UTILEV UT25C Operation And Maintenance Manual Download Page 123

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117

1. Wire Harness End View and

1. Wire Harness End View and Pin Definition

Pin Definition

A-

20 pin plug

8 pin plug

210

111 112 113 114 115 116 117 118 119 220

11 22 33 44

11 22 33 44
55 66 77 88

55 66 77 88

Function

Function Definition

Definition

Controller Power + (+12 V)

Power Ground

Parking brake

Parking brake light outlet

light outlet (high efficiency)

(high efficiency)

Mast lifting and

Mast lifting and lowering output

lowering output (high efficiency)

(high efficiency)

High- and low-speed solenoid valve (high efficiency)

Reverse sole

Reverse solenoid valve

noid valve (high efficiency)

(high efficiency)

Forward

Forward solenoid

solenoid valve

valve (high

(high efficiency)

efficiency)

A10

Output

Output on

on (high

(high efficiency)

efficiency)

A11

+12V reserved, for external connection to power supply of indicator light, not for

connection to large current loading. (cancelled)

A12

Power Ground

A13

BATT+

BATT+ reserved, for external connection to pow

reserved, for external connection to power supply of indicator light, not for

er supply of indicator light, not for

connection to large current loading. (cancelled)

A14

Seat

Seat switch

switch (high

(high efficiency)

efficiency)

https://www.forkliftpdfmanuals.com/

Summary of Contents for UT25C

Page 1: ...d Forklift Truck 3 5T Internal Combustion Counterbalanced Forklift Truck Emission Compliant Emission Compliant OPERA OPERATION AND M TION AND MAINTENANCE M AINTENANCE MANUAL ANUAL Original Instruction Original Instruction October 2015 October 2015 https www forkliftpdfmanuals com ...

Page 2: ...ize the truck s potential All operators service All operators service technicians and supervisors should read this manual thoroughly before working with the forklift technicians and supervisors should read this manual thoroughly before working with the forklift Product specifications in this manual may vary from your actual truck Product specifications in this manual may vary from your actual truc...

Page 3: ...L DUAL DUAL YQXD25 YQXD25 2 2 UT25P UT25P PSI PSI 2 4L 2 4L LPG LPG YQXD25 YQXD25 2 2 UT25C UT25C PSI PSI 2 4L 2 4L LPG LPG YQXCD25 YQXCD25C 5 C 5 3 0T 3 5T 3 0T 3 5T UT30P UT30P YANMAR YANMAR 3 3L 3 3L DSL DSL 4TNE98 4TNE98 YQXD30 YQXD30 UT30P UT30P MAZDA MAZDA 2 2L 2 2L DUAL DUAL YQXD30 5 YQXD30 5 UT30P UT30P MAZDA MAZDA 2 2L 2 2L LPG LPG YQXD30 5 YQXD30 5 UT30C UT30C MAZDA MAZDA 2 2L 2 2L LPG L...

Page 4: ...25 4 Operator Protection Equipment 4 Operator Protection Equipment 34 34 5 5 Maint Maintenanc enance e 35 35 5 1 Daily Maintenance 5 1 Daily Maintenance 8 hours 8 hours 35 35 5 2 Weekly Maintenance 5 2 Weekly Maintenance 40 Hours 40 Hours 39 39 5 3 Monthly Maintenance 166 Hours 5 3 Monthly Maintenance 166 Hours 45 45 5 4 Sem 5 4 Semi Annual Ma i Annual Maintenance 1 intenance 1000 H 000 Hours ours...

Page 5: ... 66 66 8 2 Long Term Storage 8 2 Long Term Storage 67 67 8 3 Forklift Operation after Long 8 3 Forklift Operation after Long Term Storage Term Storage 68 68 9 Maintenance 9 Maintenance 69 69 9 1 Preventive Maintenance Schedule 9 1 Preventive Maintenance Schedule 69 69 9 3 Periodic Replacement of Chain and Hydraulic Parts 9 3 Periodic Replacement of Chain and Hydraulic Parts 75 75 9 4 Forklift Flui...

Page 6: ...neumatic 112 112 14 Operator Presence Sensing System required in most markets 14 Operator Presence Sensing System required in most markets 115 115 15 Operation and Notice about LPG Forklift 15 Operation and Notice about LPG Forklift 121 121 16 Operational Method of 16 Operational Method of Lead Acid Battery Lead Acid Battery 134 134 17 Use Installation and 17 Use Installation and Safety Rules of A...

Page 7: ... truck smoothly when starting turning traveling braking and parking On a slick or wet road decrease speed when turning road decrease speed when turning 5 5 Lower the forks and tilt the mast backwards when traveling with a load Lower the forks and tilt the mast backwards when traveling with a load 6 6 Be careful when traveling on a grade If the slope angle is bigger than 10 travel forward up slope ...

Page 8: ...rks down make the shift lever is in neutral shut down the engine and cut the power When parking on a grade make sure to tighten the brake lever If necessary use a block and cut the power When parking on a grade make sure to tighten the brake lever If necessary use a block when parking on a grade for a long time when parking on a grade for a long time 18 18 If the truck suddenly malfunctions or for...

Page 9: ...ay arrange for a modification or alteration to a powered industrial truck provided the user business the user may arrange for a modification or alteration to a powered industrial truck provided the user shall shall a a Arrange for Arrange for the m the modification or odification or alteration alteration to be to be designed tested designed tested and implemented and implemented by an by an engine...

Page 10: ... cylinder 5 Lifting cylinder 6 Steering wheel 6 Steering wheel 7 Mast 7 Mast 8 Overhead guard 8 Overhead guard 9 LPG Tank 9 LPG Tank 10 Seat 10 Seat 11 Counter Weight 11 Counter Weight 12 Hood 12 Hood 13 Truck frame 13 Truck frame 14 Rear wheel 14 Rear wheel 15 Front wheel 15 Front wheel 1 1 2 2 3 3 4 4 5 5 6 6 7 7 9 9 8 8 10 10 11 11 12 12 14 14 15 15 13 13 https www forkliftpdfmanuals com ...

Page 11: ...5 5 2 1 Instruments 2 1 Instruments Standard Standard Optional Operator Presence Optional Operator Presence https www forkliftpdfmanuals com ...

Page 12: ...ns the indicator is in green Under normal conditions the indicator is in green zone 60 C zone 60 C 115 C 115 C Caution Caution If the indicator is in the red zone stop the If the indicator is in the red zone stop the truck immediately Decrease engine speed to truck immediately Decrease engine speed to allow the engine to cool Check engine allow the engine to cool Check engine coolant level and ins...

Page 13: ...s lamp indicates the pressure of the engine lube oil The lamp comes on when the ignition switch is lube oil The lamp comes on when the ignition switch is set to ON but goes out after the engine starts and set to ON but goes out after the engine starts and the accelerator pedal is pressed the accelerator pedal is pressed Caution Caution If the light continues to stay lit or comes If the light conti...

Page 14: ...ch is set to the ON position After the engine starts the lamp should go out After the engine starts the lamp should go out During operation the indicator light will come on if During operation the indicator light will come on if the oil temperature exceeds the normal range 60 C the oil temperature exceeds the normal range 60 C 120 C 120 C Caution Caution If the lamp comes on stop the truck If the ...

Page 15: ...he indicator light will be on be on The truck can be started up only in the neutral The truck can be started up only in the neutral position position It s prohibited for truck in the neutral position slipping It s prohibited for truck in the neutral position slipping when it s on the slope when it s on the slope Parking Indicator Parking Indicator Parking indicator shows on means brake is applied ...

Page 16: ...verse lever 2 Reverse lever 3 Turn signal lever 3 Turn signal lever 4 Light switch 4 Light switch 5 Strobe light switch 5 Strobe light switch 6 Horn button 6 Horn button 7 Fuel Selection switch 7 Fuel Selection switch https www forkliftpdfmanuals com ...

Page 17: ...key to Start position turn the key to Start position CAUTION CAUTION 1 Do not leave the key in the 1 Do not leave the key in the ON ON position when engine is off Doing so will position when engine is off Doing so will discharge discharge battery battery 2 Do not turn key to the START 2 Do not turn key to the START position when the engine is running Doing so position when the engine is running Do...

Page 18: ...ubber cover at the center of steering Press the rubber cover at the center of steering wheel to sound horn wheel to sound horn Dual Fuel Toggle Switch 7 Dual Fuel Toggle Switch 7 Only for LPG Only for LPG gasoline forklift gasoline forklift From LPG to GAS From LPG to GAS 1 1 With the truck off change the dual fuel toggle With the truck off change the dual fuel toggle switch from LPG position to G...

Page 19: ...efore driving check cylinder and pipe Before driving check cylinder and pipe for leakage USE a sealant on all LPG for leakage USE a sealant on all LPG connections having NPT threads connections having NPT threads 2 2 After LPG is working before shutting After LPG is working before shutting down the engine down the engine a a Before storing for a long time you should Before storing for a long time ...

Page 20: ...or Pedal 12 Lift Lever 12 Lift Lever 13 Tilt Lever 13 Tilt Lever 14 Side Shift Lever 14 Side Shift Lever 15 Parking Brake Lever 15 Parking Brake Lever 16 Steer Colum 16 Steer Column Tilt Adjustment n Tilt Adjustment 17 Hood Latch 17 Hood Latch 18 Emergency Disconnect Switch 18 Emergency Disconnect Switch If Equipped If Equipped https www forkliftpdfmanuals com ...

Page 21: ...thout delay Inching Pedal 9 Inching Pedal 9 Depress the pedal partially to decrease hydraulic Depress the pedal partially to decrease hydraulic oil pressure Use inching pedal for Forklift loading and oil pressure Use inching pedal for Forklift loading and unloading and when slow speed is required When unloading and when slow speed is required When pedal is depressed all the way forklift will slow ...

Page 22: ...tronic pedal Electronic pedal Lift Lever 12 Lift Lever 12 For lifting or lowering the forks For lifting or lowering the forks Pulling up Pushing down Pulling up Pushing down Lift forks by tilting lever backward Lower forks by Lift forks by tilting lever backward Lower forks by tilting lever forward Control lifting lowering speed tilting lever forward Control lifting lowering speed with accelerator...

Page 23: ... tilt forward while the engine is being shut down forward while the engine is being shut down even if the tilt lever is pushed forward even if the tilt lever is pushed forward Side Shift Control Lever 14 Side Shift Control Lever 14 Used for left shifting and right shifting of the side Used for left shifting and right shifting of the side shift bracket shift bracket Push forward Push forward move t...

Page 24: ...able to suit individual operators The steering adjustable to suit individual operators The steering column is unlocked by pushing down the lever at the column is unlocked by pushing down the lever at the left side of steering column then adjust the angle suit left side of steering column then adjust the angle suit to the driver and pull up the lever to lock to the driver and pull up the lever to l...

Page 25: ...r to the right Unlock seat by moving the adjusting lever to the right Before operating truck make sure that seat is securely Before operating truck make sure that seat is securely locked locked Warning Warning a Place a Place key in OFF position before key in OFF position before adjusting the seat adjusting the seat b DO NOT attempt to adjust seat while truck b DO NOT attempt to adjust seat while ...

Page 26: ... belt sooner if damaged Replace safety belt sooner if damaged Overhead Guard Overhead Guard DO NOT operate forklift without the overhead DO NOT operate forklift without the overhead guard It is designed to protect the operator from falling guard It is designed to protect the operator from falling objects and meets the safety standard objects and meets the safety standard Hood Hood The hood can be ...

Page 27: ...t open higher than 70 degrees Celsius do not open the pressure cap of the radiator Loosen cap the pressure cap of the radiator Loosen cap slowly to allow steam to escape After that slowly to allow steam to escape After that tighten cap securely It is good practice to tighten cap securely It is good practice to use a thick waste cloth or the like when use a thick waste cloth or the like when removi...

Page 28: ...Safety Step and Safety Grip Safety Step and Safety Grip Safety steps are provided on both sides of the Safety steps are provided on both sides of the truck body The safety grip is located on the front left truck body The safety grip is located on the front left pillar of the overhead guard Use both the safety step pillar of the overhead guard Use both the safety step and safety grip when mounting ...

Page 29: ...brake securely Make sure apply the parking brake securely Make sure there is no naked flame near the area DO there is no naked flame near the area DO NOT smoke while handling fuel DO NOT NOT smoke while handling fuel DO NOT remain seated when adding fuel remain seated when adding fuel 2 After adding fuel securely close the 2 After adding fuel securely close the reservoir cap A loose cap could caus...

Page 30: ...ep the cap connected to the truck and tether to keep the cap connected to the truck and prevents the cap from venting to the environment per prevents the cap from venting to the environment per certification requirements certification requirements Rearview mirror Rearview mirror There are two rearview mirrors on the overhead There are two rearview mirrors on the overhead guard for operator to see ...

Page 31: ...ake care not to slip and take care not to slip If any warning lamp comes on move to a safe If any warning lamp comes on move to a safe place and check or repair the trouble place and check or repair the trouble When performing maintenance take care not to cut When performing maintenance take care not to cut hands head or other parts of body on truck edges hands head or other parts of body on truck...

Page 32: ...rks to the ground or floor and tilt them forward a little Shut down the engine and remove the forward a little Shut down the engine and remove the key key 11 11 Operate the controls smoothly DO NOT jerk the Operate the controls smoothly DO NOT jerk the steering wheel Avoid sudden stops starts or turns steering wheel Avoid sudden stops starts or turns 12 12 Control speed and observe traffic signs C...

Page 33: ...sles and other locations where vision is other locations where vision is restricted The speed restricted The speed should be kept slower than 1 3 of should be kept slower than 1 3 of max speed max speed 20 20 Keep fluid cans row cotton paper or chemicals Keep fluid cans row cotton paper or chemicals away from the truck during operation since they may away from the truck during operation since they...

Page 34: ...wn or control of the truck or cause the truck to bog down or turn over turn over Clear away trash and debris Pick up anything that Clear away trash and debris Pick up anything that might puncture the tires or cause the load to become might puncture the tires or cause the load to become unbalanced unbalanced Slow down when driving on wet and slippery Slow down when driving on wet and slippery roads...

Page 35: ...tently 25 25 It is dangerous to travel with forks higher than the It is dangerous to travel with forks higher than the appropriate position regardless of whether they are appropriate position regardless of whether they are loaded or not Maintain a good traveling posture loaded or not Maintain a good traveling posture When traveling the forks should be 15 to 30 cm When traveling the forks should be...

Page 36: ...ded qualified personnel should perform a off If needed qualified personnel should perform a sling operation making use of a hook or crane arm sling operation making use of a hook or crane arm attachment attachment Make sure the fork does not protrude from underneath Make sure the fork does not protrude from underneath the load The protruding fork tips may damage or turn the load The protruding for...

Page 37: ...t and overhead guard which may cause loss of life DO NOT place hands into the interspace of inner DO NOT place hands into the interspace of inner mast and outer mast mast and outer mast 34 34 When load is to be retrieved from a pile enter the When load is to be retrieved from a pile enter the area squarely Engage forks into the pallet carefully area squarely Engage forks into the pallet carefully ...

Page 38: ... On the truck with an attachment such as a load grab make certain the load is securely and correctly grab make certain the load is securely and correctly grabbed and pull the loading control level to the full grabbed and pull the loading control level to the full increase to relieve pressure increase to relieve pressure 38 38 Never lift loads when the truck is on an incline Never lift loads when t...

Page 39: ...riately for operating the truck Dress appropriately for operating the truck overalls or other protective uniforms safety helmet overalls or other protective uniforms safety helmet safety shoes etc Avoid wearing neckties or other safety shoes etc Avoid wearing neckties or other articles of clothing which may present a hazard if they articles of clothing which may present a hazard if they come into ...

Page 40: ...it must not be considered a substitute for good judgment be considered a substitute for good judgment and care when handling loads Do not remove and care when handling loads Do not remove the overhead guard the overhead guard The The SEAT SEAT BELT BELT AND AND HIP HIP RESTRAINT RESTRAINT provide additional means to help the operator provide additional means to help the operator keep the head and ...

Page 41: ... meters for problems Check the tires tire pressure and the entire truck Check the tires tire pressure and the entire truck for loose bolts for loose bolts 3 Check Fuel Mass 3 Check Fuel Mass A A fuel fuel level level gauge gauge is is provided provided on on the the indicator indicator panel Make sure the fuel level is sufficient for the panel Make sure the fuel level is sufficient for the day s w...

Page 42: ...the hot season cooling system in the hot season W Wa ar rn ni in ng g When the water temperature of the When the water temperature of the engine is engine is higher than 70 higher than 70 degrees Celsius degrees Celsius do do not open the pressure cap not open the pressure cap of the radiator of the radiator Loosen cap slowly to allow steam to escape Loosen cap slowly to allow steam to escape Afte...

Page 43: ...p of oil drain port insert tube into oil drain port and waste oil collection insert tube into oil drain port and waste oil collection bottle and loosen oil drain screw At the same time bottle and loosen oil drain screw At the same time have another in truck press brake pedal repeatedly have another in truck press brake pedal repeatedly The brake oil should flow from oil drain port watch the The br...

Page 44: ...ver Tilting Lever and Attachment 15 Lifting Lever Tilting Lever and Attachment Lever Check Lever Check Check the loading levers for lift tilt and optional Check the loading levers for lift tilt and optional attachment for looseness and smooth operation attachment for looseness and smooth operation Increase the rotate speed of engine make certain Increase the rotate speed of engine make certain tha...

Page 45: ...bolts should be properly installed and tightened before inflating tire and rim assembly An tightened before inflating tire and rim assembly An inflated tire contains potentially explosive energy DO inflated tire contains potentially explosive energy DO NOT overinflate NOT overinflate Pneumatic tires only Pneumatic tires only Tire Pressure GB T2982 2001 Tire Pressure GB T2982 2001 Truck type Truck ...

Page 46: ...t tube 4 4 Inspect the filter element for voids cuts or tears Inspect the filter element for voids cuts or tears and replace if required and replace if required 5 5 Install the filter element into the canister Install the filter element into the canister 2 Fan Belt Tension Check 2 Fan Belt Tension Check Stop the engine Stop the engine Use finger to press the belt at the midway point Use finger to ...

Page 47: ...eck the rollers rotation 4 4 Check the mast for cracks or bends Check the mast for cracks or bends 5 5 Operate the lever for lifting tilting and Operate the lever for lifting tilting and attachment attachment Check the overall Check the overall condition of condition of the mast the mast 5 Lift Chain Tension Check 5 Lift Chain Tension Check 1 1 Raise the fork about 10 Raise the fork about 10 15 cm...

Page 48: ...ing lubrication grease stop When applying lubrication grease stop the truck on a smooth road engine off and the truck on a smooth road engine off and pull hand brake Avoid injury to hand or body pull hand brake Avoid injury to hand or body and avoid falling off from high place Keep and avoid falling off from high place Keep safe safe 7 Chain Mast Lubrication 7 Chain Mast Lubrication For the lubric...

Page 49: ...2 2 Divided rim bolt Divided rim bolt 3 3 Drive shaft bolt Drive shaft bolt Specified Torque N m Specified Torque N m Capacity Capacity 2 2 3 5T 3 5T Hub nut Hub nut 441 441 588 588 Steering Wheel Steering Wheel Rear Wheel Rear Wheel 4 4 Rear hub nut Rear hub nut Specified Torque N m Specified Torque N m Capacity Capacity 2T 2T 3 5T 3 5T Hub nut Hub nut 157 157 176 176 5 5 Divided rim bolt Divided...

Page 50: ... should be more than60mm Check the inching pedal and clutch ped Check the inching pedal and clutch pedal using al using the same method the same method Height And The Free Clearance H Height And The Free Clearance H Free Free height height Press Press height height Free Free clearance clearance Brake Brake pedal pedal 120 120 130 130 60 60 1 1 3 3 Inching Inching pedal pedal 120 120 130 130 60 60 ...

Page 51: ... for repair repair Very thin oil indicates that the oil contains Very thin oil indicates that the oil contains gasoline Contact an authorized technician for repair gasoline Contact an authorized technician for repair 3 3 Drain plug tightening torque 29 N m Drain plug tightening torque 29 N m 39 N m 39 N m 4 4 Detach the oil filter using the appropriate tool Detach the oil filter using the appropri...

Page 52: ... hot h DO NOT touch the hot hydraulic oil or ydraulic oil or parts parts 1 1 Detach the rubber washer and the front Detach the rubber washer and the front baseplate baseplate 2 2 Detach Detach the the filter filter Handle Handle according according to to local local regulations regulations 3 3 Wipe the filter Wipe the filter base clean base clean Confirm that the Confirm that the old old washer on...

Page 53: ...Fuel System Diesel Diesel During fueling or draining water from separator During fueling or draining water from separator it s also necessary to bleed air in the it s also necessary to bleed air in the fuel system fuel system 1 1 Loosen the purging bolt Loosen the purging bolt 2 2 Pump the hand pump until no more air comes Pump the hand pump until no more air comes out at the purging bolt out at t...

Page 54: ...ess brake pedal repeatedly The brake oil should flow from oil drain repeatedly The brake oil should flow from oil drain port watch the liquid level of brake fluid reservoir add port watch the liquid level of brake fluid reservoir add new oil until the oil from oil drain port is clean and new oil until the oil from oil drain port is clean and then screw down screw of oil drain port then screw down ...

Page 55: ...and operate multiple valve joystick and turn system fill hydraulic oil in all system joystick and turn system fill hydraulic oil in all system 7 7 Check each hydraulic component and pipeline Check each hydraulic component and pipeline for leaks for leaks 8 8 Close the engine retract all mast cylinder rods Close the engine retract all mast cylinder rods check the oil level of hydraulic oil box Add ...

Page 56: ...y accelerate the wear of filter as this may accelerate the wear of fuel fuel system parts system parts 4 4 Install new filter Install new filter 5 5 Turn the new filter till the airproof mat adheres to Turn the new filter till the airproof mat adheres to surface surface 6 6 Screw down 2 3 turns Screw down 2 3 turns 5 5 Annual Maintenance 2000 hours 5 5 Annual Maintenance 2000 hours Perform the fol...

Page 57: ... 3 Remove breather plug and oil fluid position plug Remove breather plug and oil fluid position plug Put the oil from orifice bend to steering axle shell until Put the oil from orifice bend to steering axle shell until oil overflows from level plug oil overflows from level plug 4 4 Press level and install breather plug Press level and install breather plug 5 5 Start Start up forklift Run engine le...

Page 58: ...ot allow loose nuts before the front wheels leave the ground wheels leave the ground 7 7 Support forklift truck by putting additional Support forklift truck by putting additional wooden blocks under each side of the front wooden blocks under each side of the front end frame end frame as shown below Stop the engine as shown below Stop the engine 8 8 Take out the wheel nuts and replace the front Tak...

Page 59: ...ift trucks on level concrete Place lift trucks on level concrete 2 2 Pull the parking brake lever and place chocks Pull the parking brake lever and place chocks before front wheels to prevent movement of forklift before front wheels to prevent movement of forklift 3 3 Put the lifting jack under the counterweight Put the lifting jack under the counterweight C Ca au ut ti io on n Make sure the jack ...

Page 60: ... sure that wooden blocks used to support lift truck are solid one support lift truck are solid one piece units piece units c Never get under forklift while it is c Never get under forklift while it is supported only by wooden blocks supported only by wooden blocks 7 7 Retighten nuts as shown in figure below Retighten nuts as shown in figure below 8 8 Remove the wooden block under chassis body Remo...

Page 61: ...apor place the muzzle to compressed air or vapor place the muzzle to radiator a right angle radiator a right angle 5 The operation of 5 The operation of engine while overheated engine while overheated If the engine is too hot DO NOT stop it at once If the engine is too hot DO NOT stop it at once Instead perform the following steps Instead perform the following steps 1 1 Reduce speed Reduce speed 2...

Page 62: ... includes tire forks and body includes tire The lift truck keeps the balance of weight between the The lift truck keeps the balance of weight between the truck body and the load on the forks with the center of the front truck body and the load on the forks with the center of the front wheels as a fulcrum when the rated capacity load is placed in wheels as a fulcrum when the rated capacity load is ...

Page 63: ...er to make the truck stable the combined In order to make the truck stable the combined center must be within the triangle which is made up of center must be within the triangle which is made up of the two points where the two front wheels touch the the two points where the two front wheels touch the ground and the midpoint of the back driving axle ground and the midpoint of the back driving axle ...

Page 64: ...e truck because the speed of tipping is much faster than you You should firmly grasp the steering faster than you You should firmly grasp the steering wheel holding it close to your chest and lean away from wheel holding it close to your chest and lean away from the the direction direction of of the the tip tip AL ALWAY WAYS S WEAR YOUR WEAR YOUR SEATBELT SEATBELT https www forkliftpdfmanuals com ...

Page 65: ...he load s center of gravity depends on whether the mast is tilted forward or backward raised or the mast is tilted forward or backward raised or lowered which means that the combined center of lowered which means that the combined center of gravity also changes accor gravity also changes accordingly dingly The forklift s combined center of gravity is The forklift s combined center of gravity is de...

Page 66: ...he load LOAD and LOAD CENTER DISTANCE is specified on the load capability chart If the load center is moved near the front of capability chart If the load center is moved near the front of forklift the load should be reduced forklift the load should be reduced Caution Caution Load Capability Chart Load Capability Chart This chart shows the relationship of MAX LOAD And This chart shows the relation...

Page 67: ...ous to press the brake suddenly It may result in capsizing or sliding down of the load because of huge force to the front of the load because of huge force to the front Centrifugal force is present during turning and its direction is from the turning center to the Centrifugal force is present during turning and its direction is from the turning center to the outer If the force is strong enough it ...

Page 68: ...engine starts when engine starts Caution Caution The time to start should be less than 5 The time to start should be less than 5 seconds each attempt and the interval between seconds each attempt and the interval between attempts should be at least attempts should be at least 2 minutes 2 minutes After engine has After engine has started started Check the rotation sound or gear of the engine Check ...

Page 69: ... than when turning the front wheels of a car of a car Stopping or parking the truck Stopping or parking the truck 1 1 Slow down and press the brake pedal to stop the Slow down and press the brake pedal to stop the truck in the case of clutch type machine the clutch truck in the case of clutch type machine the clutch pedal is used pedal is used 2 2 Place the shift lever in neutral Place the shift l...

Page 70: ...e loads from o raise loads from the ground the ground 1 1 First lift the forks 5 to 10 cm off the ground First lift the forks 5 to 10 cm off the ground or floor and make sure loads rest stable or floor and make sure loads rest stable 2 2 Then tilt the mast backwards fully and lift Then tilt the mast backwards fully and lift forks up to 15 to 20 cm off ground then start moving forks up to 15 to 20 ...

Page 71: ...n when approaching the area where the load is to be retrieved load is to be retrieved Stop the truck in front of the load so that the Stop the truck in front of the load so that the distance between the load and fork tips is about 30 distance between the load and fork tips is about 30 cm cm Check the condition of the load Check the condition of the load Tilt the mast forward until forks become hor...

Page 72: ...ed repaired immediately immediately Do the following things Do the following things 1 1 Clean oil and grease stains with a cloth and Clean oil and grease stains with a cloth and water on the water on the truck body truck body 2 2 Check the whole truck especially the tires Check the whole truck especially the tires 3 3 Fill the fuel tank with the proper fuel Fill the fuel tank with the proper fuel ...

Page 73: ...st once a week If the Start the forklift at least once a week If the coolant has already been drained then add coolant to coolant has already been drained then add coolant to the radiator Then run the engine at low speed the radiator Then run the engine at low speed 5 5 DO NOT park the forklift on asphalt surfaces DO NOT park the forklift on asphalt surfaces during summer during summer W Wa ar rn ...

Page 74: ...e hydraulic oil reservoir and fuel Clean the hydraulic oil reservoir and fuel reservoir removing any dirt or water and add with reservoir removing any dirt or water and add with new hydraulic oil fuel new hydraulic oil fuel 4 4 Check the clearance of the valve gas valve cap Check the clearance of the valve gas valve cap and other parts on the engine and other parts on the engine 5 5 Add antifreeze...

Page 75: ...tions and maintenance to keep the truck in good working condition good working condition 4 4 Do not ignore Do not ignore routine inspection and maintenance routine inspection and maintenance 5 5 Only use original approved parts Only use original approved parts 6 6 Don t use different oil when changing or adding oil Don t use different oil when changing or adding oil 7 7 Dispose of waste Dispose of...

Page 76: ...ator 1 1 O O O O O O O O 7 Clean or replace the filter element of air cleaner 7 Clean or replace the filter element of air cleaner O O O O The remaining part of engine maintenance refer to engine manual The remaining part of engine maintenance refer to engine manual NOTE NOTE 1 If the work place has a lot of dirt or other pollutants time between maintenance intervals should be decreased 1 If the w...

Page 77: ... portion for damage 3 Piping or pipe connector portion for damage O O O O O O O O 4 Mounting bracket of LPG cylinder for looseness or 4 Mounting bracket of LPG cylinder for looseness or damage damage O O O O O O O O 5 Filter for LPG 5 Filter for LPG O O O O The remaining part of engine maintenance refer to engine manual The remaining part of engine maintenance refer to engine manual NOTE NOTE 1 If...

Page 78: ...ce clearance O O O O O O O O Check or Replace brake fluid Check or Replace brake fluid O O O O Check for proper brake operation Check for proper brake operation O O O O O O O O Check inching brake pedal for free travel and Check inching brake pedal for free travel and clearance clearance O O O O O O O O Hydraulic Hydraulic system system Check for oil level Change oil Check for oil level Change oil...

Page 79: ...ng cylinders for proper operation and connection connection O O O O O O O O Check tilting cylinders for proper operation and Check tilting cylinders for proper operation and connection connection O O O O O O O O Check for forks and stopper pins for damage or Check for forks and stopper pins for damage or wear wear O O O O O O O O Check fork base and hook welding for defective Check fork base and h...

Page 80: ... 376 376 376 502 502 22 22 230 230 290 290 290 290 350 350 384 384 512 512 512 512 683 683 24 24 300 300 377 377 370 370 450 450 488 488 650 650 651 651 868 868 27 27 450 450 530 530 550 550 700 700 714 714 952 952 952 952 1269 1269 30 30 540 540 680 680 680 680 850 850 969 969 1293 1293 1293 1293 1723 1723 33 33 670 670 880 880 825 825 1100 1100 1319 1319 1759 1759 1759 1759 2345 2345 36 36 900 9...

Page 81: ... service life has expired sooner if they damaged Name of Name of key safe part key safe part service life years service life years Brake Brake hose hose or or hard hard tube tube 1 2 1 2 Hydraulic Hydraulic rubber rubber hose hose for for lifting lifting system system 1 2 1 2 Lifting Lifting chain chain 2 4 2 4 High High pressure pressure rubber rubber hose hose or or tube tube for for hydraulic h...

Page 82: ... 10 1 11 1 Industrial Vaseline Industrial Vaseline 2 2 Electrode of Storage Electrode of Storage battery battery Lubrication grease Lubrication grease Use lithium grease Use lithium grease Remark Remark the 2T the 2T 3 5T trucks have been added antirust antifreeze liquid you need not discharge the liquid even 3 5T trucks have been added antirust antifreeze liquid you need not discharge the liquid ...

Page 83: ...r ass 5 Converter ass torque oil torque oil 6 Brake oil 6 Brake oil Notice Notice 1 The detail of lubricating 1 The detail of lubricating oil for different truck are oil for different truck are listed in the listed in the T Table for the able for the oil used in the truck oil used in the truck 2 Lubrication for mast 2 Lubrication for mast please see the 8 hour please see the 8 hour daily or every ...

Page 84: ...il hydraulic oil hydrodynamic power transmission oil gear oil brake liquid lubrication grease and used battery lubrication grease and used battery 3 The used liquid referred above should only be disposed of according to local environment protection laws and 3 The used liquid referred above should only be disposed of according to local environment protection laws and regulations regulations NOTE NO...

Page 85: ...79 79 10 Labels 10 Labels https www forkliftpdfmanuals com ...

Page 86: ...plate Label Label 19 19 No No Riders Riders Label Label 20 20 Nameplate Nameplate Label Label 21 Hand Injury Risk Label 21 Hand Injury Risk Label 22 No Boron Antifreeze 22 No Boron Antifreeze Label Label 23 23 Antifreeze Antifreeze Label Label 24 24 LPG LPG Label Label 25 25 Parking Parking Brake Brake Label Label 26 26 Park Park Brake Brake Warning Warning Label Label 27 27 Operator Operator Warn...

Page 87: ...operated not be operated from outside the cab from outside the cab 2 2 Mast Warning Label Mast Warning Label The inner and outer masts and fork carriage are vertically The inner and outer masts and fork carriage are vertically sliding parts DO NOT put your hand or sliding parts DO NOT put your hand or any other body part between any other body part between the inner and outer masts Failure to the ...

Page 88: ...ng Label DO NOT stand on or DO NOT stand on or under the forks or carriage under the forks or carriage failure to follow this warning may lead to serious bodily injury or death failure to follow this warning may lead to serious bodily injury or death https www forkliftpdfmanuals com ...

Page 89: ...ge forklift 6 6 Truck Lift Label Truck Lift Label Use lift points as shown with appropriate chains or Use lift points as shown with appropriate chains or cables Improper lifting or lifting equipment may result in damage to the cables Improper lifting or lifting equipment may result in damage to the forklift or cause serious bodily injury or death forklift or cause serious bodily injury or death ht...

Page 90: ...84 84 7 7 Tip Over Warning Label Tip Over Warning Label https www forkliftpdfmanuals com ...

Page 91: ...85 85 8 Model Label 8 Model Label Pneumatic Pneumatic 8 Model Label 8 Model Label Cushion Cushion 9 Utilev Label 9 Utilev Label https www forkliftpdfmanuals com ...

Page 92: ...s equipped with a Indicates the forklift is equipped with a diesel engine and should only use diesel fuel diesel engine and should only use diesel fuel 10 Gasoline Label 10 Gasoline Label 11 Driving Warning Label 1 11 Driving Warning Label 1 https www forkliftpdfmanuals com ...

Page 93: ...ne Entry of water through the air inlet is strictly forbidden Keep water from entering here when the forklift is being flushed Keep water from entering here when the forklift is being flushed with water with water 13 Ethyl Ether Warning Label 13 Ethyl Ether Warning Label Do not use either to Do not use either to start forklift start forklift 14 Utilev Label 14 Utilev Label https www forkliftpdfman...

Page 94: ...ie Down Label Use these labeled Use these labeled points for securing forklift during points for securing forklift during transporting transporting 16 Gas Spring Lock Label 16 Gas Spring Lock Label https www forkliftpdfmanuals com ...

Page 95: ...89 89 17 Hood Cover Open Label 17 Hood Cover Open Label 18 Nameplate Label 18 Nameplate Label 1 1 2 2 WARNING WARNING https www forkliftpdfmanuals com ...

Page 96: ...ders Label DO NOT allow riders on the DO NOT allow riders on the forklift forklift 20 20 Nameplate Label Nameplate Label Contains specifications for Contains specifications for the forklift the forklift https www forkliftpdfmanuals com ...

Page 97: ...91 91 21 Hand Injury Risk 21 Hand Injury Risk Label Label 22 No 22 No Boron Antifreeze Label Boron Antifreeze Label 23 Antifreeze Label 23 Antifreeze Label DANGER DANGER https www forkliftpdfmanuals com ...

Page 98: ...e the park brake lever to direction to move the park brake lever to set or release it set or release it Away from opperator will release the Away from opperator will release the park brake park brake Towards the operator will set th Towards the operator will set the park e park brake brake https www forkliftpdfmanuals com ...

Page 99: ...rward Drive carefully keeping forks and attachments as low as possible fully tilted back Never Forward Keep a careful look out for people obstructions and the path of travel Watch clearance especially overhead and tail swing Yield right of Keep a careful look out for people obstructions and the path of travel Watch clearance especially overhead and tail swing Yield right of way to pedestrians way ...

Page 100: ...29 Tire pressure 29 Tire pressure Label Pneumatic Label Pneumatic 30 LP GAS fuel system selector Label 30 LP GAS fuel system selector Label Tire Pressure Tire Pressure Front Front Rear Rear 0 83MPa 0 83MPa 0 79MPa 0 79MPa https www forkliftpdfmanuals com ...

Page 101: ... 31 Shift Label 31 Shift Label 32 Operate Labels 32 Operate Labels 33 33 Noise Level Label Noise Level Label INCHING INCHING BRAK BRAKE E ACC ACCELE ELERAT RATOR OR L LWA WA https www forkliftpdfmanuals com ...

Page 102: ...96 96 34 Lubrication System Label 34 Lubrication System Label 35 Horn Label 35 Horn Label https www forkliftpdfmanuals com ...

Page 103: ... position of the model series on the truck body body Each truck has a unique truck body series number its Each truck has a unique truck body series number its print position is at the right front side of the truck body print position is at the right front side of the truck body https www forkliftpdfmanuals com ...

Page 104: ...ar rn ni in ng g When hoisting the truck DO NOT coil the overhead guard with the steel wire When hoisting the truck DO NOT coil the overhead guard with the steel wire The steel wire ropes and the lifting device must be very firm to support the truck because the truck is The steel wire ropes and the lifting device must be very firm to support the truck because the truck is very heavy very heavy DO ...

Page 105: ...o the front and rear wheels and bind the truck body with enough rope to avoid slippage during transportation enough rope to avoid slippage during transportation Towing Towing The towing rod on the bottom of the counter balance is used to pull and drag the truck For installing the rod first The towing rod on the bottom of the counter balance is used to pull and drag the truck For installing the rod...

Page 106: ...m 500 500 500 500 Max lifting height mm Max lifting height mm 3000 3000 3000 3000 Free lifting height mm Free lifting height mm 130 130 135 135 Max lifting speed mm s Max lifting speed mm s 600 600 540 540 Tilting angle Tilting angle 5 8 5 8 5 8 5 8 Max traveling speed km h Max traveling speed km h 21 21 19 5 19 5 Max grade ability Max grade ability 26 26 32 32 Min turning radius mm Min turning ra...

Page 107: ...gh mm 2115 2115 2115 2115 Service weight kg Service weight kg 3815 3815 4210 4210 Tire F R Tire F R 21X7X15 21X7X15 16X6X10 5 16X6X10 5 21X8X15 21X8X15 16X6X10 5 16X6X10 5 Voltage Capacity Voltage Capacity V V A h A h 12 60 12 60 12 60 12 60 No No load braking distance M load braking distance M 6 6 6 6 EE nn gg iinn ee Type Type MAZDA 2 2L MAZDA 2 2L Rated capacity Rated capacity 37kW 2700r min 37...

Page 108: ... height mm Max lifting height mm 3000 3000 3000 3000 3000 3000 3000 3000 Free lifting height mm Free lifting height mm 140 140 140 140 155 155 155 155 Max lifting Max lifting speed mm s speed mm s 580 580 580 580 460 460 370 370 Tilting angle Tilting angle 6 12 6 12 6 12 6 12 6 12 6 12 6 12 6 12 Max traveling Max traveling speed km h speed km h 20 20 20 20 18 18 18 18 Max grade ability Max grade a...

Page 109: ...170 2170 Service weight kg Service weight kg 3440 3440 3765 3765 4255 4255 4555 4555 Tire F R Tire F R 7 00 7 00 12 12 12PR 12PR 6 00 6 00 9 9 10PR 10PR 7 00 7 00 12 12 12PR 12PR 6 00 6 00 9 9 10PR 10PR 28 9 28 9 15 15 12PR 12PR 6 50 6 50 10 10 10PR 10PR 28 9 28 9 15 15 12PR 12PR 6 50 6 50 10 10 10PR 10PR Voltage Capacity Voltage Capacity V A V A h h 12 60 12 60 12 60 12 60 12 60 12 60 12 60 12 60...

Page 110: ...ree lifting height mm Free lifting height mm 140 140 140 140 Max lifting speed mm s Max lifting speed mm s 530 530 535 535 Tilting angle deg Tilting angle deg 6 12 6 12 6 12 6 12 Max traveling speed km h Max traveling speed km h 20 20 20 20 Max grade ability Max grade ability 20 20 15 15 Min turning radius mm Min turning radius mm 2260 2260 2320 2320 Ground clearance mm Ground clearance mm 105 105...

Page 111: ...7 00 7 00 12 12 12PR 12PR 6 00 6 00 9 9 10PR 10PR 28X9 28X9 15 15 12PR 12PR 6 50 6 50 10 10 10PR 10PR Voltage Capacity Voltage Capacity V V A h A h 12 90 12 90 12 90 12 90 No No load braking distance M load braking distance M 6 6 6 6 EE nn gg iinn ee Type Type 4TNE92 4TNE92 HRJ HRJ YANMAR YANMAR Rated capacity Rated capacity 32 8 kW 2450r min 32 8 kW 2450r min Max torque Max torque 149 4N m 1600 r...

Page 112: ...ree lifting height mm Free lifting height mm 155 155 155 155 Max lifting speed mm s Max lifting speed mm s 460 460 350 350 Tilting angle deg Tilting angle deg 6 12 6 12 6 12 6 12 Max traveling speed km h Max traveling speed km h 18 18 18 18 Max grade ability Max grade ability 20 20 20 20 Min turning radius mm Min turning radius mm 2480 2480 2520 2520 Ground clearance mm Ground clearance mm 130 130...

Page 113: ...8 9 28 9 15 15 12PR 12PR 6 50 6 50 10 10 10PR 10PR 28 9 28 9 15 15 12PR 12PR 6 50 6 50 10 10 10PR 10PR Voltage Capacity Voltage Capacity V V A h A h 12 90 12 90 12 90 12 90 No No load braking distance M load braking distance M 6 6 6 6 EE nn gg iinn ee Type Type 4TNE98 4TNE98 BQFLC BQFLC YANMAR YANMAR Rated capacity Rated capacity 42 1 Kw 2300r min 42 1 Kw 2300r min Max torque Max torque 186N m 170...

Page 114: ...000 3000 Free lifting height mm Free lifting height mm 130 135 130 135 Max lifting speed mm s Max lifting speed mm s 600 510 600 510 Tilting angle Tilting angle 5 8 5 8 5 8 5 8 Max traveling speed km h Max traveling speed km h 20 19 20 19 Max grade ability Max grade ability 20 20 20 20 Min turning radius mm Min turning radius mm 2020 2200 2020 2200 Ground clearance mm Ground clearance mm 83 5 80 8...

Page 115: ...ht kg Service weight kg 3490 3490 3815 3815 Tire F R Tire F R 21X7X15 2 21X7X15 2 16X6X10 5 2 16X6X10 5 2 21X7X15 2 21X7X15 2 16X6X10 5 2 16X6X10 5 2 Voltage Voltage Capacity Capacity V A V A h h 12 45 12 45 12 45 12 45 No No load braking distance M load braking distance M 6 6 6 6 EE nn gg iinn ee Type Type PSI 2 4L PSI 2 4L Rated capacity Rated capacity 55kW 55kW 2800r min 2800r min Max torque Ma...

Page 116: ... height Max lifting height mm mm 3000 3000 3000 3000 3000 3000 3000 3000 Free lifting Free lifting height mm height mm 140 140 140 140 155 155 155 155 Max lifting Max lifting speed mm s speed mm s 560 560 560 560 460 460 390 390 Tilting angle Tilting angle 6 12 6 12 6 12 6 12 6 12 6 12 6 12 6 12 Max traveling Max traveling speed km h speed km h 21 21 21 21 19 19 19 19 Max grade ability Max grade a...

Page 117: ...ce weight kg 3440 3440 3765 3765 4255 4255 4555 4555 Tire F R Tire F R 7 00 7 00 12 12 12PR 2 12PR 2 6 00 6 00 9 9 10PR 2 10PR 2 7 00 7 00 12 12 12PR 2 12PR 2 6 00 6 00 9 9 10PR 2 10PR 2 28X9 28X9 15 15 12PR 2 12PR 2 6 50 6 50 10 10 10PR 2 10PR 2 28X9 28X9 15 15 12PR 2 12PR 2 6 50 6 50 10 10 10PR 2 10PR 2 Voltage Capacity Voltage Capacity V V A h A h 12 45 12 45 12 45 12 45 12 45 12 45 12 45 12 45...

Page 118: ...112 112 13 Operation Disassembly and Installation of Cab Pneumatic 13 Operation Disassembly and Installation of Cab Pneumatic https www forkliftpdfmanuals com ...

Page 119: ...113 113 https www forkliftpdfmanuals com ...

Page 120: ...plugs from left rear and right rear legs remove 4 bolts from left rear and right rear legs 4 4 Using a crane Using a crane lift the cab lift the cab slightly slightly 5 5 Disconnect wiring at switches for fan wiper alarm lights etc Place Disconnect wiring at switches for fan wiper alarm lights etc Place any trailing wires inside cab support any trailing wires inside cab support legs legs 6 6 Put d...

Page 121: ...ition the alarm will stop sounding b b While the forklift is started While the forklift is started the operator the operator must sit on the seat correctly must sit on the seat correctly and put the direction control lever in and put the direction control lever in forward or reverse before the forklift will travel If the operator is not forward or reverse before the forklift will travel If the ope...

Page 122: ... and the OPS light will illuminate Pulling up the parking brake or sitting on the seat correctly will will sound after 3 seconds and the OPS light will illuminate Pulling up the parking brake or sitting on the seat correctly will cancel the alarm cancel the alarm b If the park brake is not engaged when the driver leaves the seat without the engine running but the key switch is on the b If the park...

Page 123: ... valve high efficiency High and low speed solenoid valve high efficiency A8 A8 Reverse sole Reverse solenoid valve noid valve high efficiency high efficiency A9 A9 Forward Forward solenoid solenoid valve valve high high efficiency efficiency A10 A10 Output Output on on high high efficiency efficiency A11 A11 12V reserved for external connection to power supply of indicator light not for 12V reserv...

Page 124: ...1 B1 R2 indicator R2 indicator low low efficiency efficiency B2 B2 R1 indicator R1 indicator low low efficiency efficiency B3 B3 Alarm high efficiency Alarm high efficiency B4 B4 Alarm ind Alarm indication ication high high efficiency efficiency B5 B5 Auto ind Auto indication ication low low efficiency efficiency B6 B6 F2 indicat F2 indicator or low low efficiency efficiency B7 B7 F1 indicat F1 in...

Page 125: ...119 119 2 Wiring 2 Wiring 1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 9 9 11 11 12 12 13 13 14 14 15 15 16 16 17 17 18 18 19 19 19 19 20 20 10 10 Controller Controller https www forkliftpdfmanuals com ...

Page 126: ... Solenoid 10 Forward Solenoid Valve Valve 11 Reverse Solenoid 11 Reverse Solenoid Valve Valve 12 High and Low speed 12 High and Low speed Solenoid Valve Solenoid Valve 13 Starting Output 13 Starting Output 14 Mast Lifting and 14 Mast Lifting and Lowering Output Lowering Output 15 Mast Forward and 15 Mast Forward and Backward Tilt Output Backward Tilt Output 16 Alarm Output 16 Alarm Output 17 Manua...

Page 127: ... LPG cylinders tanks or fill LPG cylinders tanks per your local regulations See dealer 2 Using the Dual Fuel Toggle Switch 2 Using the Dual Fuel Toggle Switch 1 Flip the dual fuel toggle switch to GAS and the engine fuel becomes gasoline 1 Flip the dual fuel toggle switch to GAS and the engine fuel becomes gasoline 2 Flip the dual fuel toggle switch to LPG and the engine fuel becomes liquefied pet...

Page 128: ... LPG connections having NPT threads 2 Dual fuel forklifts should use 93 gasoline or vehicle use LPG as fuel Otherwise ignition timing 2 Dual fuel forklifts should use 93 gasoline or vehicle use LPG as fuel Otherwise ignition timing accuracy will be accuracy will be affected which will reduce power affected which will reduce power 3 If the forklift i 3 If the forklift is stopped for more than 10 mi...

Page 129: ...el Display c LPG Level Display Provides a direct visual display of the LPG level inside the cylinder Provides a direct visual display of the LPG level inside the cylinder d Flow Limiting Valve d Flow Limiting Valve Automatically closes when flow volume is too large Ex System damage or flow exceeds design value Automatically closes when flow volume is too large Ex System damage or flow exceeds desi...

Page 130: ...he cylinder flat and set the LPG i and set the LPG inflow shut off valve to the top nflow shut off valve to the top Twist off the Twist off the dust cover from the inflow shut off valve Insert the charging connector and open the LPG inflow shut off valve dust cover from the inflow shut off valve Insert the charging connector and open the LPG inflow shut off valve When the LPG has been filled to ab...

Page 131: ...t off shut off valve valve and and loosen loosen the the outflow connector outflow connector 3 3 Locate Locate the the buckle buckle belt belt and and tensioner tensioner 4 4 Grip Grip the the tensioner tensioner with with your your right right hand hand Pull Pull out out the the lock lock catch catch with your index finger middle finger and ring finger with your index finger middle finger and rin...

Page 132: ...evice device Remove Cylinder and Charge Remove Cylinder and Charge Notice Notice a 1 may use more than 20 C a 1 may use more than 20 C b 2 may use more than 10 C b 2 may use more than 10 C c 3 may use more than 0 C c 3 may use more than 0 C Caution Caution 1 Avoid banging cylinder against truck when removing 1 Avoid banging cylinder against truck when removing 2 Make sure the outlet shut off valve...

Page 133: ...eft hand and belt with the left hand and align it with the open slot of align it with the open slot of the the ratchet shaft ratchet shaft 3 Pass the buckle belt through the open slot of the 3 Pass the buckle belt through the open slot of the ratchet shaft ratchet shaft 4 Pull down tightly on the buckle belt with your left hand 4 Pull down tightly on the buckle belt with your left hand Pull out th...

Page 134: ...ith your left hand Firmly grip the tensioner with your right hand and let go of the lock the tensioner with your right hand and let go of the lock catch Turn the tensioner up and down a few times until catch Turn the tensioner up and down a few times until its position cannot be shifted its position cannot be shifted 7 Pull down until it bumps against the cylinder 7 Pull down until it bumps agains...

Page 135: ... all the line connectors If a leak is cylinder outlet shut off valve Check for LPG leaks by applying soap bubbles to all the line connectors If a leak is discovered DO NOT start the forklift truck work until after it is eliminated After each use of the forklift truck close the discovered DO NOT start the forklift truck work until after it is eliminated After each use of the forklift truck close th...

Page 136: ... addition store abnormal cylinders separately 7 7 When the assembly i When the assembly is filled with s filled with LPG either the v LPG either the volume method or the w olume method or the weight method may be eight method may be used If it is used If it is filled filled using the weight method the cylinder needs to be placed standing upright If the volume method is used then using the weight m...

Page 137: ...ecified fill quantity 18 DO NOT use up all the gas in the cylinder leave residual gas equal to at least 0 5 of the specified fill quantity 19 Absolutely DO NOT alter the embossed and color marks on the cylinder 19 Absolutely DO NOT alter the embossed and color marks on the cylinder 20 In accordance with established testing dates the cylinder must be delivered for periodic inspection to a testing 2...

Page 138: ...inishing the LPG forklift debugging a After finishing the LPG forklift debugging and one day well run or a f nd one day well run or a full container of LPG is used up you should ull container of LPG is used up you should adjust the LPG vaporizer a adjust the LPG vaporizer again to ensure proper ratio gain to ensure proper ratio of fuel to air of fuel to air 6 6 Check the electric system every thre...

Page 139: ...133 133 IMPCO Single Fuel System IMPCO Single Fuel System https www forkliftpdfmanuals com ...

Page 140: ...e place for storing battery should be clean dr attery should be clean dry y airy and the battery should be charged every airy and the battery should be charged every 3 months 3 months 2 2 Maintenance 2 2 Maintenance Make sure there is Make sure there is no terminal corrosion link part looseness no terminal corrosion link part looseness outer crack and fastening looseness on outer crack and fasteni...

Page 141: ...ttention to the liquid level when using the forklift There is an aperture for adding liquid in the cover of the battery Please add enough water up to the UPPER LEVEL when the liquid level is below the LOWER LEVEL and be sure the Please add enough water up to the UPPER LEVEL when the liquid level is below the LOWER LEVEL and be sure the water is not so much that can spill out to erode your forklift...

Page 142: ...ive earth wire to avoid discharging by additional current release 3 Keep the battery charge completely 3 Keep the battery charge completely 4 Make a general schedule charge every 30 4 Make a general schedule charge every 30 45 days if truck is not used during this period 45 days if truck is not used during this period 5 When the battery electrolyte level is lower than LOWER LEVEL please add distil...

Page 143: ...led on the truck one must disconnect ground cable When connecting and disconnect battery charger cable make sure charger power is off When connecting and disconnect battery charger cable make sure charger power is off Notice Notice Safe place for battery charging should be at open ground Never charge in bad ventilated Safe place for battery charging should be at open ground Never charge in bad ven...

Page 144: ...r cover electric things on the battery to avoid battery short cut Never cover electric things on the battery to avoid battery short cut T To avoid electrolyte contact o avoid electrolyte contact eyes skin or eyes skin or clothes clothes Never let the children close the battery Never let the children close the battery Emergency measure to electrolyte Emergency measure to electrolyte If the electrol...

Page 145: ... cargo is too large DO NOT DO NOT move a truck with attachment when load is in a high position If the size of cargo is too large DO NOT move the truck When transporting cargo ensure ground clearance between the bottom of cargo and ground is move the truck When transporting cargo ensure ground clearance between the bottom of cargo and ground is less than 300mm and the mast is inclined back less tha...

Page 146: ...oad load capacity capacity attachment attachment load load capacity capacity combined load capacity of truck and attachment combined load capacity of truck Generally combined load capacity of truck and attachment combined load capacity of truck Generally speaking the combined load capacity of truck is the least Attachment load capacity may depend on speaking the combined load capacity of truck is ...

Page 147: ...L LPG UT20P PSI 2 4L LPG UT20P PSI 2 4L DUAL UT20P PSI 2 4L DUAL 83 103 83 103 UT25P PSI 2 4L LPG UT25P PSI 2 4L LPG UT25P PSI 2 4L DUAL UT25P PSI 2 4L DUAL 83 103 83 103 UT30P PSI 2 4L LPG UT30P PSI 2 4L LPG UT30P PSI 2 4L DUAL UT30P PSI 2 4L DUAL 83 103 83 103 UT35P PSI 2 4L LPG UT35P PSI 2 4L LPG UT35P PSI 2 4L DUAL UT35P PSI 2 4L DUAL 83 103 83 103 Vibration p Vibration parameters arameters in...

Page 148: ...142 142 Maintenance Record Maintenance Record Date Date Item of Maintenance Item of Maintenance Maintenance Maintenance Personnel Personnel https www forkliftpdfmanuals com ...

Page 149: ...tate of California to cause cancer birth defects or other reproductive harm or other reproductive harm UTILEV TECHNICAL PUBLICATIONS UTILEV TECHNICAL PUBLICATIONS UTILEV is a registered trademark THE UTILITY LIFT TRUCK and UTILITY YOU CAN TRUST are UTILEV is a registered trademark THE UTILITY LIFT TRUCK and UTILITY YOU CAN TRUST are trademarks in the United States and certain other jurisdictions t...

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UTILEV UT25C, Operation And Maintenance Manual

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