive.com to maximize the productivity of your UniCarriers FD20 Series forklift.

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RELATIONSHIP BETWEEN LOAD AND STABILITY OF TRUCK ................................................................3-2
REMOVING WATER FROM SEDIMENTER ...............................................................................................4-2

1

REPLACING FUSES ...................................................................................................................................4-2

5

REPLACING LAMP BULBS ........................................................................................................................4-

28

REPLACING TIRES AND REPAIRING FLAT TIRE .....................................................................................4-2

6

S 

SAFETY STEP AND HAND GRIP ...............................................................................................................2-2

0

SEAT BELT ..................................................................................................................................................2-1

5

SEAT BELT WARNING LIGHT ......................................................................................................................2-9
SEDIMENTER WARNING LIGHT .............................................................................................................

..

..2-

9

SERIAL NUMBERS OF MAJOR COMPONENTS ......................................................................................5-

13

SERVICE DATA ......................................................................................................................................

..

.....5-

8

SHIFT LEVER .............................................................................................................................................2-1

1

SIDEVIEW MIRRORS .................................................................................................................................2-2

4

SOUND VOLUME-ADJUSTABLE BACK-UP BUZZER ...............................................................................2-2

5

SPECIFICATIONS .........................................................................................................................................5-2
SPEED ALARM SYSTEM (SAS) .................................................................................................................2-2

5

SPEEDOMETER (SM) ................................................................................................................................2-2

5

SPEED RANGE SHIFT LEVER ..................................................................................................................2-1

1

STABILITY OF LIFT TRUCK .........................................................................................................................3-3
STARTER SWITCH .......................................................................................................................................2-5
STARTING THE ENGINE WITH AUXILIARY BATTERY .............................................................................4-

28

STEERING COLUMN TILT LEVER .............................................................................................................2-1

2

STEERING WHEEL ....................................................................................................................................2-1

2

STORING ....................................................................................................................................................3-13
SWITCHES ..........................................................................................................................................2-5,  2-2

6

T 

TILT LEVER .................................................................................................................................................2-1

0

TIRE CHAIN (TC) ........................................................................................................................................2-2

5

TORQUE CONVERTER OIL FILLER ..........................................................................................................2-2

3

TRANSPORTING LIFT TRUCK ....................................................................................................................3-4
TRAVELING ................................................................................................................................................1-18
TRAVELING AND LOAD HANDLING INTERLOCK SYSTEM WARNING LIGHT ........................................2-9
TRAVELING AND STARTING ON A SLOPE .................................................................................................3-4
TRUCK BODY .............................................................................................................................................2-1

4

TRUCK SERIAL NUMBER ..........................................................................................................................5-

13

TRUCKS WITH POWER BRAKE (POB) .....................................................................................................2-2

5

U 

USING INCHING PEDAL ..............................................................................................................................3-3

6-5

INDEX

Summary of Contents for FD20 Series

Page 1: ...t is the responsibility of the operator and supervisor to read and understand this manual Protect the earth and be kind to your lift truck OPER MAINT MANUAL No OMFBE CK9140 OPERATION MAINTENANCE MANUA...

Page 2: ...e UniCarriers forklift truck Read this original manual thoroughly and become completely familiar with the lift truck before using it If you have any questions see your dealer Due to improvements in de...

Page 3: ...Rated load Truck model Engine model 2 tons FG20T3C K21 FD20T4C V2403 FD20T3CZ C240 2 5 tons 3 tons FG25T3C K21 FD25T4C V2403 FD25T3CZ C240 FG30T3C K21 FD30T4C V2403 FD30T3CZ C240...

Page 4: ...SING INCHING PEDAL 3 3 TRAVELING AND STARTING ON A SLOPE 3 4 TRANSPORTING LIFT TRUCK 3 4 MOVING LIFT TRUCK IN AN EMERGENCY 3 5 OPERATING LIFT TRUCK 3 6 MEASURES AGAINST COLD OR HOT WEATHER 3 10 IN COL...

Page 5: ...DATA 5 8 SERVICE DATA 5 8 BOLT AND NUT TORQUE 5 9 AFTER THE SALE SERVICE 5 13 TRUCK SERIAL NUMBER 5 13 SERIAL NUMBERS OF MAJOR COMPONENTS 5 13 NAME PLATE 5 13 ENGINE SERIAL NUMBER 5 14 GENUINE UniCar...

Page 6: ...N Indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury CAUTION Indicates a hazardous situation which if not avoided may result in damage to the truck...

Page 7: ...e operator are other common causes of accidents It is not possible to describe all potentially hazardous situations which may occur while operating inspecting or servicing a forklift truck The warning...

Page 8: ...ator who is feeling unwell or an operator who is intoxicated must not be allowed in the driver s seat WEAR PROTECTIVE GEAR Gloves Safety Shoes Work Clothes Goggles Hard Hat Always wear proper work clo...

Page 9: ...LANES Designate the travel lanes for the lift truck and mark them clearly so they will be kept free of obstruction SET SPEED LIMITS Example Yard Speed Limit Set appropriate speed limits on your compan...

Page 10: ...gnals PROVIDE ADEQUATE LIGHTING Safe operation requires well lit traveling routes so pedestrians and obstacles can be easily seen Use headlights taillights helmet lamps or other lights as appropriate...

Page 11: ...ings DO NOT RELY ON THE OVERHEAD GUARD The overhead guard is a protective device that will moderate the impact of an object falling from overhead but it cannot withstand every impact If a heavy object...

Page 12: ...other 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 circumstances Examples of Improper Use Transp...

Page 13: ...s Do not raise people or allow them under forks No passengers allowed on truck 11 Park only in authorized areas never on inclines Lower forks to bottom put direction control in neutral turn off key an...

Page 14: ...e truck tipping If necessary have a qualified operator use a hook or crane arm attachment Popular Attachment Examples Crane Arm For slinging work Roll Clamp For paper roll or drum handling Rotating Fo...

Page 15: ...f 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 easily come apart and be sure the weight is evenly...

Page 16: ...st seals 1 2 Power steering hose 2 3 Reserve tank tubing 2 4 4 Fuel hose Engine powered trucks 2 4 5 Torque converter rubber hose Engine powered trucks 2 6 Rubber parts inside power steering unit 2 7...

Page 17: ...t to use a self loading trailer truck equipped with a jack and winch For loading tilt the truck bed with the jack attach the winch to the towing pin of the lift truck and pull it up The operator must...

Page 18: ...ic 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 tow another vehicle even on company property OB...

Page 19: ...acturer is no longer in business and there is no successor in the interest to the business the user may arrange for a modification or alteration to a powered industrial truck provided however that the...

Page 20: ...VITY SHIFTS Truck s center of gravity with standard mast raised Truck s center of gravity with high mast raised Lift truck viewed from front The higher the load the higher the truck s center of gravit...

Page 21: ...t 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 will fall over in that direction...

Page 22: ...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 truck is turning there is a ce...

Page 23: ...ne Do not try to adjust them during operation otherwise a serious accident might occur After adjustment make sure they are securely locked 4 Seat yourself in the operator s seat and fasten the seat be...

Page 24: ...ter of gravity as far as possible Never use man as an additional counterweight Do not use man as an additional counterweight Do not offer rides to others Avoid sharp starts stops and turns Start stop...

Page 25: ...look in the direction of travel failure to do so will lead to an accident When passing an oncoming truck each other slow down and use caution to have a safe distance Moreover maintain a safe distance...

Page 26: ...les Rear steer rear swing When the truck is turned in forward driving the rear of the truck swings outwards Before turning make sure there is enough clearance from the wall and other obstacles Have a...

Page 27: ...ering and power brake Engine powered trucks If the engine stops during traveling both the power steering unit and the power brake goes inoperative Do not turning off key switch during traveling Electr...

Page 28: ...r that their operating controls have their own characteristics even if the trucks are of the same specification If you change the trucks keep this point in mind In particular pay attention to the brak...

Page 29: ...to do that Pay attention to the fork tips The fork tips are sharp and could cause personal injury In addition if they catch on obstructions the truck might lose control leading to an accident Adjust f...

Page 30: ...ads on the forks by hand Do not hold loads on the forks by hand If the truck moves unexpectedly the load might fall off getting the person caught under it Make loads in contact with load backrest Inse...

Page 31: ...e forks are raised Never overload WARNING Know the rated capacity of your lift truck and its attachment if any and never exceed it otherwise the rear wheels will be raised thus making it difficult to...

Page 32: ...ight result In particular the use of a wire rope hung on one of the forks might cause the truck to turn over Use a hook attachment or crane arm attachment to hang loads Make sure that the wire ropes a...

Page 33: ...r 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 faulty load handling mechanism attach a sign to the tip of the forks to prevent pe...

Page 34: ...d make the fork tips in contact with the ground surface 3 Apply the parking brake Engine powered trucks 4 Place the shift levers direction and speed range in neutral 5 Turn the key switch to the OFF p...

Page 35: ...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 other defects No fire when handl...

Page 36: ...ut off Unless otherwise specified turn off the key switch Electric trucks Unless otherwise specified inspection or maintenance should be performed with the key switch turned off Before starting inspec...

Page 37: ...ve unexpectedly pinching or cutting your 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 p...

Page 38: ...aulic lines from the truck make sure to shut off the engine and pump the brake pedal at least 10 times to remove the oil pressure from the accumulator and lines Incomplete removal of the accumulator o...

Page 39: ...truck use Lifting Eyes WARNING Never hoist your lift truck by attaching ropes or wires to its overhead guard or counter weight otherwise there is the possibility of the chassis getting damage or fall...

Page 40: ...k such as the engine Engine powered trucks If the tool touches metal parts there might occur sparks causing an accident Remove the negative terminal of the battery first and reinstall it last Engine p...

Page 41: ...d voltage When connecting the booster cable to the battery pay attention to the polarity of the pole Two batteries shall be connected in parallel not in series Obey regulations When disposing of waste...

Page 42: ...run the truck to check to see if the hub nuts are securely tightened If a loose hub nut is found tighten it to the specified torque Leave the disassembly and reassembly of tires tubes and rims to a sp...

Page 43: ...ical attention as required and contact your employer so he can monitor threshold limit values Consideration should be given to shutting off the operator s internal combustion engine Control of noxious...

Page 44: ...sure the plugs are securely connected Before starting the day s work or before each shift check the cables and wiring for looseness twists stiffened or cracked insulation and fraying Also check for mi...

Page 45: ...the burning vehicle observing the following procedure Lower the forks on the ground apply the parking brake and turn off the starter switch to shut off the engine Get out of the burning vehicle quick...

Page 46: ...explain cautions to be taken when using the truck and procedures for operating the truck Read messages on the caution plates as well as the description in this manual Damaged or missing decals must b...

Page 47: ...in this manual may differ from those on the caution plates attached to the truck body In such a case observe the instructions on the caution plates attached to the truck body View looking from C OVERH...

Page 48: ...er s work rules about fuel battery and tire maintenance hazards 10 Forks can fall rapidly even with light loads Do not raise people or allow them under forks No passengers allowed on truck 11 Park onl...

Page 49: ...ES EVERY 2 YEARS 5 Warning decal for front guard WARNING AVOID SEVERE INJURY OR DEATH DO NOT CLIMB ON FRONT GUARD 6 Warning decal for load handling means WARNING AVOID SEVERE INJURY OR DEATH DO NOT GE...

Page 50: ...ettes Shield eyes with goggles Keep away from children Do not allow contact with electrolyte Read instruction carefully Hazardous Explosive 11 Wear a seat belt and follow the tip over safety procedure...

Page 51: ...MEMO...

Page 52: ...afety alert symbol Signal word designates the degree of hazard Definition DANGER Indicates an imminently hazardous situation which if not avoided will result in death or serious injury WARNING Indicat...

Page 53: ...FRONT COMBINATION LAMP FUEL TANK FILLER COVER SIDE COVER REAR WHEEL SAFETY STEP FRONT WHEEL DRIVE WHEEL REAR COMBINATION LAMP SIDEVIEW MIRROR OPERATOR S SEAT COUNTERWEIGHT DRAWBAR OVERHEAD GUARD HAND...

Page 54: ...HORN BUTTON STEERING WHEEL SHIFT LEVER STEERING COLUMN TILT LEVER GLOVE BOX INCHING PEDAL LIFT LEVER TILT LEVER COMBINATION LEVER PARKING BRAKE LEVER DRINK HOLDER STARTER SWITCH ACCELERATOR PEDAL BRAK...

Page 55: ...METER PANEL DIESEL POWERED TRUCKS FUEL GAUGE HOUR METER COOLING WATER TEMP GAUGE METER PANEL GAS POWERED TRUCKS FUEL GAUGE HOUR METER COOLING WATER TEMP GAUGE 2 4 INSTRUMENTS AND CONTROLS...

Page 56: ...starts up remove your hand from the key The starter switch will automatically return to the ON position NOTE 1 Do not keep the starter switch in the ON position while the engine is not running otherwi...

Page 57: ...traveling direction of the truck L Left side lights turn on N Off R Right side lights turn on NOTE The turn signal lever automatically returns to neutral when the steering wheel is returned to the st...

Page 58: ...NING LIGHTS INDICATOR LIGHTS 4 NEUTRAL LIGHT 5 GLOW INDICATOR 6 FUEL LEVEL WARNING LIGHT 7 ENGINE OIL PRESSURE WARNING LIGHT 8 SEDIMENTER WARNING LIGHT 9 CHARGE WARNING LIGHT METERS AND WARNING LIGHTS...

Page 59: ...of an hour 6 minutes Use it to determine maintenance schedule COOLING WATER TEMPERATURE GAUGE This gauge indicates the temperature of the engine cooling water Under the normal operating condition the...

Page 60: ...hat the engine oil level is low or the lubricating oil system is defective Stop the operation immediately and ask your local UniCarriers dealer to check your truck 2 9 INSTRUMENTS AND CONTROLS SEDIMEN...

Page 61: ...ring speed of the forks TILT LEVER CAUTION Seat yourself in the operator s seat and make sure there is no one around the truck before operating the tilt lever Pull back on the tilt lever to tilt back...

Page 62: ...r is in neutral The engine won t start if the shift lever is not in neutral The truck is equipped with a single shift lever on the steering column 1 speed for forward and reverse When the shift lever...

Page 63: ...he truck hold the steering wheel knob with your left hand Do not remove your hand from the knob during traveling STEERING COLUMN TILT LEVER CAUTION Adjust the steering column angle properly before sta...

Page 64: ...the pedal is further pressed the clutch is completely disengaged and the brakes are applied to the truck For more information look up USING INCHING PEDAL on page 3 3 BRAKE PEDAL Press the brake pedal...

Page 65: ...ck and vibration to provide comfort during traveling and operation SEAT POSITION ADJUSTMENT LEVER B RECLINING CONTROL LEVER C CAUTION Adjust the seat position before starting the day s work or each sh...

Page 66: ...at the right side and insert it into the receptacle at the left side until it clicks into place To unfasten the seat belt press the red button by the receptacle and the belt will automatically wind u...

Page 67: ...nnector and insert it into the receptacle until it clicks into place To unfasten the seat belt press the red button by the receptacle and the belt will automatically wind up into the seat GLOVE BOX Th...

Page 68: ...the load backrest Otherwise The operator might get injured from a falling load The forks might disengage from the carriage ENGINE HOOD CAUTION When opening or closing the engine hood place the steeri...

Page 69: ...sing the hood The engine hood stopper is located at the middle part of the gas damper To close the hood hold the hood and press the engine hood stopper with your finger while lowering the hood SIDE CO...

Page 70: ...ases otherwise the forks might disengage from the carriage causing personal injury When removal of the forks is needed When gathering the right and left forks together to the center for some reason Wh...

Page 71: ...th a safety step at each side of the truck body and a hand grip on the left front pole of the overhead guard When mounting or dismounting use the safety step and hand grip FUSE BOX The fuse box is loc...

Page 72: ...get off the truck After adding fuel tighten the cap securely A loose fuel cap might cause fuel leaks leading to a serious accident Before starting the engine make sure the fuel tank cap is securely ti...

Page 73: ...ated or the fuel injection pump might be damaged HYDRAULIC OIL TANK CAP The hydraulic oil tank cap is located at the right side area inside the engine hood The cap is provided with an oil dipstick RAD...

Page 74: ...the accelerator pedal under the floorboard The filler has a cap with an oil dipstick LIGHTS AND LAMPS CAUTION Check that lights and lamps come on and off properly If any light bulb is blown out repla...

Page 75: ...ors Keep the mirror surfaces always clean Adjust the sideview mirrors to gain full rear vision The sideview mirrors are provided on the front poles of the overhead guard one for each Rear side The tru...

Page 76: ...s the road or floor behind the truck at night to allow the operator to recognize obstacles if any on the road or floor easily BEACON LIGHT Use an optional beacon light in the case when the truck is re...

Page 77: ...SWITCHES The switches for the rear work light and others are located as shown above Follow the instructions on the decal near each switch 2 26 INSTRUMENTS AND CONTROLS...

Page 78: ...safety alert symbol It is used to warn the reader about a potential source of human injury To prevent injury or death make sure you understand and follow all the safety messages following this safety...

Page 79: ...hanges and lubrication are recom mended to do earlier than specified Do not run the engine needlessly at high rpm without load RELATIONSHIP BETWEEN LOAD AND STABILITY OF TRUCK The lift truck keeps a b...

Page 80: ...ndustrial standards and UniCarriers lift trucks are manufactured complying with these standards However note that the stability of lift trucks is not assured at all times but only when the following c...

Page 81: ...n the trailer while being transported For the dimensions and weight of the lift truck refer to page 5 2 SPECIFICATIONS After the lift truck has been transported to a new destination pre operation and...

Page 82: ...bridge is secured On rainy days the lift truck is apt to skid on the ramp or loading bridge Use ramps or loading bridges with an anti skid surface If they are not available cancel or postpone the ope...

Page 83: ...tarter key will automatically return to the ON position 5 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...

Page 84: ...the starter motor Wait for a while and start all over again If the engine is hard to start despite several tries check the fuel level in the fuel tank the fuel system for mixing of air or the electric...

Page 85: ...g the truck to a complete stop SLOWING DOWN Ease up on the accelerator pedal If necessary press the brake pedal TURNING CAUTION Note that the rear end counterweight of the truck swings when you turn t...

Page 86: ...on the ground 3 Turn the key switch OFF to shut down the engine 4 Remove the key and keep it sure 5 Dismount from the truck carefully GROUND CONDITION CAUTION Use due caution when traveling on a rough...

Page 87: ...y s work When the truck has a label given above it uses cooling water containing 30 LLC Long Life Coolant If this is the case there is no need to change the cooling water for 2 years The freezing temp...

Page 88: ...g or closing the radiator cap Hot cooling water might spout out to cause serious burns To get a good cooling effect use caution not to allow leakage of cooling water and the forming of scale or corros...

Page 89: ...area Slowly lower the load into position Make sure the load is securely stacked 8 Disengage the forks from the pallet or load using necessary lift tilt operation and then back away 9 After making sur...

Page 90: ...load handling levers several times slowly to remove the residual pressure from the cylinders and hoses Remove the starter key and keep it in a safe place LONG TERM STORAGE Perform the following checks...

Page 91: ...MEMO...

Page 92: ...ymbol It is used to warn the reader about a potential source of human injury To prevent injury or death make sure you understand and follow all the safety messages following this safety alert symbol S...

Page 93: ...il level checks and addition of oil should be made with the truck parked on a level surface Preventive maintenance services should be done in an orderly manner and due care taken to prevent personal i...

Page 94: ...ading to a serious accident If you find any failure contact your local UniCarriers dealer Keep the inflation pressure of the tires always at proper level NOTE Low air pressure reduces tire service lif...

Page 95: ...s All hub nuts should be tightened to the specified torque Hub nut tightening torque Front wheels Rear wheels 128 190 N m 13 19 4 kgf m 94 140 ft lbs Single and doubles tires 471 549 N m 48 56 kgf m 3...

Page 96: ...osen the split rim connecting bolts using a special tool It is advisable to ask a specialist to retighten the connecting bolts disassemble and reassemble the tire and rim and inflate the tire The disa...

Page 97: ...of causing an explosion Raise the left side cover to remove Check the battery electrolyte level Keep the electrolyte level between the UPPER LEVEL and LOWER LEVEL on the battery case Clean the top of...

Page 98: ...the engine or when the engine is cold When removing the radiator cap loosen it slightly to release the pressure and then remove Loosen the two radiator cover mounting bolts and remove the radiator cov...

Page 99: ...in and check the oil level The level should be within the range between the upper and lower marks on the dipstick Do not add engine oil above the upper mark on the dipstick NOTE Engine oil level check...

Page 100: ...reas indicated by arrows Check also for cracks or damage of the belt If defective adjust or replace it with a new one Engine model Belt deflection K21 12 14 mm 0 5 0 6 in When a pressure of 98 N 10 kg...

Page 101: ...to read oil level H mark Highest position of the standard truck L mark Lowest position of the standard truck S mark For trucks with a lift height of 6 m or more or for special trucks the oil level sho...

Page 102: ...FLUID LEAKAGE Check the master cylinder and brake piping for fluid leaks 14 LOAD BACKREST Check the load backrest for deformation cracks or damage or loose or missing mounting bolts Retighten where ne...

Page 103: ...attached to the vehicle frame tongue and the buckle are not damaged and can be engaged and disengaged properly webbing does not have frayed stitching 18 ADJUSTING OPERATOR S SEAT AND STEERING COLUMN A...

Page 104: ...r switch from OFF to ON Make sure the warning lights come on in red and go out soon after the engine has started 24 FUEL LEVEL Check the fuel level using the fuel gauge on the meter panel Make sure th...

Page 105: ...play ask your local UniCarriers dealer for inspection and repair Press each pedal to check if it operates smoothly Release the pedal to check if it returns securely Also check each pedal for proper he...

Page 106: ...N TENSION Raise the forks 50 mm 2 in off the ground or floor surface and check that the right and left lift chains have the same tension If uneven tension is found adjust the tension using the adjusti...

Page 107: ...l or fuel leaks and never leave waste cloth or paper inside the engine room Check the condition of exhaust gas after the engine has been warmed up Colorless or light blue Normal Complete combustion Bl...

Page 108: ...low speed and turn the steering wheel a little to the right and left to check if the truck is steered properly 37 PARKING BRAKE TEST Pull the parking brake lever to check if the truck is properly brak...

Page 109: ...ERATOR 3 RADIATOR RESERVOIR TANK 4 BATTERY 5 FUSE BOX 6 FUEL FILTER 7 ENGINE OIL FILTER 8 DISTRIBUTOR 9 ENGINE OIL FILL PORT 10 HYDRAULIC OIL TANK CAP 11 CARBURETOR 12 AIR CLEANER 1 2 3 4 5 6 7 8 9 10...

Page 110: ...4 COOLING FAN 5 ENGINE OIL FILL PORT 6 FAN BELT 7 RADIATOR HOSE 8 RADIATOR RESERVOIR TANK 9 BATTERY 10 ENGINE OIL DIPSTICK 11 FUSE BOX 12 FUEL PUMP 13 SEDIMENTER FUEL FILTER 14 BLOW BY GAS HOSE 15 EXH...

Page 111: ...ANER 2 GENERATOR 3 COOLING FAN 4 INJECTION NOZZLE 5 RADIATOR RESERVOIR TANK 6 BATTERY 7 FUSE BOX 8 SEDIMENTER FUEL FILTER 9 ENGINE OIL FILTER 10 CRANKCASE BREATHER 11 ENGINE OIL FILL PORT 12 HYDRAULIC...

Page 112: ...turns to loosen it NOTE Do not loosen the drain cock excessively otherwise fuel might spill 3 Pump the priming pump a few times to drain water from inside the sedimenter 4 Tighten the drain cock plug...

Page 113: ...nstall the sedimenter Reset the cock into the original position 5 Loosen the fuel filter drain plug 6 Pump the priming pump on top of the fuel filter a few times to drain water from inside the filter...

Page 114: ...ing a fire hazard Whenever the fuel filter is replaced or the fuel tank is drained air bleed the fuel system in the following manner C240 1 Loosen the air bleeding plug overflow valve of the injection...

Page 115: ...ing will be completed in a couple of minutes 4 Turn the starter switch to the START position to crank the engine Check for fuel leakage in the fuel system 5 Turn the air bleeding plug clockwise to clo...

Page 116: ...rnt bulb with a new one of the same capacity They function regardless of the key switch position They function when the key switch is in ON FUSIBLE LINK MAIN FUSE As the main fuse for the entire truck...

Page 117: ...ified personnel The lift truck uses tires which have an inflation pressure far higher than those of general passenger cars The use of improper parts or work procedure will cause a serious accident Tir...

Page 118: ...e ground Remove the hub nuts loosened 5 Remove the tire from the hub 6 When reinstalling the tire use the reverse order of removal Tighten the hub nuts in a diagonal order and evenly Hub nut tightenin...

Page 119: ...cable finally Connect the cable to a point away from the battery such as the engine hood catch mounting bolt but not to the terminal of the battery This will help prevent the occurrence of sparks whic...

Page 120: ...s in the reverse order of connection ADJUSTING OPERATING FORCE OF PARKING BRAKE LEVER ADJUSTMENT 1 Engage the spring scale to the parking brake lever as shown in the sketch and measure the force requi...

Page 121: ...TION Be sure to read INSPECTION AND SERVICE in Chapter 1 SAFETY before checking or servicing the truck PERIODICAL REPLACEMENT OF SAFETY PARTS In order to perform safe operation the importance of preve...

Page 122: ...ck for oil leak Rod arm and king pin Check for looseness warping or damage Rear axle Check for bend damage or installation Steering cylinder Check for loose mounting part or joint Brake piping Check f...

Page 123: ...ake oil change job if required CAUTION Do not try to change the engine oil immediately after the engine is shut down The engine oil is very hot Change the engine oil when the oil is properly warm Befo...

Page 124: ...ile check the oil level using the oil level dipstick The oil level should be between the H and L marks on the dipstick If the level is low add oil CHANGING ENGINE OIL FILTER CAUTION The engine is very...

Page 125: ...TING LIFT CHAIN Apply engine oil to the lift chains using an oiler or brush To allow oil to enter between each pin and link plate of the lift chain observe the following conditions Loosen the chain su...

Page 126: ...1 point A Rear axle 8 points in all B Axle support 2 king pin 3 knuckle 3 Mast support 2 points C Tilt cylinder 4 points D Inner and outer channels in areas which come in contact with end rollers Appl...

Page 127: ...ides shown in the sketch for masts with free lift mechanism CAUTION Do not climb the mast Do not put your hand or foot on the connecting members or into the mast assembly You might get injured if the...

Page 128: ...diesel powered trucks Cooling water Change every 2 years for trucks using LLC Fork stopper pins Check for damage or wear Distributor Check for cracked cap gas powered trucks Spark plug Adjust the gap...

Page 129: ...you want to drain contamination or water from the filter CHANGING FUEL FILTER Diesel powered trucks CAUTION Wipe away any spilt fuel around the fuel filter There is a danger of causing a fire hazard...

Page 130: ...ing gas powered trucks Fuel tank Clean inside B rake uid Change Torque convertor oil Change Torque converter inline lter Change Front axle Change oil Wheel bearing Disassemble and change grease Mast s...

Page 131: ...der and wheel cylinder Change piston cup and check valve Wheel brake Disassemble check adjust and change brake drum and brake shoe Wheel brake Check back plate for deformation cracks or loose installa...

Page 132: ...Retighten cylinder head bolts G E Torque wrench first time only C240 Check cylinder compression pressure Compression gauge Blow by gas reducing device Check metering valve and piping for clogging or d...

Page 133: ...Daily Monthly 200 hrs Trimonthly 600 hrs Semiannually 1200 hrs Annually 2400 hrs Transmis sion Check shift levers for operation and looseness Operate Check for oil leaks Visual Change oil Operate Tor...

Page 134: ...SYSTEM Checking item Service Required Tools Daily Monthly 200 hrs Trimonthly 600 hrs Semiannually 1200 hrs Annually 2400 hrs Steering wheel Check for play Operate Check for looseness in axial or radia...

Page 135: ...erence Visual Check for loose connections or clamp Touch Wheel brake Check for fluid leaks oil leaks for trucks with power brake Visual Check fluid level Visual Check master cylinder and wheel cylinde...

Page 136: ...only Check for looseness of lift cylinder tail bolts piston rod head bolts U bolts piston head guide bolts Test hammer first time only Check rollers roller pins and welds for cracks or damage Visual C...

Page 137: ...Semiannually 1200 hrs Annually 2400 hrs Ignition device gas powered trucks Check distributor cap for cracks G Visual Check spark plug for burn G Visual Adjust spark plug gap G Plug gap gauge Clean sp...

Page 138: ...r operation and installation Operate Sideview mirrors Check for contamination or damage Visual Check for proper visibility Visual Warning lights meters Check for operation Operate Rear reflector Licen...

Page 139: ...MEMO...

Page 140: ...or death make sure you understand and follow all the safety messages following this safety alert symbol Signal word designates the degree of hazard Definition DANGER Indicates an imminently hazardous...

Page 141: ...Specifications are subject to change without notice H A F B L K J D G C M E P 6 12 5 2 SPECIFICATIONS...

Page 142: ...mast raised H mm in 4030 158 7 Wheelbase mm in 1600 63 0 Tread front mm in 970 38 2 rear mm in 970 38 2 Fork size mm in length K x width M x thickness L 1070 x 122 x 40 42 1 x 4 8 x 1 6 Fork spacing P...

Page 143: ...mast raised H mm in 4030 158 7 Wheelbase mm in 1600 63 0 Tread front mm in 970 38 2 rear mm in 970 38 2 Fork size mm in length K x width M x thickness L 1070 x 122 x 40 42 1 x 4 8 x 1 6 Fork spacing P...

Page 144: ...t raised H mm in 4250 167 3 Wheelbase mm in 1700 66 9 Tread front mm in 1000 39 4 rear mm in 970 38 2 Fork size mm in length K x width M x thickness L 1070 x 125 x 45 42 1 x 4 9 x 1 8 Fork spacing P m...

Page 145: ...tay Radiator reservoir tank Tilt steering wheel Turn signal Full transistor ignition system G Sedimenter D Hour meter Engine water temp gauge Fuel gauge Engine oil pressure gauge Charge warning light...

Page 146: ...pecifications and those with high mast whose lifting height is less than 5 m Note that load charts for lift trucks with a high mast whose lifting height is more than 5 m or those with an attachment ha...

Page 147: ...Pa kgf cm2 13 7 140 11 76 120 Compression pressure MPa kgf cm2 rpm 1 45 14 8 250 3 2 3 7 33 38 300 3 0 31 200 Valve clearance both intake and exhaust valves mm 0 38 when warm 0 18 0 22 when cold 0 45...

Page 148: ...223 N m 15 1 22 7 kgf m 109 164 ft lbs A 100 120 N m 10 12 kgf m B 32 49 N m 3 3 5 kgf m Engine mount bolts BOLT AND NUT TORQUE Rear axle mount bolts 77 115 N m 7 85 11 7 kgf m 57 85 ft lbs 5 9 SERVI...

Page 149: ...le tires 471 549 N m 48 56 kgf m 347 405 ft lbs Drive shaft mount bolts 96 111 N m 9 8 11 3 kgf m 71 82 ft lbs Hub nuts rear wheel 128 190 N m 13 19 4 kgf m 94 140 ft lbs Hub nuts front wheel Inner nu...

Page 150: ...13 F above SAE 10W ATF DEXRON 40 C above 40 F above ATF DEXRON 5 Radiator 7 6 2 0 9 8 2 6 11 3 2 9 Soft water LLC Note 1 6 Fuel tank 70 18 5 Note 2 7 Engine crankcase 3 8 1 0 7 6 2 0 5 4 1 4 Engine oi...

Page 151: ...s Oil 32 ESSO Teresso 32 Nuto HP 32 CALTEX Rando Oil 32 Rando Oil HD32 ATF DEXRON Class Supplier GM make DEXRON or equivalent MOBIL MOBIL ATF 220 SHELL SHELL Dexron ESSO ESSO ATF CALTEX Texamatic Flui...

Page 152: ...ajor components are imprinted on the truck or indicated on name plates The above sketch shows the serial number plate of the mast These decals should be replaced immediately if missing or defaced dama...

Page 153: ...DIESEL ENGINE C240 ENGINE SERIAL NUMBER GASOLINE ENGINE K21 DIESEL ENGINE V2403 5 14 AFTER THE SALE SERVICE...

Page 154: ...long time use To ensure the best performance of the lift truck use genuine UniCarriers parts which are used for new trucks When ordering spare parts be sure to designate UniCarriers genuine parts GENU...

Page 155: ...AST TYPE MAST SERIAL NUMBER ENGINE SERIAL NUMBER KEY NUMBER TRUCK CONTROL NUMBER NAME OF SUPERVISOR ATTACHMENT DRIVER S LICENSE NO ISSUED ON DATE OF PURCHASE AUTHORIZED UniCarriers DEALER PHONE NUMBER...

Page 156: ...CONTENTS 0 9 6 2 A E 6 2 E L 6 3 L R 6 4 R U 6 5 6 1 6 INDEX...

Page 157: ...YTE LEVEL WARNING LIGHT 2 9 BEACON LIGHT 2 25 BOLT AND NUT TORQUE 5 9 BRAKE AND CLUTCH FLUID RESERVOIR 2 21 BRAKE PEDAL 2 13 C CAUTION PLATES 1 41 CHANGING ENGINE OIL 4 32 CHANGING ENGINE OIL FILTER 4...

Page 158: ...2 21 FUSE BOX 2 20 FUSIBLE LINK MAIN FUSE 4 25 G GENUINE UniCarriers LUBRICANTS 5 15 GENUINE UniCarriers PARTS 5 15 GLOVE BOX 2 16 GLOW INDICATOR 2 9 GREASING POINTS 4 35 H HIGH LOAD BACKREST HBR 2 25...

Page 159: ...25 OVERHEAD GUARD 2 17 OVERHEAD GUARD WITH WIRE NETTING 2 25 P PARKING 1 28 PARKING BRAKE LEVER 2 12 PARKING BRAKE WARNING LIGHT 2 9 PERIODICAL REPLACEMENT OF SAFETY PARTS 4 30 PERIODIC INSPECTION 4...

Page 160: ...P BUZZER 2 25 SPECIFICATIONS 5 2 SPEED ALARM SYSTEM SAS 2 25 SPEEDOMETER SM 2 25 SPEED RANGE SHIFT LEVER 2 11 STABILITY OF LIFT TRUCK 3 3 STARTER SWITCH 2 5 STARTING THE ENGINE WITH AUXILIARY BATTERY...

Page 161: ...ISSUED AUG 2014 MARKETING GROUP Bellport E 6 22 7 Minami Oi Shinagawa ku Tokyo 140 0013 Japan FAX Japan 81 3 6730 3371 All rights reserved Printed in China No OMFBE CK9140...

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