Hyundai 14BRJ-7 User manual

Руководство по эксплуатации рич-траков
HYUNDAI, моделей
14/16/20/25BRJ-7
Публ. №: 91HJ-30040
Март 2009

0-1
Lift trucks are specialized machines with unique operating characteristics, designed to perform a specific
job. Their function and operation is not like a car or ordinary truck. They require specific instructions
and rules for safe operation and maintenance.
Safe operation of lift trucks is of primary importance to HYUNDAI.
Our experience with lift truck accidents has shown that when accidents happen and people are killed or
injured, the causes are:
ÂÂ Operator not properly trained
 Operator not experienced with lift truck operation
ÂÂ Basic safety rules not followed
 Lift truck not maintained in safe operating condition
For these reasons, HYUNDAI wants you to know about the safe operation and correct maintenance of
your lift truck.
This manual is designed to help you operate your lift truck safely.
This manual shows and tells you about safety inspections and the important general safety rules and
hazards of lift truck operation. It describes the special components and features of the truck and
explains their function. The correct operating procedures are shown and explained. Illustrations and
important safety messages are included for clear understanding. A section on maintenance and
lubrication is included for the lift truck mechanic.
The operator's manual is not a training manual. It is a guide to help trained and authorized operators
safely operate their lift truck by emphasizing and illustrating the correct procedures. However, it cannot
cover every possible situation that may result in an accident. You must watch for hazards in your work
areas and avoid or correct them. It is important that you know and understand the information in this
manual and that you know and follow your company safety rules!
Be sure that your equipment is maintained in a safe condition. Do not operate a damaged or
malfunctioning truck. Practice safe operation every time you use your lift truck. Let's join together to set
high standards in safety.
Remember, before you start operating this lift truck, be sure you understand all driving procedures. It is
your responsibility, and it is important to you and your family, to operate your lift truck safely and
efficiently.
Be aware that the Federal Occupational Safety and Health Act(OSHA) and state laws require
that operators be completely trained in the safe operation of lift trucks; It is also an (OSHA)
requirement that a machine inspection be performed before every shift. If you need training in
operating or inspecting your lift truck, ask your supervisor.
HYUNDAI lift trucks are built to take hard work, but not abuse. They are built to be dependable, but they
are only as safe and efficient as the operator and the persons responsible for maintaining them. Do not
make any repairs to this truck unless you have been trained in safe lift truck repair procedures and are
authorized by your employer.
This manual describes procedures for operation, handling, lubrication, maintenance, checking and
adjustment. It will help the operator realize peak performance through effective, economical and safe
machine operation.
A MESSAGE TO HYUNDAI LIFT TRUCK OPERATORS

0-2
HYUNDAI welcomes you to the growing group of professionals who own, operate and maintain
HYUNDAI lift trucks. We take pride in the long tradition of quality products and superior value the
HYUNDAI name represents. This manual familiarizes you with safety, operating, and maintenance
information about your new lift truck. It has been specially prepared to help you use and maintain your
HYUNDAI lift truck in a safe and correct manner.
Your HYUNDAI lift truck has been designed and built to be as safe and efficient as today's technology
can make it. As manufactured, for some models, it meets all the applicable mandatory requirements of
ANSI B56.1-1988 Safety Standard for Powered Industrial Trucks. Some trucks are also furnished with
equipment to help you operate safety; for example, load back rest, parking brake and horn are standard
equipment.
Safe, productive operation of a lift truck requires both skill and knowledge on the part of the operator.
The operator must know, understand, and practice the safety rules and safe driving and load handling
techniques described in this manual. To develop the skill required, the operator must become familiar
with the construction and features of the lift truck and how they function, the operator must understand
its capabilities and limitations, and see that it is kept in a safe condition.
Routine Servicing and Maintenance
Regular maintenance and care of your lift truck is not only important for economy and utilization
reasons; it is essential for your safety. A faulty lift truck is a potential source of danger to the operator,
and to other personnel working near it. As with all quality equipment, keep your lift truck in good
operating condition by following the recommended schedule of maintenance.
Operator Daily Inspection - Safety and Operating Checks
A lift truck should always be examined by the operator, before driving, to be sure it is safe to operate.
The importance of this procedure is emphasized in this manual with a brief illustrated review and later
with more detailed instructions. HYUNDAI dealers can supply copies of a helpful Drivers Daily
Checklist. It is an OSHA requirement.
Planned Maintenance
In addition to the daily operator inspection, HYUNDAI recommends that a planned maintenance and
safety inspection program(PM) be performed by a trained and authorized mechanic on a regular basis.
The PM will provide an opportunity to make a thorough inspection of the safety and operating condition
of your lift truck. Necessary adjustments and repairs can be done during the PM, which will increase the
lift or components and reduce unscheduled downtime and increase safety. The PM can be scheduled
to meet your particular application and lift truck usage.
The procedures for a periodic planned maintenance program that covers inspections, operational
checks, cleaning, lubrication, and minor adjustments are outlined in this manual. Your HYUNDAI dealer
is prepared to help you with a Planned Maintenance Program by trained service personnel who know
your lift truck and can keep it operating safely and efficiently.
Service Manual
In-depth service information for trained service personnel is found in Service Manual.
INTRODUCTION

0-3
This manual is a digest of essential information about the safe operation, the features and functions and
explains how to maintain your lift truck. This manual is organized into eight major parts:
Section 1. General Safety Rules, reviews and illustrates accepted practices for safe operation of a lift
truck.
Section 2. Operating Hazards, warns of conditions that could cause damage to the truck or injury to
the operator or other personnel.
Section 3. Know Your Truck, describes the major operating components, systems, controls, and other
features of your truck and tells how they function.
Section 4. Daily Safety Inspection, presents details on how to perform the operator's daily safety
inspection and refuel the lift truck.
Section 5. Operating Procedures, discusses specific instructions on the safe, efficient operation of
your lift truck.
Section 6. Emergency Towing, gives instructions for towing your truck in an emergency and for using
battery jumper cables to start your truck in an emergency.
Section 7. Planned Maintenance, describes the PM (Planed Maintenance) program.
Section 8. Specifications, provides reference information and data on features, components, and
maintenance items.
ö The descriptions and specifications included in this manual were in effect at the time of printing.
HYUNDAI reserves the right to make improvents and changes in specifications or design, without notice
and without incurring obligation. Please check with your authorized HYUNDAI dealer for information on
possible updates or revisions.
The examples, illustrations, and explanations in this manual should help you improve your skill and
knowledge as a professional lift truck operator and take full advantage of the capabilities and safety
features of your new lift truck.
The first section of the manual is devoted to a review, with illustrations and brief messages, of general
safety rules and the major operating hazards you can encounter while operating a lift truck. Next, you
will find description's of the components of your specific lift truck model and how the instruments,
gauges, and controls operate. Then, you will find a discussion of safe and efficient operating
procedures, followed by instruction's on how to tow a disabled lift truck. The later sections of the manual
are devoted to maintenance and truck specifications.
Take time to carefully read the K
Know Your Truck section. By acquiring a good basic understanding of
your truck's features, and how they function, you are better prepared to operate it both efficiently and
safely.
In Planned Maintenance, you will find essential information for correct servicing and periodic
maintenance of your truck, including charts with recommended maintenance intervals and component
capacities. Carefully follow these instructions and procedures.
Each major section has its own table of contents, so that you can find the various topics more easily.
HOW TO USE THIS MANUAL

0-4
We urge you to first carefully read the manual from cover to cover. Take time to read and understand
the information on general safety rules and operating hazards. Acquaint yourself with the various
procedures in this manual. Understand how all gauges, indicator lights, and controls function. Please
contact your authorized HYUNDAI dealer for the answers to any questions you may have about your lift
truck's features, operation, or manuals.
Operate your lift truck safely; careful driving is your responsibility.
Drive defensively and think about the safety of people who are working nearby. Know your truck's
capabilities and limitations. Follow all instructions in this manual, including all symbols (
mssages to avoid damage to your lift truck or the possibility of any harm to yourself or others.
This manual is intended to be a permanently attached part of your lift truck. Keep it on the truck as a
ready reference for anyone who may drive or service it. If the truck you operate is not equipped with a
manual, ask your supervisor to obtain one and have it attached to the truck. And, remember, your
HYUNDAI dealer is pleased to answer any questions about the operation and maintenance of your lift
truck and will provide you with additional information should you require it.
ö
)

0-5
1 Model name
2 Warning mast
3 Logo
4 Circuit diagram
5 Maintenance instructions
6 Battery handling
7 Load capacity chart
8 Hanger
9 Hook
10 Brake pedal
11 Accelerator pedal
12 Warning safety
13 Name plate
14 Label-UL
15 EE mark
16 Lift joystick
17 Tilt joystick
18 Reach joystick
19 Option joystick
1. LOCATION
Always keep these labels clean. If they are lost or damaged, attach them again or replace them with
new labels.
14/16BRJ-7
12 5
91FH-00320
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OPENTHEBATTERYCOVER WHEN CHARGING.
BATTERY BEING CHARGED NOT ONLY HEAT,
BUT ALSO INFLAMMABLE HYDROGEN GAS
IS PRODUCED.
KEEP FIRE AWAY.
HOISTINGTHEBATTERYCASE,USE 2 OR 4
WIRES WITH HOOK AND HANDLE CAREFULLY,
NOT TO SHOCK.
THEELECTROLYTESOLUTIONOF BATTERY
IS DILUTE SULFURIC ACID( ).
BE CAREFUL NOT TO DROP ON CLOTHES
AND MECHANICAL PARTS.
91FH-00350
HSO
24
91FH-01500
F4
10A F6
15A F7
10A F8
10A
LH RH T/S B/USTOPTAIL
BRAKE
LAMP
SWITCH
HEAD
LAMP
SWITCH B
L
FLAS
-HER
UNIT
F9
10A F10
10A
T/S B/USTOP
TAIL
COMBI.
LAMP
-LH
BACKUP
BUZZER
T/S
LAMP
-LH
T/S
LAMP
-RH
COMBI.
LAMP
-RH
C-
LAMP
RELAY
E
T/S
S/W
C-
2
2424A
4B 4A 4C
25
40
40A
02D
26
41
42A
45A
27
46A
46A
02M02N 02H 02L 02N02N 02E
44 02C
42 45
FUSEBOXASS'Y
4
4B 46B
F12
10A
BEA
CON
LAMP
47
02L
52
47B
LAMP
-S/W
52A
47A
F11
10A
REAR
WORK
LAMP
59
02J
55
LAMP
-S/W
02P
59B
55A
59A
REV
LAMP
S/W
02Q
46
20
LCCOIL
BATTERY 80V
LINE
CONTACTOR
B-
B+
SEATS/W
350A
TIB+
TRACTION
INVERTER
DUALAC-2
TEMPSENSOR
C35(PTHERM_L)
21D
M
WS
VS
US
TRACTION
MOTOR-LH
C34(NTHERM_L)
C11(PENC_L)
C12(NENC_L)
C22(PHA_L)
C23(PHB_L)
194
192
191
195
KEYC3
SEATC5
KO
ACCEL.S/W
FORWARDC6
PARKINGC10
ENABLEC8
REVERSEC7
BRAKEC9
COMMONC4
92
90
99
95
91
98
122A
01
PLCC27120
94
CPOTC21
93
PPOTSTC16
21C
CAN_HA1
96
06
126
125
CAN_LA6
193
196
LIFT
POTENTIOMETER
300A
PUMP
INVERTER
AC-2
TEMPSENSOR
(PTHERM)F6
21D
M
W
V
U
PUMP
MOTOR
(NTHERM)F12
(ENCVCC)D1
(ENCGND)D2
(ENCA)D3
(ENCB)D5
294
292
293
291
295
296
F1KEY
KO
LIFTS/W
E5LIFTENABLE
E61stSPEED
F102ndSPEED
E73rdSPEED
E13SR
F11-BATT
60
61
62
63
222A
04
05
F5SAFETY
B1-BATT
04
05B2MODE
65
64
03
PPOTE2
NPOTE3
CPOTE1
C3CAN_H
126
125C1 CAN_L
EMERGENCY SWITCH
ACCELERATOR
PEDAL
KO
122D
122
TEMPSENSOR
C25(PTHERM_R)
M
WM
VM
UM
TRACTION
MOTOR-RH
C24(NTHERM_R)
C1(PENC_R)
C2(NENC_R)
C13(PHA_R)
C14(PHB_R)
394
392
391
395
393
396
FWDS/W
PARKING
REVS/W
BRAKES/W
122B
122C
122D
122D
NLCC26
STEER
SENSOR
CPOTSTC17
NPOTSTC15
222A
E4COMMON
TILTS/W
AUX1S/W
AUX2S/W
TIB-
222
TIB-
TIB+
10W300?
NPOTC2007
CAN_HOUTA7
325
326
CAN_LOUTA4 C2CAN_LOUT
C4CAN_HOUT
120?
225
226
GRAPHICSMARTDISPLAY
KEYA621A KO
CAN-L
A4
B- A1-BATT
00B
CAN-H
A3
A2-BATT
326 325
00B
B3CAN-T
326A
‚j‚d‚x
S/W
00A
B-
02A
21
C-
INPUTOUTPUT
(IN)(OUT)
DC-DC
CONVERTER
GNDGND
22
KO
21B
KO
29
49
02G
49A
29A
02B
TNR
49B
MCVSOL.
08
PHYDROF3221
NHYDROF9
F13
10A
TNR
5
02F
M
FAN-
LH
5A
02T
M
FAN-
REAR
M
F14
10A
6
OPT
5D 5C
02V 02U 02S
M
FAN-
CONT
5D
02V
FAN-
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5B
1.B+:BATTERYPOSITIVE
B-:BATTERYNEGATIVE
C-:CONVERTEROUTPUTNEGATIVE
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2.WIRENO.&COLOR
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COLDSTORAGEWIRING
WIRINGDIAGRAMCABIN
CASSETTERADIO
WIPERSWITCH
CS-101
DIODE
DO-1
CN-102
WIPERMOTOR
WASHER
CN-103
DIODE
DO-2
F1315A F1410A 424
DIODE
DO-3
CN-107
FAN
02T
422
02U
DC/DCCONVERTER
DC/DCCONVERTER
OUTPUT(+)
OUTPUT(GND)
02A
22
F510A
727
72E
72D
72C
72B
72A
09B 09C 09D 09E
09A
F410A
2
2022
02E 09
FUSEBOXASS'Y
BATTERY
HEATER
-LIFT
SENSOR
HEATER
-TILT
SWITCH
HEATER
-AUX1
SWITCH
HEATER
-AUX2
SWITCH
HEATER
-PARK
SWITCH
SENSOR
-TEMP
INPUTOUTPUT
(80V)(12V)
DC-DC
CONVERTER
GNDGND
(IN)(OUT)
HEATER
-LIFT
SENSOR
CHECK
REPLACE
91HD-00100
REPLACE(Initialonly)
FILLORLUBRICATE
(HO:HydraulicoilGO:GearoilG:GeaseEO:EngineoilBF:Brakefluid)
DAILY
50HrsOr1Week
250HrsOr1Month
1000HrsOr6Month
2000HrsOr12Month
HYD.PUMP
100HrsOr2Week
MASTROLLERS
LIFTCHAINS
DRIVEMOTOR
HEADGUARD
BRAKEPEDAL
BRAKEFLUID
STEERINGWHEEL
CONTROLLER
HARNESS
&CABLE
STEERAXLE
LINKAGE
HORN
FORKS
DRIVEUNITOIL
MASTMTG.BLOCK
FRONTTIRE&
WHEELNUTS
DISPLAY
LAMP
ACCELERATOR
CONTROLLEVER
BATTERY
ELECTROLYTE
HYD.SUCTION
STRAINER
&HYD.OIL
PUMPMOTOR
REARTIRE&
WHEELNUTS
FUSEBOX
CONTACTOR
FAN
STEERSENSOR
STEERING
CYLINDER
TILTPINS
TILTPIN
BACKBUZZER
FAN
EO
BF
GO
HO
HO
GO
G
G
G
G
HYD.RETURN
FILTER
91FP-00350
91FP-00340
91FP-00340
kg
mm
91FH-01540
1100
600
1100
1600
2100
1500
1900
2200
500 700 900 1100 1300 1500
500 700 900 1100 1300 1500
SIDE PLATE-LH
*
1
3
2
16
17
18
19
6
4
7
8
9
10 11
15
9
13
14
12
FINGERTIP
SAFETY LABELS
14BRJ7OM101
1)

0-6
2. DESCRIPTION
There are several specific warning labels on this machine please become familiarized with all warning
labels.
Replace any safety label that is damaged, or missing.
WARNING MAST(ltem 2)
This warning label is positioned on the side
of the mast.
Never stand or work under the raised
forks even if the hydraulic safety lock
lever is applied.
In case of working under the forks, it is
essential to support the carriage with
blocks.
1)
D35AOM62
HANGER(Item 8)
This warning label is positioned on the
front frame.
Refer to page 1-18 for safe loading
procedures.
2)
14BRJ7FW12
(1)
Battery handling(Item 6)
This battery handling is located on the right
side frame of the cab.
Refer to page 7-20 for a safe battery
removal.
Open the battery cover when charging.
Battery being charged not only heat, but
also inflammable hydrogen gas is
produced. Keep fire away.
Hoisting the battery case, use 2 or 4 wires
with hook and handle carefully, not to shock.
The electrolyte solution of battery is dilute
sulfuric acid (H2SO4).
Be careful not to drop on clothes and
mechanical parts.
91FH-00350
15BT7FW11
3)
ö
ö
ö
౦ୢ් ݡۀ ࢼഉࠤ ಝ࣊ࠜ વઘ சૈ౦ୢ
ண઩ۀ વր ඒࢳন ৤ী ԧԧ ࢳ঍෇࢛ߦ ฃ
׆ࠜ ୣ۩ߦ ԧגଲ ෇஺ ࠬૈ
Open the battery cover when charging. Battery
being charged not only heat, but also
inflammable hydrogen gas is produced. Keep
fire away.
ࢼഉࠤࠜ ݅ઘ ોࠧݡۀ ࢱ݁ ށۀ Թଭ ճ
ࠤ઩ ૕ଲઘ ߦඹࠜ Տઘ ౦գଲ ԧැ஺஺ ܑ
ߧ சଭ෇ૈ
Hoisting the battery case, use 2 or 4 wires with
hook and handle carefully, not to shock.
ࢼഉࠤ ୢැઁଠ ࢅଠจઁ ଲ࢛ߦ ૒ր ׆ծ
ඨ઩ ۨ஺ ܑߧ சଭ෇ૈ
The electrolyte solution of battery is dilute
sulfuric acid (H
2 SO 4 ).
Be careful not to drop on clothes and
mechanical parts.

0-7
WARNING SAFETY(Item 12)
This warning safety is located on the right
side frame of the cab.
Before putting this truck in operation, test
brakes, steering controls, horn and other
devices for safety and easy of operation.
Only trained and qualified persons should
operate this truck.
Operate truck or auxiliary devices only
from operator's seat.
Use drivers overhead guard and load
backrest extension unless conditions
prevent their use.
Before key switch ON, place shift lever in
neutral position.
2D0900060
4)
15BT7FW05
(1)
(2)
(3)
(4)
(5)
Spread forks far apart and place them on
center completely under loaded.
Do not handle unstable of loosely stacked
loads.
Use extreme care with long, high or wide
loads and do not overload truck. (See load
chart)
Travel with load or lifting mechanism at
minimum ground clearance and tilted
back. Except on ramps travel with the load
trailing when the load interferes with
visibility.
Operate on ramps with load upgrade.
Travel slowly with caution and do not turn
on inclines.
Avoid sudden starts, stops direction
reversals, unsafe speed and reverse
braking. Reduce speed for turns or
uneven or slippery surface.
Never lift or lower loads while truck is in
motion.
Do not allow anyone to stand or pass
under load or lifting mechanism keep all
body parts out of upright and within
confines of truck.
Do not carry passengers. Do not elevate
personal without secured safety platform.
Lift with mast vertical or tilted sightly back.
Never forward.
Lift loads smoothly and slowly-avoid
sudden jerks.
When leaving truck, turn off power, lower
lifting mechanism, place shift in neutral.
Key or connector plug removed. Also
check wheel if truck is on an incuse or to
be worked ON.
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
FOR SAFETY
Before putting this truck in operation, test brakes, steering controls, horn and
other devices for safety and easy of operation.
Only trained and qualified persons should operate this truck.
Operate truck or auxiliary devices only from operator's seat.
Use drivers overhead guard and load backrest extension unless conditions
prevent their use.
Before key switch ON, place shift lever in neutral position.
Spread forks far apart and place them on center completely under loaded.
Do not handle unstable of loosely stacked loads.
Use extreme care with long, high or wide loads and do not overload truck.
Travel with load or lifting mechanism at minimum ground clearance and tilted
back. Except on ramps travel with the load trailing when the load interferes
with visibility.
Operate on ramps with load upgrade. Travel slowly with caution and do not
turn on inclines.
Avoid sudden starts, stops direction reversals, unsafe speed and reverse
braking. Reduce speed for turns or uneven or slippery surface.
Never lift or lower loads while truck is in motion.
Do not allow anyone to stand or pass under load or lifting mechanism keep
all body parts out of upright and within confines of truck.
Do not carry passengers. Do not elevate personal without secured safety
platform.
Lift with mast vertical or tilted sightly back. Never forward.
Lift loads smoothly and slowly-avoid sudden jerks.
When leaving truck, turn off power, lower lifting mechanism, place shift in
neutral. Key or connector plug removed. Also check wheel if truck is on an
incuse or to be worked ON.
10.
11.
12.
13.
14.
15.
1.
2.
3.
4.
5.
6.
7.
8.
9.
SEE LOAD CHART

0-8
GUIDE
1. DIRECTION
The direction of this machine indicate forward,
backward, right and left when machine is in the
travelling direction.
Front
Rear
Left
Right
Inform following when you order parts or the machine is out of order.
MACHINE SERIAL NUMBER
It's shown on the rear right side of the frame.
1)
14BRJ7OM07
2. SERIAL NUMBER
Serial No.
14BRJ7OM06
Important safety hint.
It indicates matters which can cause the great loss on the machine or the surroundings.
It indicates the useful information for operator.
3. SYMBOLS
ö

CONTENTS
1. GENERAL SAFETY RULES
1. Daily inspection --------------------------------------------------------------------------------------------------------
1-1
2. Do’s and don’ts
--------------------------------------------------------------------------------------------------------
1-2
3. No riders
------------------------------------------------------------------------------------------------------------------- 1-4
4. Pedestrians -------------------------------------------------------------------------------------------------------------- 1-5
5. Operator protection -------------------------------------------------------------------------------------------------- 1-6
6. Fork safety ---------------------------------------------------------------------------------------------------------------- 1-7
7. Pinch points ------------------------------------------------------------------------------------------------------------- 1-8
8. Travel ------------------------------------------------------------------------------------------------------------------------ 1-9
9. Grades, ramps, slopes and inclines ------------------------------------------------------------------------- 1-10
10. Tip over
-------------------------------------------------------------------------------------------------------------------- 1-11
11. Surface and capacity
-----------------------------------------------------------------------------------------------
1-12
12. Parking --------------------------------------------------------------------------------------------------------------------- 1-13
13. Lifting, jacking and blocking -------------------------------------------------------------------------------------
1-14
14. Loading and unloading by crane
----------------------------------------------------------------------------- 1-19
2. OPERATING HAZARDS
1. Loose loads -------------------------------------------------------------------------------------------------------------- 2-1
2. Long and wide loads ------------------------------------------------------------------------------------------------ 2-2
3. Rear swing --------------------------------------------------------------------------------------------------------------- 2-2
4. Low overhead clearance ------------------------------------------------------------------------------------------ 2-3
5. Fast turns and high loads
----------------------------------------------------------------------------------------- 2-3
6. Drop-offs ------------------------------------------------------------------------------------------------------------------ 2-4
7. Right-angle stacking ------------------------------------------------------------------------------------------------ 2-4
8. Chain slack --------------------------------------------------------------------------------------------------------------- 2-5
9. Pallets and skids ------------------------------------------------------------------------------------------------------ 2-5
10. Caution for electrical lines ---------------------------------------------------------------------------------------- 2-6
3. KNOW YOUR TRUCK
1. General locations ----------------------------------------------------------------------------------------------------- 3-1
2. Data/safety plates and decals ---------------------------------------------------------------------------------- 3-2
3. Instruments and controls ------------------------------------------------------------------------------------------ 3-5
4. Instruments panel ---------------------------------------------------------------------------------------------------- 3-6
5. Operating switches and levers --------------------------------------------------------------------------------- 3-11
6. Seat adjustment ------------------------------------------------------------------------------------------------------- 3-14

7. Battery connector ----------------------------------------------------------------------------------------------------- 3-14
8. Support and safety parts ----------------------------------------------------------------------------------------- 3-14
4. DAILY SAFETY INSPECTION
1. Inspecting your truck ------------------------------------------------------------------------------------------------ 4-1
2. Visual checks ----------------------------------------------------------------------------------------------------------- 4-2
3. Functional checks ---------------------------------------------------------------------------------------------------- 4-3
4. Concluding the inspection ----------------------------------------------------------------------------------------- 4-3
5. OPERATING PROCEDURES
1. Before operating the truck ---------------------------------------------------------------------------------------- 5-1
2. Starting from a safe condition ---------------------------------------------------------------------------------- 5-1
3. Starting the truck ----------------------------------------------------------------------------------------------------- 5-2
4. Controlling speed ---------------------------------------------------------------------------------------------------- 5-4
5. Braking --------------------------------------------------------------------------------------------------------------------- 5-4
6. Plugging ------------------------------------------------------------------------------------------------------------------- 5-4
7. Operating safely ------------------------------------------------------------------------------------------------------- 5-6
8. Load handling ---------------------------------------------------------------------------------------------------------- 5-8
9. Shut down procedure ---------------------------------------------------------------------------------------------- 5-14
6. EMERGENCY TOWING
1. Towing precautions
-------------------------------------------------------------------------------------------------- 6-1
2. Towing procedures --------------------------------------------------------------------------------------------------- 6-2
7. PLANNED MAINTENANCE
1. Introduction -------------------------------------------------------------------------------------------------------------
7-1
2. Lift truck maintenance
---------------------------------------------------------------------------------------------- 7-1
3. Planned maintenance
----------------------------------------------------------------------------------------------
7-1
4. Planned maintenance intervals ------------------------------------------------------------------------------- 7-2
5. Major component locations
--------------------------------------------------------------------------------------
7-3
6. Daily maintenance checks --------------------------------------------------------------------------------------- 7-4
7. Periodic maintenance checks
---------------------------------------------------------------------------------- 7-5
8. Safe maintenance practices
------------------------------------------------------------------------------------ 7-6
9. Maintenance guide -------------------------------------------------------------------------------------------------- 7-8
10. Visual inspection ------------------------------------------------------------------------------------------------------ 7-12
11. Checking the hydraulic fluid ------------------------------------------------------------------------------------- 7-14
12. Critical fastener checks -------------------------------------------------------------------------------------------- 7-14
13. Air cleaning the truck ------------------------------------------------------------------------------------------------ 7-15
14. Electric truck battery maintenance -------------------------------------------------------------------------- 7-16
15. Battery handling ------------------------------------------------------------------------------------------------------- 7-17

16. Battery charging ------------------------------------------------------------------------------------------------------- 7-18
17. Battery installation & removal from truck ----------------------------------------------------------------- 7-20
18. Battery cleaning and care ---------------------------------------------------------------------------------------- 7-22
19. New machine oil ------------------------------------------------------------------------------------------------------- 7-23
20. Recommended lubricants ---------------------------------------------------------------------------------------- 7-23
8. SPECIFICATIONS
1. Specification ------------------------------------------------------------------------------------------------------------- 8-1
2. Specification for major components ------------------------------------------------------------------------- 8-3
3. Tightening torque ----------------------------------------------------------------------------------------------------- 8-7

1-1
At the beginning of each shift, inspect your
truck and fill out a check, maintenance and
lubrication table.
Check for damage and maintenance problems.
Have repairs made before you operate the truck.
Do not make repairs yourself. Lift truck
mechanics are trained professionals. They
know how to make repairs safe.
1. GENERAL SAFETY RULES
1. DAILY INSPECTION
14BRJ7OM00

1-2
Do watch for pedestrians.
2. DO'S AND DON'TS
D35AOM03
Do wear safety equipment when required.
D35AOM05
Don't mix drugs or alcohol with your job.
Don't block safety or emergency equipment.
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D35AOM02
Don't smoke in NO SMOKING areas or when charging.
D35AOM06

Don't operate the truck outdoors in rainy day.
D35AOM033
Don't perform battery charging service in the room without
adequate ventilation.
D35AOM034
1-3

1-4
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3. NO RIDERS
The operator is the only one who should be
on a truck.
Never transport personnel on the forks of a
lift truck.
1)
2)

1-5
Make people stand back, even when you
are parked.
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Watch for people in your work area even if
your truck has warning lights or alarms.
People may not watch for you.
D35AOM14
Watch where you are going. Look in the
direction of travel. Pedestrians may use the
same roadway you do. Sound your horn at
all intersections or blind spots.
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4. PEDESTRIANS
1)
2)
3)

1-6
5. OPERATOR PROTECTION
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Keep under the overhead guard.
Always keep your body within the confines
of the truck.
1)
2)
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Be specially careful when traveling and
maneuvering in tight areas.
3)

1-7
Never allow anyone to walk under raised forks.
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There is special equipment to raise people for
overhead work.
DO NOT USE LIFT TRUCKS.
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6. FORK SAFETY

1-8
Keep hands, feet and legs out of the
mast.
B207OM20
Don't use the mast as a ladder.
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Never try to repair the mast, carriage,
chain, or attachment yourself. Always
get a trained mechanic.
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7. PINCH POINTS