UniCarriers FG20 Series Manual

No. OMFBE-CK9140
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-CK9140
OPERATION &
MAINTENANCE MANUAL
FG20 - FD30
FG20 - FG30
FD20 - FD30

Thank you very much for your purchase of UniCarriers’ product.
This original 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 original 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.

Rated load Truck model Engine model
2tons FG20T3C K21
FD20T4C V2403
FD20T3CZ C240
2.5 tons
3 tons
FG25T3C K21
FD25T4C V2403
FD25T3CZ C240
FG30T3C K21
FD30T4C V2403
FD30T3CZ C240

1. SAFETY
FOR SUPERVISORS ..........................................1-2
QUALIFIED OPERATORS ..............................1-3
PLANNING AND WORKING AREA.................1-4
PROPER AND IMPROPER USES ..................1-7
TYPES OF VEHICLES AND LOADS ..............1-8
INSPECTION.................................................1-11
TRANSPORTING THE LIFT TRUCK ............1-12
TRAVELING ON PUBLIC ROADS ................1-13
MODIFICATIONS ..........................................1-14
HOW THE LIFT TRUCK WORKS? ...................1-15
TRAVELING ......................................................1-18
LOAD HANDLING .............................................1-24
PARKING...........................................................1-28
INSPECTION AND SERVICE ...........................1-30
PREVENTING VEHICLE FIRES .......................1-39
CAUTION PLATES............................................1-41
2. OPERATING CONTROLS
PICTORIAL NOMENCLATURE...........................2-2
INSTRUMENTS AND CONTROLS .....................2-3
SWITCHES......................................................2-5
METERS AND WARNING LIGHTS .................2-7
LEVERS AND PEDALS.................................2-10
TRUCK BODY ..............................................2-14
OPTIONAL EQUIPMENT ..............................2-25
3. OPERATION
PROPER OPERATION .......................................3-2
DURING BREAK-IN ........................................3-2
RELATIONSHIP BETWEEN LOAD AND
STABILITY OF TRUCK....................................3-2
BASIC LOAD CENTER AND RATED
LOAD...............................................................3-3
STABILITY OF LIFT TRUCK ...........................3-3
USING INCHING PEDAL ................................3-3
TRAVELING AND STARTING ON
A SLOPE .........................................................3-4
TRANSPORTING LIFT TRUCK ......................3-4
MOVING LIFT TRUCK
(IN AN EMERGENCY).....................................3-5
OPERATING LIFT TRUCK ..............................3-6
MEASURES AGAINST COLD OR
HOT WEATHER ................................................3-10
IN COLD WEATHER .....................................3-10
IN HOT WEATHER........................................3-11
LOAD HANDLING ...........................................3-12
PICK-UP ........................................................3-12
STACKING.....................................................3-12
UNSTACKING ...............................................3-12
STORING ..........................................................3-13
BEFORE STORING; DAILY STORAGE........3-13
LONG-TERM STORAGE;
OPERATING AFTER
LONG-TERM STORAGE...............................3-13
4. MAINTENANCE
PREOPERATIONAL CHECKS............................4-2
GENERAL RULES ON INSPECTION .............4-2
ITEMS TO BE CHECKED ...............................4-3
PREVENTIVE MAINTENANCE.........................4-18
ENGINE ROOM.............................................4-18
REPLACING TIRES AND REPAIRING
FLAT TIRE .....................................................4-26
REPLACING LAMP BULBS .........................4-28
STARTING THE ENGINE WITH
AUXILIARY BATTERY...................................4-28
ADJUSTING OPERATING FORCE OF
PARKING BRAKE LEVER.............................4-29
PERIODIC INSPECTION ..................................4-30
PERIODICAL REPLACEMENT OF
SAFETY PARTS ............................................4-30
MONTHLY (200 HOURS) CHECKS ..............4-31
3 MONTHS (600 HOURS) CHECKS.............4-37
6 MONTHS (1200 HOURS) CHECKS...........4-39
ANNUAL (2400 HOURS) CHECKS...............4-40
PREVENTIVE MAINTENANCE
SCHEDULE ..................................................4-41
CONTENTS

5. SPECIFICATIONS & SERVICE DATA
SPECIFICATIONS...............................................5-2
EQUIPMENT .......................................................5-6
LOAD CHART .....................................................5-7
SERVICE DATA...................................................5-8
SERVICE DATA...............................................5-8
BOLT AND NUT TORQUE...............................5-9
AFTER-THE-SALE SERVICE ...........................5-13
TRUCK SERIAL NUMBER ............................5-13
SERIAL NUMBERS OF MAJOR
COMPONENTS.............................................5-13
NAME PLATE ................................................5-13
ENGINE SERIAL NUMBER...........................5-14
GENUINE UniCarriers PARTS ......................5-15
GENUINE UniCarriers LUBRICANTS ...........5-15
TRUCK DATA ................................................5-16
6. INDEX
CONTENTS

This is the safety alert symbol. It is used to warn the
reader about a potential source of human injury. To
prevent injury or death, make sure you understand
and follow all the safety messages following this safety
alert symbol.
Signal word
(designates the
degree of hazard)
Denition
DANGER Indicates an imminently hazardous
situation which, if not avoided, will
result in death or serious injury.
WARNING Indicates a potentially hazardous
situation which, if not avoided, could
result in death or serious injury.
CAUTION Indicates a potentially hazardous
situation which, if not avoided, may
result in minor or moderate injury.
CAUTION Indicates a hazardous situation which,
if not avoided, may result in damage to
the truck or other property.
NOTE Indicates information which will help
extend the service life of the truck.
CONTENTS
FOR SUPERVISORS .......................................... 1-2
QUALIFIED OPERATORS ............................. 1-3
PLANNING AND WORKING AREA................ 1-4
PROPER AND IMPROPER USES ................. 1-7
TYPES OF VEHICLES AND LOADS ............. 1-8
INSPECTION.................................................1-11
TRANSPORTING THE LIFT TRUCK ........... 1-12
TRAVELING ON PUBLIC ROADS ............... 1-13
MODIFICATIONS ......................................... 1-14
HOW THE LIFT TRUCK WORKS? ................... 1-15
TRAVELING ...................................................... 1-18
LOAD HANDLING ............................................. 1-24
PARKING........................................................... 1-28
INSPECTION AND SERVICE ........................... 1-30
PREVENTING VEHICLE FIRES ....................... 1-39
CAUTION PLATES............................................ 1-41
1. SAFETY
1-1

Right
Left
Forward
Backward
The diagram above indicates the meanings of the
terms “forward”, “backward”, “right” and “left” used
in this manual.
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 efciently, 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 1-3 through 1-14 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 1-15 and the following pages contain
•
specific precautions directly related to the
operation of the lift truck.
1-2
FOR SUPERVISORS

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.
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.
1-3
FOR SUPERVISORS QUALIFIED OPERATORS

KNOW WHO TO CALL IN AN
■
EMERGENCY
Contacts in emergency
....................................
....................................
.............................
...........................
Keep information on hand to allow immediate
calls for help in case of a fire, 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.
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.
1-4
FOR SUPERVISORS PLANNING AND WORKING AREA

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 trafc guide in conned 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.
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.
1-5
FOR SUPERVISORS PLANNING AND WORKING AREA