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PERIODIC INSPECTION

4-22

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LUBRICATING 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:

1) Loosen the chain sufficiently.

2) After applying engine oil, move the mast up and down at least

10 times.

NOTE

If your lift truck is used near a port or coastal area, the lift
chains might be damaged from salty breezes. After a storm
or typhoon, it is advisable to wash them with water before
lubricating in the above manner.

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Содержание FD160-2

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

Страница 2: ......

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

Страница 4: ......

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 80: ...MEMO...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 98: ...MEMO...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 144: ...MEMO...

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

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

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

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

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

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

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

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

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

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

Страница 155: ...MEMO...

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

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