PDF Download: UTILEV UT15PFE UT35PFE 1.5T-3.5T Electric 4-Wheel Forklift Truck Operator's Manual

1.5T-3.5T Electrical Four-Wheel Forklift Truck OPERATION AND MAINTENANCE MANUAL

UT15PFE – UT35PFE

Part No. 76502796(R5)

Foreword Thank you for purchasing the Utilev electric four-wheel forklift. The electric four-wheel forklift truck is Utilev’s new product line. It has a small turning radius, small dimensions and low center of gravity.

This operation and routine maintenance manual explains how to properly use and maintain a 1.5T-3.5T Utilev electric four-wheel forklift. The safe and efficient operation of lift trucks requires skill and alertness on the part of the operator. To develop the necessary skill, operators must receive training required by OSHA 1910.178(l) in the proper operation of THIS lift truck, understand the capabilities and limitations of this lift truck, become familiar with the construction of this lift truck and see that it is maintained in good condition, and read and properly understand the warnings, instructions, and operating procedures in this manual.

Some of the components and systems described in this Operating Manual may NOT be installed on your unit.

Please contact your authorized Utilev dealer if you have any questions or comments regarding Utilev forklifts.

This electric four-wheel forklift truck has passed the requirements for and is approved for operation in countries adhering to CE regulations.

b

MODELS Model

Drive Controller

Pump Controller

Rated Capacity(t) / Load Center(mm)

UT15PFE

Curtis 1234

Curtis 1234

1.5 / 500

UT18PFE

Curtis 1234

Curtis 1234

1.75 / 500

UT20PFE

Curtis 1236

Curtis 1234

2.0 / 500

UT25PFE

Curtis 1236

Curtis 1234

2.5 / 500

UT30PFE

Curtis 1236

Curtis 1236

3.0 / 500

UT35PFE

Curtis 1238

Curtis 1236

3.5 / 500

c

CONTENTS

Contents 1. Truck View and Main Components ........................................................................................................ 1 2. Instruments and Controls ...................................................................................................................... 2 2.1 Instruments........................................................................................................................................ 4 2.2 Controls ........................................................................................................................................... 11 2.3 Seat .................................................................................................................................................. 20 2.4 Seat Switches (CE) .......................................................................................................................... 21 3. Labels: ................................................................................................................................................... 22 4. Performance Parameters ..................................................................................................................... 36 5. Operating Instructions ......................................................................................................................... 38 6. Truck Carrying, Lifting and Towing ..................................................................................................... 47 7. The Structure and Stability of the Truck ............................................................................................. 50 8. Safeguards for Initial Use..................................................................................................................... 56 9. Routine Maintenance............................................................................................................................ 57 10. Operation ............................................................................................................................................ 65 10.1 Starting .......................................................................................................................................... 65 d

10.2 Driving............................................................................................................................................ 65 10.3 Decelerating................................................................................................................................... 65 10.4 Steering.......................................................................................................................................... 66 10.5 Parking ........................................................................................................................................... 66 10.6 Loading .......................................................................................................................................... 67 10.7 Stacking ......................................................................................................................................... 67 10.8 Unstacking ..................................................................................................................................... 68 10.9 Post-Operation Checks ................................................................................................................. 69 11. Storage ................................................................................................................................................ 69 12. Battery ................................................................................................................................................. 70 13. Maintenance Summary ....................................................................................................................... 84 13.1 Weight of Counterweights: ........................................................................................................... 85 13.2 Maintenance Schedules ................................................................................................................ 86 14. Attachments ...................................................................................................................................... 105 15. Operation, Detaching, and Installing the Operator Cab (Optional Equipment) ............................ 108 16. Automatic Battery Watering System (Optional) .............................................................................. 114 17. Safety Directives and Standards ..................................................................................................... 122 17.1 CE Certificate............................................................................................................................... 123 18. Operator Presence Sensing System (Optional) .............................................................................. 124 e

WARNING FAILURE TO FOLLOW THESE INSTRUCTIONS CAN CAUSE SERIOUS INJURY OR DEATH! AUTHORIZED, TRAINED OPERATOR ONLY! KNOW THE EQUIPMENT:

LOOK WHERE YOU ARE GOING:

•

KNOW operating, inspection, and maintenance instructions in Operating Manual.

•

IF YOU CAN'T SEE, DON'T GO.

•

DO NOT operate or repair truck unless trained and authorized.

•

TRAVEL in reverse if load blocks forward vision.

•

MAKE SURE tail swing area is clear before turning.

•

INSPECT truck before use.

•

•

DO NOT operate if truck needs repair. Tag truck and remove key. Repair truck before use. Always use Utilev Approved parts when making repairs.

Replacement parts must meet or exceed the specifications of the original equipment manufacturer.

SOUND horn at intersections or whenever vision is blocked.

•

USE attachments for intended purpose only.

•

MAKE SURE truck is equipped with overhead guard and load backrest adequate for the load.

• WATCH clearances, especially overhead.

KNOW YOUR LOADS: •

HANDLE only stable loads within specified weight and load center. See Nameplate on this truck.

• DO NOT handle loose loads higher than load backrest.

•

SPACE forks as far apart as load allows and center load between forks. Keep load against load backrest.

KNOW THE AREA: •

CHECK dock board width, capacity, and security.

1. Truck View and Main Components ITEM

DESCRIPTION

1

Forks

2

Load Backrest Extension

3

Mast

4

Side View Mirror

5

Overhead Guard

6

Seat

7

Counterweight Cover

8

Counterweight

9

Towing Pin

10

Rear Wheel

11

Battery cover

12

Front Wheel

2. Instruments and Controls

2

ITEM

DESCRIPTION

13

Forward/Reverse Switch

14

Multi-Function Display

15

Horn Button

16

Combination Light Switch

17

Lift Lever

18

Tilt Lever

19

Emergency Disconnect Switch

20

Parking Brake Lever

21

Warning Light Switch

22

Steering Wheel Tilt Lever

23

Brake Pedal

24

Accelerator Pedal

25

Steering Wheel

2. Instruments and Controls (continued)

3

ITEM

DESCRIPTION

26

Key Switch Ignition (KSI)

27

Lock to Battery Cover

28

Locking Bolt to Battery Box Side cover retention

29

Gas Spring for Battery Cover

30

Fuse Box

31

Fork Position Lock

2.1 Instruments Multi-Function Display [14] The multi-function display shows battery capacity, service hours, operating mode, travel speed and fault code information. Graphic illustrations on the display act as warning indicators. Through the display’s right button, it is also possible to check fault code and parameter settings.

ITEM A

Battery Capacity Indicator

B

Service Hours Meter

C

F

Operating Mode Indicator Vehicle Speed or Fault Code Indicator Slow Speed Indicator Light

G

Fault Indicator Light

H

Low Battery Indicator Light

I

Lifting Low Speed Indicator Light

J

Seat Switch Indicator Light Parking Brake Applied Indicator Light Mode Toggle / Menu Navigation Buttons Menu Button

D

K L M

4

DESCRIPTION

As the figure shows below from left to right, the segments of the indicator bar gradually disappear as the battery charge is depleted. When only the last segment remains, the battery is at less than 20% of its capacity. At this point the entire indicator bar will blink. Stop working and immediately charge the battery. We recommend charging the battery promptly when two segments remain (around 20% of capacity remaining), otherwise battery life may be significantly shortened.

Main Display Interface

CAUTION Timely charging is essential to maintain the service life of the battery.

Battery Capacity Indicator [A]

Service Hours Meter [B]

The hour meter starts counting when the vehicle key switch is turned on. Display provides reading to nearest tenth of an hour.

When the key is turned off the hour meter will stop counting.

Indicates the available residual capacity.

5

Operating Mode Indicator [C]

NOTE The system defaults to E Mode. Whenever power is restored after a power failure, the system will revert to E Mode regardless of which mode was selected before the power failure. However, when the key switch is turned off and on again, the system will revert to the same mode as was last selected.

As shown in the above figure from left to right, this indicator respectively indicates: S Mode→P Mode →E Mode →SPE Mode S Mode: Super mode allows for the fastest acceleration and deceleration and the maximum grade ability. It is used for climbing steep inclines and handling a large number of goods in a short period of time. However, it consumes the most power and should therefore be used sparingly.

P Mode: Power mode offers slightly lower performance than Super mode and is used for long-distance transport situations that require greater power or speed.

E Mode: Economy mode offers optimized all-round performance and energy savings. It is suitable for prolonged operation on a single charge and is recommended for normal work.

SPE Mode: Safe mode limits the maximum travel speed to about 7 km/h. It is used for working in congested warehouses and confined spaces.

In this mode, the slow indicator [F] illuminated.

Vehicle Speed or Fault Code Indicator [D] Vehicle Speed Display

This area displays the vehicle’s travel speed in real time.

Fault Code Display: Displays electronically controlled fault codes TRA= HYD=

will be

6

Traction Controller Pump Controller

Indicator Lights

Lifting Low Speed Indicator Light [I] (Red)

When the battery charge is only 10%, this lamp comes on and the mast lift speed slows down to remind the user to charge the battery as soon as possible

Slow Speed Indicator Light [F] (Green)

Seat Switch Indicator Light [J] (Red)

The slow speed indicator lights up when the forklift is in SPE mode.

Fault Indicator Light [G] (Red)

If equipped, this lamp illuminates whenever the driver leaves the seat, indicating the seat switch status, the vehicle does not have powered movement or hydraulics capability. This feature requires the seat to be fitted with a seat switch.

In the event of an electronic control failure or operating error, this lamp will illuminate and a fault code will be displayed on the instrument.

Parking Brake Applied Indicator Light [K] (Red)

Low Battery Indicator Light [H] (Red)

This lamp illuminates whenever the manual parking brake is applied.

When only one segment remains, this lamp comes on to remind the user to charge the battery as soon as possible.

7

Button

NOTE: after entering the instrument menu, these four buttons become directional buttons which are used to navigate the menu.

Mode Toggle / Menu Navigation Buttons [L]

Menu Button [M]

(1) In the main display interface, press the button , to enter the fault code interface. The fault code shows as follows:

Mode Settings In the main display interface, you can switch between S, P, E and SPE modes using the mode toggle buttons shown above.

For example, when in the main display interface, pressing the screen:

button will display the following

8

(2) In the main display interface, press the button

Advanced Settings (This menu requires a password.)

over 2 seconds, and then enter the main menu.

The main menu includes: – Operation Menu – Advanced Settings – Exit

This instrument supports both Chinese and English and will set to your desired language. The instructions below show how to use the Menu Button [M] parameters to switch the language from English to Chinese. ① From the main display interface, press the Menu

Operation Menu Tap the Menu Button [M] to enter the "OPERATION MENU" The operation menu includes：software version information, language settings, LCD contrast settings, LCD brightness settings, programmer settings and exit.

Button [M] ( main menu.

9

) over 2 seconds, and then enter the

② Select the “OPERATION MENU” using the up

④ Select the “LANGUAGE” using the up button

button (

(

) or down button (

③ Press the Menu Button [M] ( operation menu.

).

) or down button (

).

⑤ Enter the language setting state using the left

), to enter the

button (

10

) or right button (

).

⑥ Using the up button ( ) or down button ( select the Chinese language.

The forward-reverse switch is used to select forward and reverse travel directions. When the direction lever is pushed forward and the accelerator pedal is depressed, the forklift truck will travel forward. When the direction lever is pulled rearward, the forklift will travel in reverse.

),

NOTE: When the forklift is moving and the forward/reverse switch is operated, the electrical brake will be applied and the forklift will decelerate to a standstill before gradually moving in the opposite direction.

⑦ Refer to steps ⑤ ④ ③ ② ①, return the main display interface.

The language has now been set up.

2.2 Controls Forward Reverse Switch [13]

NOTE: If the forward/reverse switch is not in neutral or the accelerator pedal is depressed, the forklift will not start when the key switch is turned to ON. In this situation, return the direction lever to the neutral position and move your foot off the accelerator pedal before attempting to start the forklift.

Sets the Direction of Travel 11

Combination Light Switch [16] NOTE: The turn signal lever does not automatically return to the neutral position. It must be reset manually.

Lift Lever [17]

The combined light switch has both a turn signal light switch and a head/signal light switch. The turn signal light switch indicates the intended turning direction of the forklift. The turn signal light blinks when the lever is in the turn position. The head/signal light switch has two settings: signal light on and head light + signal light on.

Push Forward

Left Turning Lamp Flashes

Centered

Lamp Goes Off Raises / Lowers the Forks

Pulled backward Right Turning Lamp Flashes

To raise the forks pull back and to lower the forks push forward. The lifting speed is controlled by the distance that the lever is moved backward. The lowering speed is controlled by the distance that the lever is moved forward or rearward.

12

Tilt Lever [18]

Emergency Disconnect Switch [19] In an emergency, press this red button to cut off the vehicle's main power supply. The vehicle will not be able to move, turn or lift.

NOTE: Do not use the emergency switch to stop the forklift under normal circumstances. In these cases, use the key switch.

Parking Brake Lever [20] When stopped, pulling on the brake lever generates a braking force on the front wheels. To release the brake, simply push the lever forward.

The hand brake is equipped with a micro-switch on the left side that prevents the forklift from moving when the brake lever is engaged.

OPS feature: if the driver leaves the seat without engaging the brake lever, an alarm sounds reminding the driver to engage the hand brake.

Tilts the Forks Forward / Backward The tilt lever is used to tilt the mast forward and backward. Push forward to tilt forward, pull backward to tilt back. The tilting speed is determined by the distance that the lever is moved.

CAUTION The control valve is equipped with a front tilt self-locking valve. When the flow is cut off, the mast cannot tilt forward even if the lever is pushed forward.

WARNING If parking on an incline is unavoidable, block the wheels with heavy-duty wheel chocks.

Failure to secure the forklift could result in serious injury or death.

13

Steering Wheel Tilt Lever [22]

Accelerator Pedal [24] Slowly depress the accelerator pedal. The drive motor will start running and the forklift will move. The travel speed can be increased gradually based on the force applied to the pedal.

NOTE: By gently releasing the accelerator pedal while driving soft braking will occur.

NOTE: Do not depress the accelerator pedal before turning on the key switch, otherwise the meter display will display a fault. Keep your foot off the accelerator pedal when turning the key switch on. To clear this code, turn the key back off and then on without pressing the accelerator pedal.

The inclination of the steering column can be adjusted to suit the operator’s needs. Move the handle upward to release the steering column; move it downward to lock the steering column.

Brake Pedal [23] Depressing the brake pedal will slow down or stop the forklift and activate the brake lights.

CAUTION Do not depress the accelerator and brake pedals at the same time, as this will damage the drive motor.

14

Steering Wheel [25] When the steering wheel is turned right, the forklift will turn to the right; when the steering wheel is turned left, the forklift will turn to the left. The rear end of the forklift swings out when turning.

NOTE:  If the direction lever is not in neutral or the accelerator pedal is depressed, the forklift will not start when the key switch is turned to ON.  At this point a fault code will be displayed, which is perfectly normal.  Return the direction lever to the neutral position and move your foot off the accelerator pedal before attempting to start the forklift.  The fault code will then disappear.

CAUTION This forklift uses a fully hydraulic steering system. Therefore, increased steer effort is required when the hydraulic pump motor stops running.

Immediately restart the truck starting the oil pump motor before turning wheel again.

Lock to Battery Cover [27] Locks the battery cover hood to frame.

Locking Bolt to Battery Box [28] Holds the plates or covers on either side of the battery box closed.

Gas spring for Battery Cover [29] Supports the battery cover in the open position. To close the cover, press the red button on side of gas spring and push down on the cover at the same time.

Key Switch [26] The key switch has two positions: ON and OFF. First set the direction lever to the neutral position, take your foot off the accelerator pedal, then turn the key clockwise to the ON position.

15

Fuse Box [30]

Fork Position Lock [31]

Used when adjusting the spacing of the forks. Pull up the fork positioning pin and rotate it 90°, then adjust the forks to the desired positions according to the load to be handled. Rotate and allow pin to drop into slot.

CAUTION

CAUTION When replacing a fuse, always use a new fuse of the same capacity.

Failure to do so could result in property damage.

If the fork/locking pins are not fully engaged, there may be a risk of the load accidentally falling. Be sure to properly engage fork position lock

16

WARNING Fork spacing should be adjusted symmetrically to the truck centerline and fork position locks should always be set.

WARNING The lower bars of the carriage have a notch to install or remove forks.

DO NOT position the forks over the notch.

FIGURE A

REPLACING FORKS Removing Forks

WARNING Do not try to move a fork without a lifting device. The forks can weigh up to 180 kg (400 lb.) Failure to avoid this hazard could result in property damage or injury.

A fork can be removed from the carriage for replacement of the fork or other maintenance. Slide a hook fork to the fork removal notch on the carriage. See Figure A. Lower the fork onto blocks so that the bottom hook of the fork moves through the fork removal notch.

Lower the carriage further so that the top hook of the fork is disengaged from the top carriage bar. Move the carriage away from the fork, or use a lifting device to move the fork away from the carriage.

Installing Forks Move the fork and carriage so that the top hook on the fork can engage the top carriage bar. Raise the carriage to move the lower hook through the fork removal notch. Slide the fork on the carriage so that both upper and lower hooks engage the carriage.

Engage the lock pin with a notch in the top carriage bar.

WARNING Check the bolt at the middle of the fork bracket used to prevent fork load at the notch.

17

Battery Cover

Left/Right Battery Cover Panels

The wide-opening cover facilitates inspection and battery maintenance.

Cover panels are located on each side of the battery.

To remove these cover panels, first release the locking bolts on the front of the cover panel.

You can lift up the cover with little effort due to a cover gas spring. To lock the cover, push down on the front of hood cover while pushing button on spring until it latches.

Step and Handgrip Handle A step is provided on both sides of the forklift and a handle is located on the front left pillar of the overhead guard leg. Use the step and handle on the left side to move on and off the lift truck. Maintain three points of contact getting on and off the forklift.

CAUTION Be careful not to trap your fingers when closing the hood. This can result in an injury.

Press the gas spring release before closing the hood.

Brake Fluid Cup The brake fluid cup is located under the front floor plate.

Overhead Guard

CAUTION

The OVERHEAD GUARD is intended to offer reasonable protection to the operator from falling objects, but cannot protect against every possible impact. Therefore, it must not be considered a substitute for good judgment and care when handling loads.

The overhead guard opening is used for lifting batteries.

DO NOT use the forklift without the overhead guard.

When adding brake fluid, prevent dust and debris from entering the cup. Brake fluid is corrosive and toxic. Failure to keep this system clean may result in loss of braking, property damage or injury.

18

Rear work lights are mounted on the overhead guard. Replace damaged rear work light immediately.

Hydraulic Oil Filler Cap The hydraulic oil filler is located at the right rear end, below the battery cover. To top off the hydraulic oil, open the right battery cover. Add clean hydraulic oil

Rear Work Light Switch [Optional] The rear work light switch is a pull on / push off switch.

X — indicates connected

through the filler opening, and then install the filler cap.

Breather The top of the hydraulic oil reservoir is fitted with a breather, which should be checked frequently for debris.

Connector Position 0 1

Headlights and Front Combination Lights Two front headlights and front combination lights (turn signal and clearance lights) are installed on the front overhead guard legs. Protect the lights from damage and wipe clean if dusty. Replace damaged lights immediately.

Rear Combination Lights The rear combination lights include turn signal lights, clearance lights, brake lights and reversing lights.

Protect the lights from damage and wipe clean if dusty. Replace damaged lights immediately.

Rear Work Light [Standard for CE or Optional] The rear work light is mounted on the overhead guard. If damaged replace immediately.

This forklift can be equipped with rear work lights.

Battery X X

Rear Work Light X

NOTE: Rear work lights do not turn off automatically regardless of key switch position. They must be turned off manually.

19

2.3 Seat

Forward and Backward Adjustment of the Seat  Pull up the adjustment lever ② and push the driver’s seat forward or backward to the desired position.  When the handle is released, the seat will lock automatically.

WARNING The seat must only be adjusted when the truck is stationary. Adjusting seat while truck is moving may result in serious injury or death.

1: Weight Adjustment Lever 2: Forward And Reverse Adjustment Lever 3: Backrest Angle Adjustment Lever

Adjustment of Seat Backrest  While seated with back fully against the seat backrest, pull the backrest angle adjustment lever ③ upward with your left hand.  Do not release the lever until properly positioned in the seat by moving the body forward or backward.  Release the backrest adjustment button ③ to lock the backrest in position.

Adjusting the Seat to the Driver's Weight: To adjust the seat to the driver’s weight, pull up the weight adjustment lever and then move the lever to the left or right horizontally.  

To set the seat for less weight, push the weight adjustment lever ① to the left.

To set the seat for more weight, push the weight adjustment lever ① to the right.

20

Seat Belt Always fasten the seat belt ④ before starting the truck. The seat belt may protect against serious injury. Clean the seat belt regularly.

WARNING The lift truck must never be used if the seat belt is damaged or defective in any way. Replace damaged seat belts immediately. Failure to use a properly operating seat belt may result in serious injury or death.

Do not alter the belt setting. Always replace seat belt after an accident.

Correct Use of the Seat Belt:  When fastening the seat belt, sit upright with back firmly against the back of the seat.  The seat belt is not to be knotted or twisted.  Wear the seat belt low around the waist.  Fasten seat belt securely and snugly.

Regularly Check the Seat Belt for the Following:  cut or frayed straps  worn or damaged hardware, including anchor points  buckle or retractor malfunction  loose stitching

2.4 Seat Switches (CE) For complete description of OPS - See Operator Presence System, Section 18.

For (CE), OPS System includes Single switch and double switch functions:  Single “Locked”- when operator leaves the seat, the truck automatically shutdown the truck and traction motor.  Double “Locked”- when operator leaves the seat, the truck automatically shutdown the truck, traction motor and the hydraulic valve causing the mast not to lift or lower the load.

21

3. Labels: 26 7

27 9

6

8

10 11

2

7 6

12 26

5

13 14

4 13

3

HYD

油 压 液

OIL

2

Hydraulic oil tank 1 15

9 24 23

25

16

22 21

20

25

19

17 18

12 27

Warnings and notices such as rated capacities, capacity graph, warning labels and name plate must always be legible. Replace as necessary.

Labels and Label locations may vary.

22

1.Product nameplate

2. Warning label (Forks)

3. Warning label (Mast)

4. Warning label (Climbing)

5.Notice to user label

6.Lift point label

7.Truck Lifting label

8.Warning label (Mast)

9. No Rider label

10.Safe belt label

11. Operation warning label

12. Pin Stripe decal

13. Battery latch label

14. Hydraulic oil label

15.UTILEV(Counterweight)

16.Tie point label

17.Brake fluid indicating

18. Tire pressure label

19. UTILEV(side frame)

20. Model label

21.Gas spring locking label

22.Hand brake label

23. Parking brake warning label

24.Battery warning label

25.Pneumatic Wheel Warning Rim label

26. Snowflake label(only for cold store truck)

27. Big snowflakes label(only for cold store truck)

23

Nameplate: Contains specifications for the forklift.

Warning Label (Forks): DO NOT stand on or under the forks or carriage; failure to follow this warning may lead to serious bodily injury or death.

24

Park Brake Warning Label: Apply Park Brake Manually or Alarm will sound.

Truck Lifting Label: Use lift points as shown with appropriate chains or cables. Improper lifting techniques or equipment may cause damage to the forklift or cause serious bodily injury or death.

25

Lift Point Label: Use these labeled points for lifting the forklift truck. Lifting from other points may cause damage to the forklift or serious bodily injury or death

Warning Label no climbing: (DO NOT enter mast) warning: You may be seriously or fatally injured if your body is squeezed between the mast, the frame, and/or the overhead guard. This forklift cannot carry passengers and must not be operated from outside the cab

26

Mast Warning Label: The inner and outer masts and fork carriage are vertically sliding parts.

DO NOT put your hand or any other body part between the inner and outer masts.

Failure to follow this warning may lead to serious bodily injury or death.

Gas Spring Lock/Unlock Label:

27

Seat Belt Label and Tip over Warning Label:

28

Capacity Label

Fuse Label

Warning Label (Mast):

29

WARNING SERIOUS OR FATAL INJURY MAY RESULT TO YOURSELF OR OTHERS IF NOT FOLLOWED This lift truck should not be operated by anyone who is not authorized and properly trained.

Read the Operator Manual and all warnings carefully, and make yourself familiar with your lift truck.Operator Manual and Service Manual are supplied with this truck or available from our forklift truck dealers.

Inspect and check your lift truck daily before and after use. Do not operate faulty or damaged lift trucks.

Repair work should be done by authorized and trained persons only.

To protect from falling objects, make sure the Overhead Guard and Load Backrest Extension are correctly mounted and in good condition.

Before starting engine, always set forward/reverse lever in neutral, with hand brake on.

Drive carefully, keeping forks and attachments as low as possible & fully tilted back - Never Forward.

Keep a careful look out for people, obstructions and the path of travel. Watch clearance, especially overhead and tail swing. Yield right of way to pedestrians.

Do not stick hands, feet or other parts of your body outside the operator compartment.

Drive forward when you are climbing a slope with a load. Drive in reverse when you are descending with loads. Do not turn while on a slope.

Slow down before turning. Avoid any sudden start, stop or turning. Lateral tip over can occur if truck is improperly operated.

Do not load lift truck over capacity limit designated on the load chart. Do not lift unstable loads.

This lift truck is not designed for raising or transporting people. Do not use lift truck for those purposes under any circumstances.

Before you get off lift truck, make sure the hand brake is set, lower forks or attachments, put forward/reverse lever in neutral position and turn off key switch. Do not park on a slope.

Operation Warning Label

Hydraulic Oil Label:

Noise Level Label:

30

Tie down Point Label (CE): Use these labeled points for securing forklift during transport.

Brand Label:

Tire Pressure Label (Pneumatic):

31

Model Label: Example

Park Brake Label: Indicates the direction to move the park brake lever to set or release it.

• Away from operator will release the park brake • Towards the operator will set the park brake.

Emergency Stop:

32

Tip over Warning Label: Non U.S.

33

Battery Retention Label

Pneumatic Wheel Warning

34

Snow Flake: For Cold Usage

Brake Fluid Label

35

4. Performance Parameters Model

UT15PFE

UT18PFE

UT20PFE

UT25PFE

UT30PFE

UT35PFE

Rated Lifting Capacity (kg)

1500

1750

2000

2500

3000

3500

Load Center Distance (mm)

500

50

500

500

500

500

Standard Lift Height (mm)

3000

3000

3000

3000

3000

3000

Free Lift Height (mm)

145

145

140

140

145

145

Mast Tilt Angle (front/back) (°)

5/10

5/10

5/10

5/10

5/10

5/10

14/14

13.5/14

14/14

14/14

14/14

12/13

Maximum Travel Speed Under Full Load (km/h) Maximum Lifting Speed Under Full Load (mm/s)

290/440 285/440 280/440 230/430

250/400 210/400

Maximum Grade Ability Under Full Load (%)

15/16

15/16

13/14

13/14

13/14

13/14

Minimum Outside Turning Radius (mm)

1900

1900

2090

2090

2230

2310

36

Model

UT15PFE

UT18PFE

UT20PFE

UT25PFE

UT30PFE

UT35PFE

Minimum Ground Clearance (mm)

110

110

120

120

125

125

Maximum Braking Distance (m)

2.5

2.5

2.5

2.5

2.5

2.5

Length (to fork face) (mm)

2098

2098

2342

2342

2502

2582

Dimensions

Width (mm)

1120

1138

1265

1265

1265

1302

2050

2050

2075

2075

2110

2110

Service Weight

Height to Overhead Guard (mm) Include Battery Box (kg)

2940

3090

3700

4180

5050

5450

Battery

Standard (V/Ah)

48 / 420

48 / 420

48 / 630

48 / 630

80 / 500

80 / 500

Driven Motor (kW)

8.0 AC

8.0 AC

11 AC

11 AC

15 AC

15 AC

Pump Motor (kW)

8.6 AC

8.6 AC

8.6 AC

8.6 AC

10 AC

10 AC

Front x 2

6.00-9

21X8-9

23X9-10

23X9-10

23X9-10 23X10-12

Rear x 2

5.00-8

5.00-8

18X7-8

18X7-8

18X7-8

Motor

Tire

37

200/50-10



5. Operating Instructions

When performing maintenance on the mast, front and rear lights, or other high places, be adequately secured and take care not to slip.  Take measures to avoid burns when inspecting the motor, controller, etc.  Whenever you discover a fault, stop the forklift, hang a "DO NOT OPERATE" or "OUT OF ORDER" sign on it, remove the ignition key and notify an appropriate manager.

 Only trained and certified operators are permitted to operate forklifts.

 Inspect the truck before each shift for leaks, deformation, damage, etc. If neglected, the life of the truck will be shortened or an accident could occur.  Make sure to repair or replace all damaged or non-operating components observed during periodic inspections.  Wipe off oil, grease or water from the floor plate and foot and hand controls.  Strictly prohibit smoking and sparks near the storage battery when checking it.



38

The truck may only be used after all faults have been eliminated.



Arrange immediate repair in the event of a fault when lifting or driving uphill or downhill, or a leakage of battery electrolyte, hydraulic oil or brake fluid.

and off the truck. Maintain three points of contact while getting on and off the truck, such as two feet and one hand.

 Operators must wear the appropriate work clothes required by the specific application.  Batteries generate explosive gases. Keep sparks and open flames away from the battery.  Keep tools away from the battery terminals to prevent sparks or short-circuits.  The truck is designed to operate on solid and flat cement, asphalt or concrete surfaces. Surfaces covered with snow, ice, standing water or other foreign objects or obstacles must be cleared before working, otherwise the vehicle may spin out of control or tip, resulting in serious or fatal accidents.  The truck is designed to operate in the following climatic conditions: temperature range -20° C to +50° C; maximum wind speed 5 m/s; maximum relative air humidity 90% (at 20°C).  The truck is not suitable for use in flammable or explosive work environments.  Do not operate the truck at an altitude greater than 2000 meters.  Never get on or off the forklift while it is in motion.

Always use the step and the handle when getting on





39

Never attempt to work the controls unless properly seated.  Before starting the vehicle, adjust the seat position to facilitate hand and foot control.

Before starting the forklift, make sure that:  the seat belt is fastened  the park brake is released  the service brake is pressed  the directional lever is in neutral  all persons are clear of the truck  accelerator pedal is not depressed  lift or tilt levers are not operating







 Select appropriate attachments and tools according

Operate the controls smoothly and do not jerk the steering wheel. Avoid sudden stops, starts or turns.  Sudden braking may cause the vehicle to tip over.

Always look in the direction of travel and keep a clear view of the travel path. It is especially important to look in the direction of travel when reversing.

to the shape and material of the load to be handled.  Do not lift loads by suspending ropes from the forks or attachment, as the ropes may slip off. If necessary, arrange for a lifting hook or jib to be attached by someone qualified for rigging.  Be careful not to let the forks touch the floor, so as to avoid damaging the fork tips or driving surface.  Know the rated capacity of the forklift and its attachments, if fitted, and never exceed it.

Do not allow other people to sit on the forks, pallets or the truck itself. Do not use people as an additional counterweight.

40

 

Concentrate on your task at hand.

Keep your head, hands, arms, feet and legs inside the operator compartment at all times.

forklift without the overhead guard and load backrest extension.  No one may stand or walk under the forks or attachments. DO NOT allow anyone to stand on the forks.

 Pallets and skids should be strong enough to support the weight of the load. Never use damaged pallets.  Users can purchase various types of attachments, such as side-shifting carriages, forks and push-pullers. They are for specialized use only.

Modifications to attachments are NOT allowed without prior approval from the manufacturer. DO NOT attempt to modify attachments. Contact your authorized dealer.

The overhead guard provides reasonable protection from most falling objects for the operator. The load backrest is installed to keep loose parts of the load from falling back toward the operator. Do not use a 41

 Extending any part of your body into the gap between the mast and the overhead guard is strictly prohibited.

Risk of serious injury or death due to entrapment along with other hazards may exist.  NEVER put your hands inside the inner or outer mast.







ALWAYS keep the load centered on the forklift.

When the load is not centered, it could fall off during a turn or when traveling over uneven surfaces, or cause the forklift to tip over.

DO NOT stack loads on forks in such a way that the top of loads exceeds the load backrest extension height. If unavoidable, make sure the load is secured. When handling bulky loads that restrict your vision operate the forklift in reverse or have a spotter.

42

When using a spotter, make sure you know and understand the meaning of all hand, flag, whistle or other signals being used. When transporting long loads, such as piping, lumber or oversized cargos, or operating vehicles with elongated attachments, pay close attention to the front end when driving around corners or along narrow aisles. Always be aware of other people, especially, the spotter.

Failure to know where a spotter is at all times may result in serious injury or death to the spotter.





Use minimum forward and reverse tilt when stacking and un-stacking loads. Never tilt forward unless the load is slightly above the stack or at low lift height.  When stacking loads on a high place, make the mast vertical at a height of 15–20 cm above the ground and then lift the load. Never attempt to tilt the mast beyond vertical when the load is raised high.  To remove loads from high places, insert forks into the pallet, lift slightly and drive backwards, then lower the load. Tilt the mast backwards after lowering. Never attempt to tilt the mast with the load elevated.  It is hazardous to travel with the forks elevated, regardless of whether loaded or not. When travelling, the forks should be 15–30 cm from the ground with the mast tilted backward. Be careful when operating the side-shift mechanism when the forks are raised and loaded. This could cause the forklift to become unbalanced.  When operating in congested areas, be aware of your surroundings: intersections, entrances/exits and other obstructions.  Slow down and sound horn at cross aisles and other locations where vision is restricted.

 

 



43

Turning speed should be limited to 1/3 of the vehicle's top speed.

Be sure to keep your distance from the roadside or platform edge.

When driving over a dock board or a bridge, make sure that it is properly secured and strong enough to withstand the weight of the forklift with load.

When operating a loaded forklift, ascend and descend inclines with the front end of the machine pointing uphill.

When operating an unloaded forklift, ascend and descend inclines with the front end of the machine pointing downhill.

Never turn sideways on an incline because of the danger of the forklift turning over

 Do not allow cargo to move away from the center of the forks. Off-center loads may fall easily when turning corners or driving on uneven surfaces and increase the risk of the vehicle tipping over.

 Never lift loads with the truck inclined. Avoid loading work on a grade.

 Never permit anyone to stand or walk under upraised forks or attachments.

 Inspect the surface over which you will drive the forklift. Solid, level surfaces, such as asphalt or concrete roads, are recommended operating surfaces for forklift trucks. Look for holes, drop-offs, obstacles, protrusions, bumps or anything that might cause a loss of control.  Clear away debris and pick up items that might puncture a tire or unbalance the load.  Slow down on wet/slippery areas. Do not drive near the edge of the travel path. If unavoidable, be extra cautious.

44





When snow, ice, water, or other foreign matter has accumulated on the surface, do not operate until the operating surface has been completely cleared  Do not use the forklift during sandstorms, snowfall, lightning, torrential rain, typhoons or other harsh weather conditions.  Park the forklift on a level surface and apply the parking brake. Do not park on an incline. If parking on an incline is unavoidable, be sure to block the wheels with wheel chocks.  Lower the forks to the floor and tilt slightly forward.

Turn off the key switch and remove the key.  Disconnect the battery connector.  Park the forklift away from exposed flames and sparks.  If the forklift breaks down, move it to a place where traffic will not be obstructed. If the breakdown was caused by the braking system or a steering system failure, then transport it using an appropriate transport forklift. If there was another cause, then use an appropriate Service towing forklift. See towing instructions in Section 6.  DO NOT operate the truck or load cargo after removing the hood, radiator cover plate, overhead guard, or mast backrest.





 

45

The workplace should be equipped with fire extinguishers. Users can also select a vehicle equipped with fire extinguisher. The fire extinguisher is generally installed on the rear leg of the OHG or frame and is easily accessible.

The working area should be adequately lit. When working at night, switch on the headlights and work light. Be sure there is adequate lighting in the working area.

When traveling forward and turning, use the side view mirrors to monitor tail swing. Due to the forklift’s rear steer tires, the back of the forklift will swing out beyond the forward path of travel when turning. Be cautious when turning, taking into account tail swing while monitoring for pedestrians and obstacles. Adjust the side view mirrors to the correct angle to best observe conditions beside the forklift.

Cold store truck is not allowed to interrupt the electric power parking in cold storage environment.

Except as stated in the section below, no modifications or alterations to a powered industrial truck, which could affect, for example, capacity, stability or safety requirements of the truck shall be made without the prior written approval of the original truck manufacturer, its authorized representative, or a successor thereof. This



includes changes affecting, for example, braking, steering, visibility and the addition of removable attachments. When the manufacturer approves a modification or alteration, the manufacturer shall also make and approve appropriate changes to the capacity plate, labels, tags and operation and maintenance manual.

If the manufacturer is no longer in business and there is no successor in the interest to the business, the user may arrange for a modification or alteration to a powered industrial truck, provided, however, that the user: a) arranges for the modification or alteration to be designed, tested and implemented by an engineer(s) expert in industrial trucks and their safety b) maintains a permanent record of the design, test(s) and implementation of the modification or alteration

c)

d)

46

approves and makes appropriate changes to the capacity plate(s), decals, tags and instruction handbook affixes a permanent and readily visible label to the truck stating the manner in which the truck has been modified or altered, together with the date of the modification or alteration and the name and address of the organization that accomplished those tasks

6. Truck Carrying, Lifting and Towing Carry Forklifts are generally used for loading, unloading and short-distance transportation. They are not designed to be a long-distance mode of transport. A forklift that needs to be transported over a long distance should be transported in a ship, train or a truck having a sufficient load capacity. Use a loading platform or lifting device to load and unload a forklift.

Engage the parking brake and block the wheels with suitable chocks. Tie down the forklift using wire ropes or other lashings of sufficient strength to prevent it from moving during transit.

Hoist the Truck

Securely fasten wire ropes or other lashings to the lifting holes in both ends of the outer mast crossbar and to the counterweight hook, and then hoist the forklift with a lifting device. The wire rope or other lashings fastened to the counterweight end must pass through the gap in the overhead guard, without putting stress on the overhead guard.

47

WARNING When hoisting a forklift, make sure not to wrap the wire ropes around the overhead guard.

The wire ropes and lifting device must be strong enough to safely support the weight of the forklift.

Do not lift a forklift by its cab frame (overhead guard).

Never walk under a forklift when it is being lifted.

Towing 

If the forklift becomes inoperable and must be towed using the tow pin. Use a towing link made of steel that attaches to the tow pins in the counterweights of both lift trucks 1. The towed lift truck must have an operator.

2. Tow the lift truck slowly.

3. Raise the carriage and forks approximately 0.30 m (1 ft.) from the surface. Install a chain to prevent the carriage and mast channels from moving.

4. The Service lift truck used to tow the disabled lift truck must have an equal or larger capacity than the disabled lift truck. Install an approximate half-capacity load on the forks of the Service lift truck that is being used to tow the disabled lift truck. This half-capacity load will increase the traction of the Service lift truck. Keep the load on the forks as low as possible.  Contact an authorized technician to disable the parking brake for towing. Be sure to enable the parking brake after transport. The disabled truck may be damaged if it is towed with the parking brake engaged. (Applies to OPS option trucks)  DO NOT tow the disabled lift truck if there is no power. Poor traction can cause the disabled lift truck or towing vehicle to slide.

48

 The tow pin on the rear of the counterweight is for towing the forklift.  Turn off the key switch and disconnect the power plug.  Release the parking brake per instructions.  Put the direction lever in neutral.

WARNING  ONLY connect towing link made of steel to towing pin.  DO NOT tow a truck with steel wire ropes.  The truck may be damaged if towed with the electric brake engaged. Have authorized technician disable the parking brake. Be sure to enable the parking brake after transport.

49

7. The Structure and Stability of the Truck In order to prevent the forklift from tipping over, it is very important operators to understand the forklift’s structure and the relationship between load and stability.

The Structure of the Truck A forklift truck essentially consists of the lifting device (forks and mast) and the truck itself (with tires).

The front wheels are the fulcrum of the forklift and keep the center of gravity (CoG) of the forklift and load balanced.

The relationship between the forklift's CoG and the load's CoG is very important to maintaining the operation of the forklift.

Load Center A forklift handles loads of different shapes, from crates to boards and elongated objects. In order to assess the forklift and its stability, it is very important to distinguish between the CoG of different-shaped loads.

50

The Stability Zone of the Center of Gravity In order to stabilize the forklift, the combined CoG must be located inside a triangle formed by the front wheels and the midpoint of the rear axle.

If the combined CoG is located on the front axle, the two front tires will form a fulcrum point on which the forklift will tip forward.

If the combined CoG moves out of the stability zone, the forklift will tip in the direction that the combined CoG has moved.

Maximum Load and Load Center The horizontal distance between the CoG of the load on the forks and the backrest or the front face of the forks (whichever is shorter) is called the load center distance. Maximum load is the maximum load that a forklift truck can carry at a standard load canter distance. The relationship between maximum load and load center distance is stipulated in the forklift truck's load capacity graph. If the load center distance moves towards the front of the forks, the overall CoG shifts forward. Therefore, the load capacity decreases.

51

Gravity and Stability

Forklift stability depends on the combined CoG of the forklift. When the forklift is unloaded, the CoG remains unchanged. When the forklift is loaded, the CoG is formed by the combined CoG of the forklift and load.

The load's CoG depends on whether the mast is tilted forward or backward, raised or lowered, which means that the combined CoG also changes accordingly.

The forklift's combined CoG is determined by the following factors:  Load size, weight and shape;  Lifting height;  Mast tilt angle;  Tire inflation pressure;  Acceleration, deceleration and turning radius;  Driving surface conditions and inclination;  Attachment type.  Slope, or effective slope

52

WARNING! If the forklift begins to tip over, DO NOT attempt to jump off. The truck will tip much faster than you can jump. Brace your feet inside the truck and grip the steering wheel with both hands to keep yourself within the confines of the forklift. Keep your seat belt fastened at all times. Lean forward and away from the point of impact.

53

Warning

Load Capability Chart

This graph shows the relationship between the position of the load center distance and the maximum load. Prior to loading, check whether the load and the load center distance are within the limits of the load capacity graph. If a load has a complex shape, the heaviest part of the load should be centered over the forks and close to the backrest.

54

Warning

Speed and Acceleration

A stationary object will remain stationary unless an external force acts on it. Similarly, in the absence of an external force, a moving object will continue moving at the same speed. This is inertia.

Due to inertia, a rearward force is exerted when the forklift starts moving, and a forward force is exerted when the forklift stops moving.

Sudden braking can be hazardous because it generates a large forward force that can cause the forklift to tip over, or the load to slide off.

When the forklift turns a corner, a centrifugal force is exerted outward from the center of the turn. This force pushes the forklift outward and can cause it to tip sideways.

The truck has narrow lateral stability, so cornering must performed slowly to prevent the forklift from tipping sideways. If the forklift is handling an elevated load, the overall center of gravity is higher and therefore the forklift is more prone to forward or lateral tip over.

55

8. Safeguards for Initial Use New forklifts should initially be run under low-load conditions. In particular, the following requirements should be met within the first 100 hours of operation:  Battery over discharge must be prevented during initial use. In general, the battery should be recharged promptly when the charge level has decreased to 20% of its capacity  Required preventative maintenance must be carried out thoroughly  Avoid sudden braking, acceleration and cornering  Carry out oil changes and check lubrication points ahead of schedule and in accordance with the maintenance schedule  Limit the weight of the load to 70–80% of the rated load

56

9. Routine Maintenance

2. Check Pneumatic Tires (Option) Turn tire valve cap counter clock-wise and remove it. Using a tire pressure gauge, measure the inflation pressure, and adjust it to the specified pressure (using safety guidelines), if needed. After making sure there is no air leakage from the tire valve, reinstall the cap.

Inspect the tires for wire, rocks, glass, pieces of metal, holes, cuts, and other damage on the tread surface or side face or bending at the rim.

Proper maintenance will keep the forklift truck in good working condition. It helps keep the forklift in a condition which will help optimize your personal safety at work.

WARNING Except when testing lights and checking operating performance, and before checking the electrical system, turn off the key switch and disconnect the battery plug.

Never use a forklift that has any kind of fault.

Even a small fault can cause a serious accident.

WARNING (Pneumatic Only) 1. Since the forklift truck needs tires that have a high inflation pressure to carry heavy loads, even a small bending of rims or damage at the tread surface could cause an accident.

2. When using an air compressor, first adjust the air pressure of the compressor. Failure to do so will cause a serious accident, since the compressor delivers the maximum pressure.

3. All nuts and bolts should be properly installed and tightened before inflating tire and rim assembly. An inflated tire contains potentially explosive energy. DO NOT overinflate. The explosion of wheel parts can cause serious injury or death.

1. Check for Leakage of Hydraulic Oil, Electrolytes and Brake Fluid Check for oil spills or leakage around the hydraulic fittings, battery, and brake systems by carrying out a visual inspection. Never use an open flame.

57

(Pneumatic Tires Only) Model 1.5T-1.8T 2.0T-3.5T

3. Pneumatic Tire Replacement Replace any damaged tires immediately. Jack up forklift so that the tire is just off the ground, and then install a sturdy wooden block under the frame to support the truck. Loosen the wheel nuts and replace the tire with a new one. Tighten the nuts to the specified torque using a cross pattern.

Tire Pressure Front Wheel Rear Wheel 790 kPa 1000 kPa 900 kPa 800 kPa

4. Wheel Nut Torque Check  Park the forklift on a solid, level surface.  Tighten the wheel nuts crosswise using a torque wrench.

Bolt Tightening Torque Model

WARNING (Pneumatic Only) When air is added to the tires, use a remote air chuck. The person adding air must stand to the side of the safety cage and not in front of it.

An inflated tire contains potentially explosive energy. DO NOT overinflate.

The explosion of wheel parts can cause serious injury or death.

58

Front Wheel Nut Rear Wheel Nut

1.5T-1.8T

157-176 N.m

76-107 N.m

2.0T-3.5T

441-588 N.m

157-176 N.m

5. Wheels and Solid (Cushion) Tires

Drive Wheel (Front Wheels)

WARNING The type of tire is shown on the Nameplate.

Make sure the Nameplate is correct for the type of tires on the lift truck.

Wheels must be changed and tires repaired by trained personnel only.

 Solid rubber tires made from softer or harder materials can be installed as optional equipment.

The tread on solid rubber tires can be either smooth or it can have lugs. Electric or dual compound tires are recommended. Do not mix types of tires or tread on the lift truck  Raise the lift truck as described above using blocks.  Remove the wheel nuts or spindle nut and remove the wheel assembly from the lift truck. Lift truck wheels are heavy.

Steering Wheel (Rear Wheels)

WARNING The correct tools, equipment, and a press ring must be used for each size of wheel. Use a press to push the wheel from the rim and tire. The capacity of the press must be approximately 355 to 1779 kN (80,000 to 400,000 lb.).

59

wheel on the spindle. Install the outer bearing cone and castle nut. Tighten the castle nuts of the steer wheel spindles of these units to 68 N•m (50 lbf ft) while rotating the wheel in each direction at EACH installation. Loosen the nuts 1/4 turn. Pull and push at top of wheel to check for movement (end play). If there is movement, tighten the castle nuts to 3 N•m (25 lbf in). Install the cotter pins at the nearest alignment positions. Install the hub cap. Additional torque checks are not required

WARNING Failure to follow these procedures will cause damage to the tire and wheel assembly and can cause an injury

    

Clean and inspect all parts of the wheel before installing the tire.

DO NOT use any damaged or repaired wheel parts.

Make sure that all parts of the wheel are the correct parts for that wheel assembly.

DO NOT mix parts between different types or manufacturers of wheels.

DO NOT mix types of tires, type of tire tread, or wheel assemblies of different manufacturers on any one lift truck.

6. Brake Pedal Check •

Depress the brake pedal and check that it moves freely without jamming.

• The correct braking distance without a load is 2.5 meters.

• Adjust pedal height: regulate the brake light switch so that the midpoint of the upper face of the pedal pad is 115–125 mm from the front floor plate.

• Adjust the length of the pushrod of the brake master cylinder so that the pedal free play is 1–3 mm.

• The brake light switch should turn on fully when the brake pedal is gradually depressed 10–20 mm

NOTE: If proper equipment is not available, purchase wheel and tire assembly. 

Install Drive Wheels using Pneumatic wheel instructions lists above.

Steer Wheel and tire assembly  The steering wheels are fastened to the spindle of the steering axle with a large castle nut. Make sure the inner and outer bearings are correctly lubricated with grease. Install the inner bearing assembly and 60

7. Park Brake Lever Check

NOTE

The operating force is regulated by means of an adjusting screw on the handle cap. Twist clockwise to increase the operating force. The parking brake holding force should be able to hold a fully laden truck on a 15 percent grade.

Use either HZY3 or DOT3 brake fluid. Do not mix different grades of brake fluid.

Do not spill brake fluid on painted surfaces, otherwise it will damage the paint.

When adding brake fluid, avoid getting dust and water in the reservoir.

NOTE Depressing the brake pedal helps to tighten or loosen the hand brake lever.

10. Check Hydraulic Oil Unscrew the hydraulic oil filler cap on the inside of the right frame side, pull out the dipstick and check whether the oil is between the marks. Top off if necessary

8. Accelerator Pedal Check As the accelerator pedal is depressed through its full stroke, there should be a clear increase in the rate of acceleration, and the pedal should return freely to its original position when released.

9. Brake Fluid Check Open the front floor plate. Remove the cap of the brake fluid cup and check whether the brake fluid level is between the scale marks. Top off if necessary.

If the brakes feel spongy during operation, this can be a symptom of entrapped air. Have an authorized technician check for air trapped in the brake line or other system components.

WARNING At operating temperature the hydraulic oil is HOT. Do not permit the oil to contact the skin and cause a burn.

61

•

CAUTION Do not permit dirt to enter the hydraulic system when the oil level is checked or the filter is changed.

•

Never operate the pump without oil in the hydraulic sys- tem. The operation of the hydraulic pump without oil will damage the pump.

•

11. Hydraulic Oil Change Hydraulic oil should be changed every six months.

Always park the truck on level ground before checking the oil level or changing the hydraulic oil.

• Park the truck on a level surface.

• Lower the forks to the ground, put the direction controller in neutral, engage the park brake, and turn off the engine. Place a drain pan of adequate capacity under the drain plug.

• Remove the oil filler cap and the oil pan drain plug, and then drain the old oil.

• Dispose of waste oil in accordance with local environmental protection laws and regulations.

• Add recommended type and amount of hydraulic oil, referring to the “Recommended Oils” table.

Start the motor/pump and check for oil leaks around the drain plug and oil filter.

Fully warm up the motor/pump, then switch it off the truck, visually check for leaks. Wait awhile before checking the oil level. Top off if necessary.

Do not try to locate hydraulic leaks by putting hands on pressurized hydraulic components. Hydraulic oil can be injected into the body by the pressure.

12. Seat Adjustment Move the seat adjustment lever to the right until the seat is comfortably positioned relative to the hand and foot controls, then lock seat in place.

Adjust the weight setting to match the driver’s weight.

13. Battery Check • • •

62

Check that the lock pin is securely inserted and the battery is firmly fixed.

Check the specific gravity of the electrolyte.

See battery section.

Check if the wiring of both terminals is loose or damaged. Adjust or replace the wiring if necessary.

16. Mast Check the mast and the forks to ensure that: • The forks are free of cracks and bends and are firmly and correctly installed on the carriage.

• Check the lift cylinders and hoses for leaks.

• Check the rotation of the rollers.

• Check for cracks and distortions in the mast.

• Check that the mast is working normally that there are no abnormal noises or movements.

17. Mast Lubrication Lubricate the inside and outside of the mast on a regular basis in accordance with the Periodic Maintenance Table.

The period between lubrications should be changed as appropriate depending on work conditions. During busy months, increase the frequency of component lubrication.

Depending on the operation of the forklift, apply a layer of lubricating grease on the lift pulleys and on the contact surfaces of the inner and outer masts.

Pull in the plug and close the hood Turn on the key switch 14. Instrument Display Check (including Battery Capacity Check and Error Diagnosing) Refer to the Instruments and Controls Section.

15. Lifting Lever, Tilt Lever & Attachment Lever Check whether the lift lever and the tilt lever are loose and that they return to center properly.

Increase engine speed and manipulate the lift lever, the tilt lever, and the attachment lever separately.

Make sure that they fully lift and lower the fork and tilt the mast forward and backward.

18. Lift Chain Tension Check Raise the forks to a height of 10-15 cm, with the mast vertical.

Press down on the middle of the chain with your thumb. Check to see if the tightness of the left chain 63

and the right chain are equal.

20. Check of Turn Signals, Horn and Other Lights  Move the turn signal control lever back and forth, to check whether the turn signal lights are functioning properly.  Press the horn button to check whether the sound of the horn is normal.

If the chain tension is not equal, contact an authorized technician to make repairs Tension Adjustment: Undo the lock nut ① and turn the adjuster nut ② to adjust the chains so that they both have the same tension. Then tighten the lock nut. ①.

 Check all other lights and the reversing buzzer.

21. Battery Maintenance Refer to the Battery Section.

22. Miscellaneous Check for abnormal noises

19. Steering System Check Turn the steering wheel to the left and right to check the functionality of the steering system.

64

(5) Operate the directional control lever.

(6) To drive forward: push the direction lever forward; (7) To reverse: pull the direction lever back.

(8) Release hand brake lever: depress the brake pedal; push the hand brake lever all the way forward.

(9) Grip the steering wheel knob with your left hand and rest your right hand on the steering wheel.

10. Operation WARNING A forklift that has any damage or malfunction must not be used until it has been properly repaired. Failure to repair the forklift prior to operating may result in severe injury or death.

10.2 Driving Slowly depress the accelerator pedal until the forklift starts to travel forward or backward while looking in the direction of travel.

10.1 Starting (1) Put the directional control lever in the neutral position.

(2) Connect the battery plug.

(3) Turn on key switch: grip the steering wheel knob with your left hand and turn on the key switch with your right hand.

(4) Tilt mast backwards: use the lifting lever to raise the forks 150 to 200 mm off the ground. Then use the tilt lever to tilt the mast all the way back.

10.3 Decelerating Slowly release the accelerator pedal, the forklift will slow down

CAUTION Never depress the accelerator pedal and the brake pedal at the same time. This behavior may result in property damage.

65

（2）Place the shift lever in neutral. （3）Apply the parking brake by pulling up on the parking brake lever. （4）Lower the forks on the ground, and tilt the mast all the way forward. （5）Place the key switch in “OFF” position to shut down the engine. For diesel trucks, pull out the engine stop button. Remove the key and take it with you.

CAUTION Always decelerate in the following situations:  When turning  When approaching cargo or pallets  When approaching stacked cargo areas  When entering narrow aisles  When ground or road is in poor condition

10.4 Steering CAUTION

A forklift is not like an ordinary vehicle in that it has rear-wheel steering, which means that the rear counterweight swings outward when cornering.

Decelerate, and then rotate the steering wheel in the direction that you want to turn. The steering wheel needs to be turned slightly earlier than it would in a vehicle with front-wheel steering.

Dismount carefully — use three points of contact — DO NOT JUMP OFF. The vehicle must not be parked along driving routes.

NOTE Drive slowly and operate the steering wheel carefully. Ensure that there is sufficient room for the rear end to swing out when making the turn.

10.5 Parking （1）Slow down and press the brake pedal to stop the truck (in the case of clutch type machine, the clutch pedal is used).

66

10.6 Loading 

Adjust the spacing between the forks to ensure a well-balanced load.  Position the forklift square to the load.  Pallets should be placed symmetrically with respect to the forks.  Insert the forks into the pallet as far as possible, but not into a pallet positioned behind the target pallet.  Lifting the load: o First raise the forks 5–10 cm off the ground and make sure that the load is secure. If the load is not against the load backrest, move back slightly, set the load down, and fully engage the forks. o Tilt the mast the entire way back, raise the load 5–10 cm off the ground, and then move off.  When a bulky load restricts vision, the forklift should be driven in reverse, except when driving up a gradient. If driving forward with a load that restricts vision, use the assistance of a spotter.

10.7 Stacking    

67

Slow down when approaching the deposit location.

Stop the vehicle in front of the deposit location.

Check the condition of the deposit location.

Tilt the mast forward so the forks are parallel to the floor and raise them until they are slightly above the drop-off position.

    

10.8 Unstacking

Inch forward until the load is over the drop-off position, then stop.

After making sure that the load is squarely over the drop-off position, slowly lower the forks and then check that the load is safely deposited.

To perform necessary lifting and tilt operations, reverse the forklift to remove the forks from the loads.

Make sure that the fork tips are clear of the load, and then lower the forks to 15–20 cm off the ground.

Tilt the mast all the way back.

 Slow down when approaching the pick-up location.  Stop when the forklift is 30 cm away from the load.  Check the condition of the load.  Tilt the mast forward until the forks are parallel to the floor, and then raise the forks to the level of the pallet or rack.  Make sure that the forks are aligned with the pallet, move forward slowly and insert the forks all the way into the pallet, then stop.

NOTE:

WARNING

When it is difficult to insert the forks fully into the pallet, drive forward so that the forks are inserted to 3/4 of their length. Raise the forks by 5–10 cm, back up 10–20 cm, and then lower the pallet or rack. Drive forward again until the forks are fully inserted.

Never tilt the mast with loads upraised 2m or more. The lift truck can tip forward if the mast is tilted forward with a load in the raised position.

WARNING

 Raise the forks 5–10 cm off the stack.  Look around the vehicle to make sure there are no obstacles in your path, and then back up slowly.  Lower the forks 15–20 cm off the ground, tilt the mast all the way back, then carry the load to its destination.

Always lower the mast assembly when leaving the lift truck unattended.

68

10.9 Post-Operation Checks

11. Storage

After use, clean the forklift and carry out the following checks:  Check for damage and oil leaks.  Add lubricant if needed.  Check tires for damage and foreign bodies embedded in the treads.  Check for loose wheel nuts.  Check the electrolyte level.  If the forks have not been elevated to their maximum height during the day, after finishing work raise them to their maximum height 2 to 3 times.

Daily Storage  Park the forklift in a designated area. Put the shift lever in neutral.  Engage the hand brake.  Turn off the key switch. Operate the multi-way valve lever several times to release the residual pressure in the cylinders and lines.  Disconnect the power plug.  Chock the wheels.  Remove the key and keep it in secure place.

Long Term Storage

NOTE:

In addition to those for daily storage, pay attention to the following points when storing the forklift truck for extended periods:  Disconnect the battery plug to prevent discharge and store the vehicle in a dark place.  Apply anti-corrosion agent to shafts, rods and other exposed parts.  Cover the breather and other openings where moisture may enter.  Fully cover the vehicle with a sheet or something similar.  Lubricate with oil or grease where necessary.

If you discover any defects or faults have them repaired immediately. Do not use the forklift until it has been fully repaired.

Failure to repair the forklift prior to operating may result in severe injury or death.

69

Forklift Operation after Long-Term Storage

Long Term Storage (cont’d)

 Remove anti-corrosion agent from exposed parts.  Drain out the gear oil in the drive axle and reduction gearbox and then fill with fresh oil.  Charge the battery, install it on the forklift and connect to the battery cables.  Carry out a careful inspection before using the forklift, checking motor start-up, forward and reverse drive, steering and the lifting, lowering and forward/backward tilt functions.



Support the underside of the body and counterweight with wooden blocks to reduce the weight on the rear wheel.  Start the forklift at least once a week. Raise the forks to their maximum height several times.  Measure the specific gravity and level of the battery electrolyte on a monthly basis.  Apply one equalizing charge every month.

12. Battery

WARNING  The wooden blocks must be single pieces that are sturdy enough to support the weight of the forklift.  Do not use wooden blocks that are more than 300 mm (11.81 inches) in height.  Raise the forklift just enough to allow it to be placed onto the wooden support blocks.  Place wooden blocks of identical size under left and right sides of the frame.  After supporting the forklift with the wooden blocks, rock the forklift back and forth from all four sides to make sure that it is safely secured.

Precautions for Battery Use: 1. No Open Flames Batteries generate explosive gases. Smoking, exposed flames and sparks can all cause batteries to explode.

70

2. Prevent Electric Shock

WARNING An insufficient level of electrolyte will cause the battery to overheat and even cause the battery and electrical system components to catch fire.

The battery electrolyte contains sulfuric acid which may cause burns if it comes into contact with the body. In the event of accidents, administer first aid immediately and see a doctor.

NOTE Battery has high voltage and energy.

Do not cause a short circuit.

Keep tools away from the battery terminals to prevent sparks or short-circuits.

3. Correct Wiring Never connect the battery's positive and negative terminals to each other, as this may cause a spark, fire or explosion.

(1) Contact with skin or eyes: flush with running water for 15 to 20 minutes.

(2) Contact with clothing: take off immediately.

(3) Accidental ingestion: drink plenty of water and milk.

4. DO NOT Completely Drain Before Recharging Do not wait to recharge the battery until the battery has completely discharged as this will shorten the battery's life. Charge the battery immediately once the battery display shows no electrical signal.

Wear protective eyewear, rubber boots and rubber gloves.

5. Check Electrolyte Level Do not use the forklift when the electrolyte level is low. Check the electrolyte level once a week. When the level is low, add distilled water to the specified height.

71

6. Keep Battery Clean Make sure the battery surface is clean and dry. The connection terminals should be kept clean and dry.

Tighten the battery vent caps.

Summer Measures During summer the water in the electrolyte evaporates more quickly, so the electrolyte level should be checked regularly. If it is low, add distilled water.

WARNING WARNING

In order to prevent static electricity, which may cause an explosion, never rub the surface of the battery with a dry cloth or fabric.

Do not overfill when adding distilled water.

Electrolyte overflow will cause corrosion and leakage.

NOTE

Winter Measures

Disconnect the battery plug.

Wipe the battery with a damp cloth.

Wear protective eyewear, rubber boots and rubber gloves.

Maintain a good charging environment.

When the ambient temperature is low, disconnect the battery plug to prevent discharge.

Take measures such as covering the battery to keep it warm.

Upon completion of work, charge battery immediately.

Precautions for Battery Charging     72

Charge the battery in a designated and well-ventilated location.

Display a "No Open Flames" sign when charging.

Before charging, check the wires and socket for damage.

Check for loose battery connections and tighten if necessary.



 

Do not charge the battery when the wires or socket are damaged.

Charger

 When the charger is in use, its casing must be reliably grounded.  When changing the fuse, disconnect the input and output circuits.  Only qualified professionals are permitted to disassemble the charger casing for testing, inspection or maintenance.  Do not modify or disassemble the charger.  During the summer, take measures to prevent damage caused by charger overheating. If necessary, suspend work temporarily.  If using other non-automatic chargers, adjust the charging voltage and current, control the charging time and measure the specific gravity of the battery electrolyte regularly to ensure the optimum state of charge of the battery bank. Adjust the parameters, referring to the "Battery Charging" section below.  Never charge batteries continuously. Continuous charging of multiple batteries will overheat the charger and may even damage it. After charging, let the charger rest for an hour before re-using it.  Select correct charger based on battery volt and capacity (see table below).

When charging, open the battery cover to release the explosive gases.

During the charging process, do not disconnect the power switch or battery plug, as this may damage the plug and electrical components. Only disconnect the plug after pressing the “stop charging” button on the charger.

73

Battery Charging

Technical Requirements for Distilled Water

Users can choose between smart charging and constant current charging, depending on the situation.

The first time a battery is charged, use constant current charging.

New forklift batteries are supplied without electrolyte.

Index Name Outward Appearance Dry Residue

Electrolyte Preparation Battery Parameter Model Values

D-420

D-500 D-630B

Parameter Name Specific Gravity of Acid

Water-toAcid

1.265g/cm3

Volume Ratio

3.1:1

2.6:1

Mass Ratio

1.7:1

1.65:1

Specific Gravity of Sulphuric Acid

1.835g/cm3

Requirements for Sulphuric Acid

Compliant with GB4554-84 or dedicated battery sulphuric acid

Index

74

%

Colorless, Clear ≤0.005

Resistivity (25℃ )Ω cm

≥7X104

Fe

%

≤0.0004

Cl

%

≤0.0005

Mn

%

≤0.00002

Organic Substances (O based) %

≤0.0002

MgO + CaO

≤0.005

%

NH4 %

≤0.0008

Nitrate or Nitrite %

≤0.0005

Preparation Process

NOTE:

 Wear protective eyewear, rubber shoes and rubber gloves.  Slowly add the acid to the distilled water, stirring constantly with an acid-proof stirring rod until a uniform mixture is obtained.

Make sure the charger voltage is the correct voltage for the battery.

Use only battery chargers approved by the battery manufacturer or dealer.

Always make sure the color in the window of the charger connector is the same as the color in the window of the battery connector.

WARNING Do not pour water into acid, as the surface temperature of the liquid may suddenly rise to boiling point, leading to splash injuries.  When the electrolyte solution has cooled to 30℃, pour it into the battery cells. Add electrolyte until the level is about 10–15 mm higher than the splashguard level (batteries without hydrometer), or the float is 1 mm from the cap (batteries with hydrometer).  Leave to stand for 3 to 5 hours until the electrolyte temperature drops below 35℃. Then commence initial charging.

(7) Inspection

 The supply voltage required is 3 times the number of battery cells in series.  Inspect the charger.  Check the polarity of each battery cell.

NOTE: Initial charging must be commenced within 12 hours of pouring electrolyte into battery cells. 

Connect the random charging cable to the charger.

75

Truck Type

Battery

1.5T-1.8T 2.0T-2.5T 3.0T-3.5T

D-420 D-630B D-500

Battery Voltage (V) 48 48 80

(8) Charging Method

c)

(See table for times and currents) a) First Stage: Charge the battery until the terminal voltage of the cells generally rises to 2.4 V; b) Second Stage: Continue charging until the electrolyte bubbles up, the voltage and density values have remained steady for 4 hours and the amount of charge has reached 4.5 to 5 times the rated capacity.

d) Truck Type

1.5T-1.8T

Battery Type

Charging Charging Current (A) Voltage st nd (V) 1 Phase 2 Phase

D-420

72

40

20

2.0T-2.5T D-630B

72

63

32

3.0T-3.5T

120

50

25

35-45

35-45

e)

Adjust Electrolyte Density and Level When electrolyte density is low, raise it by drawing off some of the electrolyte and replace with a premixed sulfuric acid solution having a density of 1.400 g/cm3.

If the density is high, lower it by drawing off some of the electrolyte and topping up with distilled (or purified) water to the required level.

After adjusting the electrolyte density and level, continue charging for 1 hour until the density of the electrolyte is uniform. At this point, initial charging is complete.

Fasten the filler caps and wipe acid from the battery surface. The battery is now ready for use.

NOTE D-500

Charging Time (h)

During the charging process, the electrolyte temperature must not exceed 45°C. If necessary, adopt cooling measures. If the temperature remains high, stop charging and allow the battery to cool down before resuming.

76

Normal Charging   



Batteries that have undergone initial charging and been used for day-to-day work can undergo normal charging.

The procedure for normal charging using the constant current charging method is basically the same as that for initial charging.

The amount of charge given should be about 1.2 times the amount of the previous discharge.

However, for new batteries, the first 5 charges should be about 1.5 times the amount of the previous discharge.

During any charge cycle, the electrolyte temperature must not exceed 45 ℃. If necessary, adopt cooling measures or reduce the charge current. If the temperature remains high, stop charging and allow the battery to cool down before resuming.

Truck Type 1.5T-1.8T

Charging Charging Current (A) Battery Voltage Type st nd (V) 1 Phase 2 Phase D-420

72

55

25

2.0T-2.5T D-630B

72

88

44

3.0T-3.5T

120

70

35

4-6

6-10

D-500

Charging Time (h)



Use smart charging to carry out normal charging. For new batteries, an equalizing charge should be carried out for the first 5 charges, based on the smart charger manual.

Equalizing Charge  With time, the voltage, density and capacity of a battery tend to become unbalanced.

The voltage and specific gravity of some cells increase more slowly compared with other cells when charging, and decrease at a faster rate when discharging. 

77





Boost Charge  When a single charge cannot meet the demands of a full day's work, provide a boost charge during rest times.  A boost charge can be given when the ambient temperature is low.

Storage Charge  Before storing a battery, give it an equalizing charge.  Apply an equalizing charge every 15–30 days during storage.  Charge special order batteries in accordance with the Battery Manufacturer. Consult your

Equalizing charge should be applied when any of the following situations occur: a. The discharge voltage frequently falls below the cut-off voltage; b. The discharge current is frequently too high; c. The battery is not charged in a timely manner after discharge is complete; d. The electrolyte is mixed with minor impurities; e. The battery frequently gets insufficient charge, or hasn't been used for a long time; f. The battery plates have been taken out for inspection or to clean out sediment.

battery dealer.

Battery Replacement

Equalizing Charge Method:  First charge the battery normally, and then let it rest for 1 hour after charging is complete.  Continue charging the battery using the second-stage charge current specified for normal charging until multiple bubbles appear, then stop charging for one hour  Repeat the above steps several times until the voltage and density stop rising and bubbles appear as soon as charging is resumed after the 1-hour interval.

NOTE Before replacing a battery, make sure that the voltage, capacity, weight and dimensions of the new battery match the forklift specifications.

Do not use replacement batteries with a different voltage, weight or dimensions without the manufacturer's permission.

78

Replacement Procedure  Park the forklift truck on a level surface and engage the parking brake.  Open the battery cover.  Disconnect the battery plug.

WARNING Lift the battery by attaching hooks to all 4 lifting holes. Do not lift using only 2 of the holes as this may subject the housing to uneven stress, causing the cells to rupture.

To prevent damage when lifting the battery housing, do not let it knock the steering wheel or other equipment.

Replace with a fully charged battery, then insert lock pin. Close the battery cover and firmly connect the battery plug.

 Remove the lock pin.  Lift out the battery with suitable lifting gear.

79

Checking Electrolyte Level

CAUTION

Battery without Hydrometer

Battery Disposal

Electrolyte should measure 15-20 mm higher than splashguard level.

Batteries must be discarded according to local environmental regulations.

Battery with Hydrometer

Measure the electrolyte level by reading vent cap hydrometer.

Battery Weight and Size Battery

1.5T-1.8T

2.0T - 2.5T

3.0T - 3.5T

Lightest Permissible

700 kg

930 kg

1200 kg

Heaviest Permissible

900 kg

1200 kg

1500 kg

Dimensions (mm)

980X465X780

1028X570X780

1028X710X780

Parameter

Electrolyte Level and Specific Gravity WARNING Using a battery when the electrolyte level is low may lead to overheating and shorten the lifespan of the battery.

80

Topping off Distilled Water  Wear protective eyewear, rubber boots and rubber gloves.  Fill a squeeze bulb pipette with a certain amount of distilled water.  Open all the vent or filler caps on the battery unit.  Inject distilled water into battery cells using squeeze bulb pipette.

Battery with Hydrometer

Battery without Hydrometer

Stop adding water when the red hydrometer float rises and a white line appears.

 Stop adding water when electrolyte is 15-20 mm higher than splashguard level.  After topping off tightly fasten the vent or battery caps.  Use a damp cloth to wipe clean the surface of each battery cell.

WARNING When adding distilled water, do not exceed the specified maximum level.

Adding too much water may cause electrolyte leakage and damage the forklift when charging or discharging the battery. Use a squeeze ball pipette to draw off any excess water.

81

Specific Gravity Reading Specific gravity of the electrolyte varies with temperature.  Use a thermometer to measure the temperature of the electrolyte.  Vertically insert the flexible tube of a pipette-type density meter into the electrolyte and squeeze the bulb. Electrolyte will enter the glass tube and the float will rise up.  Note the density reading.

NOTE Hold the density meter vertically so that the float does not touch the sides of the glass tube.

82

Specific Gravity Measurement Use a hydrometer to measure the specific gravity of electrolyte.

Wherein: D30 =

electrolyte density at 30℃

Dt =

measured electrolyte density at ℃

t=

electrolyte temperature during density measurement

All references to specific gravity in this manual refer to specific gravity at 30°C.

Specific Gravity Conversion Convert electrolyte density at the standard temperature of 30°C based on the following formula: D30＝Dt＋0.0007(t-30)

83

13. Maintenance Summary • • • • • • • •

The forklift must be regularly checked and maintained to keep it in good working order.

Inspection and maintenance should not be overlooked. Early detection enables problems to be addressed in a timely manner.

Use original Utilev replacement parts.

Do not use different types of oil when changing or topping off oil.

Waste oil and battery fluid must not be thrown away indiscriminately, but recycled or disposed of in accordance with local environmental laws and regulations.

Establish and follow a comprehensive maintenance and service schedule.

Maintain current and complete records of all maintenance and servicing activities.

Untrained personnel must not attempt to carry out forklift repairs.

WARNING    

NO OPEN FLAMES! Turn off the key switch and disconnect the battery plug before carrying out any servicing or maintenance (Except when carrying out certain obstacle checks).

Clean electrical parts using compressed air. Do not clean using water.

Do not put your hands, feet or any part of your body between the mast and dashboard.

84

13.1 Weight of Counterweights: Model

Counterweight (Mass)

1.5T

570±15 kg

1.8T

780±20 kg

2.5T

1020 kg

3.0T

1170 kg

3.5T

1540 kg

85

13.2 Maintenance Schedules 〇 - check, correct, adjust; X - change/replace

Battery Item

Operation

Daily

Weekly

Monthly

Every 3 months

Every 6 Months

(8 hours)

(40 hours)

(166 hours)

(500 hours)

(1000 hours)

Tools

Electrolyte Level

Visual Inspection

〇

〇

〇

〇

Electrolyte Specific Gravity

Hydrometer

〇

〇

〇

〇

Battery

Battery Power

〇

〇

〇

〇

〇

Check for Loose Connection Terminals

〇

〇

〇

〇

〇

Check For Loose Connection Cables

〇

〇

〇

〇

〇

Clean The Battery Surface Check for Tools Left on Battery Check that Vent Caps are Tight and Vents Unobstructed Proximity to Open Flames

〇

〇

〇

〇

〇

〇

〇

〇

〇

〇

〇

〇

〇

〇 〇

〇

86

Controller Item Controller

Daily

Weekly

Monthly

Every 3 Months

Every 6 Months

OTHER

(8 hrs.)

(40 hrs.)

(166 hrs.)

(500 hrs.)

(1000 hrs.)

AS REQUIRED

Check Condition of Contacts

〇

〇

Check Mechanical Movement of Contactors

〇

〇

Check Pedal Micro Switches are Functioning Properly

〇

〇

Check Condition of Connections between Motor, Battery and Power Unit

〇

〇

Operation

Tools

Check Controller Faults to Determine Whether System Is Functioning Properly

First Check @ 2 Years

87

Motor Item

Operation

Daily

Weekly

Monthly

Every 3 Months

Every 6 Months

(8 hrs.)

(40 hrs.)

(166 hrs.)

(500 hrs.)

(1000 hrs.)

〇

〇

〇

Tools

Clear motor housing of foreign bodies

〇

Clean or replace bearings

Motor

Check wear condition of carbon brushes, commutators and check spring force

〇

〇

〇

Wiring correct and secure

〇

〇

〇

〇

〇

Brush away carbon powder from grooves between commutator segments and on commutator surface

88

Transmission System Item

Every 3 Months

Every 6 Months

Daily

Weekly

Monthly

(8 hours)

(40 hours)

(166 hours)

Abnormal Noise

〇

〇

〇

〇

〇

Check for Oil Leakage

〇

〇

〇

〇

〇

Operation

Tools

(500 hours) (1000 hours)

X

Change Oil

Front Axle

〇

Check for Loose Wheel Bearings

〇

〇

〇

X

X

〇

〇

〇

〇

〇

〇

Check and Replace Grease

〇

Check for Leakage

Check Tightening Torque of Wheel Bolts

〇

Torque Wrench

89

Wheels (Front and Rear Wheels) Item

Operation

Check Pneumatic Tire Pressure

Barometer

Tire

(8 hours)

(40 hours)

〇

〇

〇

〇

〇

〇

〇

〇

〇

〇

〇

〇

〇

Check for nails, stones or other foreign objects in the tread

Check for damaged rims

Test Hammer

Every 6 Months

Weekly

Tools

Check for wear, cracks or damage

Check the split rims for loose bolts (Pneumatic Tires Only)

Monthly

Every 3 Months

Daily

(166 hours) (500 hours) (1000 hours)

〇

〇

〇

〇

〇

〇

〇

〇

〇

〇

90

Steering System Item

Every 3 Months

Every 6 Months

Steering Wheel Steering Gear Rear Axle

Daily

Weekly

Monthly

(8 hours)

(40 hours)

(166 hours)

Check play

〇

〇

〇

〇

〇

Check for axial looseness

〇

〇

〇

〇

〇

Check for radial looseness

〇

〇

〇

〇

〇

Check for proper operation

〇

〇

〇

〇

〇

Check mounting bolts for looseness

〇

〇

〇

Check kingpins for looseness or damage

〇

〇

〇

Check for bends, deformation, cracks and damage

〇

〇

〇

〇

〇

〇

Operation

Check for proper installation

Tools

Test Rubber Mallet 91

(500 hours) (1000 hours)

Steering System (cont’d) Item

Every 3 Months

Every 6 Months

Steering Cylinder

Daily

Weekly

Monthly

(8 hours)

(40 hours)

(166 hours)

Check for proper operation

〇

〇

〇

〇

〇

Check for oil leaks

〇

〇

〇

〇

〇

〇

〇

〇

Operation

Tools

Check hinges for looseness and proper installation

92

(500 hours) (1000 hours)

Brake System Item

Every 3 Months

Every 6 Months

Daily

Weekly

Monthly

(8 hours)

(40 hours)

(166 hours)

〇

〇

〇

〇

〇

Check for pedal travel

〇

〇

〇

〇

〇

Check for proper operation

〇

〇

〇

〇

〇

Check for air in brake lines

〇

〇

〇

〇

〇

Check that braking is safe and reliable and that stroke is sufficient

〇

〇

〇

〇

〇

Check for proper operation

〇

〇

〇

〇

〇

Check for operation

〇

〇

〇

Check for loose connections

〇

〇

〇

〇

〇

Operation

Check for free play

Tools

Ruler

Brake Pedal Parking Brake Rods, Cables, etc.

Check gear box connector for wear

93

(500 hours) (1000 hours)

Brake System (cont’d) Item

Operation

Daily

Weekly

Monthly

(8 hours)

(40 hours)

(166 hours)

Tools

Every 3 Months

Every 6 Months

(500 hours) (1000 hours)

Hoses and Pipes

Check for damage, leakage or collapse

〇

〇

〇

Check connecting and clamping parts for looseness

〇

〇

〇

〇

〇

Brake Master Cylinder

Check for leakage

〇

〇

〇

Check brake fluid level, Change brake fluid

〇

〇

〇

X

Check master cylinder & wheel cylinders for proper operation

〇

〇

Check master cylinder & wheel cylinders for fluid leaks or damage

〇

〇

Check master cylinder, piston cup, and check valve for wear or damage

X

94

Hydraulic System Item

Operation

Hydraulic Reservoir

Daily

Weekly

Monthly

(8 hours)

(40 hours)

(166 hours)

〇

〇

〇

Tools

Check oil level Change oil

Every 3 Months

Every 6 Months

(500 hours) (1000 hours) 〇

X

Clean oil filter

〇

Clear for foreign bodies

〇

Control Levers Control Valve

Check levers for looseness

〇

〇

〇

〇

〇

Check for proper operation

〇

〇

〇

〇

〇

Check for oil leak

〇

〇

〇

〇

〇

〇

〇

〇

Check relief valve and tilt lock valve for operation Measure pressure of relief valve

Oil Pressure Gauge

〇

95

Hydraulic System (cont’d) item

Operation

Line Connectors

Check for leaks, looseness, rupture, deformation and damage

Hydraulic Pump

Check hydraulic pump for leaks or abnormal noise

Daily

Weekly

Monthly

Every 3 Months

Every 6 Months

OTHER

(8 hours)

(40 hours)

(166 hours)

(500 hours)

(1000 hours)

AS REQUIRED

〇

〇

〇

Tools

X After 1-2 years

Replace hoses

〇

〇

Check pump drive gear for wear

96

〇

〇

〇

〇

〇

〇

Lifting System Item

Every 3 Months

Every 6 Months

Chains & Sheave Attachments

Daily

Weekly

Monthly

(8 hours)

(40 hours)

(166 hours)

〇

〇

〇

〇

〇

Lubricate chains

〇

〇

〇

Check connections of riveting pins and chain for looseness

〇

〇

〇

Check sheaves for deformation or damage

〇

〇

〇

Check sheave bearings for looseness

〇

〇

〇

Perform General Inspection

〇

〇

〇

Operation Check chain tension Check for corrosion, damage or rust

Tools

97

(500 hours) (1000 hours)

Lifting System (cont’d) Item

Every 3 Months

Every 6 Months

Lift and Tilt Cylinders Fork

Daily

Weekly

Monthly

(8 hours)

(40 hours)

(166 hours)

〇

〇

〇

〇

〇

Check cylinders for proper operation

〇

〇

〇

〇

〇

Check for leaks

〇

〇

〇

〇

〇

Check pins and cylinder bushings for wear or damage

〇

〇

〇

Check forks for damage, deformation or wear

〇

〇

〇

〇

〇

〇

〇

Operation Check piston rod and piston rod threading for loose connections, deformation or damage

Tools

Test Rubber Mallet

Check fork positioning locks for damage or wear Check fork base and hook welding for defective cracks or wear

〇

98

(500 hours) (1000 hours)

Lifting System (cont’d) Item

Operation

Daily

Weekly

Monthly

(8 hours)

(40 hours)

(166 hours)

Tools

Mast and Fork Carriage

Cracking or damage of welding on inner mast, outer mast and crossbars Wear, cracking or damage of welding on tilt cylinder brackets and mast Wear, cracking or damage of welding on inner and outer masts Wear, cracking and damage of welding on fork carriage Check for loose roller bearings

Every 3 Months

Every 6 Months

(500 hours) (1000 hours)

〇

〇

〇

〇

〇

〇

〇

〇

〇

〇

〇

〇

〇

〇

〇

Wear or damage of mast support bearing bushes Looseness of mast support cover bolts

Test Rubber Mallet

〇 (First Time Only)

〇

Looseness of lift cylinder piston rod head bolts and plate bolts

Test Rubber Mallet

〇 (First Time Only)

〇

〇

Check for cracking and damage of rollers, roller shafts and welded parts

〇

99

〇

〇

Other Item

Every 3 Months

Every 6 Months

Overhead Turn Guard & Load Signal Backrest

Horn Light & Reversing Lamps Buzzer

Daily

Weekly

Monthly

(8 hours)

(40 hours)

(166 hours)

〇

〇

〇

〇

〇

Check for deformation, cracks or damage

〇

〇

〇

〇

〇

Check for proper operation and tight installation

〇

〇

〇

〇

〇

Check for proper operation and tight installation

〇

〇

〇

〇

〇

Check for proper operation and tight installation

〇

〇

〇

〇

〇

Check for proper operation and mounting hardware being tight

〇

〇

〇

〇

〇

Operation

Check that mounting hardware is tight

Tools Test Rubber Mallet

100

(500 hours) (1000 hours)

Other (cont’d) Item

Operation

Instruments

Check for proper operation

Every 3 Months

Every 6 Months

Electrical Cables

Daily

Weekly

Monthly

(8 hours)

(40 hours)

(166 hours)

〇

〇

〇

〇

〇

〇

〇

〇

〇

〇

〇

〇

Tools

Loose or damaged harnesses Loose circuit connections

101

(500 hours) (1000 hours)

Periodic Replacement of Certain Parts  

Some parts are difficult to inspect during periodic maintenance. Therefore, in order to further improve reliability, users should carry out periodic replacement of the parts listed in the following table.

If any of these parts are found to be damaged or faulty before they are due for replacement, they should be replaced immediately.

Name of Safety-Critical Part

Service Life (years)

Brake Hose or Rigid Tubing

1–2

Lifting System Hydraulic Hoses

1–2

Lifting Chain

2–4

Hydraulic System High-Pressure Hoses

2

Brake Fluid Cup

2–4

Master Brake Cylinder Cover And Dust Boot

1

Hydraulic System Inner Seals and Rubber Parts

2

Shock Absorption Mount on Steer Axle

4

102

Bolt and Screw Tightening Torque Table Unit: N·m Grade

Bolt Diameter 6 8 10 12 14 16 18 20 22 24 27

4.6 4-5 10-12 20-25 35-44 54-69 88-108 118-147 167-206 225-284 294-370 441-519

5.6 5-7 12-15 25-31 44-54 69-88 108-137 147-186 206-265 284-343 370-441 539-686

NOTE: • •

Use 8.8 grade bolts in the important joint position.

A bolt’s grade can be found in the head of the bolt.

103

6.6 6-8 14-18 29-39 49-64 83-98 127-157 176-216 245-314 343-431 441-539 637-784

8.8 9-12 22-29 44-58 76-107 121-162 189-252 260-347 369-492 502-669 638-850 933-1244

Recommended Oils Name Hydraulic Oil

Grade, Code

Capacity (L)

Normally: L- HM32 Cold Environment :L-HV32

35 L

Gear Oil

GL-585W/90

Brake Fluid

(Choice) HZY3 or DOT3

Petroleum Jelly Lubrication Grease

Remarks

4.5 L

1.5T-1.8T

6L

2.0T-3.5T

1.5 L Battery Electrode Columns

2# Automobile General Lithium Base Lubricant

104

14. Attachments In accordance with international standard ISO 2328 and U.S. standard B56.1, Utilev requires the use of matching attachments, which include flat clamps, rotating clamps, paper roll clamps, coil rams and side shifters. Attachments must be removed or installed by trained personnel only.

Installation of Attachments

 No safety or performance-related modifications must be made to the forklift without technical authorization from Utilev.  The actual rated load capacity should be taken as the smallest of the following values: a) the rated capacity of the forklift b) the capacity of the attachment itself c) the overall capacity of the whole vehicle.  In general, the overall capacity of the whole vehicle is the smallest of the three values. "Attachment load capacity" is solely a method for calculating the stress on the attachment itself.  Install an attachment in a rational, reliable and safe position to prevent it from sliding relative to the fork carriage during use.  For attachments with upper hook stopper, make sure that the attachment is centered by inserting the hook stopper in the gap on the upper crossbar after installation.  The deviation from the fork carriage centerline must be less than 50 mm; otherwise the attachment will affect the lateral stability of the forklift.  After installation of rotating attachments (paper roll clamp, bale clamp, multi-purpose steel arm clamp, barrel clamp), stoppers must be welded to both sides of the fork carriage crossbar where it meets the attachment, so as to prevent the attachment from sliding during operation.  When installing attachments with lower hook fastening, the clearance between the lower hook and the corresponding location on the lower crossbar of the fork carriage must be suitably adjusted.

105

Use of Attachments

 Familiarize yourself with the information on the data plate of the forklift attachment. Carefully read the attachment manuals before use, particularly the attachment manufacturer's user manual and installation instructions. Forklift truck attachments should be operated by trained and qualified personnel.  You should familiarize yourself fully with the basic performance and operation of the forklift truck attachment.

In particular, you should have detailed knowledge of the admissible load, lifting height, load dimensions and the scope of application of the attachment.  When operating forklift attachments with side shift, clamp rotation and other various functions. Do not perform multiple tasks at the same time. Always finish one task before starting another.  A forklift fitted with attachment must not be driven with a load in an elevated position. Drive in reverse when a bulky load obscures your forward view. When transporting a load, ensure that the bottom of the load is 300 mm off the ground and the mast is tilted backwards.  Load weight must not exceed the combined load capacity of the forklift and attachment. Try to avoid transporting unbalanced loads in an elevated position; side shift operations may only be carried out for a short time and unbalanced loads must be strictly controlled to a maximum distance of 100 mm each side of center (side shifter of 5 tons or more with side shift movement ±150 mm).  In order to prevent accidents, no-one must be allowed within 2 meters of a raised attachment and load, with the exception of the driver's position which is protected by the overhead guard.  When driving a forklift with attachment, avoid sudden braking and always move loads at slow speed.  An attachment must not be subjected to external impact during operation, or used for improper purposes. Do not exceed the normal operating range of the attachment.  An attachment must not be used for improper purposes. Do not exceed the normal operating range of the attachment.  If an attachment is faulty, do not use it until the fault has been corrected.

106

Inspection and Maintenance of Attachments

 Check that the clearance between the lower crossbar of the fork carriage and the lower hook of the attachment meets the requirements specified in the manual.  Make sure that the hook is properly embedded in fork carriage groove.  After every 500 hours of use apply automotive universal lithium grease to the vertical sliding supporting surfaces.  Check for loose fasteners.  Periodically check hydraulic circuit for loose connections and damaged hoses. If damaged, do not use until repaired.  Periodically check attachment drive or rotating elements for wear or seizure. Damaged or defective components must be replaced in a timely manner.  Under dynamic load conditions, check the operation of the attachment and the condition of all of its working components. If an anomaly is found, check the hydraulic circuit to identify the leaking component and replace the seals or all of the circuit components.

107

15. Operation, Detaching, and Installing the Operator Cab (Optional Equipment) ITEM

108

DESCRIPTION

1

SIDE DOOR ASSY

2

DOOR HANDLE & LOCK ASSY

3

FRONT WINDSHIELD ASSY

4

FRONT WIPER ASSY

5

ROOF

6

FRONT WORK LIGHT

7

COVER

8

CAB FRAME

9

REAR WINDOW ASSY

CAB Components: Door Locks: The CAB is equipped with 2 doors with handle assemblies with locks and keys. To open an unlocked door using button shown in figure A. A key is required for entry if locked. The door can be opened from the inside by the operator using lever as shown in figure B.

Fig A

Fig B

Rear View Mirror: CABs come equipped with adjustable mirrors see figure C.

109

Fig C

Switch Paddles: The switch paddles includes several buttons corresponding to wipers, fans, etc., depending on options selected No. 1 2 3

Description Fan button Front wiper button Rear wiper button

4

Reserved function

Fan: The Fan is located on the rear beam of the cab with button mounted on the dashboard. Fan is adjustable by releasing the lock, see figure D.

Fig D

Fig E

110

Fig F

Wiper: (Optional) Wipers for Front and Rear wipers are available (figure E). Wiper switch is mounted on the dash display.

Washer Reservoir: (Optional) The reservoir for the Wiper Washer can be accessed & filled through a hole in the right hand side of the front floor plate under the right hand side of the front floor mat. See figure F. Heater: (Optional) CAB heater is mounted on the right side of battery cover (figure G). When heater is on, LED indicator light is lighted.

Fig G

Fig H

Fig I

Rear Window: To open window, unlock window lock, then the window will open automatically by the gas spring, see figure H. Note: Always Open Rear Window before opening the roof cover to remove Battery.

111

Roof Cover: Before opening the roof cover, open rear window. For easy access roof cover for vertical battery extraction, remove the (2) Knobs shown above in figure H, the gas spring will open the roof cover for easy access to battery compartment, see figure I

112

Item No.

Description

1

Rear combo lights

2

Strobe lights

3

Rear working light

Rear Lights: Item (1) the rear combo lights: RH/LH turn signals, backup and brake light bar. Item (2) Optional Strobe light, Strobe light switch is mounted on the rear top of CAB, item (3) Optional rear work light.

Replace lights, if damaged.

Function Power High beam lights Location 0

×

1

×

×

Note:  Maintain all gas springs in good working order, Repair or replace any damaged gas springs.  Maintain all wiper blades in good condition, replacing any worn blades.  Maintain in working order the heater, repair or replace as required.

113

16. Automatic Battery Watering System (Optional) Advantages  Saves Time  Prevents Overfilling of Battery Cells  Prevents Missed Watering of Battery Cells  Easy Operation  Simultaneously Fills all Cells to the Proper Height  Prevents spills  Acid Overflow and Corrosion are Eliminated  Extends the Service Life of the Battery  Environmentally Friendly  Reduces Battery Watering Costs Purpose – Function of the automatic watering system: the float of the automatic watering plug rises as the correct water level is reached. When the level rises in the cell, the pressure closes the valves and prevents further water from entering the cell. When the system has finished watering, the flow indicator will stop running and you can clearly see the water-level indicator through the top of the watering system.

– Besides, the material of floater can avoid damage and ineffectiveness.

– The automatic watering system is structured with a terraced step. When the electrolyte gas rises to the watering plug, the terraced part prevents the leakage of the electrolyte gas as well as quickly cools the electrolyte gas to make them go back to the storage battery in time.

114

Installation and Operation Proper care, which includes proper watering and maintenance, will extend the life of your battery. How often you use and recharge your batteries will determine the frequency of watering. Also, using batteries in a hot climate will require more frequent watering. It is best to check your battery water level frequently and add distilled water when needed. Never add tap water to your battery. Tap water contains minerals that will reduce battery capacity and increase their self-discharge rate.

In order to guarantee that the automatic battery watering system remains leak-proof, you must keep all surfaces of the auto injection system clean. We will outline here how to properly install and operate the system.

To correctly install the water tank, use the proper type and quantity of floats. Be sure to choose watering plugs, hoses, connectors and couplings designed for use with your specific battery. Also, the flow indicator must be kept clean for optimum performance.

WARNING A brand new battery may have a low electrolyte level. Charge the battery first and then add water if needed. Adding water to a battery before charging may result in overflow of the electrolyte. Failure to follow this procedure can result in serious injury.

115

Automatic Fluid System Components        

Automatic Watering Plug End Plug Float T-Connectors & Y-Connectors Flow Indicator (with filter) 6mm, 8mm, & 10mm Tubing Male & Female Couplings Water Tank

116

(1) Gravity Feed Water (2) Pump Water (3) Tap Water with Ionizer Tee (6-10-6)

Flow Indicator (Filter)

6mm Tubing

10mm Tubing

End Plug

12 pcs

1 piece

1 pcs

3m

5m

2pcs

Male/Female Couplings K10 1 piece

24 pcs

1 piece

1 pcs

5m

5m

2pcs

1 piece

30L 1 piece

40 pcs

1 pcs

1 pcs

10m

5m

2pcs

1piece

60L 1 piece

Battery Voltage

Watering Head

24V 48V 80V

T-Connector

117

Water Tank 30L 1 piece

118

Automatic Watering System for 48V Forklift BatteryIn order to achieve maximum effectiveness from the watering system, you must choose the correct float for use with your battery type. Watering hoses must be sealed with T and L connectors.

Float Installation:

T =T1-（5-17mm） Float Length

47mm

50.5mm

58mm

61mm

72mm

Float

13

16.5

24

27

38

119

Watering Hoses/Tubes  Use tubing that is designed to work with your specific battery.  There must be a watertight seal between the tubing and the connectors.

Filling the Battery  Use a flow indicator (with filter) to water the battery. The flow indicator (with filter) will prevent impurities from entering the battery and prevent overfilling.  The watering pressure should be within the range of 0.2-0.6, no less than 200mbar.  How often you use and recharge your batteries will determine the frequency of watering. Also, using batteries in a hot climate will require more frequent watering. Overflowing or watering too frequently can significantly shorten the life of the battery.

NOTE: DO NOT add water before or during the charging cycle. Water must be added after the charging cycle is complete.

Cleaning  The automatic battery watering system has been thoroughly tested and found to be completely watertight.  Remove all impurities from the battery surface when cleaning. Keep the battery clean and dry. Use a clean cloth to wash the battery with water only. Do not use detergents or other cleansing agents to clean the battery.  Thoroughly clean the watering plug on a regular basis using only water. Do not use detergents or other cleansing agents when cleaning the watering plug.

120

OPEN

CLOSE

Structure Diagram of the Watering Plug

121

17. Safety Directives and Standards CE certified models are compliant with the following directives and standards:  2006/42/EC Machinery Directive (Council Directive on the Approximation of the Laws of the Member States Relating to Machinery)  2000/14/EC Noise Directive (Council Directive on the Approximation of the Laws of the Member States Relating to the Noise Emission in the Environment by Equipment for Use Outdoors)  ISO 3691-1 (Safety of Industrial Trucks)  EN 12053:2001 (Harmonized Standard)  EN 1175-1:1998 (Harmonized Standard)  EN 13059:2002 (Harmonized Standard)  Main safety factors meet the requirements of:  Machinery Directive 2006/42/EC  ISO 3691-1  EN 1175-1:1998  Vibration parameters are measured in accordance with:  ISO 5349-2:2001  EN 13059:2002  ISO 2631-1:1997  Compliant with the requirements of Directive 2002/44/EC; the vibration acceleration of the driver's seat is less than or equal to 0.50 m/s2 with an uncertainty factor K = 0.2 m/s2.  Electromagnetic compatibility is measured in accordance with EN 12895:2000 and is compliant with the requirements of Directive 2004/108/EC.  U.S. models are compliant with Standard B56.1.

122

17.1 CE Certificate

123

18. Operator Presence Sensing System (Optional) DESCRIPTION OF OPERATOR PRESENCE SENSING (OPS) SYSTEM- Single Switch.

The Operator Presence Sensing (OPS) System is available to disable traction and hydraulic functions if the operator is not in the proper operating position. If the operator is not sitting upright in the center of the seat with their back fully against the backrest of seat, the system will interrupt travelling and hydraulic functions. If the operator leaves the seat without properly parking the truck, the system will also be engaged.

Starting Protection: The operator must sit in the seat properly with the direction control lever in neutral before the truck will start. If the truck is equipped with seat belt protection, the operator must first sit in the seat, then fasten the seat belt before the truck will be able to start.

Forward and Reverse Protection: a. While the forklift is started, the park brake light will be on and an alarm will sound if the operator is in the seat properly with the park brake engaged when the direction control lever is put into forward or reverse. If the direction control lever is returned to the center position, the alarm will stop sounding. b. While the forklift is started, the operator must sit on the seat correctly and put the direction control lever in forward or reverse before the forklift will travel. If the operator is not seated correctly and the direction control lever is put into forward or reverse, an alarm will sound and an OPS light will illuminate. If the direction control lever is returned to the center position, the alarm will stop sounding. c. While the forklift is started, the operator must remain on the seat correctly with the direction control lever in forward or reverse for the forklift to continue travelling. If the operator leaves the seat for more than 3 seconds when the forklift is travelling forward or reverse, the motor will switch to neutral, an alarm will sound, the OPS light will illuminate, and the neutral-position indicator light will flash to give the operator a reminder that the truck was shifted to neutral without the lever being in the center position. The alarm will continue to sound and the forklift will not travel until the operator returns to the seat correctly and moves the direction control lever to the center position. Once the alarm is reset, travel will resume when the direction control lever is moved into forward or reverse gear again.

124

Seat Belt Protection: Double Switches If the truck is equipped with the Operator Presence Sensing System with an interlock seat belt, disconnecting the seat belt buckle will have the same effect as leaving the seat, which is described in the sections above.

WARNING If the OPS system is activated by the operator leaving the seat or disconnecting the seat belt while traveling on a slope, the truck may roll on the slope when the motor is disabled. To avoid this, the driver must remain seated with the seatbelt fastened. Failure to follow these instructions may result in serious injury or death.

Hydraulic Function Protection: Double “Locked” If the operator is not seated properly while the engine is running, the hydraulic functions (lift, lower, tilt, and auxiliary functions) will be disabled. If the operator returns to the seat properly, the hydraulic functions will begin working. If the driver leaves the seat for more than 3 seconds, the hydraulic functions will be disabled.

Park Brake Protection: a. If the operator fails to sit on the seat properly while the forklift is running and the park brake is not engaged, the alarm will sound after 3 seconds and the OPS light will illuminate. Pulling up the parking brake or sitting on the seat correctly will cancel the alarm. b. If the park brake is not engaged when the driver leaves the seat without the engine running but the key switch is on, the alarm will sound and the OPS light will illuminate. Engaging the parking brake or returning to the seat properly will turn off the OPS light, the parking brake light, and the alarm.

125

Abnormal Function: In the event the OPS system exhibits any of the following symptoms, park the forklift immediately in a safe place and contact an authorized service technician. a. The alarm keeps sounding when the park brake is applied. b. The neutral indicator light flashes when the gear switch is in neutral. c. The OPS light does not illuminate or the alarm does not sound 3 seconds after the operator leaves the seat or disconnects the seat belt. d. The alarm keeps sounding or the OPS light stays illuminated after the operator returns to the seat properly.

Note: Seat switch, parking brake switch, backup alarm, alarm lights, and other lights are powered by battery and turning on the ignition key.

126

Maintenance Record Date

Item of Maintenance

127

Maintenance Personnel

UTILEV TECHNICAL PUBLICATIONS “UTILEV is a registered trademark. THE UTILITY LIFT TRUCK and UTILITY YOU CAN TRUST are trademarks in the United States and certain other jurisdictions.

76502796

05-2017 (03-2017) 128