Forklift Empilhadeira PDF

OPERATING MANUAL
DO NOT REMOVE THIS MANUAL FROM THIS UNIT

Part No. 4046068
10/11
This manual describes instructions for proper handling of the HYSTER forklift
truck as well as daily lubrication and maintenance check methods. To ensure safe
and highly efficient work through correct operation and servicing, please read this
manual thoroughly before using the truck.
This manual has been prepared for the standard model. Please contact the company-designated service center for details on options, special specifications and
any other unclear points.
This manual is subject to change with changes in the truck specifications.
The following marks are used in this manual to show important items related to
safety, etc. Read this points carefully in addition to the text.
Indicates items to be observed to prevent accidents that
could lead to fatalities or personal injuries.
Indicates items to be observed to prevent personal injuries or damage to the truck or surroundings.
Items that should be followed to prevent accidents and
trouble, and to allow the lift truck to be used safely for a
long time.
Make sure that this operator manual is included when transferring ownership of the lift
truck.
This operator manual describes the following truck models.

Battery size
STD
Truck type
Model
Max. load
Volt
MIN.
Ah/hr
MAX.
Ah/hr
Standard
chassis
J1.50EX
1500
440/5
600/5
J1.75EX
1750
440/5
600/5
Large Battery
chassis
J2.00EX
2000
560/5
700/5
J2.50EX
2500
560/5
700/5
48V
CONTENTS
1
Introduction .........................................................................................
Pre-operation and Periodic

Inspections
Chassis Number and Serial Number
Locations
Handling of New Vehicle
2
For Safety Operation...........................................................................

Before Starting Work
During Travel
Parking
On The Vehicle
During Work
Safety Labels / Plates Installation Positions ....................................
12
Main Components ...............................................................................
14
Operating System and Display ..........................................................
16
Handling of Each Device ....................................................................
17
Key Switch
Indication of Display Devices
Levers
Light Switch
Standard Seat
Forks
7
How to Drive ........................................................................................

Before Driving
Plug Braking
After Operation
Display
How to Set Various Modes
Pedals
Steering Wheel
Suspension Seat (Optional)
35
Starting and Traveling

Temporary Stop and Parking
Vehicle Structure and Stability...........................................................
38
Load and Vehicle Stability

Center of Gravity Position and
Stability
Range of Center of Gravity Stability
Reference Load Center and
Capacity Chart
9
Load Handling .....................................................................................

Picking up Load from The Ground
Destacking from High Place
Unloading
ii
40
CONTENTS (Continued)
10
Exchanging of Battery ........................................................................
43
Exchanging The Battery Using a

Hoist
11
How to Use The Battery ......................................................................
45
How to Use The Battery

Bulk Water Replenisher (Optional)
12
Pre-operation Inspection ....................................................................
51
Pre-operation Inspection
13
Post-operation Inspection and Storage ............................................
60
Post-operation Inspection
Daily Storage
Long-term Storage
14
Periodic Inspection .............................................................................
61
Periodic Inspection and Servicing

Weekly Inspection (Every 50 Hours)
Monthly Inspection (Every 200
Hours)
15
Work Items ...........................................................................................
70
Opening/Closing the Battery Cover

Adjusting The Parking Brake Lever
Operating Force
How to Use Coupler Pin
Changing Tires
Replacing, Repairing Simple Parts
Replacing Bulb (If Equipped)
Replacing Fuse
16
Service Data.........................................................................................
79
Adjustment Value
Fuse Capacity
Bolt Tightening Torque
17
Inspection, Lubrication and Periodic Replacement Parts...............

Inspection, Lubrication and Periodic
Replacement Parts Table
Inspection and Lubrication Chart
Periodic Replacement of Safety
Parts
Lubricants List
iii
81
CONTENTS (Continued)
18
Freezer/Refrigerator Specified Vehicles............................................

Freezer/Refrigerator Specified
Vehicles
iv
85
Introduction
Pre-operation and Periodic Inspections

It is important to conduct periodic inspections without fail to secure the safety of your
forklift truck during use and to provide economically feasible operation.
Pre-operation inspection ................This daily inspection must be conducted

before starting work with the forklift truck.
Post-operation inspection...............This inspection is carried out when the daily

operation and work have been completed.
Periodic self-inspection ..................This self-inspection must be conducted periodically within a period not exceeding one
month (monthly inspection).
Specific self-inspection ...................This self-inspection must be conducted periodically within a period not exceeding one
year (annual inspection).
For our customers, the company provides the above inspection service (excluding
daily inspection) at the designated service shops. It is recommended to use our periodic inspection service system for the safe and long-term use of your forklift truck.
Chassis Number and Serial Number Locations

The chassis number of the vehicle is stamped at the location shown in the figure
below. The model number, chassis number and serial number are stamped on the
nameplate located on the right-side of the operators seat. Please inform our company
of these numbers when making inquiries regarding repairs, etc.
-1-
Introduction
Handling of New Vehicle

Vehicles are thoroughly inspected, adjusted, and tested before delivery, but a certain
amount of time will be necessary to break the vehicle in completely. Careful breakingin of the new vehicle will lead to a long-term fault-free operation. For the first two
weeks of use, take special care not to apply excessive loads, and pay attention to the
following points.
Avoid high-speed operation, and keep the load to 70 to 80%

of the rated load.
Check the loosening of bolts, nuts and hydraulic joints during the break-in period. If any looseness is found, stop the
vehicle and retighten the loose part.
Take time to train in the usage of each device on the vehicle
before starting full operation. Even after getting used to the
handling, be careful during the actual operation to prevent
personal accidents or physical accidents.
Even if the vehicle has the same specifications, each vehicle
will have its own characteristics in terms of brakes, accelerators, and load handling devices. Always feel the vehicle out
before starting use. Take special care to get a feel of the
brakes.
-2-
For Safety Operation
It is important for the forklift operator and supervisor to observe various rules to prevent work-related disasters during transfer work. Please observe the following items
and carry out the operation and work safely.
Before Starting Work
Only operators who have completed the forklift truck operation

skill training may operate this truck
Wear designated work clothes and

protective devices.
Wear work clothes that have well closed
cuffs and collars.
Always wear safety shoes and a protective helmet.
Take sufficient time to discuss the

work before starting.
Discuss the work with the work leader
before starting work, and always follow
the work plan.
Inspect the forklift truck before

starting work.
If any abnormality is found, contact the
supervisor immediately. Do not operate
the truck until the defect has been corrected.
Do not modify or repair the forklift

truck on the site.
Contact the company-designated service center when the vehicle must be
modified or repaired.
-3-
If overhead guards, back rests or any other defects are found

in the safety devices, repair them immediately before starting
operation.
Do not remove the overhead guard.
Do not use vehicles that are not provided with the company-designated overhead guard and/or back rest.
Do not use the vehicle for purposes other than those specified.
Do not open or close the doors of railway cars or warehouses.
Do not push other vehicles.
Do not attach a wire rope onto the fork to suspend items.
Do not tow anything using the coupler pin.
On The Vehicle
Always fasten seat belt while operating the vehicle
If the vehicle is about to tip sideways, stay in the vehicle, grasp the
steering wheel tightly with both
hands, and plant your feet firmly to
hold your body securely.
-4-
During Travel
Always operate the vehicle within

the specified speed limit.
Set a safety speed limit for both when
the vehicle is loaded and unloaded considering the working environment.
Observe the work site rules and operate
the vehicle safely.
A forklift truck is built for only one

person - the operator. It is dangerous for anyone to ride on the forks,
counterweight or any other place.
Assign a guide at narrow places for

safe operation.
When assigning a guide, make sure to
predetermine signals to be used.
The operator must follow the signals
given by the guide.
If the view is obstructed, always

stop once and confirm the safety
on the left and right before proceeding.
-5-
When traveling on a slope while

carrying a load, drive forward when
going up and backward when going
down the slope. Never travel
across a slope or change directions on a slope as the vehicle
could tip over.
A forklift truck is steered by the

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

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

upper part of the forklift truck when
entering or exiting a warehouse or
other buildings, so that the truck
will not catch.
The forklift truck is more likely to

tip over when it has no load, so
take care when driving.
-6-
Take special care when carrying a

long or wide load.
Lift or lower the load slowly while confirming the surrounding safety.
Be careful of the balance of the load.
Always work with the load at a low position.
Confirm the surrounding safety when
turning, and operate the forklift truck
slowly to prevent the load from shifting.
Do not drive over wood pieces or

other objects scattered on the
ground. Doing so may cause the
load to shift or the operator to lose
control.
Traveling on the very edge of the

road may cause the vehicle to tip
over. Always keep a safe distance
from the edge.
Take care of the road condition

while traveling.
Confirm the strength of the floor.
Travel on slippery surfaces can
cause the vehicle to slip. If this is
unavoidable, slow down.
Avoid traveling on weak or nonprepared ground.
-7-
During Work
Do not travel with an excessive

load that causes the rear tires to
float.
Follow the load table and carry out the
work.
Do not use the tip of the forks as a

lever to raise a heavy load. Do not
push a load with the tip of the forks
and do not use the tilt cylinder to
pull a load.
Use pallets and skids suitable for

the load.
Use pallets and skids that can withstand
the weight of the load.
Do not use damaged, deformed or
decayed pallets and skids.
Stack the load on the pallet or skids

safely and properly.
To prevent eccentric loads, take care of
the center of gravity of the load.
If the load might become unstable, bind
the load with a rope (binder) or use other
preventive measures. The worker in
charge of loading must not get on the
fork or hold the load during travel.
Do not carry unstable loads.
-8-
Do not travel or turn with the forks

higher than 30cm from the ground
or in a vertical position or tilted forward.
Do not advance suddenly, apply the

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

cross members of the mast. Your
hand may be severed if the mast is
lowered while your hand is on it.
Before loading onto or unloading

from a truck, always confirm that
the trucks parking brakes are
applied and that the wheels are
chocked.
-9-
Before moving backward, tilt the

forks back completely and confirm
that the load is safe. Drive carefully
when backing.
When moving backward, do not depend
on the rear-view mirror. Move backward
while looking with your neck turned.
If the range of vision is poor due to

a large load, follow the instructions
given by the guide.
Do not suddenly tilt when the

forks are completely raised.
Never leave the forklift truck with
a load lifted.
Never enter under the load or forks.
- 10 -
Keep the elbows and feet within

the vehicle body during operation. Otherwise, they may be
caught by an obstacle.
Stay under the overhead guard
during operation.
Always operate the forklift truck
at the operators seat.
Parking
When leaving the forklift truck,

always carry out the following:
Park the truck in a safe area
where other work will not be
obstructed.
Lower the forks until the tips
touch the ground.
Apply the parking brakes
securely.
Set the shift lever to neutral.
Turn the key switch OFF and
remove the key.
When parking on a slope is
unavoidable, always chock the
wheels.
- 11 -
Safety Labels/Plates Installation Positions
Safety labels and other plates are attached to the positions shown below. Carefully
read them to well understand the details before starting work for safe operation and
driving of the vehicle without accidents.
- 12 -
Safety Labels/Plates Installation Positions
If any label or plate is no longer readable or missing, replace

it with a new one. Use conforming labels and plates.
- 13 -
Main Components
Link
1.
2.
3.
4.
5.
6.
Elevating
Back Rest
Fork Carriage
Fork
Tilt Cylinder
Battery Cover
7.
8.
9.
10.
11.
12.
- 14 -
Seat
Seat Belt
Overhead Guard
Front Light
Turn Signal Light
Battery (inside the cover)
Main Components
13.
14.
15.
16.
17.
18.
Rear Combination Lamp

Counter Weight
Rear Tire
Side Cover
Front Tire
Mirror
19.
20.
21.
22.
23.
24.
- 15 -
Floor Plate
Disconnect Lever
Stationary
Chain
Lift Cylinder
Rear Cover
Operating System and Display
Link
1.
2.
3.
4.
5.
6.
7.
8.
Steering Wheel
Shift Lever (optional)
Parking Brake
Steering Wheel Tilt Lever
Brake Pedal
MONOTROL Pedal
Key Switch
Tilt Lever
9.
10.
11.
12.
13.
14.
15.
- 16 -
Lift Lever
Display
Direction Indicator Lever
Light Switch
Horn Button
Control Valve Tilt Lever
Accelerator Pedal (optional)
Handling of Each Device
This section describes various devices required for driving and operating a forklift
truck.
To carry out safe and comfortable operation, it is important for users to correctly
understand how to operate these devices and display details.
Key Switch
A two-position ON/OFF key switch. Put the
forklift truck in the neutral position, release
the monotrol pedal (or accelerator pedal if
applicable), and then turn the key ON. If
these conditions are not met, the vehicle will
not travel even if the key switch is turned
ON.
Automatic power OFF function

If the key switch is turned ON and left with no operator
input for more than about 15 minutes, traveling and load handling functions will be automatically stopped.
To restart operation, turn the key switch OFF once.
- 17 -
Display
1.
2.
3.
4.
5.
Down Arrow Button

Up Arrow Button
Warning Indicator
Mode Select Button
LCD Panel
1. Battery Discharge Indicator
2. Power Mode Level Indicator
3. Hour Meter, Odometer
4. Current Speed Limit
5. Status Icons
6. Speed Limit Mode
- 18 -
Indication of Display Devices

1. Battery discharge indicator
Indicates the discharge level of the battery.
While the key switch is turned ON, all the bars will be black when the battery is
fully charged. The bars become empty sequentially from the top as the battery
discharges.
When all of the bars are empty and a message appears that
reads CHARGE REQD in the center of the LCD screen,
promptly charge the battery.
BDI interrupt
Lift operation is disabled when the message CHARGE REQD is displayed.
In this case, charge the battery

immediately.
2. Power mode level indicator
Indicates a combined set level for traveling and load handling power. The indication level changes as shown below by pressing the Mode button.
: Level 1
: Level 2
: Level 3
HYPER: Hyper mode
MY MODE: My mode
- 19 -
3. Stationary Screen
In the normal display mode when the
truck is stationary, the screen displays
the total, travel, and hydraulic hour
meters.
4. Traveling Screen
In the normal display mode while the
truck is traveling, the truck displays a
speedometer.
5. Hour meter, odometer
The following can be displayed in the
advisory windows of the normal display mode:
Hour Meter Total operating hours:
TOTAL HOURS
Hour Meter Total load handling hours: HYD HOURS
Hour Meter Total travel hours:
TRAVEL HOURS
Odometer Total Travel Distance: ODOMETER
Odometer - Trip Travel Distance: TRIP ODO
Hour Meter Key ON hours: KEYSW HOURS
Speed Limit Mode
6. Error Indicator
Error indication
There are two modes for warning icons, red and yellow. When a fault has caused
a vehicle operation to be stopped, the icon will glow red. When vehicle performance is reduced or attention of the operator, the icon will glow yellow. Red is
highest priority and will override the yellow indication.
When an error is indicated, inform a designated service shop

of the error code and the message.
- 20 -
7. Icons:
In addition to a glowing warning icon, an error indicator screen will appear with an
error icon. Error icon displayed differs according to the faulty section and detail of
abnormality.
Wrench - Indicates there is a fault that requires maintenance.
Rotating Wheel - Indicates a fault is related to the Traction

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

System.
Thermometer - Indicates a fault is related to Temperature.
Battery - Indicates a low battery condition or a fault that is battery

related.
- 21 -
8. Status Messages:
For the five most common messages the operator will see, a Chinese message
will be displayed in place of the numeric speed just above the advisory window.
At the same time, the English equivalent message will appear in the message
center.
Charge Required - This image is shown any time the vehicle performance is reduced due to a low battery or because the Battery
Discharge Indicator has reached the lift lockout threshold.
Call for Service - This image is shown anytime there is an active
fault that requires a maintenance technician to correct the issue.
Cool Down - This image is shown anytime the performance is
reduced because of excessive over temperature.
Accelerator & Brake - This image is shown anytime the traction is
disabled due to the accelerator and brake pedals are depressed
at the same time for more than 10 seconds.
Starting Sequence - This image is shown if the key is turned
while the throttle is depressed and/or direction is out of neutral. It
will also be shown if the key is turned and the seat switch is disengaged (optional).
When an error is indicated, inform a designated service shop

of the error code and the message.
If the warning indication still remains after a while, immediately contact a designated service shop.
- 22 -
How to Set Various Modes

1. Hour Meter, Odometer
Pressing the DOWN Arrow for less than 2
seconds in the normal display mode shifts
the indication sequentially as shown below.
Hour meter Total Operating Hours:
TOTAL HOURS
Hour meter - Total Load Handling hours:
HYD HOURS
Hour meter Total Travel Hours:
TRAVEL HOURS
Odometer Total Travel Distance:
ODOMETER
Odometer - Trip Travel Distance:
TRIP ODO
Hour meter Key ON hours:
KEYSW HOURS
If the DOWN Arrow is held for more than
2 seconds while the trip odometer is
displayed, the trip odometer will be reset.
- 23 -
2. Speed Limit Setting

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

Respective settings for travel and load handling can be switched at a time in accordance with the work level. Pressing the
Mode button for less than 5 seconds
changes the power mode
indication as follows:
- 24 -
:Level 1 Energy saving mode

:Level 2 Standard mode
:Level 3 Power mode
HYPER: Hyper mode A high-power mode with a speed equivalent to engine-driven
vehicles
MY MODE: My mode A mode in which the operator can set desired items in the
operator set mode described on the following page.
When Level 3 (power mode) and/or HYPER (hyper mode) are

used, the work speed increases, but the operating time
decreases. If these modes are not necessary, it is recommended to use the forklift truck in Level 1 (energy saving
mode) or Level 2 (standard mode).
Travel acceleration and load handling acceleration levels are
properly set in accordance with respective set levels. (For
detail, see the Operator Set Mode in the following.)
4. Operator Set Mode
Pressing the Mode button for 5 seconds enables the user to set desired
travel or load handling characteristics.
Each pressing of the Mode button
changes the screen to the following
set screens.
a. Exit Menu
b. Speed Limit Mode
c. MY MODE Acceleration Rate
d. Lift Speed
e. Tilt Speed
f. MY MODE Hydraulic Acceleration
g. LCD Contrast
h. Password Entry Enable
The Operator Menu adjustment will display in place of the numeric value if
the setting is not available to the user.
a. Exit Menu
Select this to exit the Operator Set
Mode
- 25 -
b. Speed Limit Mode

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

function is activated (tortoise mark displayed). (See Speed
Limit Settings on page 24.)
c. MY MODE Acceleration Rate
This setting is used to set the maximum allowable traction acceleration rate for the vehicle while
operating in MY MODE.
Settings are available from 1 to 10
in increments of 1 where:
Setting of 1 = Lowest Acceleration
Setting of 10 = Highest Acceleration
d. Lift Speed
This setting is used to set the
maximum allowable speed for
the hydraulic motor when lifting.
Settings are available from 1 to
10 in steps of 1 where:
Setting of 1 = Slowest Speed
Setting of 10 = Fastest Speed
e. Tilt Speed
maximum allowable motor RPM
when the Tilt Switch is activated.
Setting of 1 = Slowest Speed
Setting of 10 = Fastest Speed
- 26 -

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

The standard values set at the factory shipment are as follows:
a. Speed Limit Mode: 7
b. MY MODE Acceleration Rate: 5
c. Lift Speed: 8
d. Tilt Speed: 4
e. MY MODE Hydraulic Acceleration: 6
f. LCD Contrast: 100
g. Password Entry Enable: ON
- 27 -
For changing values other than those shown here (including

brake feeling and attachment spread), consult a designated
service shop.
Levers
1. Shift Lever (Option)
The shift lever is used for switching
between forward and backward moves.
When the lever is pushed forward and
the accelerator pedal is pressed, the
forklift truck moves forward. When the
lever is pushed backward and the
accelerator pedal is pressed, the truck
moves backward. When the lever is
pushed to the opposite direction during
traveling, the electric motor is used to
slow the movement. After the vehicle
stops once, it begins to move in the
opposite direction.
Turning the key switch ON does not make the forklift truck
move, if the shift lever is not in the neutral position or the
accelerator pedal is being pressed. The Chinese message
and corresponding English message Starting
Sequence appears on the display. Set the lever to the neutral
position once and release the accelerator pedal. Then the
message disappears and the vehicle is ready to move.
2. Parking brake lever
This brake is used for parking the vehicle.
Pull this brake up to the maximum when
parking. Also by turning the grip, the braking response can be adjusted. (For how to
adjust, read the descriptions on page 71)
- 28 -
When using the parking brake, pull the lever while pressing
the brake pedal. This will make the parking brake operation
lighter.
Always pull the lever when parking or stopping.
3. Lift lever
Pull this lever toward you to lift the
fork upward. Push it forward to lower
it. Adjust the rising/lowering speed
with the lever tilting degree. The maximum lowering speed is maintained at
a constant speed by the flow regulator
valve.
4. Tilt lever
Pull this lever toward you to tilt the
mast backward. Push it forward to tilt
the mast forward. Adjust the forward/
backward tilting speed with the lever tilting degree. A built-in tilt-lock device is
provided to prevent the mast from tilting forward when the key switch is OFF.
5. Direction indicator lever
Push this lever forward to flash the
left turn signal light, and pull backward to flash the right turn signal
light. This lever is used to indicate the
vehicle turning direction.
- 29 -
6. Steering wheel tilt lever

Tilting of the steering wheel can be
adjusted in four steps from front to
back.
a. The front/back position of the steering wheel can be adjusted by raising the lever left to the steering
column (lock release).
b. Release the lever at a desired position to lock the steering wheel there
(positive locking).
c. After the adjustment, check that the
steering wheel position is locked.
Do not adjust the steering wheel position when the vehicle is

moving. Adjustment must be done when the vehicle is
stopped.
7. Disconnect lever
This lever is equipped to disconnect
the battery plug from the plug on the
body.
Tilt the lever backward to disconnect
the plug.
To reconnect the plug, connect the
battery plug by hand.
Connect the battery plug securely. Improper connection may

cause a fault.
Always disconnect the battery plug before checking the
electrical system.
When any abnormality has occurred during operation and
the battery plug has to be disconnected, promptly tilt the
lever backward to shut off the power from the battery.
Do not touch this lever during operation except for an emergency. Otherwise, this may cause faults in the electrical system.
If this lever is operated during travel, the power steering will
be disabled, making the steering wheel heavier.
- 30 -
8. Control valve tilt lever

This lever is used to tilt the control
valve lever forward or backward. Tilt
the lever backward when getting on
and off from right-hand side. And tilt
forward when open the cover battery.
To tilt the control valve lever, pull up
this lever first, and tilt forward or backward.
Lower the fork onto the floor and turn off the key switch
before operating this control valve tilt lever.
Pedals
1. MONOTROL Pedal
The MONOTROL pedal is used
for both forward and backward
movement of the forklift truck.
When the left half of the pedal is
pressed (indicated by a forward
facing arrow) the forklift truck
moves forward. When the right half
of the pedal is pressed (indicated
by a backward facing arrow) the forklift truck moves backward. When the pedal is
pressed to the opposite direction during traveling, the electric motor is used to
slow the movement. After the vehicle stops once, it begins to move in the opposite direction.
2. Brake pedal
Press the brake pedal to brake the vehicle.
While the pedal is pressed, the brake lamps light up.
3. Accelerator pedal (option)
Slowly pressing the accelerator pedal starts the drive motor and the vehicle starts
moving. Continuously variable speed can be adjusted by the degree of force
applied to the pedal.
- 31 -
Stopping distance increases when traveling on a down slope

or wet surface. Always provide an allowance when braking
to avoid a sudden stop.
Do not depress the brake pedal and the accelerator pedal
simultaneously to prevent overload on the drive motor.
When depressing the brake and accelerator pedals continues for a long time, a warning message ACCEL AND BRK
appears together with warning sound.
Light Switch (48V truck: Standard).

Rotate Light Switch to turn lights on.
Steering Wheel
To steer the vehicle, hold the sub-handle
knob with your left hand. When advancing,
turn the steering wheel in the same direction
as the turning direction. When backing, turn
the steering wheel in the opposite direction
of the turning direction.
The vehicle is provided with power steering
system which makes light turn operation
possible. To sound horn, press the horn button at the center of the steering wheel.
It is quite dangerous to make a sharp steering during travel.

This may cause the load to fall and the vehicle to tip over.
Always slow down and turn the steering wheel slowly.
- 32 -
Standard Seat
The seat position is adjustable 140mm in the
front/back direction. Adjust it to an easy-to-drive
position. By pulling the seat position adjustment
lever upward, the seat lock is released and the
seat position can be adjusted.
Suspension Seat (Optional)

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

key OFF. After adjustment, return
the seat position adjustment lever
and check that the seat is securely
locked.
- 33 -
Forks
The forks can be moved to a desired position by pulling out the upper anchor pin.
Always fix the right and left forks so that they
are symmetrical to the center of the chassis.
Be careful so that the load is not eccentric
(unbalanced). After moving the fork,
securely insert the anchor pin in the fork carriage groove to lock movement.
To make this operation easier, control the tilt lever to make a

forward tilting state.
Adjust the fork position according to the size of load to be

handled.
Do not hold the fork when moving the fork. This may cause
your fingers to be caught. Push and slide the fork from
behind.
- 34 -
How to Drive
Before Driving
Before getting into the operators seat, carry
out the pre-operation checking described in
Section 12. Never fail to carry out this checking for your safety even when in a hurry.
1. Make sure that the battery charging
cord power plug is disconnected from
the charger and that the vehicle is in
operable state. Securely lock the cover
lock at the front of the battery cover.
2. Get into the operator's seat and turn
the key switch ON. Is the battery
charged fully? Check the battery
capacity gauge.
Always operate the key switch from the operators seat.
Starting and Traveling

1. Always fasten the seat belt.
2. Check the surrounding safety before
starting.
3. Lift the forks approx. 15 to 20cm from
the ground, and fully tilt the mast
backward.
4. (If equipped with standard accelerator
pedal) While depressing the brake
pedal, put the shift lever to the forward
or backward position.
5. Release the parking brake and release
the brake pedal. Then slowly push the
right side of MONOTROL pedal for
Reverse and the left side of
MONOTROL pedal for Forward
motion. The vehicle will start to move
smoothly.
6. Traveling speed can be changed by
adjusting the pressure onto the accelerator pedal.
- 35 -
How to Drive
The rear-wheel power steering is adopted, so the vehicle can

be easily steered by turning the steering wheel. Take care
not to turn the steering wheel suddenly during travel.
Do not turn the key switch OFF during travel. If the key
switch is turned OFF during travel, the steering wheel will
become heavy.
Securely put the shift lever into the forward or reverse position.
Pay attention to the following points during travel for safe operation.
Remain focused during operation. Always pay attention to

pedestrians, workers and obstacles in the area.
Lower the speed and confirm the surrounding safety when
traveling in places where the field of vision is poor. Do not
pass other vehicles.
When traveling down a slope, decelerate the vehicle speed
sufficiently while applying the brake. And when carrying a
load, travel in the backward direction. When there is no load,
travel in the forward direction.
When going up a sharp slope, take care so that the end of
the fork or the base of the pallet will not contact the ground.
And when carrying a load, go forward. When there is no
load, go backward.
Plug Braking
If the opposite direction on the MONOTROL pedal is pressed during travel, electric
motor braking will be activated. The vehicle will stop once and then will start smoothly
in the opposite direction.
Do not apply excessive pressure on the MONOTROL pedal.

This may cause sudden braking. Be careful that plug braking
does not work if there is no pressure on the MONOTROL
pedal. Adjusting the braking settings can affect electric
motor braking performance.
- 36 -
How to Drive
Temporary Stop and Parking

1. When stopping the forklift truck, release your foot from the accelerator pedal and
press the brake pedal to slow down.
2. When parking, lower the fork to the ground or floor surface, tilt the mast forward,
put on the parking brake, and then put the shift lever into neutral.
3. When leaving the truck, turn the key switch OFF and remove the key without
fail.
Always park at a designated place.

Do not park on a slope. If parking on a slope is unavoidable,
securely chock the tires.
Park the vehicle in a safe place where traffic will not be
obstructed. Install a cautionary sign, signal light or fences
as required near the parking place.
Select sufficiently hard surface for parking, and make sure
that the tires will not slip or sink into the ground.
Always lower the forks to the ground. If the forks cannot be
lowered because of a fault or other reasons, wrap the fork
ends with cloth or the like, and park in a place with the forks
facing a direction where persons and vehicles will not pass.
Get off the vehicle after it has completely stopped while facing its direction.
Never jump off the vehicle because it is dangerous.
After Operation
After operating the vehicle, always carry out the post-operation checking (see
Section 13). Do not forget to charge the battery.
- 37 -
Vehicle Structure and Stability
To safely operate the forklift truck, it is essential to understand the structure and stability of the vehicle.
Load and Vehicle Stability

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

Stability
The stability of the forklift truck is determined by the composite center of gravity
position of the vehicles and the loads center of gravity. When there is no load, only the
vehicles center of gravity is used, and when
a load is stacked, the composite center of
gravity of the vehicle and load will be used.
Since the load center of gravity varies
according to the mast tilting (forward or
backward) and the mast up/down position,
the composite center of gravity will also
change.
- 38 -
Vehicle Structure and Stability
Range of Center of Gravity Stability

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

Load Capacity Table is affixed at the operators seat. Observe the allowable load for
safe operation.
The Load Capacity Table shown here is an
example.
Allowable load: Stackable load limit
Load center: The distance from the vertical front surface of the fork to the center of
gravity of the load on the fork.
Maximum fork height
If a load exceeding the load capacity specified in the Load

Capacity Table is stacked, the rear tires may float during
travel and the steering may not function creating a very dangerous state. The risk of tipping over will also increase.
Always observe the allowable load limit when stacking.
- 39 -
Load Handling
Picking up Load from The Ground

When picking up loads from the ground or
floor, observe the following procedure:
1. Decelerate the vehicle to a safe speed
when approaching the load to be carried.
2. Stop the vehicle once in front of the
load.
3. Tilt the mast forward to the vertical
position, and direct the forklift truck straight toward the load. Confirm the fork
insertion position, slowly advance, and insert the forks into the pallet completely.
Always keep the forks parallel to the pallet and insert them
completely while taking care not to brush against the pallet.
Do not lift the forks with the forks tilted forward.
Do not insert the forks roughly into the pallet.
4. Lift the load 5 to 10cm and make sure
that the load is stable.
Keep the load height up to the back

rest height. Do not carry loads if
they are raised higher than the
back rest.
5. Hold the load in contact with the back

rest, lift the forks 15 to 20cm above the
ground, and tilt the mast backward to
the maximum.
- 40 -
Load Handling
Do not place a weight on the rear of

the vehicle, which will exceed the
allowable limit. (See the Load
Capacity Table.)
Never travel, turn or tilt the forks forward with load lifted,
because the load becomes unstable and the vehicle may tip
over.
If the load blocks the front view, travel backward.
Destacking from High Place

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

the pallet and insert them completely while taking care not to
brush against the pallet.
4. Lift the load 5 to 10cm, retract 10 to 20cm,
and then lower the load once.
5. Insert the forks fully again, lift the load 5 to
10cm, slowly back away, and then lower
the load to a safe height.
- 41 -
Load Handling
If the forks are slanted forward

while the load is lifted, tilt the mast
backward to maintain load stability.
6. Lower the forks to 15 to 20cm from the
ground, fully tilt the mast backward, and
travel to the destination.
Unloading
1. Decelerate the vehicle speed to a safe level
when the vehicle comes near the destination.
2. Stop the vehicle once in front of the unloading
place.
When stacking onto a shelf, carefully operate so as not to hit the

shelf.
3. Set the mast to the vertical position and
lift the load to a position slightly higher
than the unloading level.
4. Confirm the stacking position, and
slowly lower the forks.
5. Gently pull out the forks so as not to
drag the load.
- 42 -
Exchanging of Battery
10
Exchanging The Battery Using a Hoist

1. Turn the key switch OFF and push the control valve tilt lever forward to tilt the
hydraulic levers forward.
2. Release the cover lock and open the battery cover.
3. Remove the side door and valve cover.
4. Disconnect the battery plug.
5. Remove the stopper pin on the right rear side (1.501.75-ton trucks: left rear).
6. Put the shackles into the battery case holes (4 places).
7. Slowly hoist the battery and put it on a flat surface.
8. Put the shackles into the battery case holes of a new battery.
9. Slowly hoist the new battery and put it in the truck body.
10.Attach the stopper pin on the right rear side (1.501.75-ton trucks: left rear).
11.Connect the battery plug.
12.Attach the side door and valve cover.
13.Close the battery cover and lock it securely.
14.Tilt hydraulic levers back.
15.Return the steering wheel tilt lever to the previous position.
- 43 -
10
Exchanging of Battery
Always remount the battery on a flat surface with no load on

the vehicle.
Make sure that all the caps are tight so that the electrolyte
will not spill, then slowly hoist the battery.
The battery must be hoisted by an operator who has completed sling and hoist skill training.
When hoisting the battery, do not hit it against the vehicle
body, etc.
Use a sufficiently strong wire rope with no damage.
Pay attention so that the wire rope does not tangle with the
overhead guard, etc.
The battery weight is given below. Use a hoist, wire rope,
and hooks that are sufficiently strong.
1.51.75 ton
2.0 ton
1.51.75 ton
2.02.5 ton
1.52.5 ton
2.02.5 ton
48V
48V
48V
48V
48V
48V
390Ah
440Ah
525Ah
565Ah
700Ah
725Ah
. . . . . . . . . . . . . . . . . 685kg
. . . . . . . . . . . . . . . . . 805kg
. . . . . . . . . . . . . . . . . 840kg
. . . . . . . . . . . . . . . . 1085kg
. . . . . . . . . . . . . . . . 1180kg
. . . . . . . . . . . . . . . . 1600kg
After the battery is remounted, attach the stopper pin on the

rear side of the battery and securely lock the battery cover
without fail.
Connect the battery plug securely. Improper insertion may

cause failures in electrical parts.
When remounting the battery, do not twist the battery cable.
- 44 -
How to Use the Battery
How to Use The Battery

1. Do not overdischarge the battery.
If the battery power is used until the vehicle no longer
moves, the life of battery will be shortened. Charge the
battery immediately when the bottom bar of the battery
discharge indicator lights.
2. Do not run out of electrolyte.

When the battery is charged, only the water content of the
electrolyte (dilute sulfuric acid) is consumed. Before
charging, always replenish water to the adequate electrolyte level (electrolyte level check).
In addition, about the VCH type battery, please replenish
water after charging.
VCH type battery (Only 72V battery for premium models)
Model
1-2.5 ton
Battery capacity
320AH, 360AH, 465AH, 525AH, 600AH
Electrolyte level drop due to missing water supply may

result in short life, overheating and burning of the battery.
If the electrolyte overflows, be sure to wipe it off thoroughly.
Otherwise, overheating or explosion due to short-circuiting
may occur.
Before cleaning the battery, disconnect the power plug without fail.
Always use distilled water or purified water for replenishment.

3. Keep the battery clean.
The top surface and connectors of the battery should be
clean and dry. Tighten the fluid plugs securely.
Before starting inspection, disconnect the power plug without fail.

Wear insulating protectors such as rubber gloves during
inspection for protection from electric shock.
Never sprinkle water on the battery plug.
- 45 -
11
11
Do not clean the battery with dry cloth or fabricated fiber

cloth or by dusting it. Doing so may cause static electricity
and may lead to an explosion. Always use moist cloth.
4. Keep the battery away from fire.
Never let fire come close to the battery any time
because explosive gas is generated from the battery.
5. Do not overcharge the battery.
Always charge the battery following the charger handling
procedure.
6. Handling during winter time
The freezing temperature of the electrolyte is approx. 35C when the battery is fully charged. The specific
gravity of the electrolyte when fully charged is 1.280 (at
20C). Since the electrolyte is easier to freeze when its
specific gravity drops after discharging. Therefore, keep a good charge condition.
Especially, when it is very cold, remove the battery plugs and cover the battery or
take other warming measures to prevent discharging.
7. Handling during summer time
Since water content of the electrolyte is likely to evaporate during summer time,
check the electrolyte level frequently and replenish distilled water as specified.
Note that overfilling will lead to overflow of the electrolyte during operation, which
may cause corrosion or electrical leak.
- 46 -
11
Bulk Water Replenisher

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

right, each fluid plug is equipped
with a valve interocked with the
float. When water is replenished
to the electrolyte level limit, the
water supply port is closed to
stop water replenishment.
c. As shown in the figure, each
fluid plug is equipped with a visible fluid level indication bar.
d. Gas and acid fog generated in
the battery is individually
exhausted from each fluid plug.
The generated gas and acid fog
do not enter the tube.
e. Each fluid plug is also equipped with a measuring port for measuring the specific gravity of the electrolyte and battery temperature.
2. Handling
a. Electrolyte level check cycle.
Water content in the electrolyte decreases due to water decomposition during
charging and natural evaporation. If the battery is used with the electrolyte
extremely decreased, electrode plate degradation will occur and the battery
life is shortened substantially. Furthermore, this may cause explosion or burning of the battery, so check the electrolyte level once a week without fail.
b. Check method.
The electrolyte level can be checked by horizontally viewing the top of the
level indicator bar (red) in the fluid plug. When the level is very low and the top
of the bar is invisible or in a similar state, replenish distilled water following the
method below.
If even one cell shows the lowest level when checking, replenish water.
- 47 -
11
c. Water replenishing method

Fill the water supply tank with
distilled water. When small
volume of distilled water is in
the tank, the water pressure
drops. Be careful so that the
liquid level in the tank will not
be lower than 10cm during
replenishing.
As shown in the figure, adjust
the water supply tank position
so that the bottom of the
water supply tank comes 50
to 100cm above the top of the
cell lid. If the water supply tank position is outside the range, the water stop
ability of the fluid plug will drop and the electrolyte will overflow.
Shake the hose gently to bleed air. Open the cock, make sure that distilled
water gushes, and then close the valve.
Remove the brown cap attached to the fluid plug of the cell. Then, insert the
water supply connector of the water supply tank into the fluid plug.
Open the cock of the water supply connector and start water supply. Be
sure to open the cock to the maximum.
During water replenishing, do not touch the level indicator bar.
- 48 -
11
When water is replenished,

the red level indicator bar of
each fluid plug rises. Keep
watching while water is
replenished. When the level
indicator bars of all cells rise
as shown in the figure, water
supply is completed. (It takes
about 1 to 2 minutes from the
start of water replenishing.)
Immediately close the cock of
the water supply tank to stop water replenishing. If the battery is left for a
long time, over-replenishing (overflow) may occur.
Pull the movable ring on the water supply connector of the water supply
tank to disconnect the fluid plug of the cell from the water supply connector.
Attach the brown cap on the water supply port as before.
Check rising of the level indicator bars of all cells. Confirm that water was
normally replenished into all cells. If there is no problem, the water replenishment is completed.
3. Other handling.
a. Measurement of the specific
gravity of the electrolyte and battery temperature.
When you open the lid of the
fluid plug, you can see a measuring opening as shown in
the figure. The specific gravity
and battery temperature can
be measured by using the
general suction gravimeter
and bar thermometer.
When measurement is completed, securely close the lid
of the fluid plug.
b. Precautions when using battery
in low-temperature ambiance.
Since a water sealing chamber is provided in the fluid plug, water in the chamber may be frozen if the battery is used in a low-temperature ambiance below
0C. If the water in the chamber is frozen, bulk replenishing is impossible.
Therefore, move the battery into a high-temperature ambiance (15 - 40C).
After melting, carry out water replenishment.
c. Other precautions
Do not remove any fluid plug from the cell. In case a fluid plug has to be
removed from the cell, detach the water supply tube from the fluid plug, turn
the adapter, and remove the fluid plug together with the adapter.
Do not get on the water supply equipment.
- 49 -
11
This device can be used for 2 to 4 years in the standard operation state.
Since functional degradation will adversely affect the life of the battery, it is
recommended to replace the equipment every 2 years. If the equipment
used under heavy conditions, its filter may not function well early.
- 50 -
Pre-Operation Inspection
12
Pre-operation Inspection
To maintain safe work and vehicle performance, it is required for operators to check
the vehicle before starting daily work. This is a lawful requirement. If any abnormality is
found during inspection, contact a designated service shop.
Even small defects can lead to major accidents. If even a

slight abnormality is found, do not operate the forklift truck
until the defect is completely corrected.
Carry out the inspection at a flat place.
The table below summarizes items to be checked.
NO.
1
Check item
Abnormality found on the
previous day
Oil leak from gear cases,
cylinders and hoses
Lubrication to specified
positions
Damage, wear and air pressure of tires
Loose hub nuts
6
7
Abnormal sound
Accelerator pedal operation
16
17
8
9
Brake pedal operation

Brake fluid level
18
19
10
Parking brake performance
12
Mast
Overall
NO.
11
13
14
15
Gauges
Main body
20
Battery
- 51 -
21
Check item
Damage and operation of
mast
Damage of back rest and
overhead guard
Installation of forks and
attachment
Chain tension
Looseness of tilt cylinder
rod
Hydraulic fluid level
Operation of direction indicator
Operation of horn
Operations of lamps and
gauges/meters
Dirt and angle adjustment
of rear-view mirror
Secure connection of battery plug
12
Before getting on the forklift truck, conduct inspection in the following procedure to
make it efficient.
When carrying out checking or maintenance, park the forklift

truck at a solid and level place. Lower the forks to the
ground, turn the key OFF, put all the operation levers to
neutral, and then pull the parking brake.
1. Entire body
Check the whole forklift truck.
a. Check for excessive damage of
the body.
b. Check the ground and inside the
body for oil leak and water leak.
2. Tires and hub nuts

a. Measure air pressure using a
tire pressure gauge. Adjust the
air pressure to the specified
value.
If the air pressures of the left and

right tires are not balanced, the balance and lateral stability of the
vehicle will deteriorate, which may
cause the operator to lose steering
control.
- 52 -
Tire air pressure table
Front
wheel
Rear
wheel
Single
1.5 ton
850kPa
(8.5kgf/
cm2)
700kPa
(7.0kgf/
cm2)
1.75 ton
625kPa
(6.25kgf/
cm2)
900kPa
(9.0kgf/
cm2)
22.5 ton
900kPa
(9.0kgf/
cm2)
700kPa
(7.0kgf/
cm2)
b. Check for loose hub nuts. If

loose, tighten hub nuts uniformly.
For the reference hub nut tightening torque, see the table on
page 74.
c. Check tires for damage, cracks and abnormal wear.
d. Check wheels for damage and warp.
3. Lamps (If equipped)
Check the lenses of lamps for damage and dirt.
4. Rear-view mirror (If equipped)
Check the rear view mirror for damage and dirt. Adjust the mirror
angle to provide good rear view.
- 53 -
12
12
5. Load handling equipment

a. Check the mast for strain, biting
and cracks.
b. Check the chains for lubrication.
c. Check that the fork anchor pin is
firmly engaged with the notched
portion in the fork carriage.
d. Check that the right and left
chain tensions are even.
If the tensions of the right and left chains are not even, adjust
the tensions using the anchor bolt nut.
6. Back rest and overhead guard
a. Check the back rest and overhead guard for deformations and cracks.
b. Check for loose bolts and nuts.
- 54 -
7. Hydraulic oil
With the forks lowered to the lowest
position, pull out the level gauge,
clean it with clean cloth, and insert
it to the original position. Then
slowly pull out the gauge again and
measure the hydraulic fluid level.
When the level is between H and L
of the level gauge, the level is adequate. If the oil is contaminated,
change it.
Always check the hydraulic fluid

at a flat place.
Completely wipe off any spoiled
oil.
The periodic replacement cycle of

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

brake fluid is 6 months.
- 55 -
12
12
When replenishing brake fluid, prevent any foreign matter

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

and secure fastening.
Check that the battery cover is
securely locked.
- 56 -
12
10.Brake pedal
a. While depressing the brake
pedal, check for snagging or
abnormal resistance.
b. Check that the pedal height is
the specified value.
c. Check that the pedal play is
within the specified range while
pressing the pedal by hand until
you feel a resistance.
If the pedal play is large, pedal movement is abnormal or the

brakes do not work well, consult a designated service shop
for inspection and repair.
11.Accelerator pedal.
Check that the accelerator pedal moves smoothly when it is pressed and then
released.
12.Parking brake.
a. Check that the brake securely
works when the parking brake
lever is pulled, and that the
brake is released when the lever
is returned. Push the release
button to release the lever.
b. Check the lever operating force
when the lever is pulled to the
maximum. Lever operating
force:
1.52.5 ton 200 to 250 N
(20 to 25kgf)
If the operating force is not
within the specified range, adjust the brake. (See page 71 for adjustment
method.)
13.Confirm that the shift lever is in neutral and then turn the key switch ON.
- 57 -
12
14.Display and safety parts

a. Check that the display panel lights up when the key switch is turned ON.
(See page 17.)
b. Check that the hour meter functions correctly.
c. Check the display for damage and dirt.
15.Lights
Check that the front light, direction indicator light, brake light, tail light and backup
light turn on when respective switches are turned on.
16.Horn
Press the horn button and check that the horn sounds.
17.Load handling equipment
a. Slowly move the forks from the lowest level to the maximum height 3 times,
and check that the forks and mast move smoothly with no creak.
b. Slowly move the mast back and forth 3 times, and check that the mast moves
smoothly with no difference between right and left movements.
If there is any difference between right and left movements of

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

any abnormality is found, consult a designated service shop
for inspection and repair.
- 58 -
12
19.Steering wheel
a. Set the rear wheels in the
straight travel state, and check
the play of the steering wheel.
Play amount: 20 to 60mm
b. Operate the steering wheel and
confirm that it works smoothly.
c. Move the steering wheel up and
down and check for looseness.
20.Abnormal noise
a. Check that the drive motor is
generating no abnormal sound.
b. Check that both pump and pump
motor are generating no abnormal sound.
c. Check that electrical parts are generating no abnormal sound.
If you hear abnormal sound, do not operate the forklift truck

until the defect is completely rectified.
Forklift truck operation shall not be started unless all the above check results are normal.
- 59 -
13
Post-Operation Inspection and Storage
Post-operation Inspection
After work clean the outside and inside of the vehicle and check the following:
1.
2.
3.
4.
5.
Check any abnormal points found during operation.

Check for visible damage and missing bolts.
Check for fluid leakage.
Check tires for abnormalities.
Check bolts and hydraulic piping for looseness.
Repair defects, if any, on the same day.

Always make the forklift truck ready to operate at any time.
Daily Storage
1.
2.
3.
4.
5.
Park at a dry and flat place.

Pull on the parking brake without fail.
Tilt the mast to the vertical position and lower the fork to the ground.
Turn the key switch OFF and remove the key.
Move the lift lever and tilt lever back and forth 3 or 4 times to release the pressure
remaining in the cylinder piping.
Long-term Storage
Pay attention to the following points in addition to those above when storing the forklift
truck for a long time:
1. Disconnect the battery plug to prevent discharge and store the vehicle in a dark
place.
2. Apply anti-rust grease to shafts, rods and other exposed parts.
3. Cover the breather and other openings where moisture may enter.
4. Cover the entire vehicle with a sheet or the like.
5. Lubricate all lubrication points.
6. Set air pressures of all tires to the specified value (for vehicles with pneumatic
tires only).
7. Make the vehicle ready to operate at least once a week and check all operations.
8. Measure the specific gravity and level of the battery electrolyte at least once a
month. Charge the battery or replenish water as required.
- 60 -
Periodic Inspection
14
Periodic Inspection and Servicing

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

Always use the genuine oil and grease.
Park the forklift truck at a rigid and flat place.
When conducting inspection indoor, make the place well
ventilated.
When working with other person(s), confirm each step with
signals.
Always use proper tools. Never use makeshift tools.
Wear protective gear (helmet, safety boots, goggles, gloves,
etc.).
Lower the fork to the ground before starting inspection.
Confirm that all operation levers are in neutral.
When inspecting under lifted forks is required, place and
fasten a wood block or the like between forks, mast inner
frame and ground or floor so that the forks or mast inner
frame will not drop.
Do not place your foot under the fork.
If even a slight abnormality is found through the inspection,
report it to the supervisor, and never operate the vehicle
until the defect is completely rectified.
Improper disposal (in drainage or ground, burning, etc.) of
waste oil generated through the inspection may pollute the
surrounding (water, soil or atmosphere). This may be
banned by law.
Weekly Inspection (Every 50 Hours)

Conduct the following weekly inspection every 50 hours in addition to the daily inspection.
1. Lubrication
a. Clean the grease nipples and their peripheries with clean cloth, and apply
grease to the following points using a grease gun. Usable grease: Albania
EP2
- 61 -
14
Periodic Inspection
Apply grease until it overflows and then wipe off the excess.
b. Apply grease to the following
points using a brush or the like.
Lift chains
Fork slide section
Mast roller sliding surface.
- 62 -
Periodic Inspection
14
Wipe off old grease with clean

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

that leaks out.
Always use clean oil and grease
as well as containers to prevent
dusts from entering.
2. Battery
Daily handling and management of battery greatly affect its performance and life.
Therefore, always conduct inspection and maintenance completely to keep the
battery in the best condition.
Do not place a wrench or other metals on top of the battery.
- 63 -
14
Periodic Inspection
Always wear protective goggles, rubber gloves and rubbersoled shoes during maintenance and inspection. Directly
touching conductive parts may cause electric shock.
Remove static electricity from your body before inspection.
Disconnect the battery plug before checking the battery
electrolyte level.
Replenish distilled water before charging.
If too much electrolyte is put in the battery, it will overflow
during charging and lead to corrosion.
a. Check whether the electrolyte is insufficient referring to the figure below.
Open the cap. When the white line of the red float drops, replenish water.
Replenish water until you see the white line.
- 64 -
Periodic Inspection
14
For the daily inspection, randomly select several cells to

understand the conditions of all cells. Change the inspection
batteries at least once a month. Always record and save the
inspection results.
If the electrolyte continues to overflow during charging

although its level was within the specified range before
charging, the battery discharges too fast, the electrolyte temperature increases abnormally, or the electrolyte decrease is
remarkable (in certain cells), contact a designated service
shop.
b. Check terminals for looseness.
c. Check cells, terminals and cables for
rusts, corrosion or cracks.
d. Check whether the battery is dirty or
not. If dirty, current leakage will
occur. So, wash the battery with
water and then dry by air blow or
using clean moist cloth.
Measure the specific gravity and temperature of each cell using a hydrometer and thermometer. Convert the
specific gravity to find the specific gravity at 20C.
When electrolyte temperature exceeds
20C: The specific gravity when electrolyte temperature is 20C = Measured
specific gravity + @. For example, when
the measured specific gravity is 1.260
(electrolyte temperature is 30C), the
specific gravity when electrolyte temperature is 20C will be 1.267(1.260 +
0.007), because @ is 0.007 according to the table below.
- 65 -
14
Electrolyte
temp. (C)
21, 22
23
24
25, 26
27
28, 29
30
Periodic Inspection
@
0.001
0.002
0.003
0.004
0.005
0.006
0.007
Electrolyte
temp. (C)
31, 32
33
34
35, 36
37
38, 39
40
@
0.008
0.009
0.010
0.011
0.012
0.013
0.014
Electrolyte
temp. (C)
41, 42
43
44
45, 46
47
48, 49
50
@
0.015
0.016
0.017
0.018
0.019
0.020
0.021
When electrolyte temperature is below 20C:

The specific gravity when electrolyte temperature is 20C = Measured specific
gravity @. For example, when the measured specific gravity is 1.270 (electrolyte temperature is 10C, the specific gravity when electrolyte temperature is
20C will be 1.263 (1.270 0.007), because @ is 0.007 according to the table
below.
Electrolyte
temp. (C)
0
1, 2
3
4, 5
6
@
0.014
0.013
0.012
0.011
0.010
Electrolyte
temp. (C)
7
8, 9
10
11, 12
13
@ Electrolyte
temp. (C)
0.009
0.008
0.007
0.006
0.005
@
14, 15
16
17
18, 19
0.004
0.003
0.002
0.001
e. Check that the specific gravity is 1.2800.01 when fully charged at 20C. If the
charging is insufficient after the first charging, carry out supplementary charging. Specific gravity at the end of charging: 1.280 (20C) Specific gravity when
completely discharged: Approx. 1.150 (20C)
f. Check for unevenness in the specific gravity among cells. If the unevenness
still remains or some cells have low specific gravity even after uniform charging, specific gravity adjustment or other necessary treatment is required. Contact a designated service shop.
Precautions for handling battery electrolyte
Pay sufficient attention when handling the battery electrolyte, because dilute sulfuric
acid is used. If an accident occurs, immediately take the following first-aid measures,
and have a medical specialist diagnose the problem. Failure to do so may cause burns
or blindness.
- 66 -
Periodic Inspection
14
If the electrolyte contacts your skin, immediately wash it off

with plenty of water (tap water, etc.) and then wash well with
soap.
If the electrolyte splashes into your eyes, immediately rinse
affected eye with plenty of clean water for about 15 minutes.
If the electrolyte is taken orally, immediately gargle with
plenty of clean water repeatedly. Then drink a large amount
of milk or clean water and rest.
If the electrolyte contacts your work clothes, take off the
clothes immediately. Wash them with water and then completely neutralize using low-alkaline soap solution.
If a large amount of electrolyte splashes around or flows out,
immediately neutralize with an acid neutralizer (sodium
bicarbonate, calcium hydroxide or carbonated soda, etc.)
and then wash off with water.
Monthly Inspection (Every 200 Hours)

a. Existence of abnormalities in the braking devices, clutches and steering equipment.
b. Existence of abnormalities in the load handling equipment and hydraulic
equipment.
c. Existence of abnormalities in the overhead guard and pack rest.
Also check the following during the monthly inspection.
1. Checking the differential gear oil
and transmission.
Pull out the oil level gauge and
check the oil level. When it is insufficient, replenish oil. When the oil is
contaminated, replace it.
Replace the oil for the first time

after 6 months of use, and after
that replace it every 12 months.
- 67 -
14
Periodic Inspection
2. Checking the mast trunnion cap bolt

Refer to the lubricant table (page 82).
Bolt tightening torque.
1.51.75 ton
7186Nm (729875kgfcm)
22.5 ton
176212Nm (1,8002,160kgfcm)
3. Lubricating the trail axle link.

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

Refer to the lubricant table (page 82).
- 68 -
Periodic Inspection
5. Lubricating the control valve lever
6. Checking the overhead guard

Check the overhead guard and its
installation section for loose screws and
damage.
7. Checking the lift lever potentiometer and tilt lever switch
Operate these levers to check:
a. whether the potentiometer and switch functions correctly, and
b. whether the hydraulic motor is rotating after the lever is put to neutral.
8. Cleaning electrical equipment and checking installation
Disconnect the battery plug and then remove dust with compressed air.
Never use a steam cleaner.
Avoid all electrical parts from getting wet. This may cause
failures and malfunctions.
a. Check for loose plugging and wiring.
b. Check for excessively worn contactor contacts.
c. Check for loose bolts.
- 69 -
14
15
Work Items
Opening/Closing the Battery Cover

1. Opening
a. Slide the operator's seat back to the
maximum.
b. Release the cover lock at the front
of battery cover and lift the cover.
c. Open the cover fully and check that
the gas damper is securely locked.
Do not set the battery cover free

before confirming that the gas
damper is securely locked.
2. Closing
a. Press and release the lock while supporting the battery cover by hand.
b. Close the cover slowly and lock the cover lock securely.
When closing the battery cover, do not place

your hand on the cover. Otherwise, your
hand will be caught by the cover.
- 70 -
Work Items
Adjusting The Parking Brake

Lever Operating Force
1. Attach a spring gauge in the middle
of the parking brake lever grip.
While pulling the gauge, measure
the operating force of the lever.
2. If the operating force is not within
the specified range, release the
parking brake and then adjust the
brake lever.
Turn clockwise: Operating force
increases.
Turn counterclockwise: Operating
force decreases.
Operating force:
1.52.5 ton 200250 N
(2025kgf)
How to Use Coupler Pin

Use the coupler at the back of weight
when the forklift can no longer move as
the tire is caught in mud. The pin can
also be used when loading the forklift
truck into another truck.
Do not use the coupler pin for towing other vehicles or towing the
forklift truck.
- 71 -
15
15
Work Items
Changing Tires
1. Preparation
a. Prepare tools, jack, stoppers and new tires.
b. Remove load, move the vehicle to a level and rigid place, and pull on the parking brake.
c. Put the stoppers on the tire diagonal to the one to be changed.
2. Setting the jack
a. Changing front tires Set the jack underneath the mast bottom or hoist the
upper part of the mast or use hydraulic equipment.
b. Changing rear tires

Set the jack underneath the counterweight.
1.5-1.75 ton
3 tons or more
2-2.5 ton
5 tons or more
- 72 -
Work Items
Use a jack having a capacity higher than the specified

capacity.
Put the jack up piece right on the jack seat underneath the
counterweight.
Check that the mast trunnion bolt is tightened in normal
state.
Use a sufficiently strong wire rope with no damage.
Never hoist the vehicle by hooking the overhead guard or

frame. When the vehicle must be hoisted, consult a designated service shop.
3. Tire change
a. Jack up until the tire is barely off the ground.
b. For joint rim tire, completely bleed the air.
c. Loosen the hub nuts. Do not remove the tire at this point.
Check that the wheel joint bolt is not loose and then loosen
the hub nuts.
Differentiate the hub nut from the wheel joint nut before
starting work.
- 73 -
15
15
Work Items
4. Jack up until the tire gets off the ground. Remove the hub nuts and the wheel.
Do not put any part of your body under the truck while jacking up. If the jack comes off, it is very dangerous.
Remove load from the vehicle and put stoppers on the tire
before jacking up.
Get off the operator's seat before jacking up.
After jacking up, put a wood block or the like to secure
safety.
Ask a specialist for disassembling/reassembling a tire.
5. Mount a new tire and tighten nuts with hand as much as possible. The flat surface of the nut must be on the outside. Tighten the nut so that the tapered section
of the wheel nut comes in contact uniformly with the seat of the rim.
6. Lower the jack and torque the hub nuts in
the order shown below.
Hub nut tightening torque

Model
Front
Single
wheel
Rear wheel
1.5-1.75 ton
22.5 ton
196216Nm
196216Nm
(2,0002,200kgfcm) (2,0002,200kgfcm)
98118Nm
114136Nm
(1,0001,200kgfcm) (1,1601,390kgfcm)
7. Checking tire air pressure (See

page 53).
After the tire is installed, check the
air pressure and adjust to the specified value. The standard air pressure is indicated on the
specification plate on the battery
cover to the right of the operators
seat.
8. After the tire change, run the vehicle for a short distance and then
tighten the hub nuts again.
- 74 -
Work Items
15
Cautions for tire disassembly and reassembly

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

eyes from dusts when they are blown off by compressed air.
Replacing, Repairing Simple Parts

If faults listed below occur during daily work, check the vehicle to identify the cause
according to the check points shown below. If the cause is not clear, contact a designated service shop.
Always turn the key switch OFF and disconnect the battery
plug before starting inspection.
Problem
The vehicle does not run.
The battery cannot be charged.
Check point
Check whether the control circuit fuse is blown.
Check whether the travel circuit fuse is blown.
Check whether the battery connection plug is
loose.
Check whether the power circuit fuse is blown.
Check whether the charge cord plug is disconnected or loose.
Check whether the charger fuse is blown.
- 75 -
15
Work Items
Replacing Bulb (If Equipped)

When a lamp does not light up, the fuse may be blown or the lamp may be dead. Use
the following procedure when replacing a bulb.
1. Turn the key switch OFF.
2. Remove the screw fixing the lens, and then the remove the lens.
3. Press the bulb lightly and turn it to remove it.
Light name
Front light
Front direction indicator light
Rear
combination
lamp
Capacity
48V40W
48V25W
Tail light/brake
48V10W/20W
light
Rear direction
indicator light
48V25W
Backup light
48V10W
Use a bulb with the same rating for replacement.
Replacing Fuse
Fuses are installed inside the rear cover. When a fuse is blown, remove the cause and
then replace the fuse.
Always disconnect the battery plug before replacing a fuse.

Always use fuses with the specified capacity.
Pay attention not to short circuit between terminals with a
wrench or other metal tools during replacement.
If the fuse is still blown after being replaced or the cause is
not clear, contact a designated service shop.
- 76 -
Work Items
1.5 - 1.75 Ton
1.
2.
3.
4.
Traction Controller
Hydraulic Controller
Power Steering Fuse
Fuse #4
5.
6.
7.
- 77 -
Fuse #3
Fuse #2
Fuse #1
15
15
Work Items
2.0 - 2.5 Ton
1.
2.
3.
4.
Traction Controller
Hydraulic Controller
Power Steering Fuse
Fuse #4
5.
6.
7.
Fuse #3
Fuse #2
Fuse #1
A high voltage is alive in the control unit. There

is danger of electric shock when in contact.
- 78 -
Service Data
16
Adjustment Values
Item
Power steering motor
brush
1.51.75
ton
Model
New part
22.5 ton
mm
20
Wear remaining limit mm
10
Steering wheel play
mm
2060
Standard brake pedal

height
mm
149159
Standard brake play
mm
36
Specific gravity of
electrolyte
(20C)
1.28
Fuse Capacities
Model
Main Circuit
Operation
Circuit
1.5-1.75
Ton
2-2.5
Ton
48V
48V
Power Steering
40A
40A
Auto-Off (Fuse #1)
10A
10A
Control Circuit (Fuse #2)
10A
10A
Accessory Circuit (Fuse #3)
10A
10A
Accessory Circuit (Fuse #4)
5A
5A
- 79 -
16
Service Data
Bolt Tightening Torques

Nm (kgfcm)
4.8
8.8
Bolt size
6
3.03.6 (3137)
8.510.2 (87104)
10.9
7.48.9 (7691)
20.724.8 (211253)
30.736.8 (313375)
10
14.717.6 (150180)
40.949.0 (417500)
60.872.9 (620744)
12
25.730.8 (262314)
71.485.8 (729875)
106127 (1,0801,296)
16
63.576.1 (648777)
176212 (1,8002,160)
263315 (2,6803,216)
20
124149 (1,2701,524)
346415 (3,5304,236)
513615 (5,2306,276)
24
215258 (2,1902,628)
597716 (6,0907,308)
8861,060 (9,04010,848)
30
426512 (4,3505,220)
1,1901,420 (12,10014,520) 1,7502,110 (17,90021,480)
Remarks
Unless otherwise specified, tighten all meter bolts and nuts to the tightening torque specified
above. Appropriate tightening torque is determined according to the strength indicated on the
bolts and nuts. When replacing bolts and nuts, always use Hyster Forklift genuine parts (same
size).
- 80 -
Inspection, Lubrication and Periodic Replacement Parts
17
The table below lists parts required for pre-operation inspection and periodic inspection.
1. Carry out pre-operation inspection in the order described in Section 12. The
order makes the work completed within a short time.
2. Details of periodic inspection is described in Section 14.
Inspection, Lubrication and Periodic Replacement Parts Table

Daily
Check
Check
Weekly
(50H)
Battery
Check
Electrolyte level,
specific
gravity,
terminals, cables
Meters
Safety parts (horn, lamps,
etc.)
Controller
Contactor
Drive motor
Pump motor, power steering motor
Wiring, battery plugs
Transmission and
differential gear oil
Check
Check
Tires and wheel nuts

King pin
Bell crank
Tie rod end
Power steering
Steering wheel
Check
Shift lever linkage Accelerator pedal

linkage
Check
Check
Lubricate
Lubricate
Brake oil
Brake pedal linkage
Parking brake
Parking cable
Brake master cylinder
cups
Wheel cylinder cups
Hoses
Check
Check
Check
Lubricate
Grease
Hydraulic oil
Fluid suction strainer
Fluid return filter
Lift lever, tilt lever
Tilt pivot
Mast roller rolling surface
Lift chain
Fork sliding section
Trunnion cap bolt
Entire mast
Mast trunnion
Pump drive
Hoses
O-rings
Check
Item
Others
Load handling device
Braking device
Operation Steering Tire

Drive
device
device related conveyance
Electric equipment
Entire vehicle
Overhead guard
Monthly
(200H)
6 months
(1,200H)
12 months
(2,400H)
Replace contactor tips

if roughness is
remarkable.
Check
Check
Check
Check
Check
Check
Check
Check
Grease
Grease
Grease
Initial oil
change
Remarks
Check wear of brush.

(power steering motor
only)
Oil change
Oil quantity:
4liters (1t),
4.5 liters (2t, 2.5t)
Exchange right
and left
Check
Check
Replace
Replace
Replace every 2
years
Replace
Replace every 2
years
Replace
Clean
Replace
Oil quantity: 14 liters

(1.52.5t)
Grease
Check
Check
Grease
Grease
Grease
Grease
Replace every 2 to 4 years
Check
Check
Grease
Grease
Check
- 81 -
Replace every 1 to 2 years

Replace every 6 months to 2
years
17
The Inspection, Lubrication and Periodic Replacement Parts

Table shows the required intervals under general usage conditions (operation of about 200 hours a month). Use an interval that matches the usage conditions of your vehicle. Doing
so will reduce faults and extends the life of the vehicle.
*Use special grease for the items with an asterisk mark.
Please feel free to contact a designated service shop if you have any questions.
Inspection and Lubrication Chart
- 82 -
17
The quick-reference table below summarizes the Inspection, Lubrication and Periodic
Replacement Parts Table and the Inspection and Lubrication Table. This table does not
include the initial replacements. For the initial replacements, see pages 81 and 82.
Replacement part
Replacement time
[Lubrication related]
Hydraulic oil
Hydraulic oil return filter element
Transmission oil
Differential gear oil
Brake oil
Every 6 months or 1,200 hours

[Hydraulics related]
O-rings
Every 6 months to 2 years
[Electric devices]
Contactor tips
Every 1 to 3 years
Replace when remarkably rough.
Every 6 months to 2 years
Replace when wear limit is reached.
Power steering motor brush

[Braking device]
Parking cable
Every 2 years
Periodic Replacement of Safety Parts

Periodically replace the parts listed below related to safe operation of the forklift truck.
In order to maintain safety functions, replace these parts after their specified periods
have passed even if no abnormalities are found during the period. If any problem is
found with the parts even before the specified replacement period, repair or replace
the parts. Note that the periodic replacement and warranty process are not related.
No.
Part name
Years
Cups of master cylinder and wheel cylinder, dust seals, etc.
Brake hose or tube
12
Brake reservoir tank tube
24
Lift chain
24
Hydraulic hose for load handling
12
Power steering hose
Rubber parts of power steering system
(Source: Standard of Japan Industrial Vehicle Association)
- 83 -
17
Lubricants List
Application
Transmission oil
Differential oil
Brake oil
Hydraulic oil
Type
Applicable
Temperature
SAE 80
30C or less
SAE 90
30C or above
SAE 80
30C or less
SAE 90
30C or above
DOT 3
Shell Spylux
80EP
Shell Spylux
90EP
Shell Spylux
80EP
Shell Spylux
90EP
Seiken Genuine
BF3-N
VG 32
Anti-wear
hydraulic oil
NM Super
Highland 32
Grease
Special grease
Lubricant Brand
(used at shipment)
Albania EP2
Molybdenum
disulfide grease
- 84 -
SUMICO
Mori LG Grease
Refrigerator/Freezer Specified Vehicles
18
Freezer/Refrigerator Specified Vehicles

The freezer/refrigerator-specified vehicle is a counterbalance-type battery operated
forklift truck that is designed and manufactured for load handling work under sever
conditions in a refrigerator. There are two types; one is for working with a temperature
down to 35C, and the other down to 45C.
1. 35C type
This type is designed for work inside and outside of 35C-class refrigerator and
for 3-hour continuous work in a refrigerator at 25C.
When working with a 35C-class refrigerator, the indoor and outdoor work time
ratio is should be nearly fifty-fifty and continuous indoor work must be within 1
hour. As for a 25C class refrigerator, continuous indoor work must be within 3
hours then work outdoor or take a break for about 30 minutes.
2. 45C type
This type is designed for work inside and outside of 45C-class refrigerator and
for 3-hour continuous work in a refrigerator at 35C.
When working with a 45C-class refrigerator, the indoor and outdoor work time
ratio is should be nearly fifty-fifty and continuous indoor work must be within 1
hour. As for a 35C class refrigerator, continuous indoor work must be within 3
hours then work outdoor or take a break for about 30 minutes.
Do not leave the forklift truck inside the refrigerator (both

35C and 45C types).
Any other types of forklift truck shall not enter a refrigerator.
Always charge the battery of the vehicle outside the refrigerator.
Rustproof and low-temperature measures are provided for electrical parts and
some other parts of this type of forklift trucks. Take special care of the daily lubrication, maintenance and inspection.
3. Rustproof measures
When the vehicle enters and exits a refrigerator, water will condense on the vehicle due to the sharp change in temperature. This will cause rust to form easily.
Therefore, special rustproof paint has been applied on the vehicle mast and parts
where rust will form easily. When repairing the vehicle body or mast because of
damage, pay special attention to painting agent to be used.
Furthermore, stainless steel bolts and nuts are used at portions where rust will
form easily. The other bolts, nuts, springs, etc. are plated, so take care when
replacing them.
- 85 -
18
Refrigerator/Freezer Specified Vehicles
4. Low-temperature measures
a. Hydraulic oil
Hydraulic oil that has superior performance even at low temperatures is used.
Use the oil listed below when replacing the oil.
Oil for freezer/refrigerator specified vehicles
Application
Application
Lubricant brand (used at shipment)
Hydraulic oil
Anti-wear hydraulic oil
35C spec
Shell Tellus Oil T15
45C spec
Shell Tellus Oil T15
b. Electric parts
Waterproof and rustproof parts are used to ensure the vehicle performance
even at low temperatures.
- 86 -
Part No. 4046068
10/11

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OPERATING MANUAL

DO NOT REMOVE THIS MANUAL FROM THIS UNIT

This operator manual describes the following truck models.

Pre-operation and Periodic

For Safety Operation...........................................................................

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

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

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

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

How to Drive ........................................................................................

Starting and Traveling

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

Load and Vehicle Stability

Load Handling .....................................................................................

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

Exchanging The Battery Using a

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

How to Use The Battery

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

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

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

Periodic Inspection and Servicing

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

Opening/Closing the Battery Cover

Inspection, Lubrication and Periodic Replacement Parts...............

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

Pre-operation and Periodic Inspections

Pre-operation inspection ................This daily inspection must be conducted

Post-operation inspection...............This inspection is carried out when the daily

Chassis Number and Serial Number Locations

Handling of New Vehicle

Avoid high-speed operation, and keep the load to 70 to 80%

For Safety Operation

Before Starting Work

Only operators who have completed the forklift truck operation

Wear designated work clothes and

Take sufficient time to discuss the

Inspect the forklift truck before

Do not modify or repair the forklift

For Safety Operation

If overhead guards, back rests or any other defects are found

Always fasten seat belt while operating the vehicle

For Safety Operation

Always operate the vehicle within

A forklift truck is built for only one

Assign a guide at narrow places for

If the view is obstructed, always

For Safety Operation

When traveling on a slope while

A forklift truck is steered by the

When driving the forklift truck at

Be careful of the height of the

The forklift truck is more likely to

For Safety Operation

Take special care when carrying a

Do not drive over wood pieces or

Traveling on the very edge of the

Take care of the road condition

For Safety Operation

Do not travel with an excessive

Do not use the tip of the forks as a

Use pallets and skids suitable for

Stack the load on the pallet or skids