UniCarriers FD160-2 Manual

No. OMFBE-8B8150
FORKLIFT TRUCK
• It is the responsibility of the Operator and Supervisor to read and understand this manual.
• Protect the earth and be kind to your lift truck.
OPER. & MAINT. MANUAL
No. OMFBE-8B8150
FD160-2 – FD230-2
OPERATION &
MAINTENANCE MANUAL
Diesel Powered
FD160-2
FD180-2
FD200-2
FD230-2

CONTENTS
1. SAFETY
2. OPERATING
CONTROLS
3. OPERATION
4. MAINTENANCE
5. SPECIFICATIONS
& SERVICE DATA
Thank you very much for your purchase of UniCarriers’ product.
This Operation & Maintenance Manual was written to provide the owner/
operator with information about the safe operation and maintenance of the
UniCarriers forklift truck. Read this manual thoroughly and become completely
familiar with the lift truck before using it. If you have any questions, see your
dealer.
Due to improvements in design, it is possible that the description contained
herein may not completely apply to the truck delivered to you.
CAUTION
If the truck is to be leased, loaned or sold to anyone, this manual must
be with the truck.

1. SAFETY
CONTENTS
FOR SUPERVISORS ...............................................................1-1
QUALIFIED OPERATORS...................................................1-2
PLANNING AND WORKING AREA.....................................1-3
PROPER AND IMPROPER USES ......................................1-6
TYPES OF VEHICLES AND LOADS...................................1-7
INSPECTION.....................................................................1-10
INSPECTION/TRANSPORTING THE LIFT TRUCK .........1-11
TRAVELING ON PUBLIC ROADS ....................................1-13
HOW THE LIFT TRUCK WORKS? ........................................1-14
TRAVELING ...........................................................................1-17
LOAD HANDLING ..................................................................1-24
PARKING................................................................................1-29
INSPECTION AND SERVICE ................................................1-31
CAUTION PLATES.................................................................1-41
[C]

1-1
FOR SUPERVISORS
Lift truck accidents cause dozens or hundreds of deaths every
year, and even greater numbers of personal injuries.
UniCarriers has steadily improved the design and fabrication of
our lift trucks so they may be used more safely and efficiently,
but many accidents still occur due to improper use. Accidents
are often the result of more than just “bad driving”. The use of
inappropriate types of equipment, the selection of inappropriate
attachments or accessories, inappropriate operating environments,
careless designation of operators, and failure to properly train the
operator are other common causes of accidents.
It is not possible to describe all potentially hazardous situations
which may occur while operating, inspecting or servicing a
forklift truck. The warnings and cautions in this manual, including
the decals attached to the forklift, are not intended to cover all
possible working hazards.
If you operate, inspect or service the forklift in a manner not
described in this manual, please be careful because you do so at
your own risk.
This chapter covers the methods of accident prevention which are
primarily the responsibility of supervisory personnel.
•Pages 1-2 through 1-13 contain instructions which should be
enforced by the personnel supervising the operation of the lift
truck. Please make sure the operators also read these pages.
•Page 1-14 and the following pages contain specic precautions
directly related to the operation of the lift truck.
The following symbols, found throughout this manual, alert you to
potentially dangerous conditions to the owner and the operator.
Become completely familiar with the truck before proceeding with
operating, checking and servicing the truck.
This manual and the decals afxed to the truck use the following
safety alert indications.
SIGNAL WORD CLASSIFICATION
DANGER
Failure to follow the instructions in the
message will likely cause a serious accident or
death.
WARNING
Failure to follow the instructions in the
message might cause a serious accident or
death.
CAUTION
Failure to follow the instructions in the
message may cause personal injury or damage
to the truck or other property.
NOTE
The information will help to prolong the service
life of the truck. The message is not directly
related to accident prevention.
Right
Left
Forward Backward
The diagram above indicates the meanings of the terms “forward”,
“backward”, “right” and “left” used in this manual.

FOR SUPERVISORS QUALIFIED OPERATORS
1-2
■WEAR PROTECTIVE GEAR
Gloves Safety
Shoes
Work
Clothes
Goggles
Hard Hat
•Always wear proper work clothes for driving. Work clothes
should be designed to prevent any part from accidentally
catching on knobs or other parts of the truck or equipment. For
example, shirts and trousers should have tight cuffs.
•Always wear a hard hat and safety shoes.
•Wear other protective gear as appropriate to the conditions of
the work site, i.e., goggles or gloves.
■PROVIDE AND MAINTAIN EMERGENCY EQUIPMENT
Fire extinguishers and first aid kits should be provided and
maintained for use in case of a fire or accident. All personnel
should understand the location and use of emergency equipment.
■TRAIN OPERATOR TO STACK SAFELY
Stacking
Unstacking
“Stacking” means piling up a palleted load or material directly on
top of each other, without using racks or shelves to separate them.
If stacking work is not done properly, the loads may slip or fall,
endangering the operator as well as fellow workers in the area.
Safety classes should be held to train all operators in the proper
method of stacking and unstacking loads.
(Your UniCarriers dealer can provide information about safety stacking
training.)
■TIRED OR UNWELL? SEND THEM HOME!
Do not let people take chances. An operator who is overworked or
fatigued, an operator who is feeling unwell, or an operator who is
intoxicated must not be allowed in the driver’s seat.

FOR SUPERVISORS PLANNING AND WORKING AREA
1-3
■KNOW WHO TO CALL IN AN EMERGENCY
Contacts in emergency
.....................................
.....................................
.............................
...........................
Keep information on hand to allow immediate calls for help in case
of a re, accident or other emergency.
■MAKE AN OPERATING PLAN AND DISCUSS IT
Before using the lift truck, plan out the travel routes and operating
procedures, and thoroughly discuss the details with all involved
personnel.
■MARK THE TRAVEL LANES
Designate the travel lanes for the lift truck and mark them clearly,
so they will be kept free of obstruction.
■SET SPEED LIMITS
(Example)
Yard Speed
Limit
Set appropriate speed limits on your company grounds, and post
signs that are clearly visible.

FOR SUPERVISORS PLANNING AND WORKING AREA
1-4
■KEEP PEOPLE OUT OF THE OPERATING AREA
No
Pedestrians
Closed to
Pedestrians
No other personnel should be allowed in areas where the lift truck
is used.
Where other people must be present, post a guide whose job is to
make sure people stay clear of moving vehicles.
■KEEP UNAUTHORIZED VEHICLES OUT
No entry of
unauthorized
vehicles
Unauthorized vehicles must be kept out of the load handling
areas. Post signs or give signals as required.
■ASSIGN TRAFFIC GUIDES TO CONGESTED AREAS
Post a traffic guide in confined or congested areas where other
people or vehicles may pass. All personnel must obey the guide’s
signals.
■PROVIDE ADEQUATE LIGHTING
Safe operation requires well-lit traveling routes, so pedestrians
and obstacles can be easily seen. Use headlights, taillights,
helmet lamps or other lights as appropriate.

FOR SUPERVISORS PLANNING AND WORKING AREA
1-5
■INSTALL CURBS OR RAILINGS
If the truck is to be used on a loading dock, shore wall or other
raised surface, install curbs or railings.
■DO NOT RELY ON THE OVERHEAD GUARD
The overhead guard is a protective device that will moderate the
impact of an object falling from overhead, but it cannot withstand
every impact. If a heavy object seems likely to fall on the truck,
make every effort to prevent it from doing so.
■KEEP THE GROUND LEVEL AND DRY
Be sure that all areas where the lift truck travels are level and
regular. Clear away pools of oil or water.
■SAFETY MEASURES FOR DANGER SPOTS
Post warning signs or take other appropriate measures to ensure
that lift truck operators keep away from danger spots as they
travel.

FOR SUPERVISORS PROPER AND IMPROPER USES
1-6
■PROPER USE OF THE LIFT TRUCK
The proper use of a lift truck is to transport a load which is placed
on the pallet and stacked within the prescribed height limit.
With a proper attachment, a lift truck may be used to transport a
load which is stacked elsewhere than on the pallet.
■IMPROPER USE
Transporting a person, elevating a person, and towing another
vehicle are examples of the improper use of a lift truck. Uses
which this manual species as improper must never be requested
or permitted, under any circumstances.
(Examples of Improper Use)
•Transporting or elevating a person on the forks or pallet.
•Carrying a person on the pallet to control the load.
•Hanging wire ropes from forks to lift a load.
•Towing another vehicle.
•Pushing a load or another vehicle with the forks.
•Using the forks or truck body to close or open the door of a
freight vehicle.

FOR SUPERVISORS TYPES OF VEHICLES AND LOADS
1-7
■READ MANUAL AND DECALS
Read the Operation & Maintenance manual and caution plates on the
truck, and become familiar with your truck and operating procedures.
Remember that individual lift trucks might be different in design and
construction from one another. Observe the caution decals on the
truck. Keep this Operation and Maintenance manual on the truck as
a ready reference for anyone who may drive or service it.
■KEEP DECALS LEGIBLE
The decals on the truck describe safety precautions and operating
instructions. Replace any damaged or missing decals. Check that
the decals are legible during regular inspections.
■NO OPERATION WITHOUT LIGHTS, OVERHEAD
GUARD, OR BACKREST
Load
backrest
Overhead
guard
Lamps
The lift truck cannot be used if the headlights, taillights, overhead
guard, backrest, horn or turn signals have been removed. Any
parts that have been temporarily removed for some reason must
be reattached immediately.
■OBTAIN APPROVAL FOR ANY MODIFICATION
Modications or additions that affect the capacity, construction or
strength of the truck must not be performed by the user without
the manufacturer’s prior permission. For example, don’t add a
counterweight.

FOR SUPERVISORS TYPES OF VEHICLES AND LOADS
1-8
■USE THE RIGHT TRUCK FOR THE JOB
Be sure the type and capacity of the lift truck is suitable for the
work environment.
Check Point Choice
Capacity
Load capacities range from 0.5 to 42 tons. Pay
particular attention to the load center.
(UniCarriers Lift Truck Capacities: 0.5, 0.7, 0.9, 1,
1.35, 1.5, 2, 2.25, 2.5, 2.75, 3, 3.5, 4, 4.5, 5, 6, 7, 8,
10, 10.5, 11.5, 12, 13.5, 15, 18, 20, 22, 23, 24, 25, 30,
37, or 42 tons.)
Power Source
Gasoline, natural gas, diesel, and battery- powered
models are available. Fuel costs and exhaust
composition will vary.
Balance
On counterbalanced models, the counterweight at
the rear makes the vehicle longer than reach trucks.
A reach truck performs loading and unloading by
extending the front part of the mast outward, which
gives it the advantage of compactness.
Tires
For indoor use, there are models with solid tires (best
for reach trucks) and cushion tires (engine type or
battery type). Both are compact.
For outdoor use, pneumatic tires work well. Solid
cushion tires, with the same dimensions as pneumatic
tires, may be the best choice in cases where the
load materials or surface conditions could puncture
pneumatic tires.
Flammable Materials
For handling flammable materials such as
petrochemicals, a combustion engine is too
dangerous. An electric vehicle with explosion-proof or
safety-reinforced construction is required. (A battery
power source always offers better protection against
re than a combustion engine.)
■USE THE PROPER ATTACHMENT
WARNING
Avoid hoisting a load with wire rope hung from the forks or
an attachment, or avoid lifting a freight container with forks,
because there is danger of the truck tipping. If necessary,
have a qualied operator use a hook or crane arm attachment.
Popular Attachment Examples
⑤: Crane Arm
(For slinging work)
①: Roll Clamp
(For paper roll or drum handling)
②: Rotating Fork
(For damping work or charging work)
③: Hinged Fork
(for lumber handling)
④: Side Shift
(For precise stacking
in containers or other
narrow spaces)

FOR SUPERVISORS TYPES OF VEHICLES AND LOADS
1-9
■HAVE A GOOD VENTILATION
Engine-powered trucks
When the engine is run indoors such as in an enclosed warehouse,
have a fresh-air ventilation. Exhaust fumes can cause chemical
poisoning, and in the worst case exhaust fumes can kill. When
warming up or operating the truck indoors, open the windows and
doors or use a fan to make sure there is a good ventilation.
■USE STURDY PALLET MATERIALS
Pallets and skids must be strong enough to withstand the heavy
weights of loading and unloading. Remove or repair any damaged
pallet.
■STACK LOADS SECURELY
When stacking loads, place them in a stable manner that they will
not easily come apart, and be sure the weight is evenly distributed.
Secure the top layer with a cord wrapped like a headband or in a
similar fashion.
■KNOW THE WITHSTAND LOAD OF YOUR FLOOR
The lift truck is heavier than it appears. For example, a 2-ton truck
weighs almost 3.5 tons even when empty. Furthermore, when
loaded, 80 to 90% of the total weight is concentrated on the front
wheels. Check the strength of your floors and roadways, and if
necessary reinforce them.

FOR SUPERVISORS INSPECTION
1-10
■ALWAYS INSPECT BEFORE OPERATING
The operator should always inspect the truck before each use
to verify that all essential safety features are working. Any
abnormality is to be reported to the supervisor, who is responsible
for correcting it.
■PERIODIC INSPECTIONS ARE MANDATORY
Monthly and annual inspections must be performed thoroughly,
and any abnormality promptly repaired. Only a certified expert
who has the advanced skills and equipment is allowed to conduct
inspections. Preserve the inspection logs for at least three years.
■REPLACE SAFETY PARTS REGULARLY
Name of safety parts
Recommended
replacement interval (year)
1Master cylinder and wheel cylinder cups and
dust seals 1
2 Power steering hose 2
3 Reserve tank tubing 2 – 4
4 Fuel hose 2 – 4
5 Torque converter rubber hose 2
6 Rubber parts inside power steering unit 2
7 Lift chain 2 – 4
8 Load handling means hoses 1 – 2
Certain critical parts must be replaced at regular intervals. Since it
is difcult to detect wear on the above parts by visual inspection,
they must be replaced at the intervals specied, because a failure
would result in a falling load or runaway truck.
■NEVER USE AN UN-MAINTAINED TRUCK
Out of
Service
A truck that has not passed an inspection must never be operated.
Hang a sign on the truck and remove the ignition switch, to make
sure no one uses it. Then report the problem to the supervisor and
wait for the repair to be completed.

FOR SUPERVISORS INSPECTION/TRANSPORTING THE LIFT TRUCK
1-11
■DESIGNATE A REPAIR AND ASSEMBLY
SUPERVISOR
Repairs and the mounting and dismounting of attachments must
be performed under the direction of a designated supervisor. The
body and major parts of the lift truck are quite heavy and under
very high pressure. Repair or assembly work undertaken without
careful and thorough preparation can lead to serious injury.
■TRANSPORTING THE LIFT TRUCK
Use a level, hard road surface when loading the truck onto or
unloading from a trailer and when unloading it. Be certain that the
ramps have sufcient length and width as well as strength. Do not
load or unload the truck when it is raining, unless the ramps are
tted with an anti-slipping surfaces.
It is safest to use a self-loading trailer truck equipped with a jack
and winch. For loading, tilt the pallet with the jack, attach the
winch to the towing pin of the lift truck, and pull it up. The operator
must not ride on the lift truck during loading or unloading.

FOR SUPERVISORS INSPECTION/TRANSPORTING THE LIFT TRUCK
1-12
■USE OPTIONAL “LIFTING EYES” FOR LIFTING
YOUR LIFT TRUCK
WARNING
Never hoist your lift truck at its overhead guard or
counterweight; otherwise there is a danger of the truck falling.
If hoisting the lift truck is necessary for any reason, use
optional “Lifting Eyes.”
WARNING
Observe the following conditions when lifting the lift truck:
•Use optional “Lifting Eyes”.
•Use ropes strong enough to withstand the weight of the
truck.
•Do not use any wire rope which is kinked, deformed or
frayed.
•Lifting the truck should be performed only by qualied
personnel.
•Do not enter under a lifted truck.

FOR SUPERVISORS TRAVELING ON PUBLIC ROADS
1-13
■GOT A LICENSE?
Before traveling on a public road, be sure that the truck has been
licensed and inspected as required by local laws.
■NO LOAD, NO TOWING
It is usually illegal to carry a load on a public road. It is also not
allowed to make a sideways travel or tow another vehicle on a
public road (with the possible exception of a disabled vehicle).
Never tow another vehicle, even on company property.
■OBEY TRAFFIC LAWS, AND TURN OFF YOUR LIGHTS
On a public road, the lift truck must obey the same laws as any
other vehicle. Do not use rear working light.

HOW THE LIFT TRUCK WORKS?
1-14
■KEEPING THE TRUCK BALANCED
Lift trucks are equipped with load handling means including a mast
and forks at its front part. The front wheels of the truck work as a
fulcrum to balance the center of gravity of the truck and the center
of gravity of the load. The relationship between the locations of
those two centers of gravity is vitally important for safety.
■KNOW THE CENTER OF GRAVITY OF YOUR LOAD
Load center (from fork root) mm
Load’s
center
gravity
Distance
Allowable load (kg)
Weight x distance x moment
(constant)
Basic load center
Materials of various shapes such as boxes or flat or cylindrical
items may be loaded on the lift truck. In order to accurately judge
the stability of the truck, it is vitally important for the operator to
know the location of the center of gravity for each type of load.
■HOW THE CENTER OF GRAVITY SHIFTS
Lift truck viewed from front
The higher the
load, the higher
the truck’s center
of gravity Truck’s center of
gravity with truck
tilted
Truck’s center of gravity
with standard mast raised
Truck’s center of gravity
with high mast raised
The stability of the lift truck is determined by the overall center of
gravity, which is the product of the centers of gravity of the truck
and the load. When the truck is empty, this point is the same as
the center of gravity for the truck, and when it is loaded it shifts
according to the center of gravity of the load. Since the center of
gravity of the load changes whenever the mast is tilted forward
or backward or the fork is raised or lowered, the overall center of
gravity also changes. The center of gravity is also governed by the
following factors:
•Size, weight and shape of
the load
•Unloading height
•Tilt angle of the fork
•Tire material
•Acceleration, deceleration
and turning
•Surface condition and
gradient of the road
•Type of attachment

HOW THE LIFT TRUCK WORKS?
1-15
■OUTSIDE THE TRIANGLE OF BALANCE, THE
TRUCK TIPS
Axis of lateral stability
Lift truck Viewed from Above
Rear
wheels
Front
wheels
If the center of gravity W1 moves
outward past the axis of lateral
stability, the truck will roll.
(As the center of gravity comes
closer to the rear axle, the space
between the centerline of the truck
and the axis of lateral stability
narrows, and the truck will roll more
easily.)
For a lift truck to remain stable, the overall center of gravity must
be inside the triangle formed by the contact points of the left and
right front tires and the center point between the steering wheels.
The triangle denes the area of stability for the center of gravity.
If the overall center of gravity moves further forward than the
front wheels, the truck will tip forward with the front wheels as the
fulcrum. If the overall center of gravity moves outside the triangle
to the right or the left, the truck will fall over in that direction.
■RATED LOAD (LOAD WEIGHT AND LOAD CENTER)
HOW TO READ THE LOAD CHART
The higher the load is raised, and the further forward
from the front wheels the load is moved, the more the
weight of the load increases.
(Slightly heavier loads can be carried with dual tires)
Point D
Point C
Point A
Point B
The load center is the distance from the front face of the forks to
the center of gravity of the load. The rated load is the maximum
weight allowable with the nominal load center.
The Load Chart, showing the relationship between the load center
and the rated load, is attached to the truck as a decal. The rated
load decreases as the load center moves toward the tip of the
forks, and as the overall center of gravity moves forward.